Help - Engine light flashing, chugging - 99 Windstar

Hi,

On my way into work tonight on the highway, my 99 windstar was running fine... then all of a sudden, it felt like the front end was shaking...and my engine light started flashing. Coming to a stop, it was idling really badly, but didn't quit.

I made it to work (only another 2km or so). The engine light would flash, then quit, then start flashing again. When I was not accelerating, it seemed ok, but when I would try to accelerate, it would chug & light would flash, but got up to speed ok.

My temperature guage did not increase.. when I got out there was no smoke or bad odours coming from the motor.
I had just put gas in prior to heading to work (it was almost on empty)
I am due (probably overdue) for an oil change.
It was lightly raining, but not enough to soak anything.

My question is... anyone know what this may be?
I'm working a 12hr night shift tonight (7pm - 7am), and will I make it home tomorrow morning?
The hospital where I work is about 10-12km from home. Will having the van off for 12 hrs possibly resolve the problem? At least enough to get home?

If anyone could shed some light as to what this is may be, I would truly appreciate it.
Thanks for any help you can provide!

Mom2boyzz

Hello

Welcome to AF's! When your engine light flashes it means that there is a cylinder misfire. You should be able to make it home....it might not be a smooth ride. My 98 has done this a few times. The cause most likely is carbon build up in the EGR system in the intake manifold. How many kms on your van? (miles would be better for me if you could convert)

If it is carbon build up like I mentioned above it requires the intake manifold to be removed and the carbon cleaned out.

I hope this helps.

Regards

Dan

Mom2boyzz

Hello

How many kms on your van? (miles would be better for me if you could convert)

If it is carbon build up like I mentioned above it requires the intake manifold to be removed and the carbon cleaned out.


Dan


Hi Dan,
The van has about 135,000km (almost 84,000 miles).

Thank you for your response, I'm always worried about being stranded, but luckily (knock on wood) the van hasn't let me down yet.

If carbon needs cleaned out, is this something my husband could do (pretty handy), or would I have to take it in?

One thing to add, my spark plugs haven't been changed since I've had it (2yrs), could this be contributing to the problem?
Thanks again!

Here is a couple of links...first one is general stuff about Deathstars, i.e. what goes wrong and what is recommended for fixes....this is a good one.

http://www.automotiveforums.com/vbulletin/showthread.php?t=672854

Then this next one (below) is a step by step on a defect ALL Deathstars have that messes up the EGR system and you eventually end up with carbon build up in the ports in the manifold. If you can get the engine codes read, don't be surprised to get P0171 & P0174 and/or a P03XX for misfires. Simple fix that almost anyone can do (just get the parts and follow the steps). Don't be afraid to try and look around in this forum as there are lots of posts about this problem. I had never done much in the way of repairs, but I followed along and it was fine. You can save yourself a bunch on money because this one typically gets misdiagnosed as an O2 sensor failure which would cost you $200 to $300 with no effect. Once you have completed this repair, you will be ready to tackle all kinds of stuff.

Welcome to AF.

http://leckemby.net/windstar/windstar01.html

At the end of the pages for the above link is the Ford Technical Service Bulletins (TSB), have a read, it is interesting how Ford knew about the problem and knows that it gets misdiagnosed!

The leckemby link repair does NOT apply to the 1998 windstar.
It is for 1999 and newer, which use a different upper intake manifold.......the older ones do not have the isolator bolt issue.
However, the information relative to the clogged EGR ports and the DPFE (sensor for EGR flow) are accurate for the older windstars.....just be aware that the PCV valve on the older windstars is in the rear valve cover.....not the front one, and the intake manifold will be different.

The EGR port cleaning takes time, but is real easy once you get the upper intake manifold off.
The junk is only at the very end of the EGR port.
The upper intake manifold removal takes time....but is also not hard to do.
The upper intake manifold gaskets are re-usable......so no need to buy those.
Make sure that you get the mating surfaces (upper to lower intake manifold) clean so that they seat together nicely.
Also, try to get as little junk as possible down into the intake.
One can use a shop vac and a small screw driver or other small object to loosten the junk out of the EGR port.
It is not hard stuff....comes right out.

Wiswind

I believe her van is a 99.

Regards

Dan

Could it be possible that she got water in the fuel, when she stopped for gas? As this symptom started after putting gas in the tank!
That could also cause a missfire condition

I would change the fuel filter first and empty its contents into a container to see if there's water in the fuel

Your problem is one of the following:
-No Spark at the correct time
-Fuel is not getting to one or more cylinders
-Air is not getting to one or more cylinders
-Compression is bad on one or more cylinders


The EGR service addresses one of the issues with air. However I'm surprised that your Windstar is misfiring as badly as you describe and that it came on so suddenly if this is the issue. However, as stated, EGR passage cleaning is not too difficult, at least on my '96, so it might be a good thing to do anyway. (PS Rough idle, as related to a fault in the EGR, is normally due to an EGR valve that is stuck open).

It could be a bad coil. If a coil fails, it usually means that two cylinders will start misfiring, and it will run very, very rough. This can be checked by using an old spark plug to check for spark on each of the coils. Of course, fouled plugs would also cause misfiring, but it should have come on more gradually.

It could be a fuel problem, such as failed injectors, but it's my experience that this rarely occurs. Low fuel pressure could also be the culprit, either due to a clogged filter or faulty fuel pump.

Misfiring could be caused by low compression. This would probably be a major engine issue, such as a valve repair or cylinder ring replacement.

Your husband could check the plugs and do a few simple things to test some of the possibilities. If the problem is not found, then get the OBDII codes read or have a mechanic check it out to determine the cause. Once you have that in hand you can decide what is the best course.

