Inspection and Verification - Engine NVH
- Engine NVH symptoms should be identified using the diagnostic tools and techniques that are available. For a list of these techniques, tools, an explanation of their uses and a glossary of common terms, refer to «NOISE, VIBRATION & HARSHNESS»(ref-364038) .
- Verify the customer concern by operating the engine to duplicate the condition.
- Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change interval.
- Check the engine oil level and check the oil for contamination. Low engine oil level or contaminated oil are common causes of engine noise. If the oil is contaminated the source of the contamination must be identified and repaired as necessary.
- Visually inspect for obvious signs of mechanical damage. Refer to the following chart. Visual Inspection Chart VISUAL INSPECTION CHART Mechanical Loose mounting bolts, studs and nuts Damaged or leaking powertrain mounts Damaged or disconnected vacuum hoses Damaged or disconnected air intake components Obstruction of cooling fan Obstruction of Front End Accessory Drive (FEAD) Obstruction of Rear End Accessory Drive (READ), if equipped
- If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
- NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the DLC .
- NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the VCM . If the scan tool does not communicate with the VCM : check the VCM connection to the vehicle. check the scan tool connection to the VCM . refer to «MODULE COMMUNICATIONS NETWORK»(ref-364058) , No Power To The Scan Tool, to diagnose no power to the scan tool.
- If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(ref-364058) to diagnose no response from the PCM.
- Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(ref-364058) . If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
- Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
- If the DTCs retrieved are related to the concern, refer to «MULTIFUNCTION ELECTRONIC MODULES»(ref-364059) .
- If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise concern is related to the engine. For vibration concerns and noise concerns such as powertrain mounts, air intake system and starter, GO to «SYMPTOM CHART - ENGINE NVH»(ref-364043-S35856745712010062700000) .
In some cases, a noise may be a normal characteristic of that engine type. In other cases, the noise may require further investigation. Comparing the noise to a similar year/model vehicle equipped with the same engine will aid in determining if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope (the noise will always be louder the closer you get to the noise source) to isolate the location of the noise to one of the following areas.
- Upper end of engine
- Lower end of engine
- Front of engine
- Rear of engine
Symptom Chart - Engine Performance
Symptom Chart - Engine Performance
| Condition | Possible Sources | Action |
|---|---|---|
| Difficult starting | Inoperative or damaged ignition system Air or vacuum leak Inoperative or damaged fuel system Inoperative or damaged starting system | INSPECT each system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . |
| Damaged charging system/battery | REFER to CHARGING SYSTEM . | |
| Low oil pressure | CARRY OUT the oil pressure test. | |
| Burnt valve | INSPECT the valve(s) and valve seat(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn piston | INSPECT the piston(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn piston ring(s) | INSPECT the piston ring(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn cylinder | INSPECT the cylinder block for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged head gasket | INSPECT the cylinder head gasket(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Inoperative or damaged cooling system (if equipped, fail-safe cooling invoked) | INSPECT the cooling system for damage. INSTALL new components as necessary. Refer to the ENGINE COOLING -- EXPEDITION for the procedure. | |
| Poor idling | Vacuum leaks Inoperative or damaged EGR system | INSPECT the EGR and vacuum system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . |
| Inoperative or damaged ignition system | INSPECT the ignition system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . | |
| Inoperative or damaged cooling system (if equipped, fail-safe cooling invoked) | INSPECT the cooling system for damage. INSTALL new components as necessary. Refer to the ENGINE COOLING -- EXPEDITION for the procedure. | |
| Inoperative or damaged fuel system | INSPECT the fuel system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . | |
| Damaged hydraulic lash adjuster | INSPECT the hydraulic lash adjuster(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Incorrect valve-to-seat contact | INSPECT the valve(s) and cylinder head(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged head gasket | INSPECT the cylinder head gasket(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Low oil pressure | CARRY OUT the oil pressure test. | |
