Contour Enthusiasts Group Archives Forums General Troubleshooting V6 still won't start

This is follow up to a no start problem I posted earlier.

I replaced the clutch in my 95LX 2.5 MTX. Engine would crank, no start. Towed it to Ford to fix, they replaced underhood wiring, ignition control module, plugs, cam and crank sensors and computer under warranty, but no start. Can't afford the shop labor to troubleshoot, towed it home. Tests I've done indicate:

- I have spark at each wire end with spark tester.

- Timing light shows spark when crank pulley notch and timing chain cover mark are aligned.

- Fuel pressure gauge on test port indicates pressure and fuel pump can be heard.

- Pressure drops when cranking with fuel pump fuse removed.

- All fuses are OK.

- Installed new Idle Air Control Valve.

- No codes on computer.

What other testing can be done? Or what equipment should the local shop have on hand to troubleshoot?

Any help would be apprieciated. Thanks.

Fuel - Compression - ignition all in the right time.
If the engine is set up mechanicaly, the parts that work the ignition firing, timing, and injector timing should be a no brainer because the parts are not adjustable. The ECC does the rest once it knows the sequence. Some shops have test equipment that check the injector firing and pulse width. I had a bug in my engine years ago that Ford could not fix, they blamed the SVT parts. It turned out to be a bad relay that turned the fuel rail and ignitor on. Voltage would drop and the car would quit. Sometimes it would not restart for almost 1/2 hour. I had ignition, but the voltage (about 4 volts) was so low the injectors stayed shut. Make sure there is 12 volts to the feeds.
95s don't give you too many codes or clues to what is wrong. OBD I system is not hooked up to as many reference points as OBD II.

Where do I find the injector relay? The owner's manual diagram for fuses and relay does not list it. And where is a good place to test for 12-volts on this circuit, without having to remove the upper intake manifold?

In the box next to the battery, relay is Brown. One works the horn, other 2 fire up the ignition and fuel system. When mine died in the driveway I started to check voltage going to the ignition module. Easy to do because the plug has plenty of room to jam a voltage probe into it. Pin # 8 (green/red) is power feed in. Power comes from Fuel pump relay. You will need the wiring diagrams to check the other feeds. Many run right in front of the engine near the PS pump. I used the horn relay until I bought another one.
Funny, the Ford dealer spent hundreds of dollars troubleshooting my Contour and a $12 relay caused all the problem. I found that dealers do not corner the market on troubleshooting skills. Especially when it comes to warranty work.

Just some other stuf to test/try:

- Plug #1 fires at timing mark, how about the others? (Check plug/coil pack wiring)
- Try a couple shots of starting fluid down the intake. (Does it pop a few times?)
- How is the compression for eack cylinder?
- Are the plugs OK and gapped correctly?
- Any possible clogs in the exhaust? (unbolt flange behind Ypipe)
- Try some fresh gas.

OK, another round of tests to conduct...

... as soon as it stops snowing!

For those following along, Terrence at Haines Motor Sports emailed a couple of to-do's directly. See below:

Check the square multi pin plug harness on the driver side suspension tower is bolted together tight...then check for the extra grounds being fitted...one from the trans bell housing to inner fender...the other from the passenger side engine mount bracket to ground on the fender/firewall and check the grounds from the pcm plug behind the power steering res to the inner fender...TH, Haines Motor Sports Inc.

I helped a friend years ago hook up an Accel BEI ignition on his 1970 Corvette 454 V8. Used to have dual points. Everything said it should run, it wouldn't. Went home and fell asleep about 1 AM. About 4AM it hit me, the freakin car is fiberglas. The trigger box had no ground. I called and told him and he ran down to the garage in his underwear and hooked up a jumper - Fired up on the first turn! Normal cars have many grounds but they run better when they have the proper grounds. Especially all the high tech equipment under the hood.