07/10/2016
Reviving Your Subaru EJ255: Crate Engine Options Explored
The Subaru EJ255 engine, a stalwart in many of the brand's performance and utility vehicles, can eventually reach a point where a comprehensive rebuild or replacement becomes necessary. Whether your EJ255 has succumbed to wear and tear, a specific mechanical failure, or simply needs a new lease on life, understanding your options for a replacement or rebuilt engine is crucial. This article delves into the world of Subaru EJ255 crate engines, focusing on a specific 'quick turnaround' rebuild service, and also provides context by explaining the broader EJ engine family, including the EJ253. Getting your Subaru back on the road with a healthy engine is paramount, and knowing your choices can save you time, money, and considerable stress.
Understanding the Subaru EJ Engine Family
Before diving into specific solutions for the EJ255, it's helpful to understand its place within the wider Subaru EJ engine lineage. The EJ series, which debuted in 1989, is renowned for its horizontally-opposed (boxer) configuration, contributing to a lower centre of gravity and improved handling. The 2.5-litre displacement became a popular choice for Subaru, offering a good balance of power and efficiency.
The EJ253: A Naturally Aspirated Counterpart
The EJ253 is a naturally aspirated version of the 2.5-litre EJ engine. It shares its lineage with earlier EJ25 variants like the EJ25D, EJ251, and EJ254. The EJ253, appearing around 1999, is characterised by its use of a Mass Air Flow (MAF) sensor and Tumble Generator Valves in the intake manifold to improve emissions and combustion. Later iterations, from 2006 onwards, incorporated the i-AVLS (intelligent Active Valve Lift System), which alters intake valve lift for better performance and economy. Further revisions in 2009 saw the introduction of lighter pistons, headers, a plastic intake manifold, and new spark plugs, refining its efficiency and output. While the EJ253 is a capable engine, it is important to distinguish it from the turbocharged EJ255.
The EJ255: The Turbocharged Workhorse
The EJ255, first introduced in 2004 for the Subaru Forester, is a turbocharged variant of the 2.5-litre EJ engine. It found its way into popular models such as the 2005-2006 Impreza WRX and various Legacy models. Early versions of the EJ255 featured an open-deck short block and DOHC cylinder heads with AVCS (Active Valve Control System) on the intake camshafts. These engines typically had a compression ratio of 8.4:1 and were paired with a TD04L turbocharger, producing around 0.8 bars of boost and an output of approximately 210 horsepower. Subsequent generations, used in models from 2006-2008 WRX, 2007+ Legacy, and 2006+ Forester, employed slightly different cylinder blocks and heads. Turbocharger specifications varied, with JDM Forester STI models using a VF41, WRX III models a VF52 (0.92 bars), and Legacy GT models up to 2009 utilising a VH46 turbo (0.96 bars, 250 hp). Post-2009 Legacy GTs saw the VH46 turbo adjusted to 0.82 bars, yielding 265 hp. Understanding these variations is key when sourcing replacement parts or a crate engine.
Crate Engine Options for Your EJ255
When your EJ255 needs a replacement, a 'crate engine' is often a more appealing and potentially cost-effective solution than a full, bespoke rebuild from scratch. A crate engine is essentially a pre-assembled, ready-to-install engine. For the EJ255, a particularly attractive option is a 'Quick Turnaround Crate Engine' with upgrades, as described by Synergy Engines.
The Quick Turnaround Crate Engine: A Detailed Look
This particular rebuild service focuses on speed and reliability, offering a compelling alternative to the often exorbitant costs quoted by dealerships for new engine replacements. Let's break down what this service entails:
Core Requirements: The foundation of this rebuild is your existing engine core. Crucially, all timing components, valvetrain parts, camshafts, and phasers must be transferred from your old engine. This means your original engine needs to be sufficiently intact to allow for the salvage of these vital components. If these parts are damaged beyond repair, they will need to be replaced, potentially incurring additional costs.
Engine Specifications: The service utilises a new OEM short block. This is a significant advantage as it streamlines the machining process and provides a solid, factory-new foundation. New OEM head castings are also included, addressing a common issue where original heads may have damaged cam journals or other wear. While the focus is on speed, the service aims to recondition or replace valvetrain parts with OEM or superior quality components if they don't meet inspection standards. Timing sprockets are also either reconditioned or replaced as needed.
The 'Quick Turnaround' Aspect: The primary selling point here is the speed of the rebuild. With an estimated turnaround time of just 5 weeks (including shipping for 2023-24), this is considerably faster than many traditional rebuilds. The use of a new OEM short block significantly reduces the time spent in the machine shop, contributing to this expedited timeline. The service also notes plans for having engines in stock for even faster replacements in the future.
