P0301 and P1513 Codes

[baumbr]

For $95 a Ford dealer in Washington state "Found P0301 and P01513 Engine runs rough recomend tune up with wires injection flush also IMRC motor is not working and valves in the intake are stuck closed". Please note, I hadn't noticed any roughness in the engine, or lack of fuel economy, etc. just a nice bright CEL. They missed the blown transmission completely.

Their repair estimate:
Replace intake runner control motor and bushing = $405.00
Remove intake and clean valve for intake runner = $347.50
Replace fuel filter = $55.00
Fuel injection flush and B.G. kit (whatever that is)= $135.00
Replace spark plugs, air filter, PCV valve = $305.00
Replace spark plug wires = $242.50

Total? a cool $1490.00!

I'm glad I found this forum with all the excellent tech knowledge. I'll probably save a few cents doing it myself. BTW I have a good deal of experience working on cars and trucks and have most of the tools I need. Guess it's time to buy a code reader.

[wiswind]

Your Profile shows that you have a '98.
If you have the 3.8L engine....these pictures for my '96 3.8L may be of help to you.....
The '96 through '98 use basically the same intake manifold....upper and lower.

http://community.webshots.com/album/201931518cScpNK

P0301 is a misfire on cylinder #1. While there are many possible causes for this.....I had a dirty fuel injector cause this just after 135K miles. I physically removed all the injectors and sprayed cleaner on the spray end to flush crud off of them. The crud did not come off with fuel system cleaners added to the gas tank although the rest of the system was nice and clean.
I do use fuel system cleaners....and they DO help. For occasional use....Cheveron Techron (2 bottles to a tank of gas) or Redline Complete Fuel System Cleaner. I use the Redline in a "maintenance dose" as it contains lubricants which are good for the injectors. I am going to guess that this is the crud that the dealer's "fuel injection flush" is after. I was chasing this problem for a while until it got bad enough to light the CEL....and by then....I had replaced anything obvious.......

Another very common (the most common) cause of misfire on Cylinder # 1 and / or #4 is clogged EGR ports. The ports are located in the lower intake manifold. You do NOT have to remove the lower intake manifold to clean them. You DO need to remove the upper intake manifold to get to the EGR ports and the fuel injectors. I would clean both in the same job. The EGR ports seem to start to clog with the ports nearest to the EGR valve......leaving the ports at Cylinders #1 and #4 the last ones open......so when the EGR system operates....all the EGR gasses go into 1 or 2 cylinders....causing the misfire. If you feel the miss......and want to know if it is the EGR ports causing this.....remove and plug the vaccum line to the EGR valve.....and go for a short drive.....if the problem does not happen.....then you know it is the EGR ports causing the misfire. Of course.....removing the vaccum line will cause the EGR valve to NOT open when it is supposed to......and will cause an additional code (which will light the CEL, if it has been reset). The code would likely be P0401......insufficient EGR flow. You would not want to leave the EGR system disabled....but it is a good way to isolate the cause of your misfire.

P0401 code on it's own (not induced as above) is most often caused by the DPFE (this is what measures the EGR flow). The EGR valve rarely fails. DPFE location is in my pictures..... A common, but easy repair.

Cylinder #1 is on the back passenger side of the engine.
Cylinder #4 is on the front passenger side of the engine.

The EGR gasses and PCV vapors combine to create a tar-like buildup which is what clogs the EGR ports, Spray end of the fuel injectors, and the IMRC "valves". You can see it in my pictures.

Also....this is when you can inspect / clean / repair the IMRC. The IMRC is a series of 6 butterfly valves......3 each on 2 shafts.....1 shaft with 3 butterflies for front bank of cylinders....and another for the rear bank of cylinders.

There are several TSB's for the newer windstars, which use a different intake manifold. These TSB's do NOT apply to your '98. The TSBs deal with "isolator bolts" for the intake manifold....and a different valve cover.

P1513 is Intake Manifold Runner Control Bank #2 stuck closed.
The IMRC's are OPEN with no vaccum applied. They close when you start the car.....and will not open until you accelerate such that your engine speed is at about 2900 rpm or higher.....then they open and give you more power....(sound like the 4 barrel carb's?)
I would try cleaning the IMRC's....getting as little crud down into the engine as possible. Also check the little plastic clips to see of any of them are broken. The IMRC items are "dealer only" parts. I have bought online from Millennium Ford in Seattle. You can give them your VIN and ask them about the specific part.....and they should get an answer to you promptly. The nice thing is.....that they sell below list price on many items. Their online parts department is at http://www.trademotion.com/partlocat...?siteid=214072

Oh....the upper intake manifold gaskets are re-usable.

For spark plugs.....I would get ONLY the Motorcraft DOUBLE platinum plugs that are specified for your car. The ignition system on our engine is kind of odd.....they fire 2 plugs from each of 3 coils in the coil pack. So.....each cylinder fires on the normal cycle....AND on the exhaust cycle. Which is why it is sometimes called "wasted spark system". The important thing is.....one side of the engine has a postive spark.....the other side has a negative spark....which means that on one side of the engine....the center electrode wears the most.....and on the other side of the engine....the outer electrode wears the most..... This means that you need to have the platinum enhancement on BOTH electrodes. Bosche spark plugs do NOT do well in our engines. You should be able to get the correct Motorcraft plugs from a dealer for $30-$60 for the set of 6.....and they will be good for another 100K miles.

I get to my rear plugs from under the car.....with the front up on ramps....(rear wheels blocked) I slide under......so that I am looking up the front face of the firewall......back a bit farther than I would have thought.....and you can reach right up to the plugs.
The Motorcraft plugs are rated for 100K miles.....Mine were still going strong at 135K miles....but the gap was worn a bit wide....so I changed them.

I would stick with the Motorcraft brand of PCV valve...
I have read posts about some aftermarket PCV valves permitting too much flow....drawing more oil into the intake. We do have a strong PCV system....which does help keep the inside of the crankcase clean.

A quality aftermarket air cleaner should be fine.
I use the standart paper element....and they do last.
I am not big on the type that you clean and add oil to.
If you DO use one of them....be careful to add enough oil to catch the dirt.....but not too much oil, as it will foul the MAF.

[baumbr]

Thanks, WisWind. This info, the photos and the other info found in the forum will really help when I get to the point where I can work on the van. Right now I'm saving pennies for a new transmission. However it does get started weekly, run for 20 minutes or so, including heater and A/C, and driven up and down the driveway a few times to keep any systems from deteriorating.

[wiswind]

As you are handy.....I would recommend springing for a auxilary transmission cooler.

I saw some for good prices at www.bulkpart.com

I have a Derale 17,500 GVW unit on my windstar.
I did have to adapt the 3/8" to the 5/16" on my car.

[baumbr]

I have been seriously considering an aux. transmission cooler for the van. After my experiences I will also put one in the truck we are planning to buy in about a year.

[sheltonleon]

hi i have a 96 windstar. the cel came on so i took it to autozone .the code p0301 came up so i got new spark plugs and wires change them but the code still comes up .i read the forums from wiswind but when i pull the upper intake off do i need to buy new gaskets for it.thank u for a reply.

[wiswind]

The upper intake gaskets are re-usable and should be fine. If you do want to buy them....they are not real expensive.