Engine Controls - Spark Knock on Acceleration
TSB 04-19-209/22/04
SPARK KNOCK ON ACCELERATION - VEHICLES EQUIPPED WITH 3.8L ENGINE ONLY
FORD:
1999-2003 Windstar
ISSUE
Some vehicles equipped with 3.8L engine may exhibit spark knock on heavy acceleration with 87 octane fuel. Hot weather and lower octane fuel may contribute to the condition. This may also be caused by excessive carbon deposits in the combustion chamber.
ACTION
Refer to the following Service Procedure.
SERVICE PROCEDURE
1. Verify the condition and follow normal diagnostics found in the Powertrain Control/Emissions Diagnosis (PC/ED) Manual.
a. If the spark knock is corrected return the vehicle to the customer.
b. If the spark knock is still present continue with this TSB.
2. Perform TSB 03-16-1 if it has not been previously performed.
3. Use the New Generation Star Tester (NGS) to perform an Engine Octane Adjustment using the following procedure:
a. Using the NGS Flash Card (4.2 level or higher) and Flash Cable, select "Service Bay Functions".
b. Select "Powertrain Control Module".
c. Select "EEC-V Configure".
d. Press trigger to continue on emission compliance authorization screens.
e. Highlight the Octane Adjust column and press trigger, then rotate the dial to change the ignition timing from "No Retard" to "Retard". Press trigger again.
f. Press the Start button and you should receive a message saying that the change has been successful.
NOTE
FAILURE TO PRESS THE START BUTTON WILL RESULT IN THE CHANGES IN OCTANE ADJUST NOT BEING ACCEPTED.
g. Exit out of Service Bay Functions.
4. De-carbonize engine.
NOTE
DO NOT ADMINISTER CARBURETOR TUNE-UP CLEANER (PM-2 or PM-3) THROUGH THE THROTTLE BODY/PLATE OPENING.
a. Start engine and bring it up to operating temperature, then shut the engine off.
b. Remove the PCV valve from the valve cover and remove the PCV from the hose.
c. Have an assistant start the engine and hold at 2000 RPM:
(1) PM-2 CARBURETOR TUNE-UP CLEANER (AEROSOL) 18 OZ.: Spray the entire can into the end of the PCV hose.
(2) PM-3 CARBURETOR TUNE-UP CLEANER 16 FL. OZ. (LIQUID): Insert the PCV hose into the can allowing the engine to ingest the entire can.
CAUTION
DO NOT ALLOW THE ENGINE TO INGEST PM-3 TOO QUICKLY DUE TO POTENTIAL HYDRO-LOCK CONDITION.
d. When Step "c" is completed, shut off the engine immediately and allow it to soak for ten (10) minutes.
e. Start engine, bring it up to 2000 RPM and let it run for a few minutes at that RPM to clean it out.
f. Install the PCV valve back into the hose and insert it back into the valve cover.
g. Road test vehicle for 2-3 miles.
h. Repeat De-carbonize procedure one additional time if needed.
i. Change oil and filter after final de-carbon process.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 03-16-1
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
Disclaimer