New to the Forum, but not new to Ford Ranger, my son and I just swapped out a 94 4L V6 non EGR'd or likely non California engine for an EGR equipped 94 4L V6 low miles complete engine. Install went smoothly EXCEPT the Ignition Key will NOT turn over the engine or engage the Starter. Fuel pump runs up etc.....but in order to start the engine we must Hot Wire the starter.....????
Swap out was done since my son drove the truck till it died and died hard when Engine Coolant leaked out totally......Grrrr

I am at a loss as to what the issue is??????

Anyone who has a solution or suggestion we are open to anything here. It should be something real simple!?!??!

GARY
Stanley Idaho
Very remote from any service assistance!!!!

 

the same thing happened to me once, the problem was I put the the wrong wires in the wrong places on the starter solenoid

 

Hello Rusty Nail,
I sure wish the problem with starting the Ranger was a simple wiring problem. I have checked the Starter and Solenoid wires a zillion times and even installed a spare starter. I have checked the Clutch Safety Switch and on and on....In the mean time my son is still having to to hot wire across the Fender mounted terminal block to start the Ranger and its not any fun especially since the Temperature this morning was down to minus 5....

Still Stumped.

GARY
Stanley, IDAHO

 

The California engine has an extra connector (4 vs 3) over on the wheel well near the battery. The red/light blue wire to the starter solenoid on the Cal engine goes through that extra 8-pin connector that your truck doesn't have. Originally, the red/light blue to the non-California engine went through the 16-pin connector next to it.

If that is where the problem lies, there are probably some other wiring mismatches in the 16-pin. Maybe you can simply swap the original engine harness over to the replacement engine.

 

Hello Bob,
This sounds like this could be the whole problem....I was quite aware of the EXTRA Connector.....I just couldn't IMAGINE that it had anything to do with the Starter....But without a wiring diagram I have kept wondering.....Jumping into this issue this afternoon.

GARY

 

The California engine not only has EGR but it also has sequential fuel injection control (6 wires from the injectors to the PCM) vs bank-to-bank control (2 wires). So that's why I think there are almost surely other crossed wires in the connectors. I would choose swapping the engine harness back to the original non-California version as long as that swap doesn't cause other complications.