| Abnormal combustion | Inoperative or damaged fuel system Air or vacuum leaks EGR system fault Inoperative or damaged cooling system (if equipped, fail-safe cooling invoked) Inoperative or damaged ignition system | INSPECT each system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . |
| Malfunctioning or damaged air intake system | INSPECT the air intake system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged hydraulic lash adjuster(s) | INSPECT the hydraulic lash adjuster(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Burnt or sticking valve | INSPECT the valve(s) and valve seat(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Weak or broken valve spring | INSPECT the valve spring(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Carbon accumulation in combustion chamber | ELIMINATE carbon buildup. | |
| Excessive oil consumption | Leaking oil | REPAIR oil leakage. |
| Malfunctioning PCV system | INSPECT the PCV system for damage. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. REFER to the INTRODUCTION - GASOLINE MODELS . | |
| Worn valve stem seal | INSPECT the valve(s) and valve stem seal(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn valve stem or valve guide | INSPECT the valve(s) and cylinder head(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Sticking piston rings | INSPECT the piston(s) and cylinder block for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn piston ring groove | INSPECT the piston(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn piston or cylinder | INSPECT the piston(s) and cylinder block for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Insufficient power | Inoperative or damaged ignition system Air intake system blockage Lubrication system blockage Inoperative or damaged fuel system | REFER to the INTRODUCTION - GASOLINE MODELS . |
| Oil level too high | DRAIN oil to correct level. | |
| Incorrect engine oil | INSTALL correct specification engine oil. | |
| Low oil pressure | CARRY OUT the oil pressure test. | |
| Excessive accessory drive belt loading | INSPECT the accessory drive system for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Inoperative or damaged cooling system (if equipped, fail-safe cooling invoked) | INSPECT the cooling system for damage. INSTALL new components as necessary. Refer to the ENGINE COOLING -- EXPEDITION for the procedure. | |
| Damaged or plugged exhaust system | INSPECT the exhaust system for flow and damage. INSTALL new components as necessary. REFER to EXHAUST SYSTEM . | |
| Incorrect tire size | REFER to SUSPENSION SYSTEM - GENERAL INFORMATION . | |
| Dragging brakes | REFER to BRAKE SYSTEM - GENERAL INFORMATION . | |
| Slipping transmission | Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. | |
| Malfunctioning hydraulic lash adjuster | INSPECT the hydraulic lash adjuster for wear or damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Compression leakage at valve seat | INSPECT the valve, valve seat and cylinder head for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Seized valve stem | INSPECT the valve for wear or damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Weak or broken valve spring | INSPECT the valve spring. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn or damaged camshaft | INSPECT the camshaft for wear or damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged head gasket(s) | INSPECT the cylinder head gasket(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Cracked or distorted cylinder head(s) | INSPECT the cylinder head(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged, worn or sticking piston ring(s) | INSPECT the piston ring(s) for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn or damaged piston | INSPECT the piston for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Oil in coolant | Leaking head gasket | INSTALL a new head gasket. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Leaking oil cooler | INSPECT the oil filter adapter and seal for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Leaking oil filter adapter | INSPECT the oil filter adapter and gasket for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged cylinder head | INSPECT the engine components for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Damaged cylinder block | INSPECT the engine components for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Coolant in oil | Leaking head gasket Leaking oil cooler Leaking oil filter adapter Damaged cylinder head Damaged cylinder block | INSPECT the engine components for damage. INSTALL new components as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
ENGINE PERFORMANCE SYMPTOM CHART
Symptom Chart - Engine NVH
Note. Engine NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION & HARSHNESS . Since it is possible that any one of multiple systems may be the cause of the symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to NOISE, VIBRATION & HARSHNESS for the next likely system and continue diagnosis.
