2002 Tracker / Vitara No Start Issue - Engine Swapped but Ran

[Matty_Robz]

Hello all,

I usually never need to post in forums asking for help. Im pretty good at googling stuff but I haven't been able to find this issue in any of the forums yet and hoping someone can throw me a bone or something over here.

[b]Important Info:[/b]
2002 Chevy Tracker 2.0 (J20)
Automatic
Just finished swapping engines. Engine ran rough for short period of time while idling. Next morning would not start.
Has Spark - Tested all 4 by grounding spark plug and cranking.
Has Fuel - Spark Plugs are wet after trying to crank for a while.
Hooked up Scan tool to view live data. Nothing out of ordinary
IAT and ECT are the same after I let the vehicle sit.
RPM will go up when cranking but nothing past 300


[b]Engine History:[/b]

Timing chain decided to snap on me a few weeks ago. Towed it home did a leakdown test and found bent valves. on cyl 2/4 (Checks out with the firing order). Pulled a replacement one at the wreckers with a buddy that was scrapped for rusted out frame. When I got home I took the timing cover off and oil pan off to inspect everything. Engine was clean, chain was timed right, and looked nice. Cleaned up the engine, sanded it down, and painted it all for practice. Sidenote : I'm in the process of starting to build an engine for my 2004 Volvo S60R. The goal is to hit 500 HP next year. So I figured this would be the perfect opportunity to brush up on my painting skills. Changed all the gaskets, RTB'd the pan and timing cover, let it sit for 2 days to make sure it was cured. Replaced all the rubber lines, cleaned the bay, like a full week long cleanup of everything. Working from home has its perks. Last engine was leaking oil like a tanker in the ocean. some smartass broke the timing cover once upon a time and JB welded it back together... Apparently its already gone through and engine before I got it too. So it was a mess and a half.
[b]
After Engine Swap:[/b]

Long story short engine went in and I had grounding issues from the starter bolt because I painted the metal plate that sits between the transmission bellhousing and the engine like a rookie. Pulled the engine, sanded it down in that one spot and threw it back in. Engine started up but was really rough, but healthy if that makes sense. Idled for about 20 minutes and would die here and there but it would start back up. At times I would have to hot foot it / feather the gas pedal while cranking it to get it started but it would run, but rough. My buddy (Who is a master mechanic for 20+ years) thought my ignition timing may be off so he moved the camshaft synchronyser (See Image Below) while the engine was running and found a more ideal spot that made it run better but it was still rough. He played with a few sensors and did a few more tests and said it was either timing or it was dumping fuel from the injectors. We ended the night off with the engine getting up to temp and the car bogging out and dying on us. We both called it a night and figured maybe it went out of time somehow or something is just loose?

FYI- Went I painted the[b] camshaft synchronyser below,[/b] it left a paint mark, so yes I know where the original position is. I wouldnt have let him move it if there wasnt a mark. I left that part out for dramatic effect [img=22x22]data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7[/img]





[b]More Troubleshooting
[/b]
I went to the truck this morning to start it and it wouldnt crank over. Battery was good, checked for spark again, cleared the codes (There was none), checked the live data before and while cranking, everything looked good. I have a second tracker (2001) that I have a plow on. It has an earlier style Intake system that I guess was revised in 2002, but other than that its identical. I borrowed all the sensors from the KNOWN-WORKING Truck (Cam Posititon, IAT, MAP, TPS, MAF, I even changed the EGR with a new gasket) and swapped them in one at a time into the NO-START truck and it still wouldnt start. I put all the sensors from the NO-START truck into the KNOWN-WORKING truck and it started no problem and ran like a charm. Only thing I have yet to do is swap the coil packs and plugs over, but I know I have spark and its not a weak one so I don't think its that.

I've been reading forums all last night and this morning and some extensive google searching brought me to this post.;
"02 Aerio - HELP!!

This video basically sums up where im at with this truck. I've done all these tests hes done up to the part where he hooks up the meter to check the injector pulse and signal from the starter and sees if they sync up. (I understand when the video explains it, but this is just a little bit past my knowledge level to explain it.) I know believe my timing chain (Which I made sure was in time when I pulled the cover off to inspect it- I was going to return the engine and go pull another one if the chain or guides looked abused). I did rotate the engine when reconnecting the torq converter bolts but I've always done that with engine swaps and never had a problem. Also it ran and turned for about 20 mins or so before it turned off. I have gotten it to almost start this morning, but no luck. I tried briefly to crank it this morning (20 secs or so of total cranking over 5 tries) but I didnt want to flood the plugs again. Took them out and their on my bench. Their not bad I just want to make sure all the gas leaves the chamber so I can start fresh again next time I head out.

So I'm at my wits end with this truck. I know to time it I need to fix the ignition timing by grounding a test switch like below, but my truck DOES NOT have this monitor coupler. It is not on the driver side fender, nor it is on the passenger side near or around the fuse box. My other tracker with the plow does have it on the driver side fender.... (I dont really wanna go that route. This engine has already been in and out 3 times. Only 1 time because of my own stupidity, and the other two because we couldnt get all the dowels to allign.)



So without this cap and obviously no access to this magical suzuki scan tool I'm a little stuck when it comes to setting timing. My Buddy (the Master Tech) has a timing gun and everything else, just not a tech1. 



I found one on Ebay thats not too far away from me for a decent price, but its untested and I dont think the cartridge it has covers my car (Cartridge # 3000003 Version 3.2 ) I also have the option of getting a Tech 2 clone off Alibaba for the same price. I know a local shop that recently ordered a different scanner from the same seller and they delivered it in about a months time.

BUTT Before I can convince myself to buy this scan tool, I need to know if theres anything else I can possibly check. I called an old suzuki dealership thats now Mitsubishi and they said it would be about 150-250 to time the engine with their tool. They still have this mythical suzuki scan tool but didnt want to sell it or rent it to me. I'm just not trying to pay a tow bill on top of everything I've already spent. I love this truck but this is my winter beater. I can't spend any more money on this thing haha. It would be 1.5 - 2.0 hrs of labour, not reasonable in my opinion since everything is accessible but okay. For that price I can just spend 250 and buy the knockoff tool or pay a little bit more for an outdated Tech 1.

[b]So hopefully some grand wizzard of Suzuki / J20 engines is here and can shed some light on my situation.[/b]

-Is there somewhere on the harness that this monitor couple comes from that I can tap into. I'm very good at electrical repairs and have made custom harnesses for many cars before. I wouldn't mind even going to the wreckers, getting one one with a monitor couple and splicing it in for future use if ever needed again.

-Is it possible that my timing chain jumped out of time with all the times weve played with the timing (Moving the angle of the CPS)

-Am I fucked and need this scan tool to reset my timing.

-I'm pretty much at this part in the video but I dont have the tools to measure the timing. I could go buy one if I can see myself using it in the future but I dont really work to this extent on vehicles that are not my own. I will do the odd brake job / Axle change, wheel bearing, suspension work, starter, alternator, but nothing too messy or requiring more than 4-5 hours. I can ask some friends if they have these tools, but I dont think so.

Picture from Suzuki FSM of how the ignition triger and CMP Serensor should look.




Tell me someone has the answers I need?