Ford Repair: Missing, spark plug wires, ford windstar


Question
We're getting there.  I got a pcm today.  It took care of it to a certain extent.  I now get codes for cylinder #4 and #5 misfiring  (po304 and 305)  It has brand new plugs in it I change and even changed the fuel injectors again.  I think the crank sensor is bad and it is retarding the timing.  What do you think?
Thanks,
Jeremy
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I have had four spark plug wires off the engineas well as three plugs out of it.  It runs the same as if everything is connected.  If I unplug #3 or #5 though there is a change in the engine rpm.  I also found today that the engine is flooding with gas.  I changed all the injectors and still have the same problem.  I tried to pull codes and none came up. ( I used the snap-on scanner).  I also watched the data stream and seen nothing out of the ordinary.  I'm stumped.  I'm starting to think the computer went bad.  Any other thoughts??
Thanks,
Jeremy
95 Ford Windstar with 3.8L
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Just bought a 95 ford windstar.  Lady who owned it threw a rod.  The mechanic who took care of it had no clue what he was doing.  I replace the bad piston and rod (#4) and #1 because it got hit and I didn't trust it.  I also replaced the head gaskets and spark plugs as well as all the rod bearings.  I started it up and it misses.  I check for fuel pressure. It's at 38-40psi.  I check for spark all cylinders are sparking.  I have between 140 and 150 lbs of compression at all cylinders.  I also triple checked the firing order and the spark plug wire routing.  Everything I check looks good.  All I can think off is the crank sensor or the cam sensor.  I checked timing also.  It's right on the money.  Any thoughts??
Jeremy
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Jeremy,

In a situation like that I find it easier to put a known good engine from the salvage yard in the old ones place. Anyway, try to narrow down which cylinder is missing by pulling plug wires and watching the RPM drop. If the fuel system does not use a fuel return line then check the last injector on the rail. It gets all the crap (literally) and might not be spraying any fuel.

Also, try moving plugs around as you can have a bad spark plug.

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Jeremy,

Sounds like you got a fun one to diagnose. I seem to get a lot of these myself. They can drive you crazy after a while.

It is possible for the ECM to be bad, they really do strange things sometimes. Also, have you checked that the EGR valve is not stuck open?  I know the Windstars have a tube with 6 holes to deliver EGR and they plug up dumping all the EGR gas to one or two cylinders.

I can't think of anything else right now, but I will write you if I think of something. Also, I am curious to know what you find.

Answer
Jeremy,

First, usually when the crank sensor goes bad it won't run at all.  Since your codes are for cylinder #4 & #5 and they are right next to each other on the back I would be concerned about a warped or cracked cylinder head.  When you had the engine apart did you get the heads surfaced? I think your next step should be to perform a cylinder leak down test on those two cylinders. When you do it leave the spark plugs out so you can listen for air crossing over to the other cylinder.  Also, make sure they didn't mill the heads so far that your pushrods are too long holding valves open. I know how frustrating these can be, I have been there several times before.