I have heard of and read the infamous TSB 3-16-1 for the above mentioned codes. How can my mechanic go about diagnosising whether or not the service proceedure described in the TSB is necessary. I don't want to go on an 'odds are' diagnosis. A little history on my van. Above mentioned codes so had a tune up, fuel infection cleaning, tranny flush, coolant flush, MAF sensor cleaning about 3 weeks ago. (BTW O2 sensors replaced 2 years ago.) Cleared codes. A week later CEL back on same codes. Recalibrated PCM CEL light off for 1 week and
3 days. I have an appointment to take the van back in on Monday. I want to be armed with information. I don't want the mechanice to shot gun for a solution. I want to go in with some ideas on how to go about diagnosising the problem. One thing my mechanic thought may be causing the codes is bad gas or condensation in the tank. Is that possible? If so how is that determined? Thanks!
those are lean codes (both banks). A good start would be a fuel filter. after removal, try to blow through the "in" port. You will know if it was plugged. Also vacuum leak(s) could do it. Is the TSB for the MAF? If so clean it. Also check the fuel pressure...........gl
The TSB has to do with the injectors, it involves changing the valve cover on 99-00 models with the old baffle design, inspecting and replacing if required the vacuum line from the intake manifold to the fuel pressure regulator, removing the upper intake to clean everything including the EGR orifices, replace the isolator bolts on the manifold and perform a PCM update. The part numbers for the TSB are:
XF2Z-9H486-AA Port Seal-Package of 6(1 Pkg Req. Per Veh)
3F2Z-9S479-AA Isolator Bolt Assy. - Package of 8 (1 Pkg Req. Per Veh) XF2Z-9E498-DD Vacuum Line
3F2Z-6582-BA Valve Cover - LH
Had the fuel filter replaced at the time of tune up. As mentioned in my original post MAF was cleaned.
OK, so whats the TSB supposed to fix? I am assuming you researched it a bit and it is for your problem(lean codes)? If so it must be a vacuum leak in the intake somewhere...Anyway, I would check the O2 sensors with a scan tool under load ect to see if they can reach about 900 mV and check the fuel pressure too before doing the expensive TSB procedure...
Yes the TSB fixes vacuum leaks in the intake manifold. Ford in their infinte wisdom designed a faulty intake manifold gasket system that over time oil breaks down the gaskets both upper and lower gaskets, the port seals, the 'washer' type gasket on the isolator bolts begin to loosen than all hell breaks loose. The van will start to ping and have performance issues. My van was beginning to have performance issues and pinging like crazy. O2 sensors were replaced 2 years ago so I knew that wasn't the problem. Further testing confirmed that they were working as expected. MAF was cleaned up too. Still 171/174 codes kept popping up. My mechanic did the TSB Friday (after checking all other possible causes) plus replaced the intake manifold as suggested by Ford (the origianl TSB
Ah.....no the next TSB for the 3.8 ( 04-19-2 ) requires cleaning of the combustion chambers and flashing the PCM from "no retard timing" to "retard timing" as well as if the TSB 3-16-1 was not preformed to perform it. Your "mechanic" lied to you.
FORD: 1999-2003 Windstar
ISSUE: Some vehicles equipped with 3.8L engine may exhibit spark knock on heavy acceleration with 87 octane fuel. Hot weather and lower octane fuel may contribute to the condition. This may also be caused by excessive carbon deposits in the combustion chamber.
ACTION: Refer to the following Service Procedure.
SERVICE PROCEDURE
1.. Verify the condition and follow normal diagnostics found in the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. 1.. If the spark knock is corrected return the vehicle to the customer. 2.. If the spark knock is still present continue with this TSB. 2.. Perform TSB 03-16-1 if it has not been previously performed. 3.. Use the New Generation Star Tester (NGS) to perform an Engine Octane Adjustment using the following procedure: 1.. Using the NGS Flash Card (4.2 level or higher) and Flash Cable, select "Service Bay Functions". 2.. Select "Powertrain Control Module". 3.. Select "EEC-V Configure". 4.. Press trigger to continue on emission compliance authorization screens. 5.. Highlight the Octane Adjust column and press trigger, then rotate the dial to change the ignition timing from "No Retard" to "Retard". Press trigger again. 6.. Press the Start button and you should receive a message saying that the change has been successful. NOTE: FAILURE TO PRESS THE START BUTTON WILL RESULT IN THE CHANGES IN OCTANE ADJUST NOT BEING ACCEPTED.
7.. Exit out of Service Bay Functions. 4.. De-carbonize engine. NOTE: DO NOT ADMINISTER CARBURETOR TUNE-UP CLEANER (PM-2 or PM-3) THROUGH THE THROTTLE BODY/PLATE OPENING.
1.. Start engine and bring it up to operating temperature, then shut the engine off. 2.. Remove the PCV valve from the valve cover and remove the PCV from the hose. 3.. Have an assistant start the engine and hold at 2000 RPM: 1.. PM-2 CARBURETOR TUNE-UP CLEANER (AEROSOL) 18 OZ.: Spray the entire can into the end of the PCV hose. 2.. PM-3 CARBURETOR TUNE-UP CLEANER 16 FL. OZ. (LIQUID): Insert the PCV hose into the can allowing the engine to ingest the entire can. CAUTION: DO NOT ALLOW THE ENGINE TO INGEST PM-3 TOO QUICKLY DUE TO POTENTIAL HYDRO-LOCK CONDITION.
4.. When Step "c" is completed, shut off the engine immediately and allow it to soak for ten (10) minutes. 5.. Start engine, bring it up to 2000 RPM and let it run for a few minutes at that RPM to clean it out. 6.. Install the PCV valve back into the hose and insert it back into the valve cover. 7.. Road test vehicle for 2-3 miles. 8.. Repeat De-carbonize procedure one additional time if needed. 9.. Change oil and filter after final de-carbon process.
PART NUMBER PART NAME PM-3 Carburetor Tune-Up Cleaner 16 fl. oz. (Liquid) PM-2 Carburetor Tune-Up Cleaner Aerosol 18 oz.
OTHER APPLICABLE ARTICLES:
03-16-1
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING BASIC PART NO. CONDITION CODE RECAL 42
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
No he didn't lie, I was mistaken (called to verify) only the gaskets, port seals and isolator bolts were replaced per TSB. The lower intake manifold was replaced after my mechanic consulted with ford about something he saw with the manifold My mechanic is a friend who owns his own garage, I trust him.
MotorsForum website is not affiliated with any of the manufacturers or service providers discussed here.
All logos and trade names are the property of their respective owners.