Ok, I just bought this van. Seller would not repair before selling, but I did have the codes pulled before buying and decided that because there were no signs of leaking in the engine or trans. Well maintained with documentation.
Three codes were pulled, the crank shaft sensor was faulty, and cyl 1 and 4 were misfiring.
I bought it took her home, reset the system and allowed the check engine light to come back on. Once on, I repulled the codes and this time cyl 4 did not give a code. I replaced the Crank Sensor today. Reset the system and drove her to my brothers.
As I was going up a steady hill the check engine light came on and blinked, and the engine kind of bogged down, then came right back and was all good. Got to the top of the hill and the light stopped blinking and stayed dark.
When I was leaving the light came back on and stayed on.
I havent pulled codes again, but I am assuming it is the misfire.... but I honestly dont know the van well enough to know if what I feel is a misfire or just something normal in the engine...
If it is a misfire again, the possible causes I have are ignition system fault-spark plug(s), ignition wires, coil - vacuum leak - injector fault - high or low fuel pressure.

Where should I start? Suggestions and whatnot are appreciated.
Thanks

 

Wow, from reading other threads in here i was expecting this to be the place for help... I did take her to get the codes pulled and the codes were for cyl 1 as stated above. I went and bought a new coil and installed it on cyl 1. Unplugged the neg battery cable and allowed the system to reset. That was yesterday. Today, I went to my brothers again, and then when we left we headed to a store, on the way the same thig happened with the check engine light, it started blinking. THen it stopped blinking and i could feel the van mis-firing. but the check engine light stayed off. After we left the store and i was headed home, the light came on and stayed on. I took it straight to get the codes. It pulled both the cyl 1 and the crank sensor. I just replaced the crank sensor AND the cyl 1 coil.... WTH? The tech told me the codes needed to be erased from the computer, just pulling the neg battery cable would not do that, it just resets the system but the codes remain there. So he erased the codes and reset the system at the code port and told me to drive it some more and when the codes come back on, bring it back in and he will be able to pull the current correct codes... So thats where I am right now...

 

What engine you got in there? I have the Ford manuals from the dealership, and I can look this up for you if you need someone to do so...

 

Mike, Thanks, It is the 5.4. I got the check engine light again today, when back to have the codes pulled and only P0301 (cyl 1 mis-fire) is pulling code. I was told to put some fuel system cleaner in and the mis-fire might be caused by the injector being clogged... So I put a bottle of Lucas Oil fuel system cleaner in and am letting her run for a day or two. See what happens... If that doesnt fix the problem, he wants me to change out the spark plug and the coil (coil again) and see if that fixes it... Thanks for the help Mike, you have no idea how much I appreciate it.

 

Is that the only code you are currently getting? What were the other codes? You may also want to pose this question to the 5.4L crowd in that forum. This forum doesn't get as much traffic, and the expertise you are looking for is over in the engine forums.

 

Serp, go to your User CP and turn on your PM function. There are two types of Misfires. On a Type A, the MIL will blink once per second during the actual misfire, and a DTC will be stored. On a Type B (which will exceed the emissions threshold or cause a vehicle to fail an inspection/emissions test), the MIL will illuminate and a DTC will be stored. You appear to have a Type A, which is not as serious...a come and go type thing.

Read this thread all the way through:

https://www.ford-trucks.com/forums/1...e-p0301-2.html

 

