1994 Ford Explorer Won't Start - Ignition System

Question: The problem is that when I get ready to start the car, I turn the ignition key to the on position, battery light comes on but there's no check engine light which means I don't hear the fuel pump whining which as I’ve come to expect next, turning the key further to crank the engine fails to start the car. The engine turns over but never fires, no fuel??. Have been to both my regular service shop and the dealer’s and have had mixed results, replaced fuel pump a couple of times but the problem returns maybe a few months or years later. The last time was 1 month ago where engine diagnostics indicated a faulty ignition coil, it was replaced but the problem has returned. The problem is not always permanent, sometimes I can return to the car after some time (20, 30min) and the check engine light comes on and it fires up on the first crank, sometimes an hour may pass. It can happen in the morning the first time starting, after running the car then turn off and immediately try to restart or after being at work all day. So the engine can either be cold or warm.

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Technican: Hello, I'll look at some troubleshooting charts for some backup. At the outset I wonder if your powertrain control module circuit board is effected by temperature changes. A poor connection can be another concern. Have you disconnected the computer and looked at the terminals for corrosion? Fuses must all be good or the vehicle would not be problematic at will. (A fuse won't fix itself.) Have you tried thumping the computer when the Check Engine light is not coming on? That could help to narrow things a bit. Back soon as I can,

Owner: I have just got the truck back from the repair shop, as usual they did not find anything, started up every time they tried over a 2 day period. You mentioned the powertrain control module, in the Haynes manual it lists PCM for years 95+ on the 94 model it references the ignition control module ICM. is this what I should check ?

Technican: An ICM refers to an Ignition Control Module. This module decides when to fire the ignition coils. It takes it's commands from the PCM. The PCM is under the hood just forward of the driver's side firewall and is mounted on the left front fender panel. This is the box I'm hoping when the condition is present you can thump it and see if it helps wake things up. The PCM's connector is where I'd be looking for corrosion, terminal pins that have backed-out or show signs of a poor fit, or a missing or damaged weather seal. What engine do you have please?

Owner: 4.0L pushrod V6

Technican: Thank you. Have you located the PCM? I can fax or email a component location pic if you like.

Owner: Yes, behind passenger front right kick panel. Terminals don't appear to be corroded. Will now have to wait for the symptom to return.

Technican: Together we wait...

Technican: I'm wondering why the data base states the location of the PCM for the 1994 4.oL model to be: "The module is mounted under the hood on the firewall. On 1993-1994 models, it is mounted low on the firewall, near the left-hand fender (driver's side)." It has a 60 PIN/Wire connector. Is this what you are looking at? I can email or fax pics if you want them. Just tell me where?

Technican: How are you doing with this one, please?? Just checking,

Owner: Thanks for the inquiry, since opening this thread the problem has yet to re-occur

Technican: Thanks for the update. I hope you can catch it in the act. Standing by,

Owner: Hello, I've re-opened this question at the customer's request.

Technican: I've been waiting since March 6th to hear an update. Have you had the trouble repeat?

Owner: Not that I am excited to report but the problem has resurfaced. Went to start in the morning and no check engine light hence no fuel pump running. As suggested I gave the PCM a thump and nothing changed. Then a thump and wriggled the connector, still nothing. I then went to the power distribution box and pulled the fuel pump relay and reseated it, I also wriggled the distribution box. Turned the key, check engine light came and was able to start. Please note that I have performed this same procedure before (relay, wriggle dist-box) with mixed results, either it worked or didn't and needed to tow for repair, either a burned out fuel pump or something else (coil).

Technican: How frustrating. Have you considered disconnecting the battery and really looking at the distribution box terminals and contacts for condition? Do any wires show insulation to be chafing on anything? Any bolted connections that may be loose or corroded? Do fusible links power the distribution box? Do any of them have broken strands of wire? I'm curious about reseating the fuel pump relay. That wouldn't cause the check engine light to start working again....but could the wriggling motion of the distribution box wake up a power circuit? Just trying to think outloud,

Owner: I will try the suggestions offered, most likely will be a few days before I can get to it.

Technican: All right. I'll look for you next message.

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