Fulltext TSBs

Technical Service Bulletins

TSB
05-13-4
  • HARD START/LONG CRANK, ROUGH IDLE, ENGINE IDLE MISFIRE – MIL – DTCS P0300 THROUGH P0308, P0171, P0172, P0174, P0175, P0316, P2195, P2196, P2197, P2198
Publication Date: June 17, 2005

FORD:
2005 Expedition, F-150, F-Super Duty
LINCOLN:
2005 Navigator

ISSUE:

Some 2005 5.4L 3-valve engines may exhibit a hard start/long crank, rough idle and/or the malfunction indicator lamp (MIL) on, due to intermittently stuck open injectors causing carbon fouled or wet spark plugs.

The following diagnostic trouble codes (DTCs) may be present:

  • P0300 through P0308 (Random and or Specific Cylinder Misfire)
  • P0316 (Misfire detected on startup in first 1000 revolutions)
  • P0171 (System too lean-bank 1)
  • P0174 (System too lean-bank 2)
  • P0172 (System too rich-bank 1)
  • P0175 (System too rich-bank 2)
  • P2195 (O2 Sensor signal biased/stuck lean (HO2S11))
  • P2197 (O2 Sensor signal biased/stuck lean (HO2S21))
  • P2196 (O2 Sensor signal biased/stuck rich (HO2S11))
  • P2198 (O2 Sensor stuck biased/stuck rich (HO2S21))

ACTION:

Confirm if an intermittent injector concern is causing these symptoms using the following Service Procedure. If the concern is confirmed to be caused by an injector(s), replace the injector(s) causing the concern and any spark plugs that may have become fouled as a result.

SERVICE PROCEDURE

WARNING:DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR HAVE OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.

CAUTION:PERFORM AN INITIAL ENGINE OIL LEVEL CHECK, ALSO SMELL THE OIL DIPSTICK FOR THE PRESENCE OF FUEL ODOR. IF THE OIL LEVEL IS GREATER THAN NORMAL, OR THE OIL OR VEHICLE SMELLS OF FUEL, PROCEED DIRECTLY TO PROCEDURE 2 OF THIS TSB. DO NOT ATTEMPT TO START OR CRANK THE ENGINE.

CAUTION:FOLLOW THE STEPS BELOW IN THE ORDER LISTED TO REDUCE THE RISK OF POTENTIAL ENGINE DAMAGE WHILE TESTING THE IGNITION AND FUEL SYSTEMS WITH WDS.

SERVICE PROCEDURE 1:

  1. Retrieve DTCs and record on repair order.
  2. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc), repair as necessary following normal repair procedures. Proceed to Step 3.
  3. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
    1. If Power Balance indicates a weak cylinder proceed to Step 4.
    2. If Power Balance does not indicate a weak cylinder proceed to Step 5.
  4. Perform a Relative Compression test with WDS to determine if a base engine concern is contributing to the weak cylinder(s) identified in Step 3.
    1. If Relative Compression test indicates a low cylinder, confirm base engine concern by performing a dry compression test using a compression gauge with all plugs removed and battery condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics for base engine repair. Do not continue with this TSB.
    2. If Relative Compression test or dry compression test do not show any issues, proceed to Step 5.
  5. Run ignition tests with WDS.
    1. If ignition test indicates a concern, follow normal diagnostics to repair. Proceed to Step 6.
    2. If ignition test does not indicate a concern, remove all spark plugs and inspect for wetness and/or carbon fouling. Record the location of affected cylinders. Proceed to Step 6.
  6. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a wet/fouled plug, replace the injector for that cylinder. Proceed to Step 7.

    NOTE:IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE INJECTOR(S) ON CYLINDER(S) THAT HAD WET/FOULED PLUG(S) IN STEP 5B. PROCEED TO STEP 7.

  7. Replace the spark plug(s) that were fouled. Pre-lubricate any cylinders that had fuel present with two (2) shots of clean engine oil. Do not over-lubricate cylinders. Proceed to Step 8.

    NOTE:IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005, CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS MARKED WITH “PZT 1F” ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.

  8. Change oil and filter and clear DTCs. Proceed to Step 9.
  9. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated exhaust oxygen sensor (HO2S) switching rates, to determine catalyst condition. Normal switching frequency of the post-catalyst HO2S should be very slow with reduced amplitude as compared to the switching frequency and amplitude of the pre-catalyst HO2S. Refer to PC/ED, “Catalyst Efficiency Monitor and Exhaust Systems” for an overview of the catalyst efficiency monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.

SERVICE PROCEDURE 2:

NOTE:ONLY PERFORM SERVICE PROCEDURE 2 IF DIRECTED TO BY THE CAUTION AT THE BEGINNING OF THIS TSB.