Have to be here 10 days and make 5 posts before PM functions will work... As for codes, when I bought her, she was giving code 301, 304, and crank sensor. A friend who works on cars reached in under the passenger side dash and hit some reset he said was there in case of a roll over... I dont know. Anyway, when the check engine light came on the following day, it was just giving a code for 301 and the crank sensor. I was told by the guys at autozone that the crank sensor could be responsible for the mis-fire on 1 so I opted to change out the crank sensor. I did that and removed the negitive battery cable resetting the check engine light. The next day while driving up a steep hill the check engine light started blinking on and off, then when off when I go to the top of the hill, but after I parked and the engine cooled down, when I was leaving not even 5 minutes after starting her the check engine light came back on and stayed on. So I went to AZ and pulled codes and the only code that came on was 301. So I bought a new coil from advice from the guy there at AZ and installed it. The van started and ran awesome. then the next day while going up another hill the check engine light started to blink on and off and the mis-fire started again and you could feel it. the light went out but came back on after being parked for about an hour. I took her back to AZ to have the codes pulled and she gave the 301 code and the crank sensor again. The guy at AZ said it was a residual code and that the codes needed to be erased fromt eh computer,so he erased then and told me to come back when the light came back on. This morning the light came back on without blinking, and I took her to AZ and the only code pulled was the 301 code. After talking to the guy there he recommended I first put in a fuel system treatment to clean the injectors. He said that injectors could cause the misfire. Then if that does not fix the problem, he would replace the coil with a new one and sell me a spark plug to replace both at the same time. After reading the thread you linked me to I am thinking that since there are over 160000 miles on her, it might be worth buying a new spark plug (or a set) and replacing. I have no idea when they were replaced last. Plugs are only $4 each for motorcraft at Autozone. so..... Your abbreviations.... MIL = Check engine light? DCT = Code? This doesnt seem to be a come and go type thing, just the light comes and goes when I reset the system after making a repair/replacement of a part. If I dont touch anything the light stays on constantly.

 

MIL=check engine light and DTC is=trouble codes on computer...sorry bout that.

Yes, replace the plugs. All of them. Then replace all the springs for the coils. They are cheap as well. Inspect all of your boots really well for cracking and dry rotting. I have a feeling this is your spark plugs or springs. There are many, many posts on this down in the 4.6L, 5.4L forum. Check down there for some SERIOUS expertise on this topic.

On another note, I recently bought all the maintenance books from a closed Ford dealership. I have the complete set for your van if you plan to keep her. Big three book set with wiring diagrams, part numbers, specifications, fluid types and removal and replacement of every component on the van. Check down in the marketplace. I have a bunch of books going out to FTE members in the morning. I have books for all these E series vans from 1997 to 2007. You could have the books in 2 or 3 days and be rocking and rolling on that thing. The books have all the troubleshooting procedures for every system on the van as well.

 

Mike, weirdest thing... while out working today, the check engine light when out... i havent done anything to her since adding the fuel cleaner. I figured when the heck, I was close to both the title place and the emissions testing center, the emissions would run me $10 and a free rerun later if I failed so... Ran her through the emissions and she passed. I honestly was not expecting it to pass, was rehearsing my excuse and the questions I was going to ask the tech. Nothing wrong with her (and it is raining like crazy here today - figured if there was a problem with boots or springs on the COPs the moisture would have triggered bad episodes) got the passing certificate and went straight to the tag and title place and got my tags and title registered. Would like to keep this open, because I am scared this is a reprieve but not a full pardon...

 

As yet, no return of the dreaded check engine light, but I can feel her missing and hesitating on me as I drive her. Planning to change out the plugs this weekend. I know many of you have pulled your seats to do this, I am wondering if any of you who pulled your seats have a bulkhead installed behind the seats as I do. Wondering if it would be worth the trouble to pull the seats when I will only gain about 2 feet or so of extra space... Also I have a center console file cabinet bolted to the floor between the seats...not sure how easy it would be to remove it.

 

My F150 is doing the same thing. I just ordered new COPs from RockAuto and I bought a stethoscope to help with the diagnosis. Once I get the COPs in I'm going to look at the spark plugs and replace the COPs if necessary. I need it to hold on for a few more days before I take it out of commission for diagnosis so I get my other car back.

 

Its been two weeks for me.... she still gives me shutters of misfiring every now and then, but no return of the check engine light.... I am planning to get her into a closed up garage next weekend (it is getting cold here) and replace all the plugs and check and replace as needed the boots and springs on the COPs. Was really surprised at how well the engine took to the Lucas Oil gas treatment. Dont think I have ever had such noticable improvement from a fuel additive before..... Good luck on your COP change out....

 

If you look at my post on " e350 wont start " you'll see the culprit I found to be my issue. Not sure if the 2003 harness is placed in the same area. You might have to disconnect the harness from the ecu to see anything. I caught mine too late and it fried my ecu. Also just looking at ebay at a used 5.4l it had the same wear spot as mine. Good luck.