[EddieZ]

I don't even have 300 miles on my Ecoboost 3.5L, and, today, the "Engine Fault" and "Service Now" messages came on, while I was sitting at a McD's drive-through.

I called the dealer, and took it right in. They retrieved the fault codes, but, couldn't decipher their full meaning. After a couple of hours, it was closing time. They said I could drive it home, and they'd have me back in Monday or Tuesday, to implement whatever prescription Ford sends back.

They did not tell me not to drive the van. Fortunately, I have my old vehicle as backup, and will use it until my call-back.

I suppose and hope it's just "one of those things." But... this is also how "really bad things" may get started.

Van is entirely unmolested by me -- I have not begun any of my conversion projects.

 

[Fairgame]

It was probably that garbage that Mc D sells as food, set your computer in fault mode.. IMO

 

[Chance]

Sorry to hear of your problem. Unfortunately things can go wrong with any engine at any time -- new or old. On the other hand we need to consider that the more parts are involved, and the more complex the engine, the greater the probability of failures.

 

[star gazer]

I had a light come on when on my first trip, and the Ultragauge gave an error code. Something about fuel air mix. Went out after several restarts. Dealer could not find anything wrong after checking it when I got home. I am thinking that perhaps I over filled the fuel.

The other day I had another light and error code. Well turns out while checking my air filter for moisture I did not plug in the connector all the way. Again after several starts the light went out.

So sometimes it means nothing major. But the problem is when do we know that it is serious? If the check engine light does not go off after a few restarts then I would take it in right away. I think I read in the manual how many restarts will turn off a none serious light.

Dean

 

[onetwo]

I don't even have 300 miles on my Ecoboost 3.5L, and, today, the "Engine Fault" and "Service Now" messages came on,

keep us posted, curious to know what it is....

 

[EddieZ]

keep us posted, curious to know what it is....

Will do.

A couple of additions: I see there's an exhaust leak at the front seam of the muffler - about an inch where there's soot escaping. I wonder if a sensor could pick that up.

Seeing that reminded me that I had heard a 'pop' from behind me, earlier in my drive. I thought it odd, but put it off to something shifting in my bungied-in cargo crate.

I was also reminded that I thought I'd heard a very subtle, high pitched tone, like you might hear in an imperfect radio signal. But, the tone remained when I turned off the radio. I was not sure if it was my imagination, or, if it was a new sound, or, if it had been there all along.

 

[EddieZ]

As noted in the "Air Filter Nightmare" thread, I have noted that my ECU and the wiring connection bundle above -- all under the hood on the driver side -- had been wet, and that we had had heavy rain the night before the Engine Fault appeared. This is ALL down to poorly engineered rainwater control, where it comes down the windshield edges, and drenches key components under the hood.

TODAY, the Ford dealership service tech failed to call me for the update and return invitation that I was expecting. He also had not checked his voice mail nor email for at least 6 hours, as I had tried to contact him myself, at 10 AM. When I finally talked to him at 4 PM, he just said I had to bring the van in before he could do anything. My exasperation could have been better controlled. I also spoke with the service manager. I'm going in tomorrow morning, at 8 AM.

 

[EddieZ]

I have news!

On Saturday, the service tech could not get meaningful codes for my engine fault. He could not clear the fault. I drove home with the fault showing.

I did not drive the van for 2 days. During that time, I discovered the Air Filter Nightmare thread, and realized the water intrusion under the hood could relate to my problem

This morning, when I started the van, there was no engine fault! That right there pretty much confirmed my suspicion about water in the electronics.

Today, I made nice with the service tech and service manager. The vehicle checked out fine. I had explained the water issue, and, that made sense to the tech, since he regarded the issue as a communication problem, rather than something specific that the computer could point to. Ford advised the tech to pack the connections to the ECU with dielectric grease, to (hopefully) prevent further water intrusion.

The tech and the service manager tested water flow down the windshield, to confirm my claim about the electronics getting wet. They were astounded -- though the service manager later tried to glad-hand me with the idea that the electronics were designed to be regularly doused with water. Really? Then why are we applying dielectric grease?

The tech was more in line with my thinking -- that the dielectric grease was a good workaround, and temporary solution (hopefully). He said he will try to pursue the issue through his system, may see future service bulletins, etc. I made sure everything was documented in the repair order, to help get Ford's attention, and to have documentation in case this becomes a big friggin' issue.

What I thought had been an exhaust leak at the front of the muffler, was deemed a weep hole, designed to be there.

Regarding the poor engineering of water flow, I intend to file a formal complaint to the Ford Customer Relations Center, and will try to push it further up the corporate food chain.

 

[tdinut]

Congratulations Eddie. Continued good luck with the vehicle. Thank you for the update.

 

[Whitedog]

This morning, when I started the van, there was no engine fault! That right there pretty much confirmed my suspicion about water in the electronics.

