Hey guys,

THIS IS LONG, BUT I WANT TO FULLY EXPLAIN THE PROBLEM.

We have a 2005 ford expy and are the original owners. For about a year, my wife and I noticed a stumble when sitting at traffic lights that progressively got worse. i didn't sweat it as it wasn't throwing a code. PLugs replaced about years ago, mileage 105k or so.

In October 2012, it threw code 307. At that time, I researched the issue and people mostly pointed to coils. I bought a set of 10 off of ebay form a supplier people were reporting good results and replaced it. Vehicle seemed to run better, so I replaced all but cylinders 4 and 5 (haven't been able to easily reach them as they are under the ecu).

We stopped dring the vehicle daily and very occasionally drive it now. I got a mountain bike and started using the expy to go on rides and it progressively started running much worse. While driving it gently about a week ago, we heard a long "knock event," about 5-6 quick cylinder pings, then the check engine light came on. Checked it with my code reader and got:

p0307 - CYLINDER #7 - MISFIRE DETECTED
p0307 (twice)
p0357 - IGNITION COIL "G" (COP-G) PRIMARY CONTROL CIRCUIT / OPEN

Hmmm... maybe the COP was bad? cleared codes and replaced it with a spare new one, no change in running.

Drove it one more time when we needed to haul a car load of kids. Bad idea. started bucking pretty badly, CEL came on, CEL started flashing! Just echedked codes today and here is what I now have:

p0304 - cylinder 4 misfire
po307 - cylinder 7 misfire
p0300 - random/multiple misfires detected

OK, so now cylinder 7 is misfiring again and cylinder 4. I don't think it is a bunch of bad COPs as I changed cylinder 7 once and then have not changed cylinder 4. I also don't think it is something affecting all of one bank, sunce 4 and 7 are in different banks.

My leading suspicion is injector problems since the issues on the 2005s and extended warranty, but I can't be 100% sure.

QUESTIONS:

- Any suspicion of the problem?

- How do I take it tot he dealer and have them focus on the injector warranty work without charging me for a bunch of other BS items? I just don't trust the dealers and I can picture then wanting to change all the plugs, change al the cops back to oem, etc. only to find out its not that.

Thanks for any and all help in advance! I really don't want to dump a lot of money into this thing as its only a 3rd vehicle for us now.

 

Not very well versed on this sort of thing but the crank trigger might be in error. Someone much more knowledgeable should come along anytime now with an idea though.

 

Not sure if you fixed the problem yet but here's what I would do.

Go to your local parts store and get a stethoscope (about $10). And touch it to all your COPs. If you have an issue internally (ie the COP is bad or the spark plugs are bad) you'll hear it.

Also, you can change a COP from a 'bad' plug to a 'good' plug and see if the codes follow the COP. And I would check the plugs. I had my plugs replaced and about 6 months later I had one burnt up so bad it was causing serious problems.

 

Or you could buy a Waekon coil tester and eliminate the guess-work.

 

OK, I took the expy in to the dealer a month ago.

Turns out cylinder #7 had a loose plug and the big culprit was the cylinder 4 spark plug had liquid in it and was shorting out the COP. The tech dried out cylinder 4, put in a new plug, swapped the cylinder 1 and 4 COP and that was it. When I got it home, I replaced the cylider 1 cop (was on 4) with a new one and it ran perfectly.

2 weeks later... the misfire returns, getting code p0304 again. I assume it is once again wet with coolant.

In googling this, I found that the older 4.6's and early 5.4s had a coolant hose that would leak above the #4 cylinder causing this same issue, but would a 2005 3v engine also do this?

Of couse the tech didn't bother to look for the source of the leak or confirm what the fluid is, but told me it probably needs a new intake manifold to the tune of $1400 plus parts, but I don't want to pay them to throw parts at it.

Any help is appreciated. thanks!

 

Unless you're planning on diagnosing and fixing it yourself, screw the dealer and bring it to someone else that is willing to do the job correctly.

 

Thanks alloro. Not sure if I am going to o it myself or not, but want to get as much info as possible before doing anything. I would fior sure do it myself, but the car is so high and the engine is set back so far, plus I am getting lazy.