I'm new to this forum, but have found great info. I own a 97 Legacy 2.5 GT. 150K miles on it. Its been giving me a CEL for a blocked EGR flow. I replaced the EGR with one off an Outback with a 2.5 out of the salvage yard. Didn't fix it. So I thought then it might be the EGR solenoid. Still nothing. I was told that sometimes it can build up so much carbon that it could completely block one of the intake ports. So this weekend I purchased a couple new intake gaskets and pulled the intake manifold, still nothing. In the process I pulled the EGR pipe (pain in the a#$). I stuck a small screw driver into the bottom EGR pipe hole on the block. I could tell it was blocked. I turned it until it went through with no interference. So after all said and done I put it all back to together and went to fire it, and of course nothing. It just turned over and over. After this I pulled the fuel line back off and and there wasn't any fuel in the line. Also when I shut the ignition off some of the dash lights stayed on and were flashing. I double checked all my electrical connections and didn't find anything out of the norm. I tried turning it over one more time and nothing at all this time. I heard the starter hit, but nothing else, and no dash lights. I know this is long, sorry about the that, but I could use some serious help!

 

Thanks, Tyler

Edited May 2, 201015 yr by shredbet

First off, paragraphs, they are your friend

 

Secondly, Its my understanding that you are now dealing with a no start issue?

 

Check every connection that you unplugged, and then check all the ones you didn't unplug, start maybe with the battery connectors, if they are loose at all you'll get the issue you are describing. I once had a Taurus that wouldn't start because of a bad connection (wasn't mine, don't flame please )

 

Check for battery voltage, should be at least 12.8, anything more than around 12.2 and you should at least get a weak crank-over.

 

Under the intake is a crank position sensor, if that is not plugged in (plug is near the dog bone between the engine and the tranny) your car won't start, but it'll crank all day long.

Checked all battery connections, and they were good. I didn't check voltage yet, but I will here in a minute. As for the Crank Position sensor I'm not to sure of. I pull the air box off in front of the intake manifold and double check all elec. connections there. Thanks again for the input.

not completely sure if this could cause the problem but u said the massive carbon build was on he intake...maybe it got some where it shouldnt be? again not 100% sure on this just giveing ideas

Charge the battery. There is not much in the vicinity of the EGR valve that will prevent the car from starting unless you disconnected one of the large vacuum lines on the intake box, or the vacuum line for the brake booster. You should also make sure that the EGR valve is not jammed open by the chunks carbon crud that you picked loose with the screwdriver.

Thank for all the input. I'm an idiot. There is an engine ground on the intake manifold that I didn't tighten down. I put the bolt in it and forgot about. Thats why it was turning over at first, yet not quite enough juice to run the fuel pump or anything else. Once I tightened that down it was go time! Thanks for all the help guys.

 

Tyler