Actually, it doesn't confirm anything. It suggests that water may the issue if there has been alot of rain in your area recently and can only be confirmed by further inspection. Did the tech open up the connectors and find water intrusion?

 

[EddieZ]

I have given you all the details I have. And yes, post number 7, above, we had had heavy rain the night before the engine fault occurred.

 

[Whitedog]

My point is that you don't for sure that it was water intrusion to the ECU. Maybe it was, but until there is evidence of it, it's just a guess. Since you don't know if the tech found any signs of water intrusion into the ECU or connector, you don't have any evidence.

 

[EddieZ]

If you'll just re-read my "claim," I did leave room for error: "That right there pretty much confirmed my suspicion about water in the electronics." MY layman's suspicion.

I may not have the evidence you would like, but, I do have a vehicle that faulted after heavy rain, which recovered only after sitting for 2 days; a service tech nodding agreement to the logic of my suspicion; and his contact at Ford advising to pack the connection with dielectric grease. Make of it what you will.

 

[PeterR]

"Er, may counsel approach the Bench, your Honor?"

 

[ted]

Would be a good time to look for that evidence, at least if it's not found it would be something to cancel out and narrow down on possible causes.

 

[EddieZ]

Not even 650 miles and...

Today, the engine fault light came on again, about 330 miles since last time. There has been no rain this time, so, no suspicions about water in the electronics. The only thing slightly out of the ordinary (for me) is that I had done a rapid acceleration up the highway, a few minutes before.

I have made an appointment with the Ford dealer service department for Monday. Wonder if the fault light will clear itself, as it had, last time, after sitting for 2 days.

I have also opened a case with Ford Customer Service at 800-392-3673. I appreciate CrewVanMan having posted that reference in another thread, and had "Liked" that reply, just in case I might need it.

 

[Whitedog]

While the light is still on, stop by an AutoZone or someplace that will let you use their scanner to check the code. Write it down, but do not clear the code. The dealer will want to see the code and any data associated with it.

 

[PeterR]

Today, the engine fault light came on again, about 330 miles since last time. There has been no rain this time, so, no suspicions about water in the electronics. The only thing slightly out of the ordinary (for me) is that I had done a rapid acceleration up the highway, a few minutes before.

I have made an appointment with the Ford dealer service department for Monday. Wonder if the fault light will clear itself, as it had, last time, after sitting for 2 days.

I have also opened a case with Ford Customer Service at 800-392-3673. I appreciate CrewVanMan having posted that reference in another thread, and had "Liked" that reply, just in case I might need it.

Please let us know what the dealer has to say tomorrow. Thanks

 

[EddieZ]

While the light is still on, stop by an AutoZone or someplace that will let you use their scanner to check the code. Write it down, but do not clear the code. The dealer will want to see the code and any data associated with it.

I opted not to drive into town to check code at AutoZone, because that would have required an engine start, and, I was hoping that my next engine start -- today, though that meant sitting unused for more than a full day -- would be more likely to still have the CEL showing.

But, it did not. No CEL. Went in anyway, to get my observation documented. Of course, they could get no info from the ECU. But, this experience sort of fits with the tech's prior comment about a general communication problem (though the unit had not been wet recently, when the Engine Fault showed on Saturday).

While I was there, Ford issued a new TSB, 15-0074, addressing water flow into the engine compartment. I have more info and pics of the TSB pages in the Air Filter Nightmare thread.

So, they sent me home today with no meaningful progress on the Engine Fault. Ford Customer Service is supposed to contact me today, since I have opened a case with them. I am going to suggest to them that they add a new ECU to my service order for Tuesday. The ECU, after all, is the center of communications, and, I seem to have a communication error. Tuesday will be my 4th trip to the service center, each one eating up 2-3 hours or more. I'm not going to have a lot of patience for heading in there when the Engine Fault light comes on every 300 miles.

--- EDIT ---

Just spoke to the Ford Customer Service rep. I'm underwhelmed. She didn't tell me anything new. In fact, she explained that the dealership was -- right now -- checking out my van, when I had actually driven it home a few hours ago. I 'splained her some info she was missing.

I suggested that she recommend changing out the computer module. She said she could not tell dealer service how to proceed.

"But, you can recommend."

"No, they have to follow recommendations of their technical advisers."

"But, you could recommend that dealer service suggest it as a possibility with the technical advisers -- something to consider."

Ho-hum, she never did commit to even doing that.

I'll be speaking to her again next week, after the TSB fix for water flow is applied. But, that won't be directly related to my latest Engine Fault. Not sure what she expects to accomplish -- other than trying to make it look like someone cares.

 

[Whitedog]

Get yourself a $50 scanner and read it when it comes on. BUt, be prepared that it may not read it if it isn't an emissions code. Regardless, having a scanner to read the CEL is a good idea since it can tell you something about what is going on and if you should drive it or not.