| Condition | Possible Sources | Action |
|---|---|---|
| Drone type noise | Powertrain mount(s) | CARRY OUT the POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING procedure. |
| Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency drumming is very RPM dependent | Engine vibration excites the body resonances inducing interior noise | CARRY OUT the POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING procedure. |
| Engine drumming noise - accompanied by vibration | Powertrain mount(s) | CARRY OUT the POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING procedure. |
| Rattle - occurs at idle or at light acceleration from a stop | Powertrain mount(s) | CHECK the powertrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. For automatic transmission, Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. |
| Whine/moan type noise - pitch increases or changes with vehicle speed | Powertrain mount(s) | CHECK the powertrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. For automatic transmission, Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. |
| Clunk - occurs when shifting from PARK or between REVERSE and DRIVE | Powertrain mounts | CHECK the powertrain/drivetrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. For automatic transmission, Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. |
| Idle speed is too high | CHECK for the correct idle speed. REFER to INTRODUCTION - GASOLINE MODELS . | |
| Accessory drive bearing hoot - occurs at idle or high idle in cold temperatures of approximately +4°C (+40°F) or colder at the first start of the day | Accessory drive idler or tensioner pulley bearing is experiencing stick/slip between ball bearings and the bearing race | CARRY OUT the engine cold soak procedure. REFER to NOISE, VIBRATION & HARSHNESS . PLACE the EngineEAR probe directly on the idler/tensioner center post or bolt to verify which bearing is making the noise. INSTALL new parts as necessary. REFER to ACCESSORY DRIVE . |
| Accessory drive belt noise, squeal or chirping | Defective/worn or incorrect accessory drive belt Misaligned pulley(s) Pulley runout Damaged or worn accessory drive component or idler Fluid contamination of the accessory drive belt or pulleys Damaged or worn accessory drive belt tensioner Damaged pulley grooves | CARRY OUT the Engine Accessory Test. REFER to NOISE, VIBRATION & HARSHNESS . INSPECT components and INSTALL new parts as necessary. REFER to ACCESSORY DRIVE . |
| Clunking noise | Coolant pump has excessive end play or imbalance | CHECK the coolant pump for excessive end play. INSPECT the coolant pump for imbalance with the drive belt off. INSTALL a new coolant pump as necessary. REFER to ENGINE COOLING . |
| Whine or moaning noise | Air intake system | CHECK the Air Cleaner (ACL) and ducts for correct fit. INSPECT the air intake system for leaks or damage. REPAIR as necessary. REFER to INTAKE AIR DISTRIBUTION & FILTERING . |
| Whistling noise - normally accompanied with poor idle condition | Air intake system | CHECK the air intake ducts, ACL , Throttle Body (TB) and vacuum hoses for leaks and correct fit. REPAIR or ADJUST as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Hissing noise - occurs during idle or high idle that is apparent with the hood open | Vacuum leak noise | USE the EngineEAR to locate the source. SCAN the air intake system from the inlet to each cylinder intake port. DISCARD the leaking parts, and INSTALL a new component. |
| Vehicles with a plastic intake manifold | Acceptable condition. Some plastic manifolds exhibit this noise, which is the effect of the plastic manifold. | |
| Grinding noise - occurs during engine cranking | Incorrect starter motor mounting | INSPECT the starter motor for correct mounting. REPAIR as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Starter motor | CHECK the starter motor. INSTALL a new starter motor as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Incorrect starter motor drive engagement | INSPECT the starter motor drive for wear or damage. INSTALL a new starter motor as necessary. Refer to the STARTING SYSTEM for the procedure. INSPECT the flywheel/flexplate for wear or damage. INSTALL a new flywheel/flexplate as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Engine noise, front of engine - knocking noise from lower front of engine | Damaged or separated crankshaft pulley/damper | CHECK for obvious signs of damage or wobble during operation. INSTALL new as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Engine noise, front of engine - ticking, tapping or rattling noise from the front of the engine | Timing drive components | REMOVE the accessory drive belt. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. USE the EngineEAR to isolate the noise to the engine front cover. REMOVE the engine front cover and INSPECT the timing drive components. INSTALL new parts as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Engine noise, upper end - ticking noise near the fuel rail and intake manifold | Fuel rail clip | CHECK for loose or damaged fuel rail clip(s). REPAIR as necessary. |
