My truck has about 415,000 miles, about 300,000 miles on the new engine (2003) after the factory hydrolock took it.

I went outside and turned it over and it went half a cycle and stopped. I checked the voltage on the battery, its 12.8v idle, so I know its not dead. The truck refuses to turn over and I think its got water leaking into the cylinders. I'm going to try to pull the plugs out this afternoon and see if I can confirm my worst fears

 

I tore it down to the lower intake manifold. Turns out my Bank 2 IMRCs arent connected for some reason. I'm not sure if its a vac line or what at this point, but they're just flopping around in there. I hope thats the cause of the mystery rattle and CEL!

I need to run to VatoZone tomorrow and get the fuel rail disconnects and then the lower intake manifold is coming out.

I took off one of the valve covers to see how well this 300,000 mile engine is doing with oil. It is C-L-E-A-N!! No sludge or anything! I'm happy about that.



Also found my 2-year old 2-row radiator is leaking...so that has to get replaced as well. This sucks because I was hoping to get my tires on this weekend, looks like I'm set back another 2 weeks since I have to drop ~$200 on the engine. Oh well, hopefully this eliminates some issues and makes it run better!

Does anyone know the Ford Part Number to the lower intake manifold gasket? There is a whole slew on RockAuto and I'm not sure which to use

 

I went to O'Reillys and got a new 2-core radiator (still gotta drill it for my efans), new lower intake gasket, 3 gallons of coolant, fuel filter, and fuel disconnect tool. I continued where I left off last night- this morning I pulled the radiator and efans, got the fuel rail off, injectors and lower manifold off. Its sitting in a vat of degreaser and I'm taking my lunch break. Up next I have to clean the engine out, replace the gasket and reassemble. I hope I can have it on the road before work tomorrow.

I think this is the culprit for my hydrolock:

 

Damn man... good job working on that! Crazy how long those motors can run for

 

Well I got it all back together. Enabled the fuel pump and turned it over and it started firing. I double checked my work and noticed gas on the intake...one of the injectors wasn't fully seated. So tomorrow after work I have to take the intake off and then the fuel rail and re-set the #6 injector. Grrrr.

 

Hurry up. Three days to do an intake?

 

Well I got it put back together. Managed to get it running for a few minutes. I shut it off and cannot get it started again. It turns over a couple times and just stops.

 

Check for spark/fuel first
No spark check crank & cam sensors and your engine harness groud

 

Patrick, I've posted a video on Facebook. I had it running....shut it off, then turn over, turn over, turn over, turn over STOP like I let off the key. It feels like its hydrolocked again but I pulled the plugs and turned it over and nothing came out.

 

Good news and bad news. Took it out for a drive. Runs like ****. Like a misfire/vac leak. I took it two miles down the road and I looked down and noticed my drivers side rear cat was glowing red. I have codes P0232 and P1151.

I guess I'll search for a vac leak in the morning

 

I quadruple-checked all my hoses and wiring. Everything is buttoned up tight and its kicking and spitting and popping. I cleared the CELs and ran it a few more minutes, nothing came up. I shut it off and now its doing its thing again where itll turn over turn over turn over and just STOP like its hydrolocked. I cannot figure this out and I'm stumped. I have spent about $500 at this point and I'm broke. I don't know what to do.

 

If the manifold is not glowing & the Converter is, Then You have unburnt Fuel / Excess Fuel getting to the converter, & igniting.

 

Does anyone have a picture of what color vac line goes to the fuel pressure regulator on the 4.2L?

 

So here are some symptoms:

Truck turns over several compressions and stops, wont start. Feels like excessive compression in cylinders
Pulled the spark plugs, all covered in fuel
Turned over the engine with no plugs and the driver side spat out big splotch of fuel, pax side spit out just a little mist
Cat was glowing red hot on my test drive the other day, synonymous with fuel in the cat
Exhaust was popping, synonymous with fuel burning in the exhaust
Error codes P0232 and P1151. I have cleared them but they have not returned.

This could have been the problem from the getgo. I assumed there was water in the cylinders. It could have been the day I went to go drive my truck, there was excess fuel and not water, so I am possibly back to square one.

 

I FIXED IT!!!!!!!!!!!

Or rather, my dad fixed it. He kept saying the timing was off...well....when I put the spark plug wires on the plugs, I went 123-456. Turns out the coil pack is 123-645. I swapped the plugs and she runs BEAUTIFULLY!