03 navigator 5.4 32v tear down and rebuild project

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Andy J

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Hey guys,

My names Andy. I joined a few weeks ago when i bought my 2003 navigator. Its a very nice truck and i knew it had a few issues when i bought it. It had a very bad misfire and it would buck and jerk when i drove it. I gave it a full tune up, and changed half of the ignition coils, which took care of the majority of the misfires, but it still had a slight miss. I had a friend hook up a ford IDS, and he came back with a 10 percent drop in compression on cyl 6, but that shouldnt have been enough to cause the mis i was feeling. It wouldnt even give me a code for a miss. The other main issue was the timing chain rattle when it was first started. I knew that it probably had a bad timing chain tensioner, but it consistantly got worse.

Well, today i finally has enough and started to tear into it. I plan on tearing it down all the way to the bare block and completely rebuilding it. I bought the navigator so that i would have something larger and safer as my wife and i are expecting our first baby any day now.

I will take pictures and document the process so yall can follow along and maybe get some inspiration to tackle your own projects.

Heres where i got to today...

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Andy J

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I got the upper and lower intake off and found this in the valley, apparently its been leaking for quite a while, and the antifreeze here is.literally a slime consistency.

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Andy J

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The intake ports are literally disgusting. There is a sludge layer around every single port, with the worst one having a quarter inch thick coating and the "cleanest" having an eighth inch thick layer. I find it interesting because the only way that the oil sludge could accumulate at the top of the head port would be if it was coming from the intake manifold which is also filthy by the way, via the pcv valve. I plan on replacing the pcv valve along with a host of other parts.

Well this is as far as i got today in 4 hours. The intake was a pain in the butt. This is my first 32v engine tear down, and about my 34th modular build. I was a heavy line ford tech (mostly diesel) for a few years after going to school for auto repair and engineering before i changed career paths, but i was still kinda angry at myself that it took me this long to get the intake off, all the while wishing it was a 16v manifold lol.

I will keep yall updated, lemme know what you think.

Andy

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Bain64

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holy hell that intake port is gunked up! I look forward to following the rest of the rebuild. Thanks for sharing.
 

johnboneske

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BTW, a 2003 Navi, is just a 16 Valve motor, not a 24 valve... not sure where you got 32 valve from?

Ford/Lincoln didnt have the 24 valve engine in their SUV's until 2005...
 
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Andy J

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Lincoln offered a 32v 5.4 v8 as an option in the first gen navigators, it was the only option in the 03 and 04 navigators. The 32v went away for the 05 model year when they started using the 24v. The 32v engine was called "intech"

this is a picture of the ignition coil cover on my drivers side valve cover.

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Andy J

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It sure isnt as easy to work on as a 16v ill tell ya that lol i wish it was.
 
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Andy J

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Well... um yea lol. No wonder my timing kept hunting all over. When i first got the truck, i changed the oil, and the filter felt exceptionally heavy. Guess the aluminum i mean oil pump packed the filter full of it. This is not what i wanted to see, but i kind of expected it. I cant believe that the passenger guide is literally half missing. I was hoping the bottom end would be ok, but after seeing this, i dont think i have a choice in rebuilding it due to the fact that im 99 percent the pickup screen will be plugged and the bearingd probably got deprived of oil. Funny thing is that it wasnt knocking though. Dang, my works cut out for me isnt it.

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JExpedition07

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BTW, a 2003 Navi, is just a 16 Valve motor, not a 24 valve... not sure where you got 32 valve from?

Ford/Lincoln didnt have the 24 valve engine in their SUV's until 2005...
Fake news
 
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