HELP! Engine swap-won't start. Out of ideas...

[shihtzupug]

My 98 Outback had over 200k and had a bad head gasket. It overheated, and when it cooled down, it wouldn't restart ( would crank but not start ) Rather than rebuilding, we opted to buy a low mileage engine ( same 2.5 ltr ) and installed it with no problem. Went to start it and had the same problem - would crank but not start. We've checked fuel ( injectors spray fuel thru fine ) , checked for spark ( yep, its there ) and replaced the ignition sensor and the computer. Same problem, will crank but not start. Sometimes when cranking it sounds like it could be off-time, but checked the timing belt, checked the crank and cam sensors and the timing marks are right on. We've run out of ideas of what to try next. Anyone come across something like this before ? It seems odd that the new engine would do the same thing as the old one did !

[idosubaru]

Idle controller. On older models you can just clean out the idle controller because it gets gummed up and won't allow air through which the engine needs to start since the throttle is closed. Haven't had this issue on EJ's so not sure if the set up is similar or not?

 

Intake isn't blocked is it - mouse nest or something?

 

A disconnected vacuum hose (like the brake booster) is an easy no-start engine swap issue. But the fact that it did it before and is doing it now makes me think it's something else.

 

What all is new - is the intake manifold from your original engine or the "new" one? The problem will be with whatever is left over from your old engine so if the intake came with the new motor that pretty much rules out all sorts of stuff.

 

You definitely have fuel?

 

Are you positive you have good spark at all 4 cylinders?

I'd suspect the coil pack or ignitor is cracked up.

 

Is the motor turning over enough to start - try cranking it with jumper cables?

[bheinen74]

did you check all connectors twice checked, ie maf sensor.

[wtdash]

+1 on the connector check.

 

Did you check for CEL codes before/after the swap?

 

GL,

TD

[davebugs]

Check for spark?

 

You're still running the same ignitor.

[SPHepburn]

I had a similar problem. I had spark, I had fuel, and it would almost fire. If you still have your original engine, compare the crankshaft sprocket from it with the sprocket on the replacement engine. You may find that the timing tabs on it are different. This is also true for the left camshaft sprocket (you have to remove this one to see the difference). When I replaced both the crankshaft and camshaft sprokets from the original engine on the replacement engine, the problem was solved.