Subaru EJ engine

Subaru EJ engine
Overview
Manufacturer Subaru
Production 1988 – present
Combustion chamber
Valvetrain DOHC/SOHC
Combustion
Turbocharger Optional
Fuel type Petrol/gasoline
Chronology
Predecessor Subaru EA engine
Successor Subaru FB engine

The Subaru EJ engine is a series of four-stroke automotive engines manufactured by Subaru. They were introduced in 1989, intended to succeed the previous Subaru EA engine. The EJ series is the mainstay of Subaru's engine line, with all engines of this series being 16-valve horizontal flat-fours, with configurations available for single, or double-overhead camshaft arrangements (SOHC or DOHC). Naturally aspirated and turbocharged versions are available, ranging from 96 to 320 horsepower. These engines are commonly used in light aircraft, kit cars and engine swaps into air-cooled Volkswagens, and are also popular as a swap into the wasserboxer engined Volkswagen T3/Vanagon . Primary engineering on the EJ series was done by Masayuki Kodama, Takemasa Yamada and Shuji Sawafuji of Fuji Heavy Industries, Subaru's parent company.

EJ15

Subaru EJ15 engine (2004 Impreza)

Usage:

Specifications

EJ151

EJ152

EJ153

EJ154

EJ16

Usage:

Specifications

EJ16

EJ18

Usage:

Specifications

EJ181

EJ182

EJ183

EJ20

Subaru EJ20 SOHC NA engine (2006 Legacy)

(Japanese: Subaru EJ20)

The EJ20 is a 2-liter boxer four, with either single or double overhead camshafts. The smaller EJ18 was developed from the EJ20, as were the enlarged EJ22 and EJ25 engines.

Specifications

EJ20E SOHC naturally aspirated

  • Europe
  • 1991-1999 115 PS (85 kW) BC, BD, BF series[1]
  • Europe
  • 1994-1999 115 PS (85 kW) GC, GF series[2]

EJ20D DOHC naturally aspirated

EJ202 SOHC naturally aspirated

EJ204 DOHC naturally aspirated AVCS

EJ20N runs on compressed natural gas

EJ20 Turbocharged

All engines listed below were installed with a turbocharger and an intercooler:

EJ20T

This is not actually a valid code from Subaru, but is mostly used by enthusiasts and mechanics to describe the entire line of 2.0 litre turbocharged engines that have been available over time. The practice began with the designation of the USA-spec turbo, commonly referred to as the EJ22T, and the habit of referring to any turbocharged engine as a "T" began. When referring to the EJ20T, one is speaking of one of the following:

EJ20G

EJ20G engines fall into 3 categories:

1. Rocker-style HLA EJ20G usage

Power output ranges from 197 bhp (147 kW; 200 PS) @ 6000 rpm and 260 Nm for the GT to 220 PS (162 kW; 217 bhp) @ 6400 rpm and 270 Nm for the RS versions. Engines can be identified by coil on plug, and with 2 M6 bolts per coil and valve covers with 4CAM 16VALVE and horizontal lines above and below the plug holes. All these engines have the air-to-water intercooler setup (chargecooler) and oil squirters.

2. Bucket-style HLA EJ20G usage

Power output ranges from 220 PS @ 6000 rpm and 260 Nm for the WRX Wagons to 275 PS @ 6500 rpm and 319 Nm for the WRX STI Version II. Engines can be identified by coil on plug with 1 M8 bolt per coil and valve covers with 4CAM 16VALVE and horizontal lines above the plug holes. Generally these engines all have the slanted intercooler. Some engines may not have HLA buckets but solid buckets with shims underneath. These engines also feature lighter valves, the intake valves are marked INKO and the exhaust valves are marked EXKO. The standard HLA valves are I252 and E283 respectively. All WRX Wagon engines and automatic sedan engines came with a TD04 with 90 deg elbow, all manual WRX sedans including STI versions had a TD05 with 90 deg elbow

3. Shim-over-bucket style EJ20K usage

Power output is 250 PS @ 6000 rpm for the Japanese versions and 211 PS for the European model. Engines can be identified by smooth valve covers, plug leads and a wasted spark coil in the middle of the intake manifold. These engines were available with both manual and automatic transmission in Japan, but generally had manual transmission in Europe, in the Impreza Turbo.

