Questions and Answers
Ford Windstar Multiple Lean Codes
Q. I own a 1999 Ford Windstar SE, 3.8 liter, automatic transmission, 120,000 miles, fuel injected, ABS, P/S, A/C, cruise control and rack & pinion steering.
Problem: Service engine soon light constant lit, it came on after letting vehicle warm up on a cold day. Engine runs great, but sometimes develops a miss or stutter when restarted after a short time (after a quick stop at the grocery store).
Took it to a dealer who told me it was showing multiple lean codes. (I kick myself for not getting the code numbers). The service manager said the oil baffle inside the valve cover was worn out, and the engine was drawing oil into the PCV system.
The service manager's recommended fix was to replace the valve cover, PCV hose, and intake spacer and cleaning affected areas. Cost: $700.00. I was not convinced on this, so I paid the $79.00 diagnostics charge and left.
I purchased and installed the valve cover and PCV hose. I took the top half of the intake manifold (plastic) off and sure enough there was a film of oil on everything. I wiped down the residue, installed the new valve cover and PCV hose and valve.
My wife drove the car to work the next day, 15 miles rural and interstate, and I checked for residue in the PCV hose and valve. Unfortunately, there was oil residue inside the new parts.
Not knowing what could cause the oil to be drawn into the intake system, I left the PCV system disconnected, and plugged the intake port. After several hours on the interstate, and several days later no SES light. However, the SES light has returned and I very disappointed.
My questions: What could cause the engine to draw oil through the PCV system? Do I need to replace the intake spacer?
Thanks for your help,
MikeA. There is no doubt that the code numbers would have enabled me to be more accurate in my diagnosis. And it doesn't sound like there is a problem with the PVC system.
If the oil fill cap/breather is clean and clear, the PCV valve is new, the line between the PCV valve and intake is clear and there is vacuum at the intake port, you've done all you can and the system is fine. Some oil residue is normal, but I can't tell if yours is excessive or not.
With multiple codes indicating a lean condition, I have to go to the MAF first. Many lean conditions are attributable to the MAF. Here are some relevant articles that will help you.
Added 3/10/2004
Hi Vince,
A short while ago you answered someone's question in regards to the lean codes he was getting with his 1999 Windstar. It is on page 54 as I write this.
He had said that his service manager gave him a list of suggestions and he did the work himself. The work he did is in fact from a Ford TSB. He said he was disappointed because the light came back on and there was oil past his PCV valve again.
I want to add to this conversation:
1) The valve cover has to be of a new design. Simply replacing it with the same type will not help.
2) It is also suggested to replace the Fuel regulator hose as it can get oily and loose and cause a vacuum leak.
3) It is also suggested to clean the EGR ports in the lower intake manifold. These would have been accessible when he had the upper intake off.
I am not disputing your MAF theory by any means I just want to ensure him that according to Ford he was in the right area but he may not have finished the job.
The TSB you refer to is 03-16-1 dated 08/18/03. The part number of the modified valve cover is 3F2Z-6582-BA.
Additional Information provided courtesy of AllDATA
