Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's
TSB 10-3-303/01/10
DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X
FORD:
2004-2007 Freestar
MERCURY:
2004-2007 Monterey
This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List.
ISSUE
Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM).
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14.
2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1)
3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2)
a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4.
b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM.
4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage.
5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3)
6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil.
7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8.
8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over.
NOTE
MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY.
9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean.
10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8)
11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9)
NOTE
ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM.
12. Install the PCM in the vehicle. Refer to WSM, Section 303-14.
NOTE
ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13.
13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
100303A 2004-2005 Freestar, 0.9 Hr.
Monterey: Check DTCs,
Inspect PCM For Water
Intrusion, And Modify
Existing PCM Following
Service Procedure (Do Not
Use With Any Other Labor
Operations)
100303B 2004-2005 Freestar, 1.2 Hrs.
Monterey: Check DTCs,
Inspect PCM For Water
Intrusion, Replace And
Modify The New PCM
Following Service
Procedure. Includes Time
To Program PATS Keys
(Do Not Use With Any
Other Labor Operations)
100303C 2006-2007 Freestar, 1.0 Hr.
Monterey: Check DTCs,
Inspect PCM For Water
Intrusion, And Modify
Existing PCM Following
Service Procedure (Do Not
Use With Any Other Labor
Operations)
100303D 2006-2007 Freestar, 1.2 Hrs.
Monterey: Check DTCs,
Inspect PCM For Water
Intrusion, Replace And
Modify The New PCM
Following Service
Procedure. Includes Time
To Program PATS Keys
(Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
12A650 04
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