My 03 Ranger 3.0 has almost 200k miles and while it was still very drivable, had developed a bad missfire. I checked the compression and #4 had 0 PSI, so I decided to do a valve grind. One valve was burned badly so I replaced it but the others look ok and I reinstalled them. I ground all and replaced the stem seals. As I reassembled everything I replaced every seal and gasket in the top end, along with new head bolts. I checked the compression again and all cylinders were 95 to 110 PSI. I installed new spark plugs, and after re-checking all connections and changing the oil and coolant, I tried to start it. It only pops and sputters but won't run. With the engine popping and since I had removed the cam position sensor, I thought I may have re-installed it incorrectly. I set the engine to TDC on the compression and checked the Hall-effect vane on the sensor and it was in the center of the slot. I purchased a new sensor, which came with an installation tool, and again checked for TDC on the compression stroke and installed the new one. Again, it just pops and sputters. I've done several complete engine rebuilds and always do my own vehicle repairs but this one has me stumped. I've checked each plug and they are all firing. It sounds like timing or crossed wires but I've rechecked everything and even had a friend check using the Haynes manual as a guide. Anyone have any suggestions as to what I can check before dragging the old girl to a garage? This is my work truck, so I need help ASAP, please. Thanks in advance.

 

Are your plug wires on like this?The Haynes manual is wrong.
Just a thought.

 

Tony O, you nailed it. The diagram of the coil pack in the Haynes manual is printed backwards. Flip it 180 and it matches the layout in you pic. This was a brand new manual but the coil pack has been used for years. You'd thinks Haynes would have corrected the mistake by now. I wonder how much else in there is wrong. No wonder the pros go with the Bentley manuals.

Anyway, thanks a lot. The truck is back on the road. Send me your address in a private message and I'll send you something to show my appreciation.