Ej22 EGR Manifold swap, now it won't idle.

[xoSubieLegacyxo]

Alright to sum up what I did: I have a 99 Outback, and swapped in a ej22e out of a 96 Brighton. I had a CEL for the missing EGR, so I swapped manifolds from another ej22e phase 1 with the EGR. After I swapped the engine the car ran perfectly fine, and the only clades were for the EGR. When I swapped the manifolds I only touched the parts involving the manifold.

So here's what's happening....my car will start and climb up to 3,000 RPMS. Then it will misfire like crazy, and then shut off. I've ruled out the IACV, and the battery. Anyone else have an idea what I missed?

[harrymaneuvers]

Check that the throttle position sensor is calibrated accordingly. Also check that your throttle cables arent too tight.

How do you know it is misfiring? Flashing CEL? Solid CEL?

Any codes at all currently?

[decke48]

is the egr line hook up to the head or is the port plugged? sounds like a big vaccum leak

[Garrison]

Did you undo the wires on the coil pack?

[Navi271]

Ok, just thinking about this at work during lunch and have a theory. I remember you posting your EGR cheat on facebook, you think that could be the problem? The EGR just feeds extra air into the manifold. I'm not sure how it determines how much air to reuse, maybe that's stuck open or something? I'm thinking the IACV is working fine as you said, but there is this boost of extra air coming in from the EGR port, the MAF is sending in more fuel to compensate for the air making the rpm's rise. The misfire tho, I'm not sure. With this theory there would be a constant feed of extra air, and idk what a car would do with that.

I guess just try without the EGR cheat, plug the hole for it in the manifold and see if anything changes. At the very least it will rule out the EGR port as being the problem.

Also check injectors. One could be stuck open causing it to dump fuel and make it backfire. I think backfires mean it's running rich.

Good luck man! Hopefully you'll figure it out soon.

[86bratman]

There have been many, many people using the egr reroute in question for years. I led him to the thread on ultimatesubaru.org that had the information in it, it simply supplies the egr system with metered air to trick the ecu into thinking it's still doing its job. The air from the exhaust port or the line he's running it from makes no difference at all.

[Navi271]

Well, never mind about the EGR then!

[xoSubieLegacyxo]

I've ruled out the battery, IACV, and the one ground wire that everyone I talk to thinks I misplaced. I feel as if it is a fuel consumption issue. Either the injectors are stuck wide open, dumping fuel into the chamber, or there is a lack of fuel pressure.

[decke48]

so basicly he followed this thread http://www.ultimatesubaru.org/forum/top ... try1160910 (http://www.ultimatesubaru.org/forum/topic/137829-using-a-non-egr-engine-in-subaru-with-egr-exhaust-gas-recirculation-valve/#entry1160910) . it seems like you could run into a few problems with this. high idle could be caused by a stuck open egr. yes you are letting metered air in, but not calibrated air. since egr are not mend to run of o2, they flow exhaust gases mainly NOx and other gases and offer no/super little effect on a/f ratios . it would seem in theory well in closed loop the ECU is basing A/F mainly of MAF, IAC, TB and 02 inputs of a fix map. If the egr is open when its in closed loop the ECU is going to step back the IAC till its closed, but your still having the high idle and the ECU not going to be able to compensate because its on a fixed map. it will run way rich or lean. the other problem i see is a slight unwant acceleration went the egr opens. idk you might never notice it.

i would check the egr and make sure its not stuck open. or opening with idle

[xoSubieLegacyxo]

Correct I followed that DIY.

[86bratman]

Did you take the wiring harness off the manifold? Possibility of injector plugs being mixed up, bad ground, bad tps. Might be worthwhile to swap the throttle body off the 25d or the ej22's original manifold if you haven't tried it already. Stuck open egr valve also, could swap the one from the 25d.

You could also test the theory of the egr valve by getting an m16 oil plug from advance and plugging the hole where the pipe goes in the manifold.

[xoSubieLegacyxo]

Did you take the wiring harness off the manifold? Possibility of injector plugs being mixed up, bad ground, bad tps. Might be worthwhile to swap the throttle body off the 25d or the ej22's original manifold if you haven't tried it already. Stuck open egr valve also, could swap the one from the 25d.

You could also test the theory of the egr valve by getting an m16 oil plug from advance and plugging the hole where the pipe goes in the manifold.

I did take the harness off the manifold. I didn't think about the injector plugs. I'll swap them around and see what happens.

Nick Conrad came down for the day, and we swapped over the Cam and Crank position sensor from the ej25d spare block. Still is acting up.

[xoSubieLegacyxo]

Tried swapping the injector connectors and it is still backfiring. I don't know what else to check. :smt021

[chuckthefuk]

check the fuel lines to and from the fuel rails. you could have the return clogged from the replacement manifold. Also check the fuel pressure regulator on the manifold (fuel rails) possible its acting up.

[xoSubieLegacyxo]

http://www.sl-i.net/FORUM/viewtopic.php?f=11&t=26729

I was glancing through the forums I found this thread, and this person almost has the exact dilemma I had.

[98legwag]

Did you try that yet? Or is the snow putting things on hold right now?

[xoSubieLegacyxo]

Did you try that yet? Or is the snow putting things on hold right now?

Battery is dead, and it's on the charger. I'm going to put the intake back to stock, and see if it will start.