I am swapping out a 2.5 engine from my 2005 Legacy Outback. I bought a used engine from a 2005 Legacy. I noticed the intake manifolds were different, the old engine has a slanted intake (connection to filter) but the new engine has a more horizontal input. No big deal, I hoped. The other big difference is that there are no O2 sensors, nor a place on the wiring harness for them on the 'new' engine. 

It seems likely that I should take the intake manifold and wiring harness off the old engine and put it on the 'new' engine because my car will expect the O2 sensors. Do I have any choice in this matter.

Also, why would there be a difference? Different emission standards? 

Thanks.

Yes, swap the manifolds. Use your old one on the new engine.

Typically the manifold and wire harness stay with the car on any engine swap.

Thanks, I just finished swapping the manifold. I have a new problem. I'll put it here since it is still about the swap. 

My new exhaust ports do not match my exhaust. The engine I dual ports, the existing exhaust system is single port.  

Although I hate to assume, I'm sure the correct answer is to get an new dual port exhaust system. Any chance there is a cheaper yet valid solution?

 

Replacement engine ports on the left, existing exhaust system on the  right.

Edited August 9, 201510 yr by Daz999

You just need the Y pipe from the new engine or, if the heads are usable, you can swap the heads from your old engine to the new one.

 

You never did say why you were swapping though.

Thank you, I 

Oh, I just got the 2005, my son drove it 5k miles, it was low on oil, no indicator light, developed rod knock. Bang Bang Bang. I don't know if it is my fault, the PO's fault, my son's fault, or just a bad day. The seller gave me $800 back because he felt sorry for me and I suspect he knew there was a problem. Very nice of him. Engine had 175,000 miles on it. The engine we're putting in has 105k on it. Yes, I replaced the timing belt, water pump, and idlers before putting it in. And I had trouble when the TC came out with the engine, but luckily The Internet knew how to get the oil pump shaft out and clip it to the TC. Thanks, Internet!

I'll get the y-pipe and hopefully be on my way.

 

But one last question, perhaps they are in the FAQ.

Do I need to get Automatic Transmission Fluid from the dealer? The owner's manual says I need Subaru fluid. Also, was that a ATF filter I saw behind the battery?

Edited August 9, 201510 yr by Daz999

Thank you, I 

Oh, I just got the 2005, my son drove it 5k miles, it was low on oil, no indicator light, developed rod knock. Bang Bang Bang. I don't know if it is my fault, the PO's fault, my son's fault, or just a bad day. Engine had 175,000 miles on it. The engine we're putting in has 105k on it. Yes, I replaced the timing belt, water pump, and idlers before putting it in. And I had trouble when the TC came out with the engine, but luckily The Internet knew how to get the oil pump shaft out and clip it to the TC. Thanks, Internet!

I'll get the y-pipe and hopefully be on my way.

 

But one last question, perhaps they are in the FAQ.

Do I need to get Automatic Transmission Fluid from the dealer? The owner's manual says I need Subaru fluid. Also, was that a ATF filter I saw behind the battery?

 

Ok, I don't believe the ATF filter would be behind the battery (but I could be wrong).  The ATF filter is located on the side of the transmission.

 

I'm guessing this is an automatic and being an '05 Automatic should be a 4EAT.  If that is the case this was still the Dex III area.  I know some people have used Valvoline Maxlife with success.  

 

If this is an Outback XT things change because it may have the 5 speed automatic and that's a different beast.

It's an Automatic. Thanks. There is definitely an oil filter like thing behind the battery, I thought it was hooked to the lines that go to the trans fluid cooler portion of the radiator.

I didn't investigate thoroughly though.

 

Last question. I hope.

Are those water lines connecting to the intake? Are we regulating air temps with water? Or am I putting a hose in the wrong spot? I'm still looking for a good diagram, or a good pic of my disassembly process.

 

Thanks for the help and information.

Behind the battery is the fuel filter.

http://www.ultimatesubaru.org/forum/topic/152944-factory-service-manuals/

 

Download your Factory Service Manual, that will help a lot.

 

And water lines run through the intake to assist in idle control and other things.  They aren't there for regulating air temps.

Do I need to get Automatic Transmission Fluid from the dealer? The owner's manual says I need Subaru fluid. Also, was that a ATF filter I saw behind the battery?

Yes, there is an ATF filter in the fender behind the battery.

 

I don't remember the fluid spec for the 05, but it should say in the owners manual. You don't have to use Subaru fluid, just use a fluid that matches the spec.

 

Coolant hoses run to the manifold to keep the throttle plate from freezing to the bore in wet weather below freezing.

Edited August 10, 201510 yr by Fairtax4me

Good News! The replacement engine is in and running. I did temporarily connect the single port exhaust to the dual port heads without detectible leaks. I am ordering a new y pipe and will install with new gaskets when it arrives. The only thing I had forgotten to connect was the single wire slip-on connector to the starter. I found it when the engine would only click-click-click like the battery was dead. I did charge the battery, then found the forgotten connector. 

I've checked all my fluid levels and had the AC recharged. Thank you for all your help. The only other thing left to do is attach the lower engine shield. It was held on with only the back bolt and two upper plastic 'clips' when I took it off. The plastic clips are worthless now so I'll need to get more, or zip tie the thing up. 

At any rate.... 

Thanks for all the help, without the forum I'd never have even gotten the TC back in right.

 

Darren