Engine Controls - Basic Testing - Windstar: Other Ford Windstar I

Compression

Check engine mechanical condition using a compression gauge, vacuum gauge or engine analyzer. If using engine analyzer, see engine analyzer manual for specific instructions. Compression pressures are considered within specifications if lowest reading cylinder is within 75 percent of highest reading cylinder.

Exhaust System Backpressure

Using a vacuum or pressure gauge, check exhaust system. Remove Heated Oxygen Sensor (HO2S) or air injection check valve (if equipped). Connect a 0-5 psi pressure gauge, and run engine at 2500 RPM. If exhaust system backpressure is greater than 2 psi, exhaust system or catalytic converter is plugged.

If using a vacuum gauge, connect vacuum gauge hose to intake manifold vacuum port, and start engine. Observe vacuum gauge. Open throttle part way and hold steady. If vacuum gauge reading slowly drops after stabilizing, check exhaust system for restrictions.

PRELIMINARY CHECKS

Ensure following systems and components are in good condition and operating properly before diagnosing problems in fuel injection system

1. Check battery and charging system condition.
2. Check all wiring and vacuum connections.
3. Check air cleaner and ducting.
4. Check state of tune.
5. Check fuel delivery system.
6. Check cooling system.
7. Check inertia fuel shutoff switch.
8. Check for blown head gasket (liquid in cylinder).
9. Check fuel tank contents and fuel gauge accuracy.
10. Check for dirt, water or other contamination in fuel.
11. Check fuel lines and fittings for leaks.
12. Check fuel delivery system for proper pressure and volume.
13. Check for inoperative fuel injectors.
14. Check for improperly installed electronic equipment such as anti-theft system, CB radio, cellular telephone or stereo.

Engine Does Not Crank

Check for enabled anti-theft system. Check starting and charging system for correct operation. Check for hydrostatic lock (liquid in cylinder). Repair as necessary.

Engine Cranks But Will Not Start

1. Check fuel tank contents and fuel gauge accuracy. Check for dirt, water or contamination in fuel.
2. Check fuel lines and fittings for leaks. If no leaks are found, check fuel delivery system for proper pressure and volumes. Reset Inertia Fuel Shutoff (IFS) switch (if necessary).
3. Check for damaged or contaminated fuel injector wiring harness and connector. Ensure fuel injectors pulse when engine is cranked.
4. Check ignition system for strong spark at spark plugs. If no spark exists or if spark is weak, proceed as follows: On all EEC-V models, go to step 1) of CIRCUIT TEST JE in TESTS W/CODES article.

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel tank cap. Using Fuel Pressure Gauge (T80L-9974-B), release pressure from system at pressure relief valve (Schrader valve) located on fuel injection manifold rail. Place fuel pressure gauge in a suitable container. Using gauge, release pressure from system.
2. If fuel pressure gauge is not available, disconnect Inertia Fuel Shutoff (IFS) switch. See INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION table. Remove fuel cap to release fuel tank pressure. Crank engine for 15 seconds to release system pressure.

INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION

FUEL PRESSURE

Note. EEC-V PCM has 104-pin connector.

1. Release fuel pressure. Install fuel pressure gauge. Turn ignition on and read fuel pressure. Start engine and read fuel pressure. Compare fuel pressure reading on fuel pressure gauge with specification. For fuel pressure specifications, see «FUEL PRESSURE SPECIFICATIONS»(ref-123324) article.
2. If fuel pressure is not within specifications, check fuel pressure regulator. With engine running, connect hand vacuum pump and apply vacuum to regulator.
3. Ensure fuel pressure changes as vacuum at regulator is increased and decreased. If no pressure change occurs, replace regulator and recheck system. For additional testing information, go to CIRCUIT TEST HC in TESTS W/CODES article.

Fuel Injector Resistance

Disconnect injector harness connectors. Using digital ohmmeter, measure resistance between injector terminals. See INDIVIDUAL INJECTOR RESISTANCE table. Replace any injector not within specification.

Fuel Injector Check

Start engine and allow to idle. If engine will not start, crank engine for 10 seconds. Using a stethoscope, listen for clicking sound at each injector. If clicking sound is heard, fuel injector is operating. If clicking sound is not heard, proceed as follows

1. For all EEC-V models, go to step 8) of CIRCUIT TEST HD in TESTS W/CODES article.

Note. For additional testing and information, see SYSTEM/COMPONENT TESTS article.

INDIVIDUAL INJECTOR RESISTANCE (1)

INERTIA FUEL SHUTOFF (IFS) SWITCH

1. In event of a collision, electrical contacts in inertia switch open, automatically shutting off fuel pump. Fuel pump shuts off even if engine does not stop running. Engine will stop due to lack of fuel.
2. Engine cannot be restarted until inertia switch is manually reset. To reset inertia switch, depress button on switch. See «INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION»(ref-131320-S01904718442001121400000) table under FUEL SYSTEM PRESSURE RELEASE.

Definition

No-start is defined as engine cranks okay, but does not start. Engine may fire a few times.

Before diagnosing problems in ignition system, ensure following systems and components are in good condition and operating properly.

1. Battery.
2. Timing belt or chain.
3. Fuel delivery and injection system.
4. All wiring and vacuum connections.
5. Air cleaner and ducts.
6. Cooling system.

Spark Check

1. Perform self diagnostic QUICK TEST to check for ignition-related fault codes, and repair as necessary. See QUICK TEST in TESTS W/CODES article. If no fault codes are retrieved, check ignition system wiring harness connectors for corrosion and tight fit. See appropriate article: For 3.0L vehicles, see WIRING DIAGRAMS . For 3.8L vehicles, see WIRING DIAGRAMS . Clean or repair connectors as necessary.
2. If wiring and connectors are okay, use Neon Bulb Spark Tester (D8IP-6666-A) to check for spark at each spark plug wire while cranking engine. If spark is strong and consistent at each spark plug (one spark per crankshaft revolution), ignition system is okay. If spark is not present, go to CIRCUIT TEST JD in TESTS W/CODES article.

IGNITION COIL RESISTANCE

IGNITION COIL RESISTANCE - OHMS @ 75°F (24°C)

EEC-V Models

Manufacturer does not recommend checking timing as false readings are common and timing is not adjustable. Timing specification is for reference purposes only. See IGNITION TIMING table.

IGNITION TIMING

IDLE SPEED

Note. On all EEC-V equipped models, idle speed is controlled by Powertrain Control Module (PCM) and is not adjustable. Idle speed specifications are for reference purposes only. If idle concerns exist, see TESTS W/CODES article. If no DTCs exist, go to TESTS W/O CODES article.

Turn off all accessories before checking idle speed. Ensure cooling system is filled to correct level. Ensure there are no vacuum leaks or unmetered air entering the throttle chamber on mass airflow design systems. If vehicle is equipped with electric cooling fan, check idle speed when fan is off. For engine idle specification see IDLE RPM SPECIFICATION table.

IDLE RPM SPECIFICATION

SUMMARY

If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to SELF-DIAGNOSTICS in TESTS W/CODES article. If no trouble codes are found in self-diagnostics, proceed to TESTS W/O CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.