After 272k miles, pulled the EJ25D out of the 98 Legacy. For the next few months, the parts car EJ22 is going in until I get the EJ20G ready(when the EJ22 then moves to the Brat).

 

 

 

Unfortunately, it looks like I will need to do a little more repair on the EJ22:

Hard to tell by the picture but has the slot widened or is the woodruf key just partly sheared?  If its just sheared, then its an easy fix.

Get the key welded in by a quality welder. 

You'll be fine.

Don't need it welded, just line it up exactly the way it is there. People run them all the time like that. Make sure the crank pulley isn't chewed up, and make sure the face of the sprocket is flat. I had one that the edge of the timing sprocket was rounded over and the pulley wouldn't sit flat against it. 

 

When the crank pulley gets loose it only eats away in one direction. The other edge of the key slot is still fine. Use some blue lock-tite in the key slot to hold it in place while you torque the bolt. 

Torque the crank bolt to 140 ft lbs. 

I wouldn't weld it either.  You can fill the hogged out keyway with a hard epoxy, but once that is use, the next time will require a new crankshaft.  This situation is usually caused by a loose crank bolt, so make sure to torque that sucker down to specs.

Yeah. We've been running one for 2 years with the crank bolt tightened down extra tight.

 

There's also a kit out there that drills and bolts the crank pulley to the crank sprocket and fixes the issue. Never a need to replace the cam shaft.

 

Hard to tell by the picture but has the slot widened or is the woodruf key just partly sheared? If its just sheared, then its an easy fix.

It is widened. I did torque the bolt down to 120 today. Going to check it again tomorrow, tighten it down a tad more. Some previous owner did very half rump roast fixes on this car. And the crank pulley is slightly chewed on. I can put the 2.5 pulley on instead, now that the 2.5 is out and done.

Edited January 16, 201610 yr by Speedwagon

• yes a 2,5 hb will work fine.

You can weld up the shaft, not the key, then file the hole correct