SVThopeful
CEG'er
My Contour will not run and it's making a rattling noise in the engine. We took it down to the Roush/SVT garage and they can't find anything wrong.
Any ideas? Here's what we have done so far.
Powertrain actions taken prior to current condition:
Replaced spark plugs (Bosch), wires (Ford Racing)
Replaced air filter (Fram)
Replaced fuel pump (BAT)
Replaced fuel filter
Replaced MAF
Cleaned IAC valve; replaced gasket
Cleaned Upper and Lower Intake Manifolds
======================================
Car stumbled a bit at WOT and stalled occasionally on decel and at stop lights.
· Ran diagnostic check and found lean condition in both cylinder banks; updated to most recent calibration
· Air leak so severe that car was unable to compensate electronically with enough fuel
· Checked all vacuum hoses and replaced both upper and lower intake manifold gaskets and IMRC bushings/grommets
Car seemed to run marginally better, but scan found no appreciable improvement in air leak.
Car then began running very poorly – misfire? – stumbling and down on power.
Disassembled intake manifold again down to the lower gasket, thoroughly cleaned all surfaces; reassembled IMRC and manifold.
Upon start-up, there was no improvement -- the car ran just as poorly. After a couple of seconds with moderate throttle, a metallic rattling noise occurred, seemingly in the rear of the passenger side of the engine – and the car stalled.
Trailered the car to SVT garage.
At the garage:
Rattling upon start-up (and stalling thereafter) continued.
No error codes registered.
All but one spark plug looked good, with one not physically damaged but covered in oil.
The camshafts/lobes/followers all looked fine.
A leak-down test was negative – the engine is tight.
The secondaries are thoroughly coated with carbon.
Upon looking into the cylinders, there is no evidence of internal damage.
When spinning the engine by hand fast enough to create oil pressure (but w/o ignition), there was no rattling noise.
Any ideas? Here's what we have done so far.
Powertrain actions taken prior to current condition:
Replaced spark plugs (Bosch), wires (Ford Racing)
Replaced air filter (Fram)
Replaced fuel pump (BAT)
Replaced fuel filter
Replaced MAF
Cleaned IAC valve; replaced gasket
Cleaned Upper and Lower Intake Manifolds
======================================
Car stumbled a bit at WOT and stalled occasionally on decel and at stop lights.
· Ran diagnostic check and found lean condition in both cylinder banks; updated to most recent calibration
· Air leak so severe that car was unable to compensate electronically with enough fuel
· Checked all vacuum hoses and replaced both upper and lower intake manifold gaskets and IMRC bushings/grommets
Car seemed to run marginally better, but scan found no appreciable improvement in air leak.
Car then began running very poorly – misfire? – stumbling and down on power.
Disassembled intake manifold again down to the lower gasket, thoroughly cleaned all surfaces; reassembled IMRC and manifold.
Upon start-up, there was no improvement -- the car ran just as poorly. After a couple of seconds with moderate throttle, a metallic rattling noise occurred, seemingly in the rear of the passenger side of the engine – and the car stalled.
Trailered the car to SVT garage.
At the garage:
Rattling upon start-up (and stalling thereafter) continued.
No error codes registered.
All but one spark plug looked good, with one not physically damaged but covered in oil.
The camshafts/lobes/followers all looked fine.
A leak-down test was negative – the engine is tight.
The secondaries are thoroughly coated with carbon.
Upon looking into the cylinders, there is no evidence of internal damage.
When spinning the engine by hand fast enough to create oil pressure (but w/o ignition), there was no rattling noise.