Optional Enhancements: For those seeking a slight performance edge, porting of the cylinder heads can be added. This custom work typically adds only 2-5 days to the overall process, as it needs to be scheduled into the shop's workflow.
Cost Breakdown and Ballpark Estimate:
The pricing structure is designed to be transparent:
- Starting Price (Engine Only): $6,295
- Freight Pickup: Approximately $300
- Freight Drop Off: Approximately $300
- Total Estimated Price: $6,895
It's important to note that this price is an estimate and can vary based on the condition of your core engine and any additional services requested. The 'Bad Core' surcharge is applicable if your original engine is not suitable for the required component transfer.
Why This Option is Attractive:
- Cost Savings: Compared to dealership replacement prices, which can easily exceed $15,000, this service offers substantial savings, potentially thousands of dollars.
- Speed: A 5-week turnaround is remarkably fast for a rebuilt engine, minimising the downtime of your vehicle.
- OEM Foundation: The use of new OEM short blocks and heads provides a high level of confidence in the core components.
- Warranty: While performance rebuilds often void manufacturer warranties, this service offers an OEM warranty on the short block, providing additional peace of mind.
What to Expect and How to Proceed
If you are considering this quick turnaround crate engine for your Subaru EJ255, here’s what you need to do:
Contact Information:
- Phone: 269-282-8067
- Email: [email protected]
Information to Provide: When you contact them, be prepared to supply the following details:
- Your Full Name
- Year, Make, Model, and VIN of your Subaru
- Your preferred Pickup Address (for your old engine core)
- Your Contact Phone Number
The team will then guide you through the process of arranging core pickup and initiating the rebuild. It's always advisable to discuss any specific concerns or requirements you might have with them directly.
Important Considerations for Your EJ255 Rebuild
Regardless of the specific crate engine option you choose, several factors are crucial for a successful outcome:
- Core Condition: The viability of your original engine core is paramount. Ensure it's not catastrophically damaged, especially concerning the crankshaft, connecting rods, and pistons, as these are often part of the short block.
- Ancillary Components: While the crate engine provides the short block and heads, you will need to transfer or replace other components like the turbocharger, injectors, alternator, starter, and exhaust manifolds. Ensure these are in good working order before installation.
- Installation: While the crate engine is ready to install, the actual labour of removing your old engine and fitting the new one is a significant undertaking. If you’re not experienced, factor in the cost of professional installation.
- Break-in Procedure: After installation, any rebuilt or replacement engine requires a proper break-in period. Follow the manufacturer’s or rebuilder’s recommended procedure diligently to ensure the longevity of the new engine. This typically involves varying engine speeds and avoiding heavy acceleration for the first several hundred miles.
- Complementary Upgrades: Consider if this is an opportune time to perform other maintenance or upgrades. For example, replacing worn engine mounts, upgrading the clutch (if manual transmission), or servicing cooling system components can be more efficient while the engine is out.
Frequently Asked Questions
Q1: What is the main difference between the EJ253 and EJ255?
A1: The primary difference is that the EJ253 is a naturally aspirated engine, while the EJ255 is a turbocharged version, designed for higher performance.
Q2: Can I use an EJ255 crate engine if my original engine was an EJ253?
A2: While both are 2.5-litre EJ engines, direct swapping might require modifications due to differences in turbocharging, exhaust systems, and engine management. It is generally recommended to stick with a crate engine designed for your specific engine code (EJ255).
Q3: What does 'core required' mean?
A3: It means that the rebuilder needs your old engine to transfer certain reusable parts (like camshafts, timing components, etc.) and often as a core deposit against which the new engine is built. If your old engine is too damaged to provide these parts, you may incur an additional 'bad core' charge.
Q4: Is a 5-week turnaround time guaranteed?
A4: The 5-week timeframe is an estimate provided for the 2023-24 period. Factors like shipping delays, shop workload, and the condition of your core engine can influence the actual completion time. The service aims for this turnaround but acknowledges potential variations.
Q5: What if my EJ255's cylinder heads are damaged?
A5: The service includes new OEM head castings, which is a significant advantage. However, it's always best to discuss the specific condition of your heads with the rebuilder to understand if any additional charges might apply for parts that cannot be salvaged or transferred.
Conclusion
Reviving your Subaru with a healthy EJ255 engine is achievable through various avenues, with crate engines offering a compelling blend of cost-effectiveness and speed. The 'Quick Turnaround Crate Engine' service discussed provides a clear path to getting your vehicle back on the road, offering substantial savings over dealership replacements. By understanding the specifics of the EJ255, the process, and what to expect, you can make an informed decision to bring your beloved Subaru back to its full potential.
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