LONG process, but rough idle and stuck lean upstream o2 sensors bank 1 & 2 , already replaced them with new NTK ones, as those were on it for a few years before. Changed the intake manifold due to a leak at the passenser side crossover, got a junkyard manifold form and 07 econoline 5.4, it appears to be the exact same and bolted up the exact same, swapped the old crossover tube to the junkyard manifold due to it not being the same, 03 expedition has a coolant line in the center ish, the 07 econoline crossover tube did not, bolted right up aswell,

Issue now is the truck just runs roughhhhh, i have checked all my vacuum lines, and all are good, the back elbow behind the intake is good, so every other line, i got a new intake manifold gasket and added just a tiny bit of silicone to it, to fill in the small gaps between the gasket and have no leaks, i can aim carb cleaner at it and it has absolutely no change in the idle so im sure it isn't sucking in air,

currently the truck has no cats, took them off due to one glowing red the other day and is just straight piped into a flow master 40, checking live data while driving and stft are all over the place, they go negative into positive, timing chain was done about 10 months ago and only been driven 10k miles on it, was a cloyes kit for the 2v 5.4, did it myself with the help of my boss who made sure the marks lined up etc, so i dont think its jumped timing etc,
Did a smoke test and had no leaks until it came out of the oil dipstick after 5 ish mins which im sure is normal, changed the pcv valve since its cheap, fuel pressure read between 50-60psi, i though it was high however seems this is the normal for a 03 5.4, odd one out it seems, idk if im forgetting anything but ive taken out and cleaned the iac valve as well as the throttle body and ports, but basically no kinked or crushed vacuum lines, tested injector voltage and have cleaned the fuel injectors as well, swapped fuel rail thinking it could of been that and spark plugs were done with timing chain so about 10k miles ago but i took them out and cleaned them as well all 8 and coils are a mix of junkyard coils ive picked up along the way, truck was running fine before i did the intake manifold, it was leaking at the crossover tube but it had sealed itself somehow and stopped leaking for a few months,

are the intake manifolds different/ incompatible? I compared them and they look basically identical, dont know if there is a difference inside

anything else i should check, egr valve has been replaced but engine still idles rough, trucks only got 210,000

 

1. To be clear, did it ever run rough before replacing the intake, or smooth after replacing the intake, or has it been running rough only since replacing the intake?
2. Have you done either a leak-down or compression test yet?
3. Have you connected a scan tool to read codes, or view live data?

 

210,000 miles is a good run. Sounds like you removed the glowing cat because that was a sign of a bad misfire and possibly a dying cylinder.

Before you keep firing the parts cannon at this, pull a compression check.

 

Tried replying to someone else figuring this site out still

 

So the old manifold gave me a leak in august of 24, by september it had basically sealed itself and the car has run smoothly ever since, just how it did before even having the leak at the crossover.

I had some spare time and decided to hit the junkyard in search of an intake manifold to replace it since i figured it may start leaking again soon, which is when I remembered the e150s still use the 2v 5.4, and i figured the manifold would be the same/ similar, to which it was, besides the crossover tube

now before i replaced it it was running great, no issue nor misfire, i did end up getting some cheap cats on it about a month ago, since i bought it in 22, i though it had 1 cat on driver and 2 on pass but it had no cat on driver and both on passenger, which explained why over time it would give me a lean and rich code at the same time for the banks.

Last friday i took a look with the misfiring and the new cats bank 1 was glowing red after the first cat, posted on fb group and people told me to just gut them anyways, so i did, now they flow better but still with the issue

havent done a compression test yet, need to get a compression test kit,

and yes this is with a scan tool and live data through forscan, i have 02 stuck lean, p2197/2195 and misfire count but when i hold downto 2000+ rpm no misfire and engine smooths out,

Short fuel trims are all over the place but smooth out when being revved, and stay positive 60something when letting it back down to idle,

 

will do, but it was running great before the manifold swap, don’t know how the compression could of gotten messed up?

 

The O2 and fuel trim issues are due to there not being a catalytic converter installed. So, until you have cats in there, you have to ignore those issues, you can't do anything about them.

 

Are you 100% sure the new manifold wasn't cracked anywhere? To me, it is starting to sound like the manifold is the root cause of the rough idle, since that is when the issue started.

 

it was happening even with the cats, since its upstream o2s not downstream o2s giving the issue,

 

i did a thorough cleaning of it the first time, then just to make sure i took it off and looked over it again with after problem persisted and it has also been smoke tested and nocracks/ leaks

at least not big enough to be felt but spraying carb cleaner all throughout it doesn’t suck in any

 

When I cleaned by perfectly running IAC it never idled properly afterwards. Installed a new IAC and everything is good. Since the valve is PWM controlled there was no easy way to test it. To this day I don't know what I did wrong.

 

mmm, i have spare iac valve that is known to be good, swapped it out and no difference which leads me to believe its not iac related