04 Ford Fusion 3.0 Duratec DOHC V6. 209,100 miles.
PCV valve failed, line collapsed, and blew out the gaskets.
I replaced:
Valve Cover Gaskets (Fel-Pro)
Upper and Lower Intake Gaskets (Fel-Pro)
Throttle Body Gasket (Fel-Pro)
Timing Cover Gasket (Fel-Pro)
Front Main Seal (SKF)
Oil Pan gasket (Fel-Pro)
PCV valve (Motorcraft)
PCV hose and tube assembly (Motorcraft)
Spark Plugs (Motorcraft SP-433)
Fuel Filter (Wix)
Had to drop front exhaust to the flex pipe to drop oil pan. R&R'd harmonic balancer too, obviously. It looked good, but had a groove from old hardened seal. I installed a repair sleeve from national.
Car sat for 4 weeks on jack stands with oil drained.
Drain and fill twice with Motorcraft 5w-20 Syn Blend and Motorcraft FL-820s filter.
Now it's knocking...or ticking.
Hard to tell. It's not quite bassy enough for what I would call a knock, but not quite high pitched enough to be a tick...sounds almost like a fuel injector on steroids times 100.
VERY HARD TO PINPOINT. I used the hose trick and my mechanic's stethoscope. Can't find an obvious spot. Sounds almost like coming from valley or valve covers. I hear it loudest in the downpipes.
I hoped the hydraulic lash adjusters bled down or one collapsed, but I ran it at a steady 2300 rpm on the highway, changed oil, did it again, and nothing. It's not pumping up.
It completely disappears above 2000 RPM. Engine runs smooth. I have a scantool and there are no obvious problems. Trims are perfect, etc.
I re torqued exhaust, sprayed permatex copper spray sealant on them, and ran engine while tweaking exhaust pipes with broom handle. Made no difference.
Took serpentine belt off and ran engine, still there.
I also replaced the little rear cam driven water pump belt, and I'm aware of TSB 06-3-5 "Camshaft Tick Noise" but I wouldn't call this camshaft tick. More of a whack.
Also, TSB says it only does it when warm. This does it cold or hot.
I also did a cylinder drop test. I couldn't get to #3, but dropping all the others did not change the knock/tick.
I'm at a loss.
It started this immediately upon startup after repairs. Not soon after. I cranked the engine for about a minute while I bled the power steering system. So I know the engine was well primed. The oil light went out while I was cranking.
So stumped. Any ideas? I guess next step is to re-drop the oil pan?
PCV valve failed, line collapsed, and blew out the gaskets.
I replaced:
Valve Cover Gaskets (Fel-Pro)
Upper and Lower Intake Gaskets (Fel-Pro)
Throttle Body Gasket (Fel-Pro)
Timing Cover Gasket (Fel-Pro)
Front Main Seal (SKF)
Oil Pan gasket (Fel-Pro)
PCV valve (Motorcraft)
PCV hose and tube assembly (Motorcraft)
Spark Plugs (Motorcraft SP-433)
Fuel Filter (Wix)
Had to drop front exhaust to the flex pipe to drop oil pan. R&R'd harmonic balancer too, obviously. It looked good, but had a groove from old hardened seal. I installed a repair sleeve from national.
Car sat for 4 weeks on jack stands with oil drained.
Drain and fill twice with Motorcraft 5w-20 Syn Blend and Motorcraft FL-820s filter.
Now it's knocking...or ticking.
Hard to tell. It's not quite bassy enough for what I would call a knock, but not quite high pitched enough to be a tick...sounds almost like a fuel injector on steroids times 100.
VERY HARD TO PINPOINT. I used the hose trick and my mechanic's stethoscope. Can't find an obvious spot. Sounds almost like coming from valley or valve covers. I hear it loudest in the downpipes.
I hoped the hydraulic lash adjusters bled down or one collapsed, but I ran it at a steady 2300 rpm on the highway, changed oil, did it again, and nothing. It's not pumping up.
It completely disappears above 2000 RPM. Engine runs smooth. I have a scantool and there are no obvious problems. Trims are perfect, etc.
I re torqued exhaust, sprayed permatex copper spray sealant on them, and ran engine while tweaking exhaust pipes with broom handle. Made no difference.
Took serpentine belt off and ran engine, still there.
I also replaced the little rear cam driven water pump belt, and I'm aware of TSB 06-3-5 "Camshaft Tick Noise" but I wouldn't call this camshaft tick. More of a whack.
Also, TSB says it only does it when warm. This does it cold or hot.
I also did a cylinder drop test. I couldn't get to #3, but dropping all the others did not change the knock/tick.
I'm at a loss.
It started this immediately upon startup after repairs. Not soon after. I cranked the engine for about a minute while I bled the power steering system. So I know the engine was well primed. The oil light went out while I was cranking.
So stumped. Any ideas? I guess next step is to re-drop the oil pan?
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