Oil and Coolant Loss! Subaru Legacy Outback 2.5 AWD EJ25

After MONTHS of obstacles this EJ25 Subaru Engine is finally ready to go back in the 1999 Legacy Outback AWD. It came in with a coolant leak and oil leak in part 1, we found a leaking water pump. During service we found a seized water pump bolt which broke off during removal. After spending hours attempting a failed extraction in part 2, I gave up and ordered a salvage engine to replace it with. The engine was lost in Virginia during the Yellow Freight trucking company shut down, never to be seen again. Unable to locate a suitable replacement, attempts were restarted to extract the damaged bolt AND stud extractors that broke off in the bolt. In part 3, with the engine on the bench, we were finally able to remove the bolt, but the engine was damaged at the bolt hole and the threads were lost during extraction. During part 4 the block was drilled out and a thread insert called a time-sert was installed. Victory was short lived because immediately after, during the timing belt assembly, the belt tensioner bolt stripped out and pulled the threads. Another time-sert was installed and the engine is finally ready to be installed.

Part 2 Drove IN Pushed Out! Damaged during Repair! Subaru Outback Legacy 2.2 2.5 @I_Do_Cars    • Drove IN Pushed Out! Damaged during R...  

Part 3 Extracting the broken bolt! Welding Explosion! Intense Bolt Extraction! Will it FAIL? Subaru Outback 2.2 2.5    • Welding Explosion! Intense Bolt Extra...  

Part 4 Damaged Block Threads! Subaru Outback Legacy 2.2 2.5 Hurricane Idalia    • Damaged Engine Block Threads! Subaru ...  

Part 5 Engine Damage AGAIN! Subaru Legacy Outback 2.2 2.5 EJ25    • Engine Damage AGAIN! Subaru Legacy Ou...  

SHORT Welding Explosion! Intense Bolt Extraction! Will it FAIL? Subaru Outback 2.2 2.5    • Welding Explosion! Intense Bolt Extra...  

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