I have an issue with the catalyst converter/high-pressure pump or something else. Misfire + Cylinder head overheat

[IvanSh]

Hello everybody/ I hope you are doing better than me) Let me tell you a story.
In mid-January, I got a catalytic converter efficiency error, so I started driving slowly and carefully. About a week later, the timing system (cam phasers) started making a rattling noise. I went to the dealer—they initially said the engine was done for but later told me they could save it. I had the cam phasers replaced by another mechanic.

After that, I decided to drive normally and push the throttle a bit more. That’s when I started experiencing severe misfires. Around the same time, something happened to the valve cover gasket, causing a small oil leak onto the exhaust manifold. I had the gasket replaced at another shop, and they also replaced the spark plugs and ignition coils because some oil from the cylinder head had leaked into the spark plug wells.

Current Issues:​

• Catalytic converter efficiency errors
• The cylinder head overheats under load—up to 240°F (luckily, Ford has a gauge for this on the dashboard).
• Severe misfires when pressing the accelerator, especially at more than 40% throttle.

I have Forscan, and here’s what I found:

• Long-term fuel trim (LTFT) on Bank 2 is +13-17%, while Bank 1 is +6%.
• The catalytic converters heat up evenly according to the computer.
• Misfires mostly occur in cylinders 1, 2, and 5 when the high-pressure fuel pump (HPFP) pressure reaches around 20,000 kPa.
• Fuel rail pressure sometimes stays at 15,000-17,000 kPa even after shutting off the engine. Also, at idle, the pressure slowly increases, while the expected pressure at the same time is much lower—around 2,750 kPa.
• After the cam phaser repair, one catalytic converter was removed and looked acceptable (but I can’t say for sure).
• Forscan has extensive functionality, but if my measurements are correct, the voltage on O2S11 and O2S21 (the primary oxygen sensors) remains stable within the range of 1.01 - 1.05V. Meanwhile, the sensors O2S12 and O2S22 fluctuate between 0.1 - 0.9V at idle.
• This Thursday, we’re planning to remove both catalytic converters for a visual inspection.

I’d like to ask—what else can I check using Forscan to confirm whether the issue is with the catalytic converter? Or do you have other ideas about what could be causing these problems?

Thanks in advance!

 

[dillard09]

Did they check the O2 sensors as well? I wonder if some of that oil that leaked into the spark plugs hole got it to the cylinders when the plugs were pulled. Then upon first startup went downstream. Coated the O2 sensors and into the cats?
Just my thoughts

 

[Backroadddg]

Check your 02 Censors

 

[IvanSh]

We'll check them on Thursday. Since we’ve already removed one before, it comes off easily and is accessible from the driver’s side. On the passenger side, however, it looks like no one has ever removed it, and it’s extremely difficult to reach. I bought the truck last summer with 101000 miles on it. Currently 113000 miles. There were no issues during the warranty period.