| Fuel injector | USE the EngineEAR to isolate the noisy injector(s). INSTALL new injector(s) as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Engine noise, upper end - ticking, knocking or rattle noise that occurs during idle or high idle during the first cold start of the day and may disappear as the engine warms | Valve train noise (bled down lifter/lash adjuster) | CARRY OUT the Valve Train Analysis Component Test. INSTALL new parts as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Engine noise, upper end - occurs mostly with a warm engine at light/medium acceleration | Worn or damaged spark plugs | REMOVE the spark plugs. INSPECT and INSTALL new as necessary. Refer to the ENGINE IGNITION - 5.4L (3V) for the procedure. |
| Carbon accumulation in combustion chamber | INSPECT the cylinder using a Bore scope. ELIMINATE carbon buildup. | |
| Engine noise, upper end - rattling noise from the valve train. Worse when the engine is cold | Low oil level | CHECK the oil level. FILL as necessary. |
| Worn valve train components | CARRY OUT the Valve Train Analysis Component Test. INSTALL new parts as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Worn valve guides | CARRY OUT the VALVE GUIDE INNER DIAMETER procedure. | |
| Excessive runout of the valve seats on the valve face | CARRY OUT the VALVE SEAT INSPECTION procedure. | |
| Engine noise, upper end - pinging noise | Gasoline octane too low | VERIFY with customer the type of gasoline used. CORRECT as necessary. |
| Knock Sensor (KS) operation | CHECK the KS . INSTALL a new KS as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. | |
| Incorrect spark timing | REFER to the INTRODUCTION - GASOLINE MODELS . | |
| High operating temperature | INSPECT the cooling system for leaks. CHECK the coolant level. REFILL as necessary. CHECK the coolant for the correct mix ratio. DRAIN and REFILL as needed. VERIFY the engine operating temperature is within specifications. REPAIR as necessary. Refer to the ENGINE COOLING -- EXPEDITION for the procedure. | |
| Spark plug | CHECK the spark plugs. REPAIR or INSTALL new spark plugs as necessary. Refer to the ENGINE IGNITION - 5.4L (3V) for the procedure. | |
| Catalytic converter | Acceptable noise. | |
| Engine noise, upper end - knocking or ticking noise, occurs mostly with a warm engine at idle | Low oil level | CHECK the oil level. FILL as necessary. |
| Thin or diluted oil | INSPECT the oil for contamination. If the oil is contaminated, CHECK for the source. REPAIR as necessary. CHANGE the oil and filter. | |
| Damaged or incorrect oil filter | INSPECT the oil filter. INSTALL a new oil filter as necessary. | |
| Low oil pressure | CARRY OUT the oil pressure test. | |
| Camshaft phaser and sprocket(s) [ VCT engines only] | GO to PINPOINT TEST A . | |
| Engine noise, lower end - ticking or knocking noise near the oil filter adapter | Oil pump | USE the EngineEAR to verify the oil pump as the source of the noise at low RPM. REPAIR as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Engine noise, lower end - light knocking noise, also described as piston slap. Noise is most noticeable when the engine is cold with light to medium acceleration. The noise disappears as the engine warms | Excessive clearance between the piston and the cylinder wall | CARRY OUT the PISTON TO CYLINDER BORE CLEARANCE procedure. |
| Engine noise, lower end - light double knock or sharp rap sound. Occurs mostly with a warm engine at idle or low speeds in drive. Increases in relation to engine load. Associated with a poor lubrication history | Excessive clearance between the piston and the piston pin | CARRY OUT the PISTON PIN BORE DIAMETER procedure and the PISTON PIN DIAMETER procedure. |
| Excessive clearance between the piston and the connecting rod | CARRY OUT the Connecting Rod-to-Piston Clearance procedure. | |
