96 ej22 swap with 98 ej25d: EVAP emissions issues

[Methe]

I dug through a couple of previous ej22 to ej25d swap threads, but couldn't find anything pertaining to my particular problem.

So a couple months ago I pulled the sohc ej22 out of my 96 BD (5MT) and dropped in an ej25d out of a (wrecked) 98 LGT wagon. It runs/drives mint, and 99% of everything matched up. But after driving it for a while I threw out a CEL (P0441) which translated to an EVAP emissions control leak. When I did the swap, i removed the charcoal canister mounted right behind the passenger side headlight. On the 2.2 there were two solid lines that two hoses plugged into and ran to the top of that canister, but there are no such lines on the 2.5. I'm not terribly surprised my CEL came on, but seeing as I live in NH, and it's post MY95, I need to take care of this for inspection purposes.

I called a few local shops, and even a "Subaru specialty" shop in Berlin, VT, and they all told me there was nothing I could do to make it pass. Unfortunately I no longer know "a guy" i can get a BS sticker from. Is there anyway I can custom rig the 96 evap system around my new ej25???

[chuckthefuk]

95-97 is different the 98-99.

I believe the answer is to swap intake manifolds with all the ej22 accessories.

-Chuck (tapatalk)

[decke48]

need to swap fuel lines off the 96 ej22 intake to your new motor, maybe some sensors also

[Methe]

Dope, thanks guys. I'll try that when I go home this weekend and let you know how it turns out.

Good thing I kept the junk ej22 ;)

[jey]

You probably won't need to swap manifolds, besides I don't think the EJ22 manifold will bolt up to the EJ25. All you need is a vacuum source anyway. Use the EVAP solenoid from your EJ22. One hose goes to the intake manifold. The other goes to the charcoal canister - mount up your old EJ22 canister, run the vacuum hose from the solenoid to the canister, and then attach the one that goes to the fuel tank to the canister. Reset the ECU and go for a drive on the highway, and after a while the EVAP system readiness should clear.

[Methe]

So after dissecting my ej22, and comparing the two evap systems, I came to the conclusion that the only thing that could be tripping the evap solenoid would be the fact that I did not have a canister inline between the gas tank and the sensor. I cut the steel line that runs from the gas tank, under the intake manifold, to the solenoid, and reinstalled my canister and hooked up new hoses according the the labels on the canister (one for fuel tank, one for purge solenoid). Then I reset the ecu and took it for a spin. The CEL came back on in like 20 miles... FML

I guess my next step is to try swapping as much of the intake manifold and associated lines off the ej22 onto the ej25 as i can.

[jey]

Almost sounds like the solenoid is bad, I have the line between the solenoid and the canister disconnected and it doesn't trip a CEL...

[Methe]

I ended up getting hooked up with a sticker anyway. And next year It turns 15 years old, so I won't have to worry about NH emissions anymore. The CEL is still on tho.

[subikid90]

The 96-97 used the canister. Find a mani from a 96-97 ej25 and swap it on and use the canister. The easiest fix, maybe not the most cost effective though.

[Garrison]

I'm revving this thread to ask a question:

I do not have a canister (I've no idea why, but the canister is gone) for my EVAP system and I have to pass inspections. Are there any fixes for this?