My daughter-in-law lives in Des Moines and her van broke down in
Boone. She and my son have little money to spare and I've spent
more than I should have trying to fix this car. If you, or someone
you know, could please give us some advise, we'd all appreciate it.
Thanks, Rhonda

1. Make and Model: Ford, Windstar
2. Mileage: 136,000 Miles
3. Automatic transmission
4. 2 wheel drive
5. Strange sounds: None
6. Fluid leaks: Brake Fluid
7. 6 cyl - 3.8

A little history on this vehicle: Bought from someone who admitted
poor maintenance. It would only start if it was warm outside and
sometimes it was necessary to leave the hood up with it sitting in
the sun to get it to start.

When it started it would start hard, smell of gas and backfire once
or twice. Driven out of town and now won't start at all.

ODB Codes reflected lean fuel in both banks when running. Replaced
all 4 oxygen sensors. Also checked out the crank sensor, temperature
sensor, air temperature sensor, & Mass Air Sensor. My son used a
heat gun set on low to heat up sensors to try and figure out what
needed replaced.

He changed the plugs and they were horrible with a gap of about 80.

Engine cranks, no smell of gas. There is fuel at the rail, with good
pressure - not tested but it will shoot about 8 feet, no pulse at
the injectors. (Tested with noid light) He changed the Powertrain
control module and checked over the wiring and now have replaced the
cam position sensor - He's stumped and really disgusted.

They have 4 kids and need to get this thing running. She's stuck at
home all day with them while he's out working - can't take them
anywhere without that van.

:(

I really hope someone out there can help us.
Thanks again,
Rhonda

I don't know what to advise....
One thing I will mention, the fuel injectors are fired as follows.
There are 2 electrical connections inside the electrical plug.
1 is HOT all the time when the Key is in the RUN or START setting and all is OK to run.
The PCM creates a path to ground to fire the injector when it is time.
I don't know if the ground pulse will be long enough to see with a circuit tester or not.....I have no experience there.

The lean codes most likely had nothing to do with defective oxygen sensors.....but auto part stores very often recommend replacing them when they see lean codes.
Lean codes usually are caused by a vaccum leak........or dirty fuel injectors.
The vaccum leak fix regarding the upper intake manifold bolts that is in the "sticky" post at the top of the page is for 1999 and newer windstars ONLY.
A cracked or disconnected vaccum line (and there are a number of them connected to the back side of the upper intake manifold) is a likely cause of the lean codes.....and if bad enough.....could keep the engine from starting.

If you have fuel pressure....the fuel pump is running enough to at least fire the engine.

I would wonder where the brake fluid leak is.
If it is the pressure switch on the bottom of the master cylinder, it can be fixed very easily.
I should not prevent the vehicle from starting....but can cause the cruise control to not work.
Any other brake fluid leak is a serious problem.....as it could result in non-functioning brakes.
Not being able to stop is far more serious than not being able to go.

If one of the sensors has quit working.....one would expect a code to be set in the OBDII system.
Of course.....some sensors may require the engine to be running before the PCM looks at them.......again....that is outside my limited knowlege on how things are monitored.

A plug gap of "80" is pretty normal for that mileage......they started at around "60".
As I remember, my rear plugs were worn more than the front plugs.
I seem to remember a couple rear plugs being about that much.......and it was running just great.
So that would not prevent the vehicle from running.
I am guessing that you have verified that you are getting spark?

Thank you for this information - I will pass it along to my son.