EJ20X EJ20Y

These two motors are basically the same, The X was used in Automatic packages, and the Y in Manual packages. These both had different turbo sizes except for the JDM 07+ legacy BL5 (sedan) and BP5 (Wagon). EJ20X/EJ20Y are open deck engines whereby the cylinder walls were supported at the three and nine o’clock positions. It came with an aluminium alloy block with 92.0 mm bores – with cast iron cylinder liners – and a 75.0 mm stroke for a capacity of 1994 cc. with thicker cylinder walls than ej25 The crankcase for the EJ20X and EJ20Y engines had five main bearings and the flywheel housing was cast with the crankcase for increased rigidity. The EJ20X engine is understood to have a forged crankshaft and connecting rods, but cast aluminium pistons with forged crowns. The EJ20X and EJ20Y engines had an aluminium alloy cylinder head with cross-flow cooling, double overhead camshafts (DOHC) per cylinder bank and four valves per cylinder that were actuated by roller rocker arms. The EJ20X and EJ20Y engines were the first EJ engines to be equipped with Subaru’s ‘Dual Active Valve Control System’ (‘Dual AVCS’) which provided variable intake and exhaust valve timing. For the BL.I Liberty GT, the EJ20X engine was fitted with a twin-scroll IHI VF38 turbocharger; the EJ20Y engine, however, had a larger twin-scroll Mitsubishi TD04 HLA 19T turbocharger. For the BL.II Legacy GT, both the EJ20X and EJ20Y had an IHI VF45 turbocharger.

Both came with a 9.5:1 compression and a fast spooling turbo yields a torque filled performance. (265-280 bhp)

Turbos:

Usage: ej20x- Single Turbo 

                   -Legacy 
                   -08 wrx
                   -03'+ BL & BLII Liberty GT

ej20y- single Turbo 

                   -Legacy
                   -08 wrx
                   -03'+ BL & BLII Liberty GT

[3]

EJ205

This engine series is used for WRX models in the world market outside Japan as of 1999. The Japanese WRX models use the EJ207 from 1999~2001, except the 5-door wagon which also uses the EJ205. After 2001, all WRXs use the EJ205, until 2006 when the USDM WRX model changed engines to the EJ255. The EJ205 has an 8:1-9:1 compression ratio.

To identify an EJ205:

Usage: Impreza WRX

Forester Cross Sports, S/tb, STI

NOTE: The Australian Spec MY00 EJ205 does not have coil on plug but can be identified from the VIN of the vehicle (if known) where the 10th digit will be Y (for year 2000) and the 6th Digit will be 8 (for the 2000yr/EJ205)

EJ207

It started its life for the 9/98-8/99 GC8 in Japan/UK/Australia The EJ207 has an 8.0:1 compression ratio.

To identify a 9/98-9/2000 EJ207 (v5/v6 WRX STI GC8/GF8)

Usage:

2.0L Quad Cam Twin-turbo from JDM 1996 Subaru Legacy GT

EJ20TT

This may refer to a 2-liter DOHC Sequential Twin Turbo and intercooled engine (EJ20H/EJ20R/EJ206/EJ208). However, similar to the EJ20T, the term was never used by Subaru. Used from 1994 to 2005 in various iterations listed below. Due to the tight confines of the engine bay, the twin turbo engine was installed in Japanese-spec Legacies only, which were right-hand drive. The Pistons were lighter with a shorter skirt than the WRX EJ20T to allow for higher engine speed.

Specifications

EJ20H

Usage:

EJ20R

Usage:

EJ206

Usage:

BH5A - 9.0:1 Compression - "Phase-II", or V5/6 generation.
BH5B - 9.0:1 Compression - "Phase-II", or V5/6 generation.
BH5C - 9.0:1 Compression - "Phase-II", or V5/6 generation.
BH5D - 9.0:1 Compression - "Phase-III", or V7 generation.

EJ208

Usage:

BH5A - 8.5:1 Compression - "Phase-II", or V5/6 generation.
BH5B - 8.5:1 Compression - "Phase-II", or V5/6 generation.
BH5C - 9.0:1 Compression - "Phase-II", or V5/6 generation.
BH5D - 9.0:1 Compression - "Phase-III", or V7 generation.

