Attachment III - Technical Information
[NEW] CERTAIN 2003-2005 MODEL YEAR LINCOLN LS AND FORD THUNDERBIRD VEHICLES EQUIPPED WITH 3.9L ENGINE - EXTENDED WARRANTY COVERAGE ON IGNITION COIL ASSEMBLIES AND ON 2003 MY VEHICLES ONLY, ENGINE VALVE COVER GASKETS[NEW] OVERVIEW
This program involves stress testing and replacing the coil-on-plug assemblies on vehicles that have a drivability concern related to engine misfire. If the coil fails the stress test, dealers are to replace the ignition coil and associated spark plug. On affected 2003 model year vehicles, if any coil boot is contaminated with engine oil, dealers are to call the Special Service Support Center prior to performing repair. A flow chart has been developed to help direct you to the proper repair. See Figure 1.
CUSTOMER HAS DRIVABILITY CONCERN RELATED TO ENGINE MISFIRE.
CHECK FOR DTCs AND MODE 6 DATA
1. Connect the Vehicle Communication Module (VCM) to the vehicle and the Integrated Diagnostic System (IDS).
2. Check for misfire DTCs and Mode 6 misfire activity.
IDENTIFY AFFECTED CYLINDER(S)
1. Using DTCs and/or Mode 6, identify the affected cylinder(s).
PERFORM COIL STRESS TEST
NOTE:
The Coil Stress Test should be performed on all cylinders that have misfire activity.
1. If necessary, remove the evaporative emissions (EVAP) canister purge valve nuts and position the valve and bracket aside.
2. Remove the ignition coil cover bolts and cover.
3. Remove the identified coil-on-plug from the spark plug.
4. Connect the Vehicle Measurement Module (VMM) to the vehicle and the IDS.
5. Turn the coil-on-plug upside down so it will not spark to ground during the test.
6. Connect the coil-on-plug clip to the coil-on-plug and connect the other end of the VMM secondary ignition transducer cable to the VMM.
7. Disconnect the fuel injector electrical connector from the cylinder being tested so raw fuel is not washing the cylinder.
8. Start the vehicle and the scan oscilloscope. Record the data. Refer to Figure 2 showing the difference between a good coil pattern and defective coil patterns.
9. Turn the vehicle off.
10. Reconnect the fuel injector electrical connector.
11. Remove the coil-on-plug clip from the coil-on-plug.
REPLACE COIL(S) THAT FAILED STRESS TEST
1. If the coil failed the stress test, install a new coil-on-plug assembly and spark plug.
^ Disconnect the coil-on-plug assembly electrical connector and remove the coil-on-plug assembly.
^ Remove the spark plug.
^ Install a new spark plug and tighten to 27 Nm (20 lb-ft).
^ Apply a light coat of dielectric compound XG-3-A or equivalent, to the inside of the new ignition coil boot. Install a new coil-on-plug assembly and connect the electrical connector.
2. Perform Coil Stress Test and replace failed coils on the remaining cylinders that are misfiring.
NOTE:
If more than 2 coils are defective, call the Special Support Service Center for prior approval.
3. Clear DTCs.
INSTALL COIL-ON-PLUG COVER ASSEMBLIES
1. Remove all silicone sealant and residue from the ignition coil covers.
2. Remove all silicone sealant and residue from the area around the notch where the ignition coil harness enters the valve cover. See Figure 3.
REPLACE COIL(S) THAT FAILED STRESS TEST
1. If the coil failed the stress test, install a new coil-on-plug assembly and spark plug.
^ Disconnect the coil-on-plug assembly electrical connector and remove the coil-on-plug assembly.
^ Remove the spark plug.
^ Install a new spark plug and tighten to 27 Nm (20 lb-ft).
^ Apply a light coat of dielectric compound XG-3-A or equivalent, to the inside of the new ignition coil boot. Install a new coil-on-plug assembly and connect the electrical connector.
2. Perform Coil Stress Test and replace failed coils on the remaining cylinders that are misfiring.
NOTE:
If more than 2 coils are defective, call the Special Support Service Center for prior approval.
3. Clear DTCs.
INSTALL COIL-ON-PLUG COVER ASSEMBLIES
1. Remove all silicone sealant and residue from the ignition coil covers.
2. Remove all silicone sealant and residue from the area around the notch where the ignition coil harness enters the valve cover. See Figure 3.
3. Apply a bead of silicone sealant above and below the area of the notch where the ignition coil harness enters the valve cover. See Figure 4.
4. Install the ignition coil covers and tighten the bolts to 5 Nm (44 lb-in).
5. If the LH side ignition coil cover was removed, install the evaporative emissions (EVAP) canister purge valve bracket and nuts.
6. During the diagnosis/replacement of the ignition coil assemblies, was the evidence of water contamination on the ignition coil assemblies in the spark plug wells?
^ YES - Perform Program 07N09.
^ NO - Return the vehicle to the owner.
[NEW] 7. AFFECTED 2003 VEHICLES ONLY: During the diagnosis/replacement of the ignition coil assemblies, was there evidence of oil contamination on the ignition coil assemblies or in the spark plug wells?
NOTE:
Extended warranty coverage for oil contamination does not include 2004 and 2005 vehicles.
^ YES - Call the Special Service Support Center.
^ NO - Return the vehicle to the owner.