This article supersedes TSB 02-16-2 to update the vehicle model years, and the Service Procedure.
ISSUE:
Some 2000-2005 Lincoln LS and 2002-2005 Thunderbird vehicles equipped with the 3.9L engine and built through 5/1/2004, may exhibit a misfire condition and possible diagnostic trouble codes (DTCs) P0301-P0308. This may be caused by water or moisture in the coil on plug (COP) and coil wells, due to water leaking past the foam seal of the cowl panel grill.
ACTION:
First verify water or moisture is present in the coil wells by removing the ignition coil covers, refer to section 303-07B of 2005 Lincoln LS Workshop Manual. If signs of water or moisture are present refer to the following Service Procedure. If there are no signs of water or moisture, perform normal diagnostics as outlined in the PC/ED Manual.
SERVICE PROCEDURE
NOTE: REFERENCE SECTION 303-07B OF 2005 LINCOLN LS WORKSHOP MANUAL THROUGHOUT THIS PROCEDURE AS NEEDED. DO NOT USE EARLIER VERSIONS OF THE WORKSHOP MANUAL.
COIL SERVICE
1. Disconnect the eight (8) ignition coil electrical connectors.
2. Remove the eight (8) ignition coil bolts.
NOTE: WHEN REMOVING THE IGNITION COILS, A SLIGHT TWISTING MOTION WILL BREAK THE SEAL AND EASE REMOVAL.
3. Remove the ignition coil and inspect the boots for damage and replace as required.
4. Using shop air, blow (dry) out water from coils and coil wells.
5. Apply Silicone Brake Caliper Grease and dielectric compound (XG-3-A) or equivalent, to the inside of the ignition coil boot.
6. Reinstall ignition coils and tighten bolts to 44 lb-in (5 N-m).
7. Reconnect the ignition coil electrical connectors.
8. Install new ignition coil covers (XW4Z-12025-AD). Refer to Section 303-07B of the 2005 Lincoln LS Workshop Manual.
COWL PANEL GRILLE AND FOAM SEAL SERVICE
1. Remove the cowl panel grille refer to section 501-02 of the 2005 Lincoln LS Workshop Manual.
2. Remove the foam seal and discard (Figure 1).
3. Clean foam-sealing area using Bug and Tar Remover (ZC-42) or equivalent.
4. Install a new foam seal (5W4Z-54021A46-A), centering the seal on the hole of the cowl panel grille (Figure 1).
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Figure 1 - Article 05-16-2
5. Reinstall the cowl panel grille. Refer to Section 501-02 of the 2005 Lincoln LS Workshop Manual.
6. Clear all DTCs.
7. If misfire is still present perform normal diagnostics per the PC/ED Manual.
PART NUMBER PART NAME
XW4Z-12025-AD Coil Cover
5W4Z-54021A46-A Foam Seal
XG-3-A Silicone Brake Caliper Grease
ZC-42 Bug and Tar Remover