Rev D EJ208's can be considered a totally different motor to the A/B/C's, they run totally different cams, cam pulleys with different timing marks, different crank sprocket with different timing marks, pink 550cc injectors instead of yellow 440's, different intake manifold design. etc.

EJ22

Usage:

Specifications

EJ221 Naturally Aspirated

EJ222 Naturally Aspirated (1999)

EJ22 Enhancements and Improvements

Beginning in the 1997 model year, the 2.2 liter engine for 1997 Legacy and Impreza models had internal and external changes that yield an approximately 10% increase in power and 3% increase in fuel economy. Accomplishing this involves many factors, one of which is engine friction reduction. The pistons were coated with molybdenum to reduce friction. The thin coating reduces moving friction and reduces cylinder wall scuffing. The piston skirt was reshaped and the piston weight was reduced by approximately 100 grams. Compression ratio was increased to 9.7:1 by reshaping the piston crown. This eliminates the clearance that was available between the piston at TDC and the fully opened valve. Piston pin offset has been changed to 0.5mm (0.020 in). Piston to cylinder wall clearance has been reduced by increasing the piston diameter. Another source of high engine friction is the valve train. Hydraulic lash adjusters (HLAs) are always in contact with the valves. The hydraulic pressure of the lash adjuster must be overcome during operation and during the most critical time of engine start. To overcome this situation and to contribute to the total reduction of friction loss, 1997 and later SOHC engines have solid valve adjusters. The scheduled service of this valve train is set at 100,000 miles (160,000 km). SOHC engines now use an adjustment screw to adjust valve clearance. Engines with the earlier HLA are recommended to use 10W30 or 10W40 oil year-round; 5W30 can be used at very low winter temperatures. The roller rocker cam follower system that was introduced on the 1.8L Impreza engines, is installed on all 1995 model year and later 2.2 liter engines. The roller assemblies are not serviceable separately, but the rocker arms may be serviced as individual units. The carbon composition head gaskets with integrated o-rings are interchangeable from left to right on 1990 to 1994 NA engines only. Other Engine Modifications (2.2L 1997): The intake manifold has been reshaped to increase the airflow mass and speed, contributing to improved low and mid engine speed operation. Components located on the intake manifold have been relocated as compared to the 1996 models. EGR Solenoid, Purge Control Solenoid, etc. 1999 2.2 Liter Phase 2 Engine Enhancements (from endwrench article H-4 and H-6 service): All 2.2 liter engine for 1999 are the Phase 2 design. The 2.2 liter Phase 2 engines are a SOHC design, with a newly designed cylinder head. Changes in the 2.2 liter Phase 2 engines are as follows:

Additional Phase 2 Engine Features:

Note: Cylinder head and camcase must be replaced together (line bored).

EJ22

2.2 litre

AUDM Subaru EJ22E

135 bhp (101 kW) @ 5800 rpm 140 lb·ft (190 N·m) @ 4800 rpm Australian model - 100 kW (130 hp) @ 6000 rpm 189 N·m (139 ft·lbf) @ 4800 rpm Usage:

EJ22T

Phase one 2.2 Liter SOHC Turbo, 163 bhp (122 kW; 165 PS) fully closed deck, oil squirters, no intercooler

EJ22G

Phase two 2.2 litre closed deck, based on the EJ20K STI engine. Uses identical cylinder heads and turbocharger but with a unique closed deck 2.2L crank case. The pistons are factory forged items, the connecting rods are stock. Although being closed deck, the block does not feature oil squirters for piston cooling, opposed to the EJ20 closed deck block and the USDM-only Legacy EJ22T closed deck block.

EJ22G Turbo DOHC

Usage:

EJ25

EJ25D

There were two variations of the EJ25D sold in the US market. The engine was introduced in 1996 in the Legacy 2.5GT, LSi, and Legacy Outback. That version of the engine used HLA heads, was recommended to be run on 91 octane fuel, had lower power and torque ratings than the later '97-99 EJ25D, and was only offered with an automatic transmission. In 1997 a revised engine was introduced that used heads with shimmed bucket lifters (versus the HLAs), was designed to run on 87 octane fuel, and was available with either a manual or automatic transmission. Because of the DOHC valve architecture, the spark plugs are more difficult to service in comparison to SOHC variations. The DOHC engines are therefore installed with platinum spark plugs and an extended spark plug service life of 80,000 miles (128,747.5 km).

