Adding an EGR Port to a Non EGR Subaru Engine

Adding an EGR Port to a Non EGR Subaru Engine - AlanFixedIt

Рет қаралды 11,019

6 жыл бұрын

This video shows how to Drill and Tap a threaded hole For the EGR Tube on a 2003 Subaru Outback 2.5L. This should be the same for most Early 2000's Subaru Engines.
In this video i used the following:
-M20x1.5 Tap
-23/32 or 18.5mm Drill bit
-5/16 Drill Bit
*Early and Late 1990's Engines are Similar but use a smaller Drill bit and Tap.
-AlanFixedIt

Пікірлер: 55

@jodybarrett8832 4 жыл бұрын

Beyond thankful that you took the time to video this. Got a steal on a replacement engine for my baja only to realize after the fact that the donor engine isn't EGR equipped. You sir might've just saved me from pulling all of my hair out. Cheers!

@vipercrazy9910 4 ай бұрын

Just did this successfully on a L25 head, The left side head did not have the inner hole pre drilled so it was tougher to keep the hole centered. I would recommend going about 2mm less deep for the 18.5 bit than an actual EGR head and a couple drill bit sizes less for the center hole to account for any off centering.

@alyssahall28 Жыл бұрын

This guy saved my butt.bought a car with non EGR engine wasn't a big deal until I plan to move where they require emissions. So I have to have it fixed found a mechanic willing to do with engine in car for 200

@iansteele7962 Жыл бұрын

Thanks for the Video, I did this to a 2006 Subaru Outback 2.5L, I was able to do it while the engine was in the car. Note: The car is Right hand drive (I don't know if it would make any difference). Some pointers, * The 5/16 hole is approx 40mm before it breaks through, * The threaded hole I made 20mm. A drill needs to be short enough to fit in the space. I used a fixed handle socket so that I could go back and forth as I was threading. I used a tapered Tap which meant I was less likely to go in on an angle, the taper meant I couldn't go deep enough with the thread so I ground off half the taper after the first pass. (The thread does not need to go to the bottom of the hole. Hope this helps

@joemarshall7798 5 жыл бұрын

Thanks. Good video.

@davidschauers 6 жыл бұрын

Going to try this.

@AlanFixedIt 6 жыл бұрын

David Schauers Good luck! Just take it slow and you will be fine. Easier than you might think. Just note that the earlier generations (90s) are different sized bit and tap.

@jasonsimon9997 4 жыл бұрын

Could you accomplish the same thing by welding a bung on the header and extending the egr tube to the header? Have a motor in the car with this problem and can’t get a drill/tap in there

@jenwebb6763 3 күн бұрын

Forgot to mention you need a special drill that that huge 18 drill bit needs to fit in too..

@AlanFixedIt 3 күн бұрын

@@jenwebb6763 the one I used fit into my normal drill. Might be the drill bit you got.

@everyonedies9654 3 жыл бұрын

Do you think these would cause an engine to not start?

@jangonzalez5627 5 жыл бұрын

What its the function of the EGR? Sorry my dumb question

@xebapro 5 жыл бұрын

Why you need a EGR, it’ s for polutions regulations?

@jeffkovene4420 2 жыл бұрын

Drilled mine out straight as possible and pierced the water jacket.

@AlanFixedIt 2 жыл бұрын

Oh no! Where did it go through? On the side? I have not had that happen to me before.

@bigbadwolfxrp2800 Жыл бұрын

did you drill the correct hole location?

@troypark7263 Жыл бұрын

Hi Alan, thank you for the video, is this an FB25? if so I'm facing the opposite issue, I've got a blown non-egr eb25 and I've just bought an FB25 an EGR. what are the differences between the two and would it be possible to do this swap?

@AlanFixedIt Жыл бұрын

This is an Ej251. I'm not sure about all the differences on the FB series. But if it's just the egr, then you should be able to swap the manifold and get a threaded plug for the egr port.

@jimreiter1869 3 жыл бұрын

I have a 2002 block going in a 2005 car. I saw mention of changing timing sprockets. The 2002 block is RTR,, timed etc. Swapped out the complete manifold and electrical from 2005 block onto 2002 block. Do I have to change the sprockets as well?

@AlanFixedIt 3 жыл бұрын

The driver side cam sprocket has teeth on the back that the cam sensor reads, the crank sprocket has teeth on it as well. They may be the same and they may not, there were variations depending on what vehicle, year and transmission. The only way to check is to pull it apart and look to see if they are exactly the same.

@bowjensen9994 5 жыл бұрын

I am currently dealing with a very similar situation as this(only inverted). I had a 2003 Subaru Forester block that had a catastrophic event and I managed to find a 2007 long block that I rebuilt. I just noticed the the tapped hole for the EGR that I didn't have on my 03 Head. So, do I cork it? Also, why didn't you use the Access hole just above the location where you were drilling(with the large Alan|Hex key on it)? I'm kinda a rookie with this kind of thing. So bare with me. I removed a couple of the sealed Alan access corks on my old block, just to see what their significance really was. They appeared to be sealed emergency access points or supplimental holes to allow probing without cracking the block open. What do you think ?

