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Old 08-11-2016, 04:26 AM
davids2003 davids2003 is offline
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Angry 2003 with emissions problems

it is a sohc and its driving me nuts, there is an exhaust leak at the manifold joint to the first pipe on the passenger side. Can this leak be causing me to fail emissions testing? The state computer says there are three sensors that report "not ready", the 02 the heated 02 and the cat sensors. There are no trouble codes or cel. Whats wrong with this thing? A mechanic said the sensor that tells the pcm the engine is at temp was bad, so i replaced it, same thing.
Another told me I wasn't running hot enough(I was at 180 degrees), changed the tstat to a 195 degree, same problem.
Does anybody have a clue, cause I'm out of ideas.
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Last edited by Logan03CO; 08-11-2016 at 04:55 AM.
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  #2  
Old 08-11-2016, 04:55 AM
Logan03CO Logan03CO is offline
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Default Re: 2003 with emissions problems

(Post moved to a new thread within the technical section of the forum)
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  #3  
Old 08-13-2016, 10:57 PM
desertrunner33 desertrunner33 is offline
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Quote:
Originally Posted by davids2003 View Post
it is a sohc and its driving me nuts, there is an exhaust leak at the manifold joint to the first pipe on the passenger side. Can this leak be causing me to fail emissions testing? The state computer says there are three sensors that report "not ready", the 02 the heated 02 and the cat sensors. There are no trouble codes or cel. Whats wrong with this thing? A mechanic said the sensor that tells the pcm the engine is at temp was bad, so i replaced it, same thing.
Another told me I wasn't running hot enough(I was at 180 degrees), changed the tstat to a 195 degree, same problem.
Does anybody have a clue, cause I'm out of ideas.
The leak could definitely be the issue. If you want to be cheap about it then I would just take the manifold off weld the crack shut and put it back on. Should be easy enough and won't cost anything to do (unless you don't weld). My guess is that even if that is not the sole issue it is contributing to the problem
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Old 08-15-2016, 08:51 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Thank for the info, the manifold isn't cracked, there is a leak at the joint, i found one of the manifold studs has bad threads. Therefore i cant get a nut onto the stud. If this leak is adding to my emission woes, ill try to get a die on there to chase the threads and put a new nut on it.
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Old 08-15-2016, 01:59 PM
desertrunner33 desertrunner33 is offline
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Originally Posted by davids2003 View Post
Thank for the info, the manifold isn't cracked, there is a leak at the joint, i found one of the manifold studs has bad threads. Therefore i cant get a nut onto the stud. If this leak is adding to my emission woes, ill try to get a die on there to chase the threads and put a new nut on it.
Gotcha. A pain to fix but still doable. I'm just bullshitting here but my guess is that if you have a big leak there that is allowing exhaust out before the sensors that is probably your issue. Or at least part of it.
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Old 08-16-2016, 04:30 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Its just after the upstream sensor on the passenger side.
This truck has three sensors, two upstream and one downstream.
Is it even possible to get a die in there or should i just give in and take it to a repair shop? That stud is in a dam tough place to get to with a die.
Thanks

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Do you happen to know what the thread is, metric or sae, the nut is a 15mm but I dont know the thread size.
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  #7  
Old 09-17-2016, 10:17 PM
Rangerick03 Rangerick03 is offline
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Default Re: 2003 with emissions problems

I have the exact same truck smog mine about 8 months ago and it passed with flying colors has an exhaust leak and Cooling in the exhaust to still passed there is a coupling that fits around the connection between the exhaust manifold and the exhaust right at that connection where those bolts are it's like a big O ring that fits over it to seal it there if you have anymore questions private message me maybe I can help
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Old 10-24-2016, 09:57 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Well I bit the bullet and took it to the local Ford dealer. Cost me $90 for diag, but found out that the leak is on the driver side and IS what is causing my headaches. Tech said he monitored the PIDS and said the one from the upstream sensor on the drivers side is moving just enough for the computer to not light the cel but not enough to set the monitor. This weekend going to try to get the bolts loose without breaking them off. The OEM says there is no gasket between the two parts of the joint, the parts are supposed to fit tight one inside the other. I just have it mis-aligned and caused the leak.
If they break off then its a different story but i have a penetrating oil called Kroil and it worked on the passenger side, hope it works again. Then we go for emissions again.
Thanks for the help.
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  #9  
Old 11-07-2016, 09:39 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Well its been around 300 miles since the leak was fixed, and the pcm still reports not ready, any guesses on what could be wrong???
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  #10  
Old 11-16-2016, 08:57 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Well after purchasing a decent scan tool, i find two items that stand out:
1. bank 1 sensor 1 does move but slowly, pulses are wider than on bank two.
2. fuel trim on bank 1 sensor stays at 99% while the one on bank two moves between -5 and +5%.
Am i correct to believe that the sensor on the passenger side is dead or dying?
There are no trouble codes reported.
Help
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Old 11-16-2016, 09:27 AM
pearlkid9988 pearlkid9988 is offline
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Default Re: 2003 with emissions problems

