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2001 Ford Escort Engine – Vibration While Idling SERVICE PROCEDURE

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SERVICE PROCEDURE NOTE THE PROCEDURE CONTAINED IN THIS TSB ARTICLE MAY NOT COMPLETELY ELIMINATE ALL VIBRATION FROM THE VEHICLE. SOME VIBRATION IS INHERENT IN 1-4 ENGINE DESIGNS, SUCH AS THE SPI AND ZETEC 2.0L. THIS PROCEDURE IS DESIGNED TO REDUCE THE AMOUNT OF VIBRATION EXPERIENCED BY THE CUSTOMER. PROCEDURE FOR 2003 ESCORT ZX2 PROCEDURES FOR 1997-2002 ESCORT, ESCORT ZX2 AND TRACER ^DRIVEABILITY – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY ^ENGINE – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY 1. Neutralize engine mounts only. Refer to appropriate model year Noise, Vibration and Harshness (NVH) Workshop Manual Section 100-04. 1. Shift the transaxle into Neutral and apply the parking brake. 2. Remove battery and battery tray. 3. Support engine with Three-Bar Engine Support Tool (Rotunda 303-D063) and Lifting Brackets (Rotunda 303-050). 4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. Zoom Sized for Print 5. Remove the rear lower cross-member (attached with four (4) bolts (Figure 1)). 6. Remove the engine support cross-member that runs from front to rear of the engine (Belly Band). This can be accomplished by removing the front two (2) attaching bolts, the rear two (2) attaching nuts and the four (4) Engine Mount # 1 and # 2 nuts (Figure 1). . Modify the Belly Band on the two rear attaching Engine Mount # 1 holes by slotting the holes approximately 1/4″ (6 mm) in a front to rear direction. Use a Drill Bit (Figure 7)

2001 Ford Escort ZX2 Engine, Cooling and Exhaust Engine Timing Belt Service and Repair Manual

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Timing Drive Components-Timing Belt Removal NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure. 1. Grasp the spark plug boot firmly and with a twisting pulling motion, disconnect the spark plug wires from the spark plugs. 2. NOTE: If an original spark plug is reused, install it in the cylinder from which it was removed. New spark plugs can be used in any cylinder. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plugs . 3. Remove the valve cover. 4. Disconnect the heated oxygen sensor (HO2S) electrical connector. 5. Remove the timing belt covers. 6. Remove the catalytic converter 7. NOTE: Cylinder No. 1 is at top dead center (TDC) when the keyway is in the 12 o’clock position. Position cylinder No. 1 just prior to TDC. 8. Remove the stud bolt. 9. Install the timing peg. 10. Rotate the crankshaft clockwise against the timing peg. 11. CAUTION: If the crankshaft timing belt is to be reused, mark the direction of the camshaft timing belt to the rotation of the camshaft prior to removal, or premature wear or failure