Question about 2004 Ford Freestar

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2004 Ford Freestar 3.9 liter with 130,000 miles on it. After many failed attempts I simply cannot get this van to run right. Currently reading P2196 and P2198 O2 codes, even though I replaced them yesterday. Codes cleared right after installing all four new O2 sensors, but came back within 10 minutes of driving. I also had just replaced the EGR valve (less than 50 miles ago) as it was throwing codes as well (but not since I replaced it). Found a missing bushing on the front bank intake runner control linkage. Pulled the intake and it was nasty inside. Cleaned it up fresh as new (professional clean tank), now the butterflies move nice and freely. Replaced the missing linkage bushing and reinstalled the intake and plenum with new gaskets. Found that the plenum had been previously repaired (very poorly with JB weld) as the main vacuum fitting near the IAC was completely broke off. Have since fixed this as well. When the service engine light comes on, it immediately loses power. Can't hardly get it up to 30 mph with it floored. Put in neutral and floor it, it will clear it's throat, bounce of the rev limiter and go again for a few then loses power again. It's loading up bad, black soot and smoke out the exhaust.... Plugs, wires and coil replaced less than 3000 miles ago. Can't figure it out. The more I do, the worse it gets! HELP??

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  • Jeremy W.
    Jeremy W. Oct 08, 2010

    Whats your fuel pressure at?

    What is you coolant temp at?

    What is the MAF sensor reading?

    Have you checked for exhaust backpressure?

  • a_random_noo Oct 08, 2010

    Whats your fuel pressure at? Unknown, haven't checked it yet...

    "What is you coolant temp at?" Running normal operating temps 185 - 195F

    "What is the MAF sensor reading?" Didn't have anyway to check it, but not showing any trouble codes for it. Used MAF cleaner and changed the air filter to no avail.

    "Have you checked for exhaust backpressure?" No

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  • Ford Master
  • 5,495 Answers

How about a fuel sample and new fuel filter? When the Service Engine light comes on this time, have you checked the final codes?

The throttle position sensor, TPS, could be bad with all the work done on the Butterfly flaps. No telling how many times its been removed and replaced. The black soot is a sign of unburned gas either through timing advance or too much fuel pressure for the situation. Thats the job of the TPS.

Posted on Oct 08, 2010

  • 1 more comment 
  • a_random_noo Oct 08, 2010

    Have not changed fuel filter yet. Only codes I'm getting are the O2 sensors. Going to check fuel pressure. Also cleaned the MAF and replaced the air filter. Still reading the same and running the same.

  • fordexpert Oct 08, 2010

    Remember to do Fuel Sample

  • fordexpert Oct 08, 2010

    Okay, did some more reading. Use some Carb cleaner while the engine is running and spray the base of the Injectors and around the Intake. If there is still a Vacuum leak ,the RPM will spike as it draws in the Cleaner. You could check manifold vacuum levels anyway.

    The articles I read suggest the ECU is getting a lean condition and is enriching the fuel despite the O2 sensors saying the engine is running rich. Another idea was a leaking Fuel pressure Regulator dumping gas into the engine. This would kind of tie in the idea about Fuel pressure and a Clogged converter. Over time the converter could mess up.

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