OOPS!....sorry......I read '98......and you are correct.....'99.
One could do a test to see if it is the EGR......
Temporarily disconnect and plug the vaccum line from the top of the EGR valve......and take the vehicle for a drive.
If the misfire issue does not happen, then the problem is EGR related.
This will cause a P0401 code to be stored, too low of EGR flow.....because you have disabled the EGR..
If you still get the misfire, then the problem is not EGR.

Of course, you will want to reconnect the EGR system.....and diagnose/repair the EGR problem (DPFE is a common EGR problem as are clogged EGR ports).

Please don't fix something that ain't broke. Obviously there is something "broke" on your car ... but there's a thousand other things that are not! So do some careful analysis of what's "wrong" before beginning repairs.

... the only exception to this rule is some replacements that are good maintenance actions and that aren't likely to develop new problems themselves ... the fuel filter replacement for instance. Be careful replacing the fuel filter ... awfully easy to get a face full of gasoline! Replacing the fuel pump relay and PCM relay is another easy/safe action.

... reading the battery voltage is an easy safe action. Do it while engine is running and at rest. Low or inconsistent system voltage can cause many strange symptoms.

... if you have engine lights, get the codes first thing!

as you're talking about Km (vs miles) I think it's safe to assume you're in Canada. (me too!) I don't know where but if your tank was low, then you refilled, and a drop in temp was happening at the same time (ie: over a day or so) you could have a build up of water in the gas that started as simple condensation from a basically empty tank. If you haven't already filled up the tank with fresh gas and added a bottle of gasline antifreeze that could be a quick and easy start. I find it suspect that essentially "all of a sudden" the symptoms started. The other potential causes cited above could be the cause but I'm surprised it happened as quickly as you said. I've had the "almost empty tank water condense" stuff I describe and cleared it up with a full tank of gas and some gasline antifreeze. Usually happens to me in the fall and spring. I'm in Northern Ontario.

Piper

Hi guys,

Wow... you've all been so helpful.. maybe you can continue to help me.

SO, we've followed your advice so far... we (well...my husband doing the work, me being the beautiful assistant of course :lol:)

He has..
Changed spark plugs, done an oil change, cleaned egr ports, and put STP fuel system cleaner in the gas tank. (We couldn't find the Berrymans.. do they not sell it in Canada? We couldn't find it anywhere) He checked all the vacuum lines and all ok.
He's planning to change the spark plug wires as well, but we have to wait til Tuesday til they're in stock.

The van is still running like crap :crying:. When doing the oil change, it was really sludgy (admittedly though, it was well overdue for an oil change, and we recently found out the place we've been taking it to for the last 3 or 4 oil changes uses recycled oil, not new).

I don't know what else to do.. we've sunk quite a bit of money & time into the van now, and it's still not running well... Plus I need to do my etest within the next week or so to renew my plates.... and running like this I'm not confident it will pass.

The engine light is off... no longer comes on while driving, and no longer flashes.. but it's chugging. Accelerates ok, all thats ok, but really chugs.

The gas additive was just put in today, so we're hoping maybe if I take it for a good spin tomorrow, it might work its way through and clean it up a bit..

Can anyone help me as to what to do next, or what else could be the problem? I don't want to keep sinking money into this thing when nothing is working.

BTW.. the EGR ports were REALLY gucky.
One of my hubbys buddys were over, and said he thinks my head gasket is gone. That gave me a mini-panic attack.. is this a possibility? The van has NEVER overheated, and never does the temp guage go over the 1/2 way mark.

Please help.. I'm not sure what else to do other than trash it, but it's not even paid off yet. :eek7:

We are Having the same problem : Winstar 2002 ? The Van runs super Rough : Like its getting TOO much Gas ( BUT THERE IS NO SMELL ) or NOT enough gas : If You step on the Gas Pedal slowly it seekms to be OK : step on it to pass it chuggs and chuggs for a long time : Then the Battery Light Comes on then the Check Engine Light comes on : When it idles about every 90 Secs it will start to Chugg: Like its going to stall: ( Its not back Firing ) .
We have Changed Spark Plugs : Cleanned the MAF Sensor : Added the additives for Water in the Gas / Cleanned the fuel Injectors: Replaced the Filters air and Fuel ? We have tried it in Overdriver On / OFF , Cruise control ?........ We are Annal on maintenance ? ....... We are Just now unhooking the EGR Valve to take it for a run ....and We are replacing the TPS sensor if that doesn't work ? What else should we do ?????????????? Please and Thankyou


I have found this : Could this be happenning ? They were having the Chugging issue as well?

We kept driving the car until the alternator went out and I replaced it as well as the battery. Since I did that, we have not had another issue. It is an ac noise issue riding on the DC that must be shutting down the ECM. Don't waste your money chasing a fuel or ECM issue and do not expect that the Ford dealer knows how to fix everything. T

Windstar 2002 Chugging / Sputtering
Found the problem ? IT IS the IGNITION COIL PACK:
here where the symptons ..The first time it went .THE Van just QuIT :
The 2nd time the Symptons where : Chugging .Like not getting Gas / or too Much Gas / Battery light would Come on / Couldn't step on the Gas to pass ...slow exceleration would be all right . Intermittent Sputtering and chugging going down the Road?.. Felt like the Van wanted to stall out : Intermittent ROUGH Idle as well: I notice the Interior Fan Speed on the heater would fluctuate from very strong to almost nothing : Flashing engine light ?Seems this part is every 100,00 KM ? Hope this Helps Some-one

Pooky1,

Are you saying your van is currently OK? ... no problems now?

YES that is what I am saying?......It is running PERFECT .....We tried so many things anf The ignition Coil Pack was No _good...this is the 2nd one we have replaced the first Onr the VAN just QUIOT .this one had a whole array of differrent things going on ......