DOHC (1996) - SAE - 155 hp (116 kW) @ 5600 rpm
140 ft·lbf (190 N·m) at 2800 rpm
DOHC (1997–1999) - SAE - 165 hp (123 kW) @ 5600 rpm
162 ft·lbf (220 N·m) at 4000 rpm

Usage

EJ251

Flat four EJ251

The EJ251SOHC was the first version of a long line of Single Overhead Cam 2.5L engines by Subaru for the US market. The EJ251 was soon replaced by the EJ253 in many models due to its improved cooling to aid in head gasket life and improved engine management and sensors. The EJ251 commonly experienced head gasket failures resulting in interior channel breaches or exterior fluid leaks due to the continued use of a single layer coated gasket first introduced on the EJ25D. Intake volume is calculated by the use of a MAP sensor, unlike the EJ253 which uses a MAF sensor. Compression ratio is 10:1.

Power ISO: 123 kW (165 hp) @ 5600 RPM
226 N·m (167 ft·lbf) @ 4400 rpm

Usage:

EJ252

SOHC The EJ252 was only briefly used in North America alongside the EJ251 in the USDM Legacy Outback for the 2000 and 2001 Model Years. They are most commonly found in MY00 Legacy Outbacks manufactured before the end of 1999 while MY00 Legacy Outbacks manufactured in 2000 are rarely designated with EJ252 codes in the VIN. While Subaru has not provided a direct list of revisions between the EJ251 and less common EJ252, there is some degree of information suggesting the EJ252 was simply an alternate version of the EJ251 made to meet California Emissions Standards when the SOHC EJ engines were first introduced in North America. Power output has been reported as ISO 115 kW (156 hp) but is often speculated to share the same specs with the largely identical EJ251.[4] From unofficial analysis, the EJ251 shares the same with block, cams, heads, pistons, connecting rods with the EJ252. The only notable differences confirmed are unique intake manifold and throttle body designs to accommodate the different MAP sensor location and IACV location.[4]

Usage:

EJ253

SOHC - 165 hp (121 kW) @ 5600/rpm, 167 ft·lbf (226 N·m) torque @ 4400 rpm. Intake volume is regulated by use of a MAF sensor, unlike the EJ251 which is regulated by a MAP sensor. I-Active valves (VVL intake side) on 06+ models which have ISO 173 hp (129 kW) @ 5600 rpm, 166 ft·lbf (225 N·m) torque @ 4000 rpm. Compression ratio 10.0:1

EJ254

 Non Turbo

2005–present - SOHC with 165 hp (123 kW)

Usage:

EJ255

DOHC 

with sodium-filled valves originally designed for North American market, now sees usage in some European Imprezas and Legacies destined for Australia and South Africa. Power 210-265 hp


EJ255 Version 1: Used in the 2005 and 2006 Legacy, as well as the 2004 and 2005 Forester. This engine uses the AB440 shortblock, which is the same shortblock as the 2004-2006 STI EJ257. The heads on these EJ255 are the AB650s, while the US 04-06 STI is the familiar AB640/910. The cams are the same between the EJ255 Version 1 and the EJ257.

EJ255 Version 2: Used in the 2006-2008 WRX, the 2007+ Legacy, and the 2006+ Forester. This is the newer AIS equipped EJ255, which uses a slightly different AB630 shortblock, as well as the AB820 heads. The only difference in the shortblock of this EJ255 and the 04-06 EJ257 is the pistons. They are of nearly the same construction, but have a slightly larger dish volume. As for the heads, the AB630 heads have a smaller combustion chamber, but I do not yet know the exact specs. I suspect it is around 50ccs based on the engine config spreadsheet listed. Subaru lists the CR at 8.4:1 vs 8.2:1 for the 04-06 STI engine.

