[deftrhiney]

I recently replaced a blown engine for a new one. replaced belts, made sure timing/cams was right. Connected all cables and stuff. I go to start it and the engine cranks but no start. I check my plug end and I'm not getting a spark. I change the spark plugs, wires, and coil and still no spark through my wires! Engine just struggles to start but with no spark no combustion. Anyone have any ideas?

 

[jetrinka]

Are you sure all the grounds are connected? Not entirely sure where all of em are located on a Zetec but a disconnected ground would cause this if you are sure everything else is correct.

 

[lildisco]

Did you match the ECU Code? That may or may not make a difference. Or alteast check the connections to the harness.

 

[whynotthinkwhynot]

Do you have an electrical tester to check the coil? Test the primary and secondary on the coil for resistance. If it's not in range, then it's bad.

 

[deftrhiney]

I'm getting a PO320 code ---- Ignition engine speed input circuit performance. Where is this sensor located at?

 

[deftrhiney]

I thought it was the coil, changed it, still no spark to the wires. Could it be the ECU?

 

[sleepyboy]

I know whats wrong!! I bet you never replaced the crank position sensor with the one from your old motor!. I also bet that the motor you got was from an auto or vise versa a manual. The crank position sensors are different from the auto to the manual. The auto's point inward and the manual's point outward so when you swapped it its not pointing at anything it can read so that causes it not to spark cause it does not know where the crank is lol I did this on my swap a few years ago hahaha its a headache. You should be able to remove it from the outside or at least thats what Tom told me (turbo tom) I did'nt know this back then so I removed my tranny again and clutch and flex plate to get it. But you should be able to get it from the out side there is a I wanna say allen key type bolt just remove that and the sensor should pull right out. Its located right where the bell housing would be but on the motor side behind the header. Thats the crank position sensor. and Welcome to the forums there is a wealth of knowledge on here.[welcome] [ffrocks] [headbang]

 

[deftrhiney]

It was manual tranny to manual tranny. I even switched back the crank position sensors to see if that was the case too.

 

[sleepyboy]

hmmm? interesting. try the cam sensor that would be my next guess. Check the wires going into the coil pack too those have been known to go out. If the middle wire is not working then you will not get power to the coil.

 

[whynotthinkwhynot]

Was the crank position sensor clean? If those magnets get metal shavings on them, they don't work right.

That was my next guess, but I went for the coil first. I'm sorry you replaced it before checking it. I recommend checking first because you never know what is wrong if you don't test. My work van wasn't getting spark. I pulled the coil, checked resistance, and it passed the test. It turns out it was the rotor button- saved $30.

Anyway, I think your grounds are ok. If not, the engine would not crank. There are 2 other grounds aside of the main ground that must be connected, but these shouldn't keep the coil from firing. Could you have a bad coil connection, or bad alternator connection from unplugging?

 

[deftrhiney]

Tested the ohms of the coil. They're ok. What else could be giving me that PO230 code? Faulty PCM? What/where is the rotor button?

 

[sleepyboy]

^^we don't have a rotor button. That was a van that did. Have you checked your fuses and relays? Everything you describe is exactly what happend to me when swapping the motors out. Make sure the sensor is clean cause what Captian TMI said is very true if there is metal shavings then it won't read properly. Also have tried using both sensors maybe ones bad?

 

[stanarinze]

I'm having the same problem with mine, but in this case my ecu won't communicate with anything

 

[sailor]

I see from your other post here:http://www.focusfanatics.com/forum/...ap/296946-zetec-swap-write-up.html?highlight= that you're swapping engine types.

Don't know details on either, but for the types avail. here an exchange of wiring harness & computer is needed to make such a swap work - as well as the basic bolt up of the engine.

 

[DreamGarage]

I recently replaced a blown engine for a new one. replaced belts, made sure timing/cams was right. Connected all cables and stuff. I go to start it and the engine cranks but no start. I check my plug end and I'm not getting a spark. I change the spark plugs, wires, and coil and still no spark through my wires! Engine just struggles to start but with no spark no combustion. Anyone have any ideas?

So I had the same issue, and checked my codes and I had the crankshaft position sensor code. I switched CPSs from the old engine to the new one with no change. Then I took the sensor out to look and make sure the sensor was picking up the marks. Turns out there's two sensor mounts, one for manual and one for automatic. I didn't notice that before I installed the new engine so I have to remove the transmission and replace the mount. It should run then.