2004 with rough idle

[Rangelmil]

I have a 2004 5.4l 2v that had poor idle and smoking bad.

I pulled the engine and found issue with cylider 8.

I went and did a full engine rebuild.

I reinstalled the engine and reconnected everything.

I started the suv and it idled roughly and the muffler flexed in and out.

I did compression checks, cylinder leak down check.
I did a power contribution test and found 1,4,6,7 around -20ish.

Exhaust was check and found good, engine ran the same with exhaust disconnected.

I tested wire harness with noid lights, new motorcraft plugs, new CoPs, moved CoPs around still those 4 with issues

I am leaning towards aPCM issue.

Looking for advice

Jay

 

[BRIANGEE]

No codes? With that many cylinders acting up perhaps it's a timing issue?

 

[1955moose]

I agree with Brian, your cam timings wrong. Recheck it, make sure you were on Exaust stroke when you timed in cams. One tooth off will mess you up!

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[Rangelmil]

Timing was done with engine on the stand.
Exhaust shop stated it could be a timing issue.

I had rechecked the timing yesterday. Still the same issue.

The timing kit i used had colored links for the timing. One link for the crank sprocket and two colored links for the cams.

Is this correct for the timing?

 

[Rangelmil]

Issue is still ongoing.

2 codes for lean on bank one and two.

fuel pressure was tested, steady at 55psi.

 

[1955moose]

What's throwing me is you've got 4 cylinders down 20 pounds on compression, why? There on 2 separate banks.If you messed up and had interference with the valve hitting head, you'd be down a lot more than 20psi. You have either valves that didn't seat, or stuck lifter bores, real common with an older motor, if your 100 percent sure your cams are timed right, sounds like they are, your lean condition may be the leaky valves/rings. I'd do a leakdown test of the motor, and you haven't already done, use a screw in quality compression tester, not just a balance type electronic test. The symptoms of a failing power control module are usually different from yours, but do as many tests as you can before replacing that part, their not cheap. Also do you have a flex pipe before the muffler. I've never heard of a muffler flaring in/out while running. Could be a restriction in the cats or muffler itself. Besides the #8 cylinder, was anything weird with the old motor? You mentioned smoking, rings more than likely. Be sure your pcv, and any other ventilation is working and not plugged. This otta be a fun one to get right.

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