Quote:
Originally Posted by davids2003 View Post
Well after purchasing a decent scan tool, i find two items that stand out:
1. bank 1 sensor 1 does move but slowly, pulses are wider than on bank two.
2. fuel trim on bank 1 sensor stays at 99% while the one on bank two moves between -5 and +5%.
Am i correct to believe that the sensor on the passenger side is dead or dying?
There are no trouble codes reported.
Help
It's possible. The 02s are heated because they really need to be in a certain temp range to read correctly. That's why you run open loop at cold start because any readings would just confuse the PCM. Also the reason widebands have to be heated on startup. Anyways if enough air is getting in the heater circuit will work overtime to maintain that temp range. I have seen them where the sensor is good but the heater is bad and there is actually a code just for the heater. Now you can test them with a multi meter to prove good or bad based on the measured resistance. But Fords are also finicky about drive cycles you need about 3/4 tank of gas. No hard accelerations and a nice mix of stop and go and like 50-60mph constant driving to get it all to go through. But if you haven't already I would disconnect the PCM to clear it's memory out and then do the drive cycle. That should either let it go ready or set a code either way you know your next course of action.

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And as a side note I had a header leak from my cheap eBay headers pretty much the whole time I owned my truck. Never once failed emissions. My muffler guy chewed me out because he had to fix the leak for the guy who bought it 😂

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  #12  
Old 11-16-2016, 10:54 AM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

Everything I can find says the MAF sensor is good because only one bank is reading bad.
I think I'm going to replace the passenger side sensor.
As far as I know its never been changed. At least since i've owned the truck and that's going on 5years now.
The truck has 170k on it, runs like a raped ape will smoke the tires in first and second gear, but wont pass emissions testing. Still have three monitors not ready. Ill let you know what I find.

Thanks
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Old 11-16-2016, 12:05 PM
pearlkid9988 pearlkid9988 is offline
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Default Re: 2003 with emissions problems

Quote:
Originally Posted by davids2003 View Post
Everything I can find says the MAF sensor is good because only one bank is reading bad.
I think I'm going to replace the passenger side sensor.
As far as I know its never been changed. At least since i've owned the truck and that's going on 5years now.
The truck has 170k on it, runs like a raped ape will smoke the tires in first and second gear, but wont pass emissions testing. Still have three monitors not ready. Ill let you know what I find.

Thanks
Which monitors are not ready?

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  #14  
Old 11-16-2016, 12:49 PM
davids2003 davids2003 is offline
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Default Re: 2003 with emissions problems

o2.heated o2 and cat

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if the fuel trim is good on one bank and bad on the other, it kinda screams of a bad sensor.
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  #15  
Old 11-17-2016, 07:45 AM
pearlkid9988 pearlkid9988 is offline
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Default Re: 2003 with emissions problems

Quote:
Originally Posted by davids2003 View Post
o2.heated o2 and cat

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if the fuel trim is good on one bank and bad on the other, it kinda screams of a bad sensor.
Yeah those all tend to go together. You can try changing the sensor but that could also be the result of an incomplete drive cycle. You have to be super careful any goosing of the throttle can mess it up. I once drive a 98 f150 200 miles to get those to go ready for the test. It just wouldn't do it.

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Quote:
Originally Posted by pearlkid9988 View Post
Yeah those all tend to go together. You can try changing the sensor but that could also be the result of an incomplete drive cycle. You have to be super careful any goosing of the throttle can mess it up. I once drive a 98 f150 200 miles to get those to go ready for the test. It just wouldn't do it.

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If the sensor is cheap it probably won't hurt but I hate throwing parts at a problem but you logic seems good. It's hard to diagnose just from fuel trims though.

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