GShep
09-17-2014, 03:38 PM
...as mentioned in my introduction thread, I do own a 98 JDM Legacy GT-B Limited with a broken EJ20R engine.
It's already the second engine in this car. A year after the first german owner imported it, the first engine blew up as a valve ripped off.
He got a new engine which soon then blew up again. It still ran when I bought it, but only on 3 cylinders and it pushed out a lot of exhaust fumes through the oil cap. We figured the cause were the piston rings, so I checked the spark plugs and cylinders with and endoscope for oil
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_010-1.jpg
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_015-1.jpg
The failure why the engine was just running on three cylinders was soon found, spark plug of cylinder 2 was completely crusted in oil.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_014-1.jpg
Pulled the engine out the next day to find the reason why there was so much oil in the cylinder.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_024-1.jpg
Cylinder 2 is quite polished, you still can see the finish a little though. Thanfully the broken ring didn't leave any scratches.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_027-1.jpg
...but the actual failure is this:
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_029-1.jpg
We guess that the injector is broken and dripping, thus the cylinder overheated and melted the piston away and at some point the piston ring couldn't take the heat anymore so that it simply broke apart so that the oil wasn't kept out anymore.
I'm not sure if the previous owner exchanged these or reused them from the first engine. Might already have been the reason for the first engine failing.
Shortly after my brother and I measured the cylinders with a three point micrometer screw.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_033-1.jpg
...which looked quite promising.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_035-1.jpg
Of course we also measured the ovality/out of roudness with an inside micrometer at 12 and 3 oclock, which is where things started to look bad.
We measured differences of 0,1mm outside, 0,06mm middle and 0,04mm inside the cylinders.
The only clearance values I got though are from Haynes Repair Manual for the 2.2 and 2.5 and when I compare thouse, what we measured exceeds the limit quite a bit.
If the out of round limit is the same for the EJ20R, I'll have to go with oversized pistons.
Can anybody confirm that the out of round limit is the same for the EJ20R as for the 2.2's and 2.5's?
It also would be good to know what other parts I should replace (long/short screws of the crank housing maybe?).
So far I plan to order these things:
10105AA390 Gasket kit[/*:m:3c5mlk3o]
11095AA041 cylinder head bolts[/*:m:3c5mlk3o]
12033AA730 Piston rings (or 12033AA740 1. oversize)[/*:m:3c5mlk3o]
12006AB710 Piston (or 12006AB730 1. oversize) (according to: http://subaru.epcdata.ru/legacy/bg5/138 ... 010/12006/ (http://subaru.epcdata.ru/legacy/bg5/138-ej20r/engine/010/12006/) )[/*:m:3c5mlk3o]
16611AA231 Injector (according to: http://subaru.epcdata.ru/legacy/bg5/138 ... 062/16611/ (http://subaru.epcdata.ru/legacy/bg5/138-ej20r/engine/062/16611/) )[/*:m:3c5mlk3o]
Is there anything I would need to order in addition?
I also do need the torque specs for the cylinder head bolts and crank housing, already found this on the forum but are the values the same for the EJ20R?
viewtopic.php?p=276708#p276708 (https://sl-i.net/FORUM/viewtopic.php?p=276708#p276708)
Hope someone on here can help me out on this, I really wanna see that engine back running before next year's season starts. :smt023 :smt023
It's already the second engine in this car. A year after the first german owner imported it, the first engine blew up as a valve ripped off.
He got a new engine which soon then blew up again. It still ran when I bought it, but only on 3 cylinders and it pushed out a lot of exhaust fumes through the oil cap. We figured the cause were the piston rings, so I checked the spark plugs and cylinders with and endoscope for oil
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_010-1.jpg
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_015-1.jpg
The failure why the engine was just running on three cylinders was soon found, spark plug of cylinder 2 was completely crusted in oil.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_014-1.jpg
Pulled the engine out the next day to find the reason why there was so much oil in the cylinder.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_024-1.jpg
Cylinder 2 is quite polished, you still can see the finish a little though. Thanfully the broken ring didn't leave any scratches.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_027-1.jpg
...but the actual failure is this:
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_029-1.jpg
We guess that the injector is broken and dripping, thus the cylinder overheated and melted the piston away and at some point the piston ring couldn't take the heat anymore so that it simply broke apart so that the oil wasn't kept out anymore.
I'm not sure if the previous owner exchanged these or reused them from the first engine. Might already have been the reason for the first engine failing.
Shortly after my brother and I measured the cylinders with a three point micrometer screw.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_033-1.jpg
...which looked quite promising.
https://sl-i.net/FORUM/images/imported/2014/09/LegacyGTB_035-1.jpg
Of course we also measured the ovality/out of roudness with an inside micrometer at 12 and 3 oclock, which is where things started to look bad.
We measured differences of 0,1mm outside, 0,06mm middle and 0,04mm inside the cylinders.
The only clearance values I got though are from Haynes Repair Manual for the 2.2 and 2.5 and when I compare thouse, what we measured exceeds the limit quite a bit.
If the out of round limit is the same for the EJ20R, I'll have to go with oversized pistons.
Can anybody confirm that the out of round limit is the same for the EJ20R as for the 2.2's and 2.5's?
It also would be good to know what other parts I should replace (long/short screws of the crank housing maybe?).
So far I plan to order these things:
10105AA390 Gasket kit[/*:m:3c5mlk3o]
11095AA041 cylinder head bolts[/*:m:3c5mlk3o]
12033AA730 Piston rings (or 12033AA740 1. oversize)[/*:m:3c5mlk3o]
12006AB710 Piston (or 12006AB730 1. oversize) (according to: http://subaru.epcdata.ru/legacy/bg5/138 ... 010/12006/ (http://subaru.epcdata.ru/legacy/bg5/138-ej20r/engine/010/12006/) )[/*:m:3c5mlk3o]
16611AA231 Injector (according to: http://subaru.epcdata.ru/legacy/bg5/138 ... 062/16611/ (http://subaru.epcdata.ru/legacy/bg5/138-ej20r/engine/062/16611/) )[/*:m:3c5mlk3o]
Is there anything I would need to order in addition?
I also do need the torque specs for the cylinder head bolts and crank housing, already found this on the forum but are the values the same for the EJ20R?
viewtopic.php?p=276708#p276708 (https://sl-i.net/FORUM/viewtopic.php?p=276708#p276708)
Hope someone on here can help me out on this, I really wanna see that engine back running before next year's season starts. :smt023 :smt023