97 2.5 GT with '96 2.2 - running issues after swap

[98OBW]

So I just did this swap over the weekend. Yeah, it's not a real 2.5 GT anymore, it's now a 2.2 GT! :lol:

The 2.5 had rod knock due to the PO running it without oil. I had a 2.2 from a '96 Outback so I swapped that in. Now the Outback was a 5-speed and the 2.5 GT is an auto, it's an EGR-less engine in a car that wants to see an EGR so it's throwing a code. I'm going to swap the computer from the Outback into the 2.5 GT and see if that causes any issues with the trans (I haven't been able to find any info saying that it'll cause problems).

My problem is the car has a large hesitation when giving it throttle from idle. After a bit of tinkering, I found that the hesitation is non-existent above 1,500 RPM, but anything underneath and it hesitates. It idles smooth and runs good, but hesitates when given throttle under 1.5k RPM. There is also this strange squeal coming from the inside rear of the engine, sounds like it's coming from the torque converter area - but I have no idea what it could be. I thought it might have been the starter teeth hitting the teeth on the torque converter. I put some washers to space the starter back further but that didn't seem to change the sound at all.

Here's a video highlighting both problems. Anyone have any thoughts?

https://www.dropbox.com/s/bjshn56w8cm5y ... .42.44.mov (https://www.dropbox.com/s/bjshn56w8cm5ywt/2013-02-17%2022.42.44.mov)

[r3v_v3ng3]

I might be from the egr code. Is there a way you can install the egr sensor(s) and block off the vaccumm line to see if its any better?

[98OBW]

No, installing the EGR system would mean I'd have to change the heads and intake manifold, or attempt to tap everything myself. EGR shouldn't cause any running issues, deletes are very common.

[r3v_v3ng3]

I meant just the egr sensor(s) not the entire egr assembly. Just to somewhat fool the ecu. I read on other forums that they connect the sensor but blocked off the vaccumm lines. I don't know if it works but worth a try. I think egr works on low rpm on which you are having problem on.

[98OBW]

There's no provisions to hook up the sensors, no plugs in the harness or lines to connect the switch to. That's what I wanted to do, but the provisions aren't there unless I hack the plug into the harness.

[r3v_v3ng3]

Oh.... So basically your using the 2.2 engine harness then. I thought you reused the 2.5 engine harness to the 2.2 motor/longblock.

[98OBW]

No, the 2.2 was plug-and-play (minus the lack of EGR since it came from a 5-speed)

[98OBW]

Well, looks like the squeaking had something to do with the transmission! I was moving the car in the yard, when it just died and wouldn't crank back over, just click. After two days of screwing with it I got it started, but after idling for a few seconds it would squeak and stall, then just click. After a few tries it would start up again, to just squeak and stall. Tried to move it so I could plow, and putting it in any gear does absolutely nothing.

Wonderful.

[r3v_v3ng3]

The torque converter might of got messed up during the swap. I think this is what happened when I helped my friend rebuild his motor and when we try to return it back, we had trouble with the converter ligning up. It's a little tricky on the automatic. Next time I mess with an automatic subie (engine swap or trans swap) , I'll pull out the engine/trans together so I won't have any issue.