1999 Ford Windstar P0320 99 Windstar won't start when hot

This is all it say's regarding damage to PCM, of course the longer the water is getting in the more damage would occur .. i'm pretty sure it must have fried a few along the way ??

The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area.
ACTION
During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure.
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This is a strip of soft foam insulation Fig 7.

The relay get's power from fuse # 9 (hot in start) in under dash fuse box. Through a diode to pin #86 on relay. Inside relay is a resistor and solonoid to pin #85 which goes to ground. Relay pin # 30 goes to fuse # 1(hot all times) in power distribution box underhood and relay pin 87 goes to fuses # 19 and 20 in underhood fuse/relay box which send power to HO2s 11, shift solonoid, EGR valve solonoid

I am leaning towards PCM now as well? What I can't come to grips with, is why it would start and run ok. Before we removed the PCM plug. And now it won't?.I think the new PCM is a good price and I will be using them in the future if needs be? This is the frustrating thing. Not being able to be hands on to double check we haven't missed something. I don't want to advise you to spend $150 on a pcm. Only to find it still doesn't run. On the other hand I can't think of any other reason it will not fire up now as long as everything is back together as before. Can you double check all wires, sensors etc.. Check we are getting fuel and spark. We are obviously not getting one of them or it would be firing up?

We could do the last 2 tests, to see what voltage/ohms your getting? From PCM to CKP

1) Check CKP+ Circuit To PCM

Turn ignition off. Disconnect PCM 104-pin connector. Inspect connector for loose, damaged or corroded terminals. Repair as necessary. Turn ignition on. Measure voltage between PCM connector pin No. 21 (CKP+) and CKP+ terminal at CKP sensor wiring harness connector. See Fig. 145-Fig. 148. Also measure resistance between PCM connector pin No. 22 (CKP-) and CKP- terminal at CKP sensor wiring harness connector. If both resistance readings are 5 ohms or less, go to next step. If any resistance reading is more than 5 ohms, repair open circuit.
2) Check For CKP+ Voltage Fault

Reconnect PCM connector. Turn ignition on. Measure voltage between CKP+ terminal at CKP sensor wiring harness connector and negative battery terminal. If voltage is more than one volt, but less than 2 volts, go to next step. If voltage is not as specified, go to step 19).
3) Check For CKP- Voltage Fault

Ensure ignition is on. Measure voltage between CKP- terminal at CKP sensor wiring harness connector and negative battery terminal. If voltage is 1-2 volts, go to step 10). If voltage is not 1-2 volts, go to next step.
4) Determine Fault

If voltage reading in step 3) is less than one volt, go to next step. If voltage reading in step 3) is not less than one volt, go to step 6).
5) Check CKP- Circuit For Short To Ground

Turn ignition off. Disconnect PCM connector. Measure resistance between PCM connector pin No. 22 and negative battery terminal. If resistance is more than 10,000 ohms, replace PCM. If resistance is less than 10,000 ohms, repair CKP- circuit short to ground.
6) Check CKP- Sensor For Short To Power

Disconnect PCM connector. Turn ignition on. Measure voltage between PCM connector pin No. 22 and negative battery terminal. If voltage is.5 volt or more, repair CKP- circuit short to power. If resistance is less than.5 volt, replace PCM.
NOTE:A break in step numbering sequence occurs at this point. Procedure skips from step 6) to step 10). No test procedures have been omitted.

10) Check CKP Sensor Voltage At PCM

Turn ignition off. Reconnect CKP sensor connector. Disconnect PCM connector. While cranking engine, measure voltage between PCM connector pins No. 21 and 22. If A/C voltage stabilized at more than.4 volt, CKP circuit is okay. Go to step 17). If voltage is.4 volt or less, go to next step.
NOTE:A break in step numbering sequence occurs at this point. Procedure skips from step 10) to step 12). No test procedures have been omitted.

