I blew my 03 Outback engine at 152,000 miles. A Subaru specialist re-built the engine and the car runs great but won't re-start when warm after driving. My mechanic, who only re-builds Subarus, is stumped. He also had it checked out by another Subaru shop that couldn't figure out the problem. We are looking for help and ideas, p l e a s e !

Here's what has been done:

 

rebuilt engine- used 03 cylinder heads
with egr tubs, center block is the same

oil pump- no change

crank, cog, sprocket, changed 3 crank
sensors- cam sensors replaced

intake wiring harness replaced

upstream O2 replaced

fuel pressure regulator replaced

new fuel pump

replaced computer

replaced coil pack

replaced intake manifold assembly

new air temperature sensor w/new
coolant temperature sensor and coolant sensor

new plugs and plug wires

all grounds established plus new ground added

all electrical components checked

all timing marks checked

new factory plugs

new idler, tensioner, water pump,
bearings, seals etc.

new clutch etc.

 

Here's where we are now:

The car starts right up when cold-normal idle. It doesn't start after driving. Re-starts after it cools down.  They tested the idle control solenoid and the intake manifold has been replaced.  The Check Engine codes we are getting are the following and do not seem to be related to any driving conditions:

misfire bank 1

crank sensor

The check engine flashes after ½ hour
30+ times down to 3 times, but not in any sequence. Then it clears.
This doesn't give us any useful info.

 

Any thoughts or ideas? The car wouldn't start right after we got it back so we had the mechanic pick it up to fix it. He has the car and has tested or replaced everything he can think of, and the car still does not restart when warm.  Thanks for any suggestions you may have.

Sounds like broken or pinched wiring to the crank sensor. Very easy to do if not very careful about routing the wires correctly when bolting the intake manifold back on.

Possibly a poor connection in the large junction of the harness plugs on the bellhousing.

 

Flashing CEL indicates a current misfire. If its limited to one cylinder I would swap plug wire to another cylinder and see if the code moves. Try the injector next, then look into possible compression issues.

sure seems like an intermittent CA sensor.

 

secondary possibility; when you feel it won't start, you could  try the 'clear flood' maneuver. Crank with the gas pedal on the floor. If an injector is leaking and flooding a cylinder, that should clear the fuel out.

check the main engine conectors were the crank senser terminals plug in have seen them push out the back side and not conect well and check were the crank senser plugs in also check the countinuity on the wire harness from senser to ecu. Sounds like crank senser for shure.

Thanks for all your responses.  Our mechanic has checked and replaced almost all the sensors in his search for the problem.  We reviewed the comments above and he had done all the things suggested, often several times.  He is most puzzled by the flashing of the cel and the intermittent flashing that doesn't yield any codes.  Any ideas about this?  Thanks.

Has the timing belt covers been taken back off and the cam timing checked? Sounds like its possible the passenger side cam is off a tooth. Also, have any of the valve guides moved?