99 Expy Having Sputter Problems

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Oct 8, 2010 | 05:08 PM

jwhopson

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Tuned

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From: McMinnville

99 Expy Having Sputter Problems

I recently let my Expy sit for about ten days, the battery drained completely. I jump started it and it drove fine until things got warm. After about 20 miles I noticed it running very rough - it was almost like a sparkplug was going bad or something. It still idles but when driving it doesn't seem "max out" or when driving it misses and jumps or what I call sputters. The engine service light came on and blinked four times and then off again - I don't know what that means - if I shouldn't drive it anymore or what. I don't think it will scan because the light is not on.

Any idea's?

Oct 8, 2010 | 06:19 PM

cbradford

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From: Lost in Pa.

Sounds like a miss or two and since the CEL came on it set a code. If you can read the code or get the code read at a local auto parts store it will tell you which cylinder is missing giving you a place to start. Good chance it's a COP.

Oct 8, 2010 | 08:15 PM

alloro

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From: 0,0,1

Quote:

Originally Posted by jwhopson

The engine service light came on and blinked four times and then off again

Getting a blinking light while driving is a warning from the ECM that there's too much raw fuel being dumped into the exhaust. It also means there's enough being dumped to destroy the catalytic converters. This backs up cbradford's bad COP (or more) suggestion.

Oct 8, 2010 | 10:48 PM

jwhopson

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Tuned

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From: McMinnville

I appreciate your suggestions folks, I have had spark plugs come loose and shoot out on three ocassions - all done from the dealer. I am curious if you know a way to test the COP? The Engine Light only blinked and went off so there was no codes to scan - at least the guy said there was no codes when I took it in.

Again - if you talk about testing the COP can you be specific - I think I can use a volt meter but not sure how. I have a feeling you guys are right but I hope I can find it without replacing all of them or somehow narrow it down. Thanks again for your time and effort.

Oct 9, 2010 | 07:32 AM

cbradford

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From: Lost in Pa.

Checking COP's, Part 1

First of all I can't believe a code was not set, with the CEL blinking I would think a code would have been saved but I may be wrong. So back to your question on checking COP's and I'll have to do this in two post's since I can't upload more than 3 pics in one post.

First do a visual inspection of the COP:

1) Check top of coil (finger pointing to, right pic) where Motorcraft label is attached to coil. This material is epoxy filled in around coils and you want to check for cracks in the epoxy if cracked it will allow moisture to penetrate into coil affecting performance.

2) Check boot, squeeze boot and check for cracks (left pic), micro cracks in boot means the boots ability to insulate the high voltage directed to the spark plug has been compromised. The boots and springs can be purchased separate of COP itself.

Oct 9, 2010 | 07:33 AM

cbradford

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From: Lost in Pa.

Checking COP's, Part 2

Now for the electrical check of the COP using an Ohm Meter, I had this used COP that is a known good coil:

1) Check the Primary Coil of COP (left pic), attach Ohm Meter to the two small pins (B+ & B-) in connector and should read the resistance across primary coil, the book calls for 0.55ohms and my sample is reading 0.77ohms. The point is coil should not be open - infinite resistance or a direct short - 0ohms but close to 0.55 ohms.

2) Check the Secondary Coil of COP (right pic) attach one end of Ohm Meter to spring (red lead) and other end of Ohm Meter to B- terminal (black lead), the book calls for 5.5 K ohs or 5,500 ohms and my sample is reading 5.422 K ohms or 5,422 ohms which I think is acceptable.

Hope this helps you.

Oct 9, 2010 | 12:22 PM

jwhopson

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Tuned

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From: McMinnville

Cbradford,
Wow, thank you for taking the time and effort to post the pics and instructions. I was hoping someone would help so I could try this out today. I just parked the Expy in the shop so I will give this a try and report back. Thank you again.

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Oct 10, 2010 | 04:14 PM

jwhopson

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Tuned

Joined: Aug 2003

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From: McMinnville

I just started getting into the COP for a visual inspection - wow things are really tight - I am glad I had the dealer change the plugs. I had mentioned that I have had three plugs blow out since they originally changed them which appears tobe common with 5.4 motors. But I found a very loose COP and the screw holding it or the molding was broke so it didn't feel very durable. I also found weird things next to the COP. See the picture, part of it is the reminance of the boot from when they changed it - surprised they didn't clean up a little more - but the cylinder looking thing is odd - any idea's what this is?

Not sure that I posted the images correctly, but they are at the google web albums if interested.

Picasa Web Albums - Jason

Oct 10, 2010 | 04:45 PM

#10

alloro

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From: 0,0,1

It didn't work since that Google site doesn't allow hot linking, but I was able to right click the red X box, select properties and do a cut and paste of the link. At least this way, each of the links are clickable.

Picasa Web Albums - Jason

Picasa Web Albums - Jason

Oct 10, 2010 | 05:49 PM

#11

cbradford

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From: Lost in Pa.

The cylinder looking thing looks like the resistor that in the spring part of the COP.

Oct 10, 2010 | 09:23 PM

#12

jwhopson

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Tuned

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From: McMinnville

Well I replaced that suspected COP and drove it around a while with no issues. I will take it to work tomorrow for a good test. Thank you again, hopefully that resolved the issues. After doing this on the cylinder on the driver side, second one in from the front - I couldn't imagine changing my plugs.

Wish me luck and thanks again to your boredom

..... You have been a huge help and saved me big bucks!

Mar 2, 2011 | 10:27 PM

#13

jwhopson

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Tuned

Joined: Aug 2003

Posts: 341

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From: McMinnville

Just to follow-up on the thread - thanks to all who replied the Expy lives well again - been driving for quite a while, long enough for other COP's to go bad - so I will again try your method of testing to see if I can find the culprit. Thanks for all your time/effort.