12) Check CKP Circuit Resistance

Turn ignition off. Measure resistance between PCM connector pins No. 21 and 22. If resistance is 300-800 ohms, go to step 16). If resistance is not 300-800 ohms, go to next step.
13) Determine Fault

If resistance is less than 300 ohms in step 12), go to next step. If resistance is not less than 300 ohms in step 12), replace CKP sensor.
14) Check For Open Circuit

Disconnect CKP sensor connector. Measure resistance between CKP sensor wiring harness connector terminals. If resistance is less than 5 ohms, repair CKP+ to CKP- short circuit. If resistance is 5 ohms or more, replace CKP sensor.
NOTE:A break in step numbering sequence occurs at this point. Procedure skips from step 14) to step 16). No test procedures have been omitted.

16) Check CKP Sensor & Trigger Wheel

Check CKP sensor and trigger wheel for damage. Repair as necessary. If CKP sensor and trigger wheel are okay, replace CKP sensor.
17) Check For PCM Fault

Turn ignition off. Disconnect CKP sensor connector. Reconnect PCM connector. Measure resistance between CKP sensor wiring harness connector terminals. If resistance is 16,000-24,000 ohms, go to next step. If resistance is not 16,000-24,000 ohms, replace PCM.
18) Check For Short Circuit

Ensure CKP sensor is disconnected. Disconnect PCM connector. Measure resistance between PCM connector pins No. 21 and 22. If resistance is more than 1000 ohms, replace CKP sensor. If resistance is 1000 ohms or less, repair short circuit.
19) Determine Fault

If voltage reading in step 2) is less than one volt, go to next step. If voltage reading in step 2) is not less than one volt, go to step 21).
20) Check CKP+ Circuit For Short To Ground

Turn ignition off. Disconnect PCM connector. Measure resistance between PCM connector pin 21 and negative battery terminal. If resistance is more than 10,000 ohms, replace PCM. If resistance is less than 10,000 ohms, repair CKP+ circuit short to ground.
21) Check CKP+ Sensor For Short To Power

Turn ignition off. Disconnect PCM connector. Turn ignition on. Measure voltage between PCM connector pin No. 21 and negative battery terminal. If voltage is.5 volt or more, repair CKP+ circuit short to power. If voltage is less than.5 volt, replace PCM.

Yeah don't make sense? Unless you plug it back in. But then stage 2 say's plug it back in? We have already checked the condition of the pins. So plug it back in a test it that way.

I think $100 is a very good price. I'll keep my fingers crossed. Cars used to run just as good without all these solonoids, sensors etc. Etc. Ha ha. Let me know how it goes please.

Happy Xmas & new year

Dave H

Sorry I have not got back to you sooner. Try these steps first. I thought the PCM would have come preprogrammed with your old data?

PROGRAMMING SPARE KEY(S) WITH TWO PROGRAMMED KEYS
NOTE:This procedure will only work if 2 or more programmed ignition keys are available and there is a need to program additional keys. If 2 keys are not available, perform PROGRAMMING TWO KEYS/ERASE ALL KEY CODES. Instrument cluster PID SPARE_KY must be enabled for this procedure to operate. To enable this PID, perform SPARE KEY PROGRAMMING SWITCH and enable spare key programming switch. If programming procedure is successful, new key(s) will start vehicle and THEFT indicator will illuminate for 3 seconds. If programming procedure is not successful, new key(s) will not start vehicle and THEFT indicator will flash for one minute (after flashing for one minute, THEFT indicator will flash fault code). If necessary, repeat programming procedure. If programming of key(s) is still unsuccessful, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM. Maximum of 8 keys can be programmed into system. If procedure is not performed as outlined, programming procedure will end. Ignition keys must have correct mechanical key cut for vehicle and must be an encoded key.

Insert the first programmed ignition key into ignition lock cylinder. Turn ignition switch from OFF to RUN position (ignition switch must stay in RUN position for one second). Turn ignition switch to OFF position and remove ignition key from ignition lock cylinder.
Within 5 seconds of turning ignition switch to OFF position, insert second programmed ignition key into ignition lock cylinder. Turn ignition switch from OFF to RUN position (ignition switch must stay in RUN position for one second). Turn ignition switch to OFF position and remove second ignition key from ignition lock cylinder.
Within 5 seconds of turning ignition switch to OFF position, insert a NEW unprogrammed ignition key into ignition lock cylinder. Turn ignition switch from OFF to RUN position (ignition switch must stay in RUN position for one second). Turn ignition switch to OFF position and remove ignition key from ignition lock cylinder. The NEW ignition key should now be programmed. To program additional key(s), repeat key programming procedure from step 1.

