Intrepid 2.7 no start after engine swap - DodgeIntrepid.Net Forums - Dodge Intrepid, Concorde, 300m and Eagle Vision chat
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post #1 of 2 (permalink) Old 10-27-2011, 11:14 AM Thread Starter
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Location: Linden, MI
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Intrepid 2.7 no start after engine swap

I just put a 2.7 engine from a 2002 intrepid into a 2004 intrepid. I drove both cars into the shop. Both have the NGC control systems (The connectors to the PCM do have different color coding). It has the black key so we should be able to rule out skim issues.

It is not setting any codes, Even with the sensors disconnected and there is no RPM showing up on the scanner when cranking.

When I first checked it, I could get it to fire with the cam sensor unplugged but now it won't even do that.

I tried swapping the cam gear/tone wheel but that did not help. Based on advice from others, I pulled the engine again and swapped the flywheel to the 2004 flywheel. (The two flywheels look identical). I double checked the chain timing and swapped both the cam & crank sensors. I even tried the 2002 PCM but it still won't fire.

I now have all of the 2004 parts on the car. I have checked all grounds, verified power to the coils and injectors and continuity to the PCM but am not getting a pulse from the PCM to the injectors or coils.

Yesterday I broke down and took it to the dealer but they couldn't figure it out either.
They said that they can establish communication with the PCM and read the VIN# but nothing else.

The car does have an aftermarket remote starter/alarm/keyless entry but when I called the company, they told me that the only system it interrupts is the starter and since it will crank, it shouldn't be an issue. All functions are working will lock/unlock, sound the horn and crank remotely.

Any help would be greatly appreciated,
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post #2 of 2 (permalink) Old 10-28-2011, 11:56 PM Thread Starter
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I finally got it running - I got me a good Mitchell wiring diagram and proceeded to trace the sensor wires. I started with the crank sensor; I verified a 5v power and a good ground. Next I checked the reference wire to the PCM. No continuity. I thought I had it nailed so I pulled the upper plenum to gain access to the harness.
I checked two locations between the PCM and the sensor connector and all checked OK. I then checked between the connector & PCM again and it checked good??? I found that I would have continuity between the PCM and the crank sensor with the key off but I did not have it with the key on???
So I decided to see if I had a crank signal on my. I hit the key and the engine fired. I know that I didnít fix anything so I figured that it must have been a loose connection. I proceeded to put it all back together and then I cranked it again but it would not start. Then I got to thinking that the last time I got it to fire (Before I pulled the engine again) I had the plenum off.
So I thought about what I had disconnected when the plenum was off and started disconnecting them one at a time then cranking. When I disconnected the IAC the car started. It wouldnít stay running but it started. So I swapped the IAC with the original motor and she fired up and ran good. It must have a dead short in it.
I donít know why the IAC would cause a problem with the crank sensor but it did. They must share something in common. I certainly would not have looked to the IAC for a no spark/no fuel issue. I guess sometimes it pays to be lucky.
I thought I would share this story just in case someone else runs into this same issue.
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