01 Windstar showing no improvement

[stalldog]

On the way back from a long trip my 01 Windstar starting running rough and shaking on the freeway. After about 5 miles it stopped and ran fine. After stopping for the night, it started doing the same thing the next day along with a flashing check engine (which turned into a solid light). I took it to a shop and they said that one of the spark plug wires was bad, it needed a tune-up, and possibly new upper and lower intake gaskets.

I replaced the lower and upper gaskets, isolator bolt grommets, plugs (Autolite PT2), wires, PCV, fuel filter, and coolant. I also added fuel injector cleaner to the tank. The CEL is gone, but I still have all of the same issues along with white smoke coming from the exhaust. It idles in park between 600-800 rpm and very rough (makes the van shake). It feels like it wants to stall when it's in gear with the brake on. It seems to run fine above 1800 rpm. If the engine is taxed under under 1800 rpm it gets very rough and doesn't have a lot of power. I've checked the vacuum lines and all appear to be good. The shop that originally looked at it said they tried it with a new MAF sensor and it made no difference. I unhooked the vacuum line from the EGR valve to check the DPFE sensor, but it didn't seem to make a difference.

Any ideas? I'm especially concerned about the new appearance of white smoke. I read in another post about the same smoke after replacing the gaskets that went away eventually.

[tomj76]

Usually a large amount white smoke = coolant in the combustion chamber. Small amounts of white "smoke" are normal since water is one of the byproducts of combustion. When coolant is in the combustion chamber there is a noticable smell of the antifreeze in the exhaust.

When you changed the lower gasket, did you inspect it? Were there signs of a leak between any of the intake passages and the coolant passages? Are you sure you installed the new gasket properly?

Otherwise, it could be a problem with a head gasket or a crack.

When the engine is running and hot, feel the radiator hose between the thermostat and the radiator, make sure that it feels tight due to the coolant pressure. If it never gets tight at high temperature, then that's another sign you are leaking coolant. Coolant in the combustion chamber can leak down into the cylinder, then into the oil pan. Check the oil to make sure it doesn't show signs of coolant (a creamy or milky appearance due to emulsified water).

A compression test might direct you to the right head/cylinder for the leak.

[glennet404]

Stalldog-

If I understand you correctly - the white smoke is a new symptom - and one that is not going away after 10 minutes or so of driving.

If this is indeed the case - then I think something maybe didn't go back quite right when the manifold gaskets were installed or perhaps there was a flaw in the gasket. Sounds like you may need to take a second look at your work.

Good Luck-
Glenn

[stalldog]

The white smoke was not an original problem. The smoke didn't show up until after I put everything together and ran the van for 4-5 miles. I was confident in my work as it was the 2nd time I've done this (the first time was a success), but I would rather go back and check my gasket job than have to deal with head problems.

A leaking gasket explains the white smoke, but I still need to figure out what is causing it to run so rough.

[glennet404]

Stalldog-

You may have indeed solved your original problem with plug wires, etc. - but the repair isn't evident because of a manifold leak.

I'd say identify and fix the problem causing your white smoke - then see what you've got.

Good Luck-
Glenn

[stalldog]

I took the intake manifold off and there was coolant visible! I installed a new Ford gasket, thinking the other one may have been faulty. I put everything back together, using 7 ft-lb of torque on the manifold bolts. It ran better than ever for about 12 miles and then the chugging and white smoke showed up again. I took everything apart and there was coolant again. Am I missing something when I put the manifold back in? Why would it run for 12 miles and then start leaking again? I've done this same procedure before, successfully, and have no idea what is going wrong this time.

[glennet404]

Stalldog-

Sounds like you may have a cracked intake manifold. You may want to get an eye loupe or strong magnifying glass and see if you can identify any cracks along the water lines - if there big enough - they would appear as thin lines of discoloration.

Also- I will mention that FelPro does sell a newer style gasket that is supposed to be resistant to the acids contained in antifreeze. These acids in the antifreeze are what causes these gaskets to degrade over time - causing it to be a high replacement item. The reason why I mention this - is there any way possible when you changed or added antifreeze to your system - something else could have been added by mistake ??

Good Luck-
Glenn