| Engine noise, lower end - light knocking noise. The noise is most noticeable when the engine is warm. The noise tends to decrease when the vehicle is coasting or in NEUTRAL | Excessive clearance between the connecting rod bearings and the crankshaft | CARRY OUT the Connecting Rod Bearing Journal-to-Bearing Clearance procedure. |
| Engine noise, lower end - deep knocking noise. The noise is most noticeable when the engine is warm, at lower RPM and under a light load and then at float | Worn or damaged crankshaft main bearings | CARRY OUT the Crankshaft Main Bearing Journal-to-Bearing Clearance procedure. |
| Engine noise, rear of engine - knocking noise at rear of engine | Damaged flywheel/flexplate | CARRY OUT the FLEXPLATE INSPECTION procedure. |
| Engine vibration - vibration felt at all times | Excessive crankshaft pulley runout | CARRY OUT the Engine Accessory Test. INSTALL a new crankshaft pulley as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Damaged or worn accessory component | CARRY OUT the Engine Accessory Test. REPAIR or INSTALL a new component as necessary. | |
| Engine vibration - at idle, a low-frequency vibration (5-20 Hz) or mild shake that is felt through the seat/floorpan | Cylinder misfire | CARRY OUT the cylinder power balance and the relative compression test using the scan tool. REPAIR as necessary. Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. |
| Engine or torque converter out of balance | VERIFY the torque converter to crankshaft pilot clearance is correct. REPAIR as necessary. RE-INDEX the torque converter on the flexplate by 120 degrees for a 3-bolt converter or 180 degrees for a 4-bolt converter. Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. | |
| Engine vibration - is felt with increases and decreases in engine RPM | Powertrain mount(s) | CHECK the powertrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to the ENGINE - 5.4L (3V) -- EXPEDITION for the procedure. For automatic transmission, Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. |
| Engine or transmission contacting the chassis | INSPECT the powertrain/drivetrain for correct clearances. REPAIR as necessary. | |
| Engine vibration - increases intensity as the engine RPM is increased | Engine out-of-balance | CARRY OUT the Neutral Engine Run-Up (NERU) Test. REFER to NOISE, VIBRATION & HARSHNESS . ROTATE the torque converter, 120 degrees for 3-bolt or 180 degrees for 4-bolt. INSPECT the torque converter pilot outer diameter to crankshaft pilot inner diameter. REPAIR as necessary. Refer to the AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80 -- EXPEDITION for the procedure. |
| Engine vibration - mostly at coast/neutral coast. Condition improves with vehicle acceleration | Combustion instability | CHECK the ignition system. INSTALL new components as necessary. Refer to the ENGINE IGNITION - 5.4L (3V) for the procedure. |
| Engine vibration or shudder - occurs with light to medium acceleration above 56 km/h (35 mph) | Worn or damaged spark plugs | INSPECT the spark plugs for cracks, high resistance or broken insulators. INSTALL a new spark plug(s) as necessary. Refer to the ENGINE IGNITION - 5.4L (3V) for the procedure. |
| Plugged fuel injector | INSTALL a new fuel injector as necessary. Refer to the FUEL CHARGING & CONTROLS - 5.4L (3V) for the procedure. | |
| Contaminated fuel | INSPECT the fuel for contamination. DRAIN the fuel system and refill. |
ENGINE NVH SYMPTOM CHART
Pinpoint Test A: Engine Noise, Upper End - Camshaft Phaser and Sprocket(s) [Variable Camshaft Timing (VCT) Engines Only]
This pinpoint test is intended to diagnose the following
- Camshaft phaser and sprocket noise
PINPOINT TEST A: ENGINE NOISE, UPPER END - CAMSHAFT PHASER AND SPROCKET(S) [VCT ENGINES ONLY]
- A1 VERIFY THE CAMSHAFT PHASER AND SPROCKET(S) NOISE Ignition OFF. Disconnecting the RH and LH Variable Camshaft Timing (VCT) solenoid electrical connectors. Start the vehicle and elevate the engine RPM and then return to idle. Is the camshaft phaser and sprocket noise still audible? Yes: The concern is not VCT related. GO to «SYMPTOM CHART - ENGINE NVH»(ref-364043-S35856745712010062700000) . No: GO to A2 .
- A2 CHECK THE ENGINE MINIMUM OIL PRESSURE Check the engine oil pressure. Carry out the oil pressure test. Is the oil pressure reading within the minimum specification? Yes: GO to A3 . No: GO to «PINPOINT TEST B»(ref-364043-S41414086582010062700000) .
