Issues with poor XR6T

[XR6TTUB]

G'day ladies and gentlemen (Evening is more appropriate I guess loll)

 

I've recently purchased a 2003 BA XR6T Ute Manual in Mecury Silver, first Ford I've ever owned (Correction*First Ford was a Turbo TX5 back 16 years ago).

 

My poor XR6T recently started to develop a strange tick/knock/tapping noise, I've tried everything up my sleeves to try and rectify the problem but to no avail I've failed time and time again

 

In the mornings with cold starts, noise is evident and loud, tap tap tap tap but when the engine hits operating temperature it really wonders off and subsides (5 out of 10 times, you wouldn't be able to hear it at all cold or hot) Car idles weird when @ operating temp,idles a little lumpy like my stage 1 cam 180sx, but more irregular (not like a misfire)

Other then the symptoms above, car drives and boost's normally, Compression tested 200-205psi across all cylinders (highest was 205psi lowest was 200psi)

I'm a mechanic by trade and have never come across this situation ever

 

New Parts Fitted

 

*New genuine ford coils

*New rocker arms/Lifters (HLAS)

*New fuel filter

*Used working throttle body with tps

*New air filter

*New Garrett FG turbo

*New T/B gasket

*Fresh 10w60 penrite fully syn oil with Ryco z9 filter

 

SIDENOTE: Both exhaust and intake cams have rusted pitting and spalling on lobes, more evident on 1-2 5-6 cylinders (I guess the Car had been sitting around for sometime) as I've been rocking back and forth thinking about the pitting and spalling of the cams causing excessive clearance issues maybe? (I did use a cheap digital caliper to measure a few of the lobes, some were @ least .05-.10mm bigger and smaller)

 

I've order a new set of plugs(genuine ford) as the ones in the car now are NGK AND they are leaking (compression leaking, Noticed when hand turning engine)

 

I'm stumped! someone help before I pull more hair out.

 

I've attached a video in regards to the noise (engine had sat for 1-2 hours,so it isnt as loud)

 

I will upload other video's to outline the annoying knock/ticking noise

 

Kenny

 

[camo86T]

Nothing to do with the noise but was that FG turbo from an F6 or an XR?

[skidxr6t]

all I can hear is a possible serpentine belt noise? can ya remove it and take a listen?

 

a ticky noise is normal.

 

doesn't sound horribly wrong from my perspective

Edited 18/09/17 11:44 PM by skidxr6t

[MBAF]

hard to tell in the vid. Have you checked your manifold bolts? they like to come loose which will also cause some noise but cant really hear much in the vid

[XR6TTUB]

Thanks for the quick replies

 

The powersteering pump is a little noisy and ive got a new belt to put on, what ill do is remove the belt and video a cold start so the noise is a little more evident

 

Turbo is from an FG xr6T

[Ralph Wiggum]

Exhaust leaks. 

[XR6TTUB]

Also forgot to mention, it has new turbo to manifold gasket and exhaust manifold gasket,dump pipe gasket is also new

[XR6TTUB]

In the mornings with cold start, it sounds like this video (another owner experiencing the same issue)

I was bored after work today and took out my stethoscope to try and pinpoint the noise,front timing case is quiet,front of valve cover is quiet, intake manifold @5-6 cylinder gets a little noisier, cylinder head and valve cover @ cylinders 5-6 are most affected.

 

Trying to narrow down the possibilities, when I first purchased the car, the turbo (compressor blades and housing were lunched) seem s like a rock or nut was in there causing damage to the blades. Now, with the turbo spinning really fast, that nut/bolt or rock would've been hacked up and went into the engine. My first possibility is damaged intake valves (if valves were shot, I wouldn't have any compression in 1 or a few cylinders) but then again it does explain the rough/misfire at idle (fine when driving)

 

On the way home from work, I came up to my exit off the freeway and got off, sat at the traffic lights listening to the radio. Out of no where the car just misfired (about to stall) and rims jumped up again. 

 

I'm completely lost here, maybe someone out there has a recommendation for a workshop that specialises in this type of vehicle/engine, I'm located in Melbourne Victoria, out towards the western suburbs. Only issue I have is I can't make it during business hours as I start pretty early and finish 7pm, Saturdays would work aswell

 

A few xr6 turbo owners have recommended dyno-mite, located near me aswell, anyone heard or have experiences with them?

 

kenny

[k31th]

dyno-mite is close to you and knows these engines/cars very well. Any of the victorian tuners mentioned in this thread will be sufficient to diagnose it for you, if you are willing to travel to the east of Melbourne.

[shaness8]

Dion tunes my car I wouldn't go anywhere else.