I have remove this engine and while inspecting the cylinders I noticed that the top 1/8" +/- of the #4 sleeve looks like it has separated parallel to the block surface and bent outward about a 1/16". It is at the bottom of the hole and is about 30 degrees of the circumference.

 

Has anyone seen this problem? What might have caused it (motor over heated)? Is this repairable by other means than a resleeve? Could it be time for a new short block?

 

Thanks

I have never seen this on a 2.5L. I have seen it on a 2.2L. Yes, you can repair it with a new sleeve on the 2.2L . I would imagine the 2.5L is the same.

The usual next question. Do you know roughly how much to repair?

 

What might happen if I decked the block as it is without a new sleeve?

Ive seen it happen. The engine block is trash. This happens when the engine is cooked. The aluminum expands enough to allow the pistong sleeve to move. There are a few instances of this on the board. There is no way to ensure the sleeve is still located and aligned properly. You could have it machined down, but all the work that is needed to rebuild an engine and find out thats its not right, to take it all apart again...

 

Get a new block.

 

 

nipper

I have never seen this on a 2.5L. I have seen it on a 2.2L. Yes, you can repair it with a new sleeve on the 2.2L . I would imagine the 2.5L is the same.

 

SORRY. WRONG. You can't replace sleeves on Subaru engines they are part of the casting. The last engine that Subaru made that allows you to do this is the 1400, made in the 1970's.

 

Block is worth scrap value now. Get a new one.

SORRY. WRONG. You can't replace sleeves on Subaru engines they are part of the casting. The last engine that Subaru made that allows you to do this is the 1400, made in the 1970's.

 

Block is worth scrap value now. Get a new one.

 

I do beg to differ, Here was my experience. I owned a 1990 Legacy LS wagon from the time they were first introduced in the US ( Aug 89 ). At 14K it developed a bad miss. The local dealer her in NJ determined low compression on Cyl 3. They tore it down and called in the tech's from the region office in Orangeburg NY. The cast iron sleeve receeded by .05". They removed the block, disassembled it and pressed a new sleve in with some tools they brought. They said a certain number of early 2.2's were prone to this. After reassembly, they gave me a 100K warrenty and would replace the engine of it failed again. So I know they were doing this for the early 2.2L. But as I stated, I never heard of it being done on the 2.5L.

I had that for over 180K when it was involved in an accident in 1997 that totaled that car. I've owned Subaru's since 1978 and had one of those 1400's in MY78 2 dr DL FWD. They have been very good to me.