‘96 Windstar Check Engine Light

[wiswind]

I may have missed it....but did you clean the EGR ports inside the lower intake manifold? You have to take the upper intake manifold off to get to it......
That would be the most likely cause of the misfire on cylinder #4 at this point.

[tasteph]

wiswind, no I have not cleaned the EGR ports yet. I just recent discovered the oil residue in the air filter area and from reading your other post I’m going to be changing the PVC valve tomorrow and clean out all the oil residue throughout the assembly that houses the air filter etc. I’ve got a Motorcraft one and will see if this makes any changes first then I’ll delve into the other if needed. I do really appreciate all the information you have shared with your experiences with you ‘96 Windstar. I’ll be sure to post results from my little venture no matter what the outcome...

[tasteph]

Originally Posted by tasteph

After reading some more post here, today I looked at my Air Filter and discovered some oil residue around it....

...I did install an aftermarket PCV valve sometime back after I had made some of the other post here. I’ve got a Motorcraft PCV on order through O’Rielly’s and it should be here tomorrow and for only $5.49, so if this clears up my CEL I’ll be very happy...

Okay, just wanted to pass on that after I replaced the PCV valve, cleaned out all of the oil residue and been driving about a week I have not as of yet had anymore CEL illuminations. I’m still going to give it a few more days just in case, but if that little $5.49 part cleared up my problems then I will be truly happy.

[tasteph]

I’m still going to give it a few more days just in case...

Well... CEL is back on... but thanks to the vast amount of information here I have some more ideas on what needs to be checked.

[tasteph]

Originally Posted by wiswind

I may have missed it....but did you clean the EGR ports inside the lower intake manifold? You have to take the upper intake manifold off to get to it......
That would be the most likely cause of the misfire on cylinder #4 at this point.

I’ve been working on my ‘93 Taurus LX with 3.8L engine, removing the starter but I’m going to be looking at cleaning the EGR ports on the ‘96 Windstar too now...

The amounts of valuable information with pictures that you have provided have been really helpful and have given me some confidence in doing some of the repair work myself now.

And speaking of that starter removal ‘93 Taurus LX 3.8L, just a quick question(s) for a little bit of help and feedback... (I posted this in the Taurus forum but thought I’d post here also just for some more input.)

I already have the negative battery cable disconnected, taken off the protective cover over the terminals, disconnected the wire from one terminal, the smaller ignition wire has been disconnected. Now on the opposite side I have located two bolts, one has what appears to grounding wires attached with a nut/bolt stud and the other is just a bolt. I have removed the bolt but I am having problems with the one that has the grounding wire...

First question that I have, Is this the correct bolt that I should be removing to take the starter out? I have a Chilton manual for my ‘96 Windstar and was referencing it, now I know it is for a different vehicle and the connections, etc. may be a little different but since both vehicles have a 3.8L engine I thought there may be some similarities in the removal of the starter. My wife has found me a Haynes manual for the Taurus on ebay and it should be here in a few more days but I thought I’d check here too since there is a valuable source of information and help here.

When I first tried to remove the bolt I was using some old tools of mine which were cheap and actually broke the adapter on the ratchet I was using. I have since purchased a Craftsman socket set and removed the bolt with no problems. If the other nut/bolt turns out to be the correct bolt to remove the starter the other problem I’m having is that it appears that this nut may be slightly stripped. I had originally thought it may just be hard to turn and sprayed some lubricant and when I was using the ratchet on it I noticed the socket slipping and then felt some rough edges on the nut itself. I have a “Bolt-Out” which is supposed to help remove stripped, rusted bolts/nuts but the problem with that is that when I place it in the socket adapter it is too big for the confined space and makes it sit slightly sideways and doesn’t fit properly over the nut. I’ve tried an open end wrench with the “Bolt-Out” but again it’s to big for the small area. I have a universal-joint type adapter also for my ratchet set but as of yet had no luck in removing this nut/bolt. Any ideas on this?

[mattndebsmom]

Our check light came on and we took it to auto zone y said it was a mis fire on number 4. So we changed the spark plugs than we had to change the ignition coil.We went bk to the auto zone they removed the light from blinking than 3 days later it was towed into the shop my head gasket was blown. Ford has recalled the 95 windstars but not the 96 ones so beware it will cost about 12 to 18 houndred to fix this one. I hope no one has this much problem with theirs.

[tasteph]

Originally Posted by mattndebsmom

Our check light came on and we took it to auto zone y said it was a mis fire on number 4. So we changed the spark plugs than we had to change the ignition coil.We went bk to the auto zone they removed the light from blinking than 3 days later it was towed into the shop my head gasket was blown. Ford has recalled the 95 windstars but not the 96 ones so beware it will cost about 12 to 18 houndred to fix this one. I hope no one has this much problem with theirs.

Sorry to hear you had so much problems, my '96 has 94,000 miles on it and it really seems to be a good vehicle. I just completed the EGR port cleaning... (See this post about it.)

http://www.automotiveforums.com/vbul...d.php?t=481502