2002 windstar P0352

[tmash]

My wife has a 02 windstar with a 3.8 at 165k miles. I have the code P0352. I have replaced the Plugs,Wires, coil pack and the O2 sensors, still the code is there. I have inspected the wiring to the coil and it's ok. The only time that the engine idels rough is a start up for about 2 to 3 min then after that it idels great.

[wiswind]

P0352 Ignition Coil B primary circuit malfunction

You have done exactly what I would have done to address this issue, other than the Oxygen sensors.

I am guessing that you used the Douple Platinum plugs that are specified for this motor.
The multi-pronged plugs are not ideal for the windstar....some have reported issues with those.
Double Platinum is platinum enhanced center electrode AND ground tab (1 ground tab).

The coil pack contains 3 coils, which each coil firing 2 spark plugs.
One end of the coil delivers a positive voltage, and the other end delivers a negative voltage.

The spark plugs are connected to the secondary winding of the coil.....
The PRIMARY coil is driven by the PCM (computer).
The wiring to the computer and the computer are possible causes of this problem.
This code is not a common code on the windstar.
An inspection of the wire harness going into the coil, the bundle of smaller wires as compared to the spark plug wires, would be in order.
Look for any signs of this bundle of wires rubbing against something on its way over to the PCM.
The coil, as you know, is located on the driver's side of the engine bay, next to the firewall.
The PCM is located all the way on the passenger side of the engine bay.
It is mounted INTO the firewall with the big electrical connection in the engine bay.
You would look back up under the windshield wiper cowl.....behind the top of the passenger side strut mount.

Also look for any signs that one of the pins in the connector at the coil end, as well as the PCM end look to be pushed up out of the connector.
You should be able to do this without removing the connector.....use a flashlight (and a mirror if needed to get the correct angle of view).
You will be looking at where the wire goes into the connector.
If a pin is pushed up.....you will see it right where the wire goes into the connector......the metal of pin will be visible, sticking out of the connector as compared to all the other wires in the connector.

Why this is happening only at start-up and was not solved with a new coil pack is a strange one.

[tmash]

I used the Motorcraft plugs that are recomended. I check the wires and no evedance of rubbing through. I just replaced the coolant temp sensor reset the check engine light and drove for about 15 min and no light. I let it set over night and I started it. I ran rough for about 30 seconds then the light came on then about 45 seconds later it stop stumbling. I reset the light and I started again and it ran great and no light. Could it be a problem with an injector letting fuel leek into the cylinder when it is parked for an extended period of time and flood it out which is causing the stumble, then when burns off the excess fuel it runs great?

[2k3windstar]

One other possibility is a very small head gasket leak. Small amount of water leaking into a cylinder would cause ignition problems. Then once the cylinder/piston/etc. get warm the small amount of water becomes a small amount of steam and ignition would occur mostly like normal. The small amount I am describing would not show up as steam in the exhaust. Coolant would leak at a very very slow rate, almost not noticeable.

I had an intermittent rough idle recently on my daughter's Escort. Intermittent rough idle for a very short period, usually when first cranked. Might go weeks with no problem. Then it started to become more frequent. Initially I treated it as ignition related, until I had gone through everything. Then one Saturday white smoke came out of the exhaust and the coolant reservoir was bubbling. Diagnosis suddenly became simple.

My father taught me way back in the 60's when I handed him tools and held the flashlight that head gasket leaks sometimes start out as idle problems.

My two cents. Any thoughts?