@AlanFixedIt 5 жыл бұрын

Bow Jensen those sealed Allen caps are coolant passages, do not put anything other than that cap in there. Yes you can just cap the EGR port with a properly threaded plug if your car was not factory equipped with EGR. As far as everything else goes, you will need your complete intake manifold, crankshaft timing gear, and cam timing gears off your old motor swapped to the new one for it to run. Good luck

@bowjensen9994 5 жыл бұрын

Thank you for the quick response. Timing has been switched and belt is on. I had just dropped it in the forester when I had someone say that I would need to put my old heads onto the new block as well. Is that true. The original engine was a ej25 2.5 sohc from an 03 foresterx the one Im putting in is apparently a 07 JDM impreza ej25 2.5 sohc. Any other mods Im missing?

@2003wrx64 4 жыл бұрын

I think the hole with the Allen plug accesses a coolant passage.

@adamharrison4864 4 жыл бұрын

Would it be possible to just simply plug the EGR port on the Exhaust manifold? I am dealing with the identical situation and being in Washington state Emissions are going away entirely so i'm not too worried about legality

@AlanFixedIt 4 жыл бұрын

Adam Harrison yes, but you will have a check engine light indefinitely

@lilclutch4517 4 жыл бұрын

AlanFixedIt what would be the cause of the check engine light. i’m looking to sr20 swap my mazda miata but i’m trying to make it completely legal for california smog and i was going to put an egr valve on connected from the exhaust manifold to intake manifold and i’m not sure if that will work or not

@kevinmiller6006 6 жыл бұрын

How deep in total did you drill the hole?

@AlanFixedIt 6 жыл бұрын

Bob Adams 3/4 of an inch

@arturwisniewski2275 5 жыл бұрын

How do you think: is it possible to make it correctly on the car? Today I recognize I have exactly the same problem. There was P0400 error still on my Legacy 2.0 SOHC and I bought EGR pipe because there wasn't one. But when I started to install i find out there is no hole in the engine block. Is there any alternative to erase P0400 permanently without installing pipe?

@Jason-tf7tj 5 жыл бұрын

Did u fix this or still have code. If still a code any other problems I want to get rid of egr

@wickedeagans 5 жыл бұрын

Please tell me what u did. I’m throwing this code. Went to put pipe on and no hole

@patrickmanfrede7720 5 жыл бұрын

without the pipe installed in someway the egr actuator will never open. thus you will always get that code(since there is no flow to the egr).the actuator needs vacuum to open and without the pipe there is no way for vacuum to go through the egr

@wickedeagans 4 жыл бұрын

Patrick Manfrede so can I tie into a vacuum line then? Cuz I don’t wanna swap heads for the block I have and I don’t wanna drill a hole in the block either. I’m so tired of this check engine light

@jeffreywashburn4504 4 жыл бұрын

Do you think this would be possible in the car? I hastily ordered a non EGR head and assembled and by the time I was installing the tube then noticed.... smh

@AlanFixedIt 4 жыл бұрын

Jeffrey Washburn hmmm, I wouldn’t try it, even with a 90 degree drill it would be super hard to get straight, much less have room around the steering linkage and heater hoses. Pull the motor, only takes a few hours.

@jeffreywashburn4504 4 жыл бұрын

AlanFixedIt, I was afraid of that. By the time it was all together and already in the car I was like, the check engine light is going to be on and I’m gonna let that thing shine. I attempted to bypass using the power booster as a source of pressure but that didn’t work either. My uncle that was helping me is a machinist and said we can take it back out and drill it. I was afraid to do it until I saw your video and I thank you for that. At the time I couldn’t find a video.

@2stops131 5 жыл бұрын

Could you just swap the heads from the old engine?

@AlanFixedIt 5 жыл бұрын

Yes you can, but the purpose of this video is to avoid having to do that.

@damonmainus6049 5 жыл бұрын

What was the reason for the cam sprocket change?

@AlanFixedIt 5 жыл бұрын

Damon Mainus when swapping between different models or years, sometimes the timing marks that the sensors read are different. So to keep the ECU happy, it’s a good practice to keep the cam and crank sprockets with the ECU/car they came from, unless of course its the same model and year range.

@damonmainus6049 5 жыл бұрын

AlanFixedIt So I went from an automatic 02 outback 2.5 complete block, into a 03 outback manual. I have a misfire at idle when warm an under acceleration after 3000 rpm. Any info is great.

@AlanFixedIt 5 жыл бұрын

The best thing to do is remove the timing cover and look at the sprockets and compare. The crank is easy to see the timing reference points on, just make sure the old one and new one look exactly the same. The drivers side cam sprocket is a little tougher, but you can look through the spikes to see the marks on the back. Feel free to email me at alanfixedit@gmail.com if you need pictures

@AlanFixedIt 5 жыл бұрын

Also, did you check valve lash on the new motor?

@damonmainus6049 5 жыл бұрын

AlanFixedIt thanks bud. I'll look more into that