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Old 02-11-2010, 06:07 PM
MKC MKC is offline
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Default New Here, Engine Swap Issues

Hi everyone, this is my first time here on your site which looks like a great place for everything Ranger. I know this isn't exactly the place to introduce myself but I have issues with an engine swap that I am in the middle of. I have a 2001 Ranger with a 3.0 automatic. The engine was damaged and I had a 2004 3.0 with the same tranny to swap it out with. I replaced/swapped everything;

Full Intake With Injectors
Wire harness
Motor Mounts
Sensors

Problem:
After everything was in and hooked-up, I tried to start it but found the timming was way off. I checked the camshaft position sensor (distributor), and found that at #1 TDC it was way off. The hold down bolt was loose and it seemed as though someone had removed it and re-installed it improperly.
This is my first experience with these engines but learned that I needed the synchro positioning tool in order to pull the synchronizer. I borrowed one from a local parts supplier. Since I couldn't find one, they pulled it from the box with a new synchronizer, I guess they are sold together as a set. Anyway, again at #1 TDC I installed the synchronizer and pointed it towards the passenger side of the vehicle. The book is a little confusing since it says it should be 75 deg counter clockwise from the center of the engine. Since I didn't have a degree wheel, I put it as close to that as I thought it should be. There really is only 3 positions it would fit close to the sensor plug. Though I tried to start the engine in all 3 positions, resetting TDC everytime I removed the synchronizer, it still acted as though the timming was off and it would almost start but really never did. The plugs are fouling with fuel and I am at a loss.
Any help out there would be much appreciated!
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Old 02-11-2010, 06:09 PM
edgeman4.0 edgeman4.0 is offline
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first off welcome.

second, this is a question for bob (rwenzig) and/or john (wvcat). they are the allknowing ranger tech guru's for things like this.
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Old 02-11-2010, 06:12 PM
MKC MKC is offline
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Thanks Drew

Last edited by MKC; 02-11-2010 at 06:24 PM.
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Old 02-11-2010, 08:15 PM
wvcat wvcat is offline
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I usually mess with older trucks 98-2000 but I don't think the wiring harness from a 2004 is interchangable with a 2001. You can use the motor but the 01 harness would need to be swapped onto the 04 engine. With that said the wiring could be wrong and changing a cam sensor wouldn't fix the problem. The cam sensors I've changed were easy. I just set the front damper on TDC and slid it in and bolted it down. I think it can be 180 degrees out but it should run. If nothing else the ecm would go into limp mode and the truck would run but with a cel and a code.
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Old 02-11-2010, 08:17 PM
rwenzing rwenzing is offline
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Quote:
Originally Posted by MKC View Post
Though I tried to start the engine in all 3 positions, resetting TDC everytime I removed the synchronizer, it still acted as though the timming was off and it would almost start but really never did. The plugs are fouling with fuel and I am at a loss.
Any help out there would be much appreciated!
The Camshaft Position Sensor helps time the fuel injection events but not the ignition. A mistimed CMP sensor may give an off-idle hesitation and increased emissions but shouldn't do anything like what you're seeing here.

Are you using the 2001 engine harness or the 2004? How about the PCM and injectors?

Many (but not all) of the 2001~2003 3.0L engines were Flex Fuel capable and had different parts compared to the gasoline-only version. Among other things, Flex Fuel Vehicles had larger injectors, wiring differences and a PCM with a different calibration. To the best of my knowledge, none of the 2004 3.0 Rangers were FFV's. Ford did a major electrical revision in 2004 and that could be adding to your troubles as well.

So, if you are mixing parts from the two years, it could be a problem. Your best bet is to use all 2001 stuff in the 2001 truck, except for the base engine, of course.
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Old 02-12-2010, 04:13 AM
MKC MKC is offline
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Thanks for your help! However, I did swap the complete harness, intake with injectors and kept the 2001 computer. Everything is from the 2001 except the camshaft synchronizer & computer. The synchro sensor has the same part number on it for both years as does the crankshaft position sensor. It still acts like it is very close to starting but just a hair off timming. As I said, the plugs are fouling with fuel too. I thought the same thing, if I was close enough to the timming it should start.

Any more suggestions?
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Old 02-12-2010, 05:15 AM
wvcat wvcat is offline
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I would say swap the harness and probably the injectors.
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Old 02-12-2010, 02:59 PM
MKC MKC is offline
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Thanks,

I am using the 2001 harness and injectors.
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Old 02-12-2010, 07:35 PM
wvcat wvcat is offline
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Are you using the 01 computer?
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Old 02-12-2010, 07:42 PM
wesvo wesvo is offline
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Quote:
Originally Posted by wvcat View Post
Are you using the 01 computer?
x2
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Old 02-13-2010, 03:30 AM
MKC MKC is offline
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Yes, I figured since I swapped everything over from the 01 engine the computer should read the same. The complete intake with injectors, wire harness, exhaust manifolds (since the 01 had an EGR system & the 04 didn't), even the oil pressure sensor was swapped from the 01 engine.

How about the rocker arm/valve adjustment? The push rods were removed to make it easier to swap out the intakes. The book I am using said the adjustment is to turn the crankshaft until the lifter is all the way down then tighten the fulcrum bolts in two stages (60-132 in lbs/18-26 ft lbs), in no particular order.
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Old 02-13-2010, 06:42 AM
MKC MKC is offline
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I forgot to mention that the only sensors I didn't replace were the crankshaft position sensor & the synchro sensor. The part numbers on the sensors were the same.
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Old 02-13-2010, 08:48 AM
wvcat wvcat is offline
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Sounds like you did everything right, which makes me wonder about the fuel pump. Did the truck run before you replaced the engine? I have had a couple trucks that wouldn't run unless you put some gas in the intake, or starting fluid. One of them eventually fired up and them had no other problems but the other is going to need a fuel pump(its a friends truck)
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Old 02-13-2010, 10:33 AM
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The truck did run fine until the oil leaked out of the engine by the previous owner, (oops). Anyway, I checked the fuel pump and it runs fine hence the plugs fouling with fuel.
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  #15  
Old 07-23-2010, 01:02 PM
tacstar tacstar is offline
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Default Re: New Here, Engine Swap Issues

Did you ever find the solution to this? I have a similar issue. Thanks
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