- A3 CHECK THE VCT HOUSING OIL SCREEN FOR DEBRIS Remove the VCT housing oil screen and inspect for debris. Is the VCT oil screen clean and free of debris? Yes: INSPECT the VCT camshaft phaser and sprockets and REPAIR as necessary. REFER to «CAMSHAFT PHASER AND SPROCKET INSPECTION»(ref-364043-S16123108482010062700000) . No: REMOVE the VCT housing, Refer to the for the procedure. CLEAN and INSPECT the VCT housing. REFER to «VARIABLE CAMSHAFT TIMING (VCT) HOUSING CLEANING AND INSPECTION»(ref-364043-S09592630312010062700000) .
PINPOINT TEST B: LOW OIL PRESSURE
- B1 CHECK THE CRANKSHAFT END PLAY Check the crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-364043-S31414279192010062700000) . Is the crankshaft end play within specification? Yes: GO to B2 . No: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.
- B2 VERIFY THE CAMSHAFT BEARING CAPS ARE NOT DAMAGED AND TIGHT Check that the camshaft bearing caps are not damaged and the bolts are properly tightened. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Are the camshaft bearing caps loose or damaged? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: If the engine is equipped with VCT , GO to B3 ; for all other engines, GO to B5 .
- B3 VERIFY THE CAMSHAFT PHASER AND SPROCKET BOLT(S) ARE TIGHT Check that the camshaft phaser and sprocket bolt(s) are tight. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Are the camshaft phaser and sprocket bolt(s) loose? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B4 .
- B4 VERIFY THE VCT HOUSING BOLT(S) ARE TIGHT [ VCT ENGINES ONLY] Check that the VCT housing bolts are tight. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Are the VCT housing bolts loose? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B5 .
- B5 CHECK CAMSHAFT JOURNAL-TO-BEARING CLEARANCE Check the camshaft journal-to-bearing clearance. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Is camshaft journal-to-bearing clearance within specification? Yes: GO to B6 . No: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.
- B6 CHECK FOR RESTRICTED OIL FLOW Verify the oil supply and return passages are not plugged and clean of debris. Refer to the oil flow chart «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) in the appropriate engine article. Is oil flow restricted? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B7 .
- B7 CHECK THE TIMING CHAIN TENSIONERS FOR DAMAGE AND VERIFY THE BOLTS ARE TIGHT Check that the timing chain tensioners are not damaged or the bolts are loose. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) in the appropriate engine article. Are the timing chain tensioners damaged or bolts loose? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B8 .
- B8 CHECK THE OIL PUMP PICKUP TUBE AND SCREEN FOR DAMAGE Check that the oil pump pickup tube and screen is not plugged, cracked or that the bolts are loose. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) in the appropriate engine article. Is the oil pump screen and pickup tube damaged or loose? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B9 .
- B9 CHECK THE OIL PUMP FOR DAMAGE Verify the oil pump is not damaged. Is oil pump damaged? Yes: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure. No: GO to B10 .
- B10 CHECK CRANKSHAFT MAIN BEARING JOURNAL-TO-BEARING CLEARANCE Check the crankshaft main bearing journal-to-bearing clearance. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Is crankshaft main bearing journal-to-bearing clearance within specification? Yes: GO to B11 . No: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.
- B11 CHECK CONNECTING ROD BEARING JOURNAL-TO-BEARING CLEARANCE Check the connecting rod bearing journal-to-bearing clearance. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for Specification chart in the appropriate engine article. Is connecting rod bearing journal-to-bearing clearance within specification? Yes: The concern may have been caused by debris or an incorrect assembly. REPEAT the oil pressure test. No: REPAIR as necessary. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.
Component Tests
The following component tests are used to diagnose engine concerns.
Engine Oil Leaks
Note. If an overnight drive is done, the fan air or road air blast may cause erroneous readings.
Note. When diagnosing engine oil leaks, the source and location of the leak must be positively identified prior to repair.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and flywheel with a suitable solvent to remove all traces of oil.
Engine Oil Leaks - Fluorescent Oil Additive Method
Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak diagnosis.
- Add 29.6 ml (1 oz) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of 0.95L (1 qt) engine oil and fill through the engine oil fill. If the oil is not premixed, the gasoline engine oil dye will not have enough time to reach the crankcase, oil galleries and seal surfaces during this particular 15 minute test. The gasoline engine oil dye must be mixed with oil and added through the oil fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use 0.47L (1/2 qt).
- Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the UV Diagnostic Inspection Kit. A clear bright yellow or orange area will identify the leak. For extremely small leaks, several hours may be required for the leak to appear.
- At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove oil as necessary if it registers above the full mark.
Leakage Points - Underhood
Examine the following areas for oil leakage
- Valve cover gaskets
- Cylinder head gaskets
- Oil cooler, if equipped
- Oil filter adapter
- Engine front cover
- Oil filter adapter and filter body
- Oil level indicator tube connection
- Engine Oil Pressure (EOP) sensor
Leakage Points - Under Engine, With Vehicle on Hoist
Examine the following areas for oil leakage
- Oil pan gaskets
- Oil pan sealer
- Engine front cover gasket
- Crankshaft front seal
- Crankshaft rear oil seal
- Oil filter adapter and filter body
- Oil cooler, if equipped
Leakage Points - With Transmission and Flywheel Removed
Examine the following areas for oil leakage
- Crankshaft rear seal
- Crankshaft rear seal retainer
- Rear main bearing cap parting line
- Flexplate mounting bolt holes (with flexplate installed)
- Pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using the Gasoline Engine Oil Dye method.
Compression Test - Compression Gauge Check
- Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs.
- Set the throttle plates in the wide-open position.
- Install a compression gauge in the No. 1 cylinder.
- Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading.
- Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes.
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the COMPRESSION PRESSURE LIMIT CHART .
Scheme 274
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test - Interpreting Compression Readings
- If compression improves considerably, piston rings are faulty.
- If compression does not improve, valves are sticking or seating incorrectly.
- If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading.
Oil Consumption Test
Once all of the previous conditions are met, carry out an oil consumption test.
Pinpoint Test B
B1
one liter (quart) less
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake manifold. Run the engine at the specified idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and the altitude at which the test is performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000 ft) of elevation above sea level.
The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter.
Intake Manifold Vacuum Test - Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas. Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge readings, although helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.
Scheme 275
- NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
- NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the engine is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When the throttle is suddenly released, the needle will snap back up to a higher than normal figure.
- NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low as 51 kPa (15 in-Hg), but will be relatively steady. Some oscillation is normal.
- WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
- STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum, but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be sticking.
- BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic lash adjuster clearance will also cause this reaction.
- POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
- WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle speed, the valve guides could be worn. As engine speed increases, the needle will become steady if guides are responsible.
- WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine RPM is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
- LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
- IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady, but somewhat low, reading.
- INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
- INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
- BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head-to-cylinder block surface.
- RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine RPM is increased, the back pressure caused by a clogged muffler, kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even if the engine is only idling.
- When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on acceleration or burned valves. If the leak exists in an accessory unit such as the power brake booster, the unit will not function correctly. Always fix vacuum leaks.
Oil Pressure Test
Note. Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change intervals. Check the engine oil level and check the oil for contamination. If the oil is contaminated, engine damage can occur, the source of the contamination must be identified and repaired as necessary.
- Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.
- Connect the Oil Pressure Gauge to the oil pressure port.
- Run the engine until normal operating temperature is reached.
- With the engine at idle record the gauge reading.
- Run the engine at 2,000 RPM and record the gauge reading.
- The oil pressure should be within specifications; refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) .
- If the pressure is not within specification, GO to «PINPOINT TEST B»(ref-364043-S41414086582010062700000) .
Camshaft Surface Inspection
- Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area.
Scheme 276
Roller Follower Inspection
- Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage.
Scheme 277
Hydraulic Lash Adjuster Inspection
- Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage.
Scheme 278
Valve Inspection
- Inspect the following valve areas: The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.
Scheme 279
Flexplate Inspection
- Inspect the flexplate for: any cracks. worn ring gear teeth. chipped or cracked ring gear teeth.
Scheme 280
Bearing Inspection
- Inspect bearings for the following defects: Cratering - fatigue failure Spot polishing - incorrect seating Imbedded dirty engine oil Scratching - dirty engine oil Base exposed - poor lubrication Both edges worn - journal damaged One edge worn - journal tapered or bearing not seated
