1. Disconnect the voltage regulator connection at the alternator assembly and start the engine to see if it runs better or not and to see if the same coil-on-plug (COP) unit codes reset.
2. If the engine operation is good unless the voltage regulator connection is plugged in, it suggests a diode failure of the alternator assembly creating electrical noise.
3. If the engine operation is not any different with the voltage regulator connection unplugged, check the COP unit circuits at the PCM for battery voltage with the ignition switch in the run position and the COP's connected. Perform a wiggle test of the circuits and harness to verify that battery voltage to the PCM cannot be interrupted indicating a PCM failure.
COP 1 is controlled by a Light Green/White (LG/WH) wire at pin 1 of the C175e connector.
COP 2 is controlled by a Pink/White (PK/WH) wire at pin 12 of the C175e connector.
COP 3 is controlled by a White/Pink (WH/PK) wire at pin 24 of the C175e connector.
COP 4 is controlled by a Dark Green/Violet (DG/VT) wire at pin 35 of the C175e connector.
COP 5 is controlled by a Light Green/Yellow (LG/YE) wire at pin 36 of the C175e connector.
COP 6 is controlled by a Orange/Yellow (OG/YE) wire at pin 22 of the C175e connector.
1. There have been a lot of problems with the coil circuit wires breaking inside their insulation near the Powertrain Control Module (PCM) connector, usually within 2" of the PCM. Wiggle test the wiring harness, starting from the PCM and working toward the coil.
1. Verify battery power is present and consistent on the Red (RD) wire of multiple Coil-On-Plug (COP) unit connections.
2. If the battery power supply to the COPs is good, disconnect and inspect the C133 engine harness connector at the top of the engine for a possible connection issue. This connector is a grey 16-terminal connector. It may be behind the rear side of the intake plenum. Service the connection as necessary.
3. Disconnect the PCM connection and inspect the COP unit primary circuits and terminals at the C175E connection. Service the connection as necessary.
4. If the circuits and connections all appear to be in good condition, replace the PCM. Replacement of the PCM will require a programming function to be performed using the Ford scan tool for Passive Anti-theft System (PATS) functions and the PCM is an 8 year/80,000 mile (7/70 for CA state emissions) warranty item.
You can get the PCM repaired here without any need for programming:
http://circuitboardmedics.com/2005-2006-ford-escape-v6-pcm-ecm-repair/
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You can get the PCM repaired here:
http://circuitboardmedics.com/2005-2006-...
Updated link ishttp://circuitboardmedics.com/2005-ford-...
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