Engine System - General Information: Other Ford Expedition III

Material

MATERIAL SPECIFICATION

There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out either Inspection and Verification - Engine Performance or Inspection and Verification - Engine NVH.

Inspection and Verification - Engine Performance

1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart. Visual Inspection Chart VISUAL INSPECTION CHART Mechanical Engine coolant leaks Engine oil leaks Fuel leaks Damaged or severely worn parts Loose mounting bolts, studs and nuts
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
5. NOTE: The Vehicle Communication Module (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.
6. 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.
7. 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).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern, refer to «MULTIFUNCTION ELECTRONIC MODULES»(ref-364059) and the «INTRODUCTION - GASOLINE MODELS»(ref-355661) .
10. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART - ENGINE PERFORMANCE»(ref-364043-S28249208342010062700000) .

Cylinder Leakage Detection

When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing the exact cause.

The leakage tester is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke and compressed air is admitted.

Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of leakage. Leakage exceeding 20% is excessive.

While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the tail pipe. Leakage past the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator.

Excessive Engine Oil Consumption

Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is being added over a given set of miles.

Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the engine from reaching normal operating temperature. This prevents component clearances from reaching specified operating ranges.

The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested.

A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the geographic region in which it is driven.

Basic Pre-checks

Detailed Pre-checks

1. Check the thermostat opening temperature to make sure that the cooling system is operating at the specified temperature. If it is low, internal engine parts are not running at specified internal operating clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the conclusion of the oil consumption test.

Post Checks, Evaluation and Corrective Action

1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder compression test should be carried out with a fully charged battery and all spark plugs removed. See the «Compression Pressure Limit Chart»(ref-364043-S40757380162010062700000) for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the «Compression Pressure Limit Chart»(ref-364043-S40757380162010062700000) . If compression tested within the specifications found in this article, the excessive oil consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using a cylinder leakage tester. This can help identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related areas as the source of oil consumption. NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A typical engine with normal oil consumption will exhibit a light tan to brown appearance. See «VALVE TRAIN ANALYSIS - Camshaft Lobe Lift»(ref-364043-S36547997772010062700000) for details. A single or adjoining, multiple cylinder leak can be traced by viewing the tips.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption results.

Valve Train Analysis

The following component tests are used to diagnose valve train concerns.

Valve Train Analysis - Engine Off - Valve Cover Removed

Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the static engine analysis as follows.

Valve Train Analysis - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft

1. Check for loose mounting bolts on camshaft carriers.
2. Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads.

Valve Train Analysis - Engine Off, Camshaft - Engines

1. Check for broken or damaged parts.

Valve Train Analysis - Valve Springs

1. Check for broken or damaged parts.

Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys

1. Check for correct seating of the valve spring retainer key on the valve stem and in valve spring retainer.
2. Check for correct seating on the valve stem.

Valve Train Analysis - Engine Off, Valves and Cylinder Head

1. Check for plugged oil drain back holes.
2. Check for worn or damaged valve tips.
3. Check for missing or damaged guide-mounted valve stem seal.
4. Check for damaged hydraulic lash adjuster.
5. Check installed valve spring height.
6. Check for missing or worn valve spring seats.
7. Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).

Static checks (engine off) are to be made on the engine prior to the dynamic procedure.

Valve Train Analysis - Engine Running, Valves and Cylinder Head

1. Check for plugged oil drain back holes.
2. Check for missing or damaged valve stem seals or guide mounted valve stem seals.
3. Check for a plugged oil metering orifice in the cylinder head oil reservoir.

If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200 RPM with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled. With the valve covers off, some oil splash may overshoot camshaft roller followers.

Valve Train Analysis - Camshaft Lobe Lift

Check the lift of each camshaft lobe in consecutive order and make a note of the readings.

Scheme 310

1. Remove the spark plugs.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the camshaft lobe.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
4. Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the (1) high-lift point of the camshaft lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat the measurement.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller followers.
7. Install the spark plugs.

Sprockets

1. Inspect the sprockets for cracks and worn or chipped teeth.

Scheme 311

MATERIAL SPECIFICATION

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1. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins. If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
2. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin. If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed.
3. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket.

Camshaft Bearing Journal Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure each camshaft journal diameter in 2 directions.

Scheme 315

Camshaft Journal to Bearing Clearance - OHC Engines

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. Subtract the camshaft journal diameter from the camshaft bearing diameter.

Scheme 316

Crankshaft Main Bearing Journal Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.

Scheme 317

Crankshaft Main Bearing Journal Taper and Out-of-Round

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal.

Scheme 318

Crankshaft Main Bearing Journal-to-Bearing Clearance

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

Note. Crankshaft main bearing journals must be within specifications before checking journal clearance.

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1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.

Cylinder Bore Taper

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize limit.

Scheme 321

Cylinder Bore Out-of-Round

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.

Scheme 322

Piston Pin Bore Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within specification.

Scheme 323

Piston Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of the piston at the point indicated.

Scheme 324

Piston To Cylinder Bore Clearance

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance.

Piston Selection

Note. The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.

1. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot or specific size grade on a new piston indicates the position within the size range. Choose the piston with the correct paint color or specific size grade. Refer to the «ENGINE - 5.4L (3V) -- EXPEDITION»(ref-364032) for the procedure.

Scheme 325

Piston Pin Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification.

Scheme 326

Connecting Rod Cleaning

Note. Do not use a caustic cleaning solution or damage to connecting rods can occur.

1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages.

Scheme 327

Connecting Rod Large End Bore

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification.

Scheme 328

Connecting Rod Bushing Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

Scheme 329

1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.

Scheme 330

Connecting Rod Bearing Journal-to-Bearing Clearance

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

Note. The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance.

Scheme 331

1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing.

Scheme 332

Connecting Rod Bearing Journal Taper and Out-of-Round

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit.

Valve Stem Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification.

Scheme 333

Valve Guide Inner Diameter

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

Scheme 334

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1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide, if necessary. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.

Valve Spring Installed Length

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the installed length of each valve spring.

Scheme 336

Valve Spring Free Length

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the free length of each valve spring.

Scheme 337

Valve Spring Squareness

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square.

Scheme 338

Valve and Seat Refacing Measurements

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

Note. After grinding valves or valve seats, check valve clearance.

Scheme 339

1. Check the valve head and seat. Check valve angles. Check margin width. Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found.

Valve Seat Width

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length.

Scheme 340

Valve Seat Runout

Note. Refer to the appropriate ENGINE - 5.4L (3V) for the specification.

1. Use a valve seat runout gauge to check valve seat runout.

Scheme 341

MATERIAL SPECIFICATION

1. NOTE: If these procedures are not followed, rusting of the cylinder bores may occur. Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores. Use clean engine oil meeting Ford specification.

MATERIAL SPECIFICATION

Note. It is necessary to use Loctite® Retaining Compound 620 High Temperature sealant on all 3 valve modular engine cylinder head cup plugs. If not used, the cylinder head cup plugs could leak or seep, causing serious engine damage.

Note. Use threadlock 262 on all other applications.

All core plugs

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Scheme 348

1. Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. Install a new spark plug.
2. Check for oil fouling. Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. Correct the oil leak concern. Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs.
4. Inspect for normal burning. Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. Install new spark plugs.

Scheme 349

Powertrain/Drivetrain Mount Neutralizing

Note. Refer to the appropriate article and procedure for special instructions on loosening and tightening mount fasteners.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may occur. Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.