2000 Intrepid 2.7 "almost starts" but doesn't
 

120k miles, 2.7 engine

New parts: camshaft and crankshaft position sensors, EGR valve, spark plugs, PCV valve.

Story: It threw a 0404 code and every once in a while would sputter, then surge, then work fine for a day or two. Then one day it stalled in traffic. After it cooled, it started fine, then would run roughly as it warmed up. I replaced the EGR valve. Car still ran rough when warm. Died on the way to mechanic. Mechanic said the Crankshaft position sensor, PCV valve and plugs would need to be replaced. Still hasn't run at all. Replaced Camshaft position sensor. Still nothing. Tested MAP sensor, and it shows the proper voltage.

I can hear the fuel pump whir for a second when I turn on the ignition, so I know that system is ok. I can smell gas, like the car is flooded after attempting to start it. I know there is spark. I get 150 psi in each of the cylinders on a compression test, so I know the cams and timing chains are doing their tricks correctly. It still sputters on ether, so I'm guessing it isn't a fuel problem.

Does this sound like a MAP sensor problem even though it shows 4.75 volts at the terminals that the book shows? I don't want to gamble $91 +tax on a part that may not be causing the problem. I did unplug it to see if that would make any difference, and it didn't. It didn't go into "limp mode" like I've seen mentioned in this forum. I have checked and double-checked vacuum lines, electrical connectors, fuses, relays..... The fuel pump is only about 2-3 years old.

Running out of ideas here.....

Update
 

I have tested the intake air temperature sensor, the antifreeze temp sensor, the throttle position sensor, the map sensor, basically, every sensor on the engine. It sounds like the timing is off just a little bit and that's why it's not firing 'just right'. Ether does make it run, sort of, but it's not smooth. I have checked and re-checked every connection and vacuum line. I'm getting frustrated!

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Does it make any difference if you hold the throttle somewhat open? I would definitely check Fuel pressure.
Are you working on the car or the mechanic?

a friend of mine at another shop had a intrepid with the same problems. he finally tracked it down to a broken flywheel. the center was broken and spun slighty throwing the crank sensor out of sync. with the scanner it showed cam and crank signal. the car would almost start like it was flooded. hope that helps. he had told me he pulled the starter and could see the cracks in the flywheel

Thanks for the replies, everyone! I'm working on the car myself.

@ TNtech: As I crank the engine, the tach does read, so the crank position sensor is working. I don't know if my scan tool can give me that detailed a report on sensors or not. I'll have to look into that. I assume that sync is where the crank and cams are in proper time with each other?

@Steak59: it does seem better when the throttle is halfway open. Still doesn't start, though. I'm going to replace the idle air control motor and see if that helps.

@Fargo39: That's a scary story! At that point, I'd probably scrap the car. Although, with a transverse-mounted engine, it would be more difficult than on an inline engine like the Intrepid. I don't know. Still sounds like a lot of work for a car that's really starting to show its age.

Thanks again!

Dont think it would be the IAC, if that's the problem, Car should start with throttle half way open.
Maybe it is flooded, hold the Gas all the way to the floor and crank it, see if it clears the flood.
Also, try spray starting fluid or brake clean into the intake duct and crank. see if it is a fuel problem.

I have tried ether. It doesn't run as smoothly on it as I think it should. I have used that in other cars and they sound like they're running. This one sputters. Still sounds like an ignition timing issue. It's not loping or hesitating, so the timing wouldn't be too far advanced. It almost sounds like it's too late. Could be the cracked flywheel fargo39 mentioned. More investigation this weekend. I have the spark plugs soaking in carb cleaner to un-foul them. I'll put it all together and see what happens. It may be a fuel pressure problem or clogged injectors. I filled the tank at a station I've never been to before. Even though it's a good brand station, it's in an old section of town. Could have filled up with bad gas.

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Is it always visible through the starter hole? Do I need to use an inspection mirror?