Looks like you will have to get someone to come along and reprogram for you or have the vehicle towed to a shop.? In england we had tech's who would come out and do this. But I have never had to do this here (in the U.S.) Yet. So I don't know if they even do this.I'm sure they do I will look into it and let you know?

Key Programming - Erase All Keys & Program 2 Keys
Insert Ford Service Function (FSF) card into NGS tester. Turn ignition switch from LOCK to RUN position. With NGS tester connected to vehicle, enter PCM then select SECURITY ACCESS PROCEDURE. This procedure will take 10 minutes to perform. After the security access procedure has been completed, a new menu will be displayed with command options. Select IGNITION KEY CODE ERASE.
Turn ignition switch to LOCK position and disconnect NGS tester. Insert first encoded ignition key into ignition lock cylinder. Turn ignition switch to RUN position for 3 seconds. Turn ignition switch to LOCK position and remove first encoded key.
Within 5 seconds, insert second encoded ignition key into ignition lock cylinder. Turn ignition switch to RUN position for 3 seconds. Turn ignition switch to LOCK position and remove second encoded key. Both encoded ignition keys should now start vehicle.
NOTE:Security access must be granted to erase ignition keys, enable/disable spare key programming switch, or perform parameter resets for PCM. This procedure has a 10-minute time delay prior to granting security access during which the New Generation Star (NGS) tester must remain connected to vehicle. After security access has been granted, security access command menu is displayed which offers various command options. Multiple security access commands can be executed (if necessary) prior to exiting security access command menu. Execution of all necessary security access commands prior to exiting command menu avoids the performance of an additional security access procedure and the associated 10-minute time delay.

Key Programming - Security Access Procedure
Insert Ford Service Function (FSF) card into NGS tester. Turn ignition switch from LOCK to RUN position. With NGS tester connected to vehicle, enter PCM then select SECURITY ACCESS PROCEDURE. This procedure will take 10 minutes to perform. After the security access procedure has been completed, a new menu will be displayed with command options. Select as many functions as required before exiting this menu. Once this menu is exited, security access procedure must be performed again to perform additional commands.
NOTE:The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the owner's manual. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. The spare key programming switch state can be viewed using PCM PID SPARE_KY.

Key Programming - Spare Key Programming Switch
Insert a programmed ignition key into the ignition lock cylinder. Insert Ford Service Function (FSF) card into NGS tester. Turn ignition switch from LOCK to RUN position. With NGS tester connected to vehicle, enter VIC then select SECURITY ACCESS PROCEDURE. This procedure will take 10 minutes to perform. After the security access procedure has been completed, a new menu will be displayed with command options. The default setting on all new vehicles is ENABLE. Select SPARE KEY PROGRAMMING SWITCH. Set SPARE KEY PROGRAMMING SWITCH to ENABLE to allow keys to be programmed or DISABLE to make key programming not accessible.

NOTE:This procedure will only work if 2 or more programmed ignition keys are available and there is a need to program additional keys. If 2 keys are not available, perform KEY PROGRAMMING - ERASE ALL KEYS & PROGRAM 2 KEYS. PID SPARE_KY must be enabled for this procedure to operate. To enable this PID, perform KEY PROGRAMMING - SPARE KEY PROGRAMMING SWITCH and enable spare key programming switch. If programming procedure is successful, new key(s) will start vehicle and THEFT indicator will illuminate for 3 seconds. If programming procedure is not successful, new key(s) will not start vehicle and THEFT indicator will flash for one minute (after flashing for one minute, THEFT indicator will flash fault code). If necessary, repeat programming procedure. If programming of key(s) is still unsuccessful, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM in PASSIVE ANTI-THEFT SYSTEMS - CONTINENTAL article in ACCESSORIES & EQUIPMENT. Maximum of 8 keys can be programmed into system. If procedure is not performed as outlined, programming procedure will end. Ignition keys must have correct mechanical key cut for vehicle and must be an encoded key.