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Had this posted in the 302 forum, but got nothing that really worked.....
97 5.0, K&N FIPK 40K,
-new plugs, Wires,
-run 89 Octane.
-Drivers side Exhaust manifold was replaced
-Removed and cleaned IAC valve and Throttle Body
-Vacuum test on EGR looks good
-Ordered the Gibson Cat-back, not here yet.
When stating and running cold there is a noise up to about 2200RPM, it doesn't sound like lifters, more like a pressure leak. Sounds like it is coming from Passenger side top/rear of engine. Once the truck is warmed up it is fine. Gas Mileage, drivability is the same as always. This does not appear to be affecting the truck, but the noise is driving me nuts.
Ford dealer and Garage where I get it inspected think it is carbon. I've run Marvel Mystery Oil through the engine and was surprised how dirty the oil came out after on 1800 miles.
Today it was bitter cold and the noise and perfromance was the worst it has ever been. It felt as if the truck was "missing" throughout the entire band. Plugs are new and the old ones looked fine.
The driver’s side was replaced under warranty at about 37K. I‘ve tried to see if the passenger side is leaking but can’t find anything. The noise disappears under normal driving, noticeable when very cold and under load or under 2000 RPM. I know noise travels, but it seems to be coming from the top back passenger side, that is why I thought EGR, but it passsed vacuum test.
I have a 96 EB AWD V8 with 176K miles that also is noisy on cold starts. My guess is that until the oil gets warm and circulates well, it's lifter knock (mine is also on passenger side, and I run in Berryman B-12 Chemtool before each oil change at 3K miles)
If there are no driveability problems or codes showing up, it may just be something we'll have to live with.
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