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No start after timing chain replacement


TDI Ranger

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I need some help. Back in July I purchased a 2011 Ranger Sport with the 4.0 SOHC, The truck had a blown head gasket. I briefly heard the truck run it started up but ran with a miss. There were codes for cylinder misfire on #5+6.

I pulled the engine and sent the heads to a machine shop to be reworked. I purchased the OTC tool kit and valve spring compressor to set the chain timing. The engine was reassembled using the 2003 Ford service manual I have.

After the engine was put back in the truck it would not start, no codes, no PATS issues. I preformed a preliminary diagnosis and found there was no spark. There is a fuel injector pulse with a noid light but no spark. Referencing the 2003 service manual, for the diagnosis the CKP, PCM, and coil are the major components in the ignition system. The CKP is good, wiring good, coil is good, and proper voltage and grounds are good. I came to the conclusion the PCM had lost it's ability to close the ground on the coil. I replaced the PCM replaced with a used one and had it reflashed and PATS unlocked. No spark... I had 2 other really good technicians I know go over the truck. They came to the same conclusion. Bad PCM.

I gave up and took it to a Ford dealer with 3 master techs and informed them of everything that was done and told them to fix it. They diagnosed it with a bad PCM. I told them I wasn't convinced that was the problem but told them to go ahead. After several weeks I found out new PCMs are on back order until next year. I bought a remanufactured PCM from O'Reilly and they installed it. No Start....

I am being told the engine is out of time and it will be 23 hours labor to fix it. I am not beyond a mistake. I'm not perfect, but it was set per the 2003 manual with OTC tools.

Here is my question. Has something changed on the 2011 where the CMP is being used to control the ignition? On a lot of engines the CKP is the primary timing source and the CMP is a reference. The engine will run like crap with a failed CMP, but it will run. It will not run with a CKP failure. Using only the CKP, If the cams were out of time and somehow I didn't bend valves, wouldn't this be the same? If it was out of time it should still spark right? Just at the wrong time?

Help. I'm going to pick up the truck from the Ford dealer Monday. The first thing I'm going to check is the cam timing again. I'm really not expecting anything to be wrong, but.... I'm really at a loss. Does anyone have any information on the 2011 ignition system?

Thanks for the help
 
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Rock Auto 5% Discount Code: F9A1A579ACFAD1: October 1st, 2021

Madman54

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No spark. So I am assuming that the engine does crank, and does not fire because there is no spark?
always check you battery. Although no tlikely to be the cause of this problem, it could be, and it could save you hours of frustration chasing a problem.

assuming the battery is good and fully charged.,...
start at the problem and work backwards.
not spark at the wire? how bout the ignition coil?
what about the circuit for the ignition coil?
many times the reference woltage and/or ground are shared between mukltiple sensors. a short to ground or power can cause these issues.

beyond that you would want to check the Crank sensor, which can be done (kind of) without an oscilloscope. then the Cam sensors.

its not usually very likely, especially in something that is that new that the PCM fails. It does happen, but not often.
Its even far less likely that you have a second pcm that has failed.
 

Uncle Gump

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Even if the engine was out of time... it should still spark.

I would pull a plug on each bank and run a compression test on them. That alone will tell you if the engine is timed correctly.

If you heard it run prior to pulling it... and after install it doesn't spark. I would think it would be something you fooled with at some point. After replacing the PCM a couple times and properly configuring the PATS system?? It's probably safe to say the PCM isn't your problem. You're left with a couple components... wires and connectors.
 

TDI Ranger

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I left some details out of the first post. Most likely I did something, or it could be bad luck. I just have to find it.

The battery is good. The engine cranks over really good and the voltage while cranking is acceptable. The PCM has roughly 10.8 v while cranking.

The CKP is putting out a signal. I am getting about 1+/- volt AC while cranking. A friend read the meter while I turned the key so I don't remember exactly. The wiring is ok from the CKP to PCM. I checked continuity and for shorts at both ends of the harness. There is a tach signal and the injectors pulse normally while cranking. I did not have a oscilloscope at the time. I have one now. I can test it when I get the truck back. I don't feel like this is the problem.

The coil has 12v power and I have continuity between the 3 signal wires to the PCM. No shorts between these 3 and any wires in the harness. I have a good ground between the coil pack bolts and the engine block and the battery The PCM is just not closing the ground at each section of the coil. New spark plugs and wires were on the engine.

After testing all of this is when I put the parts shot gun after it. I have known good parts from my other ranger which was running when the engine was pulled.

One at a time I replaced the coil, CKP, and even the CMP. No start.
This is when replaced the PCM. No start. At this point I was really frustrated. I had 2 other techs start over and look at the truck. They had no luck.

At that point that is when I took it to the Ford dealer. I searched out a dealer with a master tech, because I didn't believe a regular tech would find the problem. I explained the whole situation to them. I told them I didn't think it was the PCM but something else. A few weeks later I find out they diagnosed it as a bad PCM. I told them to go ahead. After the 2nd one was installed, no start. I was told the engine is out of time and it will be 23 hours labor to fix it. I am picking up the truck Monday and bringing it home.

So here is the big question. Does the cam position sensor affect spark on a 2011 4.0? According the the 2003 manual it does not.

Thanks for the help
 


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