Usage in North America:

Usage in the rest of the world:

EJ257

EJ257 engine

DOHC 16-valve turbo. Originally designed for the North American Impreza STI in 2004 with AVCS and DBW. The same shortblock as EJ255 except the EJ255 has a different dished piston vs the EJ257. The heads also have different components. Subaru of America designates the same part numbers for an EJ255 shortblock, and EJ257 shortblock with the exception of the pistons.

Usage:

Other Data

All the EJ series share compatibility and construction similarity and are 16 valved engines. The EJ series started with the EJ15, a 1.5 liter (SOHC) and makes ~90 hp, then the EJ16, a 1.6 litre single overhead cam (SOHC). Later followed by the EJ20, a 120 hp 2.0 litre single overhead cam and the EJ22, a 135 hp 2.2 litre single overhead cam. The EJ20 turbocharged version was developed with dual overhead cams, as well as non-turbo DOHC engines and DOHC twin-turbos. The EJ18 and EJ20 were most popular in Europe.

The SOHC EJ Subaru boxer engines were non-interference engines through 1995, run by a single timing belt driving both cams (both sides of the engine) and the water pump. Because they are non-interference engines, if the timing belt fails, the engine of the models up to 1995 will not be destroyed. The oil pump is driven directly from the crank shaft and the waterpump by the timing belt. All DOHC and 1998-up SOHC EJ engines are interference engines, if the timing belt fails the engine will likely be destroyed or the valves & piston will be heavily damaged.

All Subaru EJ engines have a 1-3-2-4 firing order.

Some of the 2005 and later Subaru vehicle Engines (especially the turbo charged engines) are using CAN bus as their sole Vehicle/Vessel speed input channel. When those ABS Speed signal are removed, the ECU will force the Engine to run in limp home mode. This has posed some challenge for people who try to use the same automotive boxer 2.5L and 3.3L engines on Aerospace application, engine replacement for aged Subaru vehicles, and VW Vanagon modifications, etc.

The following table has details on a few of the commonly modified Subaru engines:

Block EJ205 EJ207 EJ255 EJ257 EJ257
Head Type US WRX SpecC US WRX US STI EU STI
Bore (mm) 92.0 92.0 99.5 99.5 99.5
Crank Stroke (mm) 75 75 79 79 79
Rod Length (mm) 130.43 130.43 130.43 130.43 130.43
Piston Pin Offset (mm) .3289 .3159 .3088 .3088 .3088
Deck Height (mm) 201 201 201 201 201
Gasket Thickness (mm) 0.8 0.8 0.8 0.8 0.8
Head Volume (cc) 51 50 51 57 50
Piston Dish (cc) 12 8 24 22 22
Piston Deck (mm) 0.38 1.48 0.39 0.39 0.39
Total Quench Height (mm) 0.98 2.08 0.99 0.99 0.99
Total Quench Volume (cc) 8.51 13.83 7.70 7.70 7.70
Total Deck Volume 18.51 19.83 29.70 29.70 29.70
Swept Volume (cc) 498.57 498.57 614.25 614.25 614.25
Compresses Volume (cc) 89.51 89.83 85.31 83.00 79.70
Static Compression Ratio 8.17:1 8.14:1 8.2:1 8.4:1 8.71:1
Rod to Stroke Ratio 1.74 1.74 1.65 1.65 1.65
Engine Displacement (cc) 1994 1994 2457 2457 2457

All Spec C are Japanese only 2.0 litre EJ207.

Awards

Subaru 2.5-liter Turbo Boxer Engine won 'best engine' in the 2.0-2.5 litre category in both the 2006 and 2008 International Engine of the Year awards.[5]

Notes

  1. ↑ Büschi, Hans-Ulrich, ed. (5 March 1998). Automobil Revue 1998 (in German and French) 93. Berne, Switzerland: Hallwag AG. p. 509. ISBN 3-444-10516-9.
  2. ↑ Automobil Revue 1998, p. 508
  3. ↑ http://australiancar.reviews/Subaru_EJ20X-EJ20Y_Engines.php
  4. 1 2 http://sl-i.net/FORUM/showthread.php?18616&p=267067&viewfull=1#post267067
  5. ↑ "Previous winners". ukipme.com. Retrieved 2009-06-30.

References

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