  1. Retrieve DTCs and record on repair order.
  2. Remove all spark plugs to determine if fuel is present in cylinder(s).
    1. Inspect spark plugs for wetness and/or carbon fouling and record the location of affected cylinders. Proceed to Step 2b or 2c.
    2. If no fuel is present leave spark plugs out and proceed to Step 4.

      WARNING:PERFORM STEP 2C IN A WELL VENTILATED AREA AWAY FROM ALL IGNITION SOURCES. HIGHLY FLAMMABLE MIXTURES MAY BE PRESENT AND COULD BE IGNITED. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY.

    3. If fuel is present, remove fuel from cylinder(s) by disconnecting the battery, and turning the engine over by hand, raising the affected piston to TDC. Use an air hose-blow gun and protective catch rag to remove any remaining fuel. Proceed to Step 3.
  3. Once gasoline is evacuated from cylinder(s), squirt two (2) shots of clean engine oil to re-lubricate cylinder(s) and prevent piston scuff. Do not over-lubricate cylinders. Proceed to Step 4.
  4. With the spark plugs removed, perform Fuel Pressure & Leakdown test and Relative Injector Flow test with WDS. If an injector fails the Relative Flow Test, and/or was on a cylinder with a wet/fouled plug, replace the injector for that cylinder. Proceed to Step 5.

    NOTE:IF THE FUEL PRESSURE & LEAKDOWN TEST FAILS, WDS WILL NOT ALLOW THE RELATIVE INJECTOR FLOW TEST TO BE PERFORMED. IF THIS OCCURS, REPLACE THE INJECTOR(S) ON CYLINDER(S) THAT HAD WET/FOULED PLUGS IN STEP 2A. PROCEED TO STEP 5.

  5. Replace the spark plug(s) that were fouled. Proceed to Step 6.

    NOTE:IF SPARK PLUG REPLACEMENT IS REQUIRED ON A VEHICLE BUILT BEFORE 4/26/2005, CHECK THE SPARK PLUG PART NUMBER STAMPED ON THE PLUG. IF SPARK PLUGS MARKED WITH “PZT 1F” ON THE PORCELAIN INSULATOR ARE INSTALLED, ONLY REPLACE THE FOULED PLUG. IF ANY OTHER SPARK PLUG IS INSTALLED, REPLACE ALL 8 SPARK PLUGS WITH THE PZT 1F-F4 PLUGS. DO NOT INTERMIX PZT 1F-F4 AND PZT 2F-F4 PLUGS.

  6. Change the engine oil and filter. Proceed to Step 7.

    NOTE:EVEN THOUGH THE ROOT CAUSE OF THE CONDITION MAY HAVE BEEN ELIMINATED IN STEPS 1-6, CONTINUE WITH ALL REMAINING STEPS OF TSB TO CONFIRM THERE ARE NO REMAINING IGNITION OR BASE ENGINE ISSUES.

  7. Perform a thorough underhood inspection. If visible concerns are found (wiring, connectors, etc), repair as necessary following normal repair procedures. Proceed to Step 8.
  8. Perform a Power Balance test with WDS to confirm or identify weak cylinder(s).
    1. If Power Balance indicates a weak cylinder proceed to Step 9.
    2. If Power Balance does not indicate a weak cylinder proceed to Step 10.
  9. Perform a Relative Compression test with WDS to determine if a base engine concern is contributing to the weak cylinder(s) identified in Step 8.
    1. If Relative Compression test indicates a low cylinder, confirm base engine concern by performing a dry compression test using a compression gauge with all plugs removed and battery condition at 100%. If low compression is confirmed, follow normal Workshop Manual diagnostics for base engine repair.
    2. If Relative Compression test or dry compression test do not show any issues, proceed to Step 10.
  10. Run ignition tests with WDS.
    1. If ignition test indicates an issue, follow normal diagnostics to repair the concern, then proceed to Step 11.
    2. If ignition test does not indicate any issues, proceed to Step 11.
  11. Clear DTCs. Drive vehicle at highway speed and bring engine to full operating temperature for a minimum of 10 minutes to clear any excess fuel from the catalytic converters. Monitor the front and rear heated exhaust oxygen sensor (HO2S) switching rates, to determine catalyst condition. Normal switching frequency of the post-catalyst HO2S should be very slow with reduced amplitude as compared to the switching frequency and amplitude of the pre-catalyst HO2S. Refer to PC/ED, “Catalyst Efficiency Monitor and Exhaust Systems” for an overview of the catalyst efficiency monitor. Follow Pinpoint test HF if needed. Recheck for DTCs and follow normal diagnostics if necessary.

PART NUMBERPART NAME
5C3Z-9F593-DAInjector

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

DEALER CODING

BASIC PART NO.CONDITION CODE
9F59369

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2005 Ford Motor Company