Installing EGR on a NON-EGR engine EJ251 EJ253

6,015

Asked by Jun 24, 2016 at 10:00 AM about the 2004 Subaru Forester XS

Question type: Maintenance & Repair

So, I bought this EJ253 from an 01 OB and it's non-EGR but it has the hole in the
casting. Both my 03 and 04 weep oil or coolant from one/both HG's and so I'm to
the point of doing the work myself. This EJ253 has already been decked, new
head bolts, and properly tq'd by a mechanic acquainted with Sub's. So I have
ordered parts and hoses and each engine will cost $508 which is a lot better than
1500-2000+. My 04 is blessed with this EGR system, my 03 isn't. I'm leaning
towards doing the 04 first. IMO, this EGR systems doesn't make sense / aka --
seems kind of shady / sly of Sub to do this half-4ss. It's only pulling air from one
cylinder (#4) or one side (#2).. I'm not sure yet, which. I found two threads on
forums.. ((1)) one bypasses by keeping air flow via the intake piping (with pics).
The other ((2)) drills a hole and taps and installs the EGR (with pics). ((2)) talks
about hitting the water jacket if you drill the big hole too far (ha - that's reassuring)
but I'm thinking we can count the threads and take a bottom reading and know
exactly how far to drill and that it won't be that big of a deal. Only recently did I find
out there was an EGR/NON-EGR issue when swapping engines for the foresters.
This has apparently been a major issue for impreza folks of the 90s. Here's link
((1)) :::::::: http://www.ultimatesubaru.org/forum/topic/137829-using-a-non-egr-
engine-in-subaru-with-egr-exhaust-gas-recirculation-valve/ :::::::::::::::::: and LINK
((2)) http://legacygt.com/forums/showthread.php/diy-egr-port-jdm-ej25-dohc-95-
98-151598.html :::::::: anyone have any experience with this? Input? Ern?

3 Answers

11,385

Finally, someones THINKING and doing some engineering for Subaru. Sketchy, Fuji heavy Industries (OLD NAME) In the U.S. we have to run the silly EGR systems hello, EPA. Regards

6,015

I don't think they're silly, if they function correctly. I just don't get why they didn't retrofit a bung to the exhaust in front of the cat and run the EGR from there like a normal EGR setup (at least, I think that's typical). And I'm not the first here! That's for sure. There's TONS of info on this but I only posted the two most relevant to my scenario. People have tried all sorts of things to trick the ECU. Since I just don't see that being a possibility, I have what seems like two solid options above.

11,385

I say no need to trick the ECU? It can be made (any of them) to perform any way you desire, what do you need the ECU to do and or be changed to NOT do? so basic in terms of the (skill set) needed electronics and serial protocols to alter these ECUs. I say silly EGR, in that concept of diluting the intake charge with hot inert gas, to lessen combustion by products by volume! really? ODD.. instead of improving thermodynamic efficiency (flow physics) etc. LAZY company's along with being cheap don't like investing in, Hard view.. real cost of fresh design I'm sure you understand TRUE engine performance has NOT, changed much in 50 years Example Mean Piston Speed. Its there ( the for those who desire to learn lots of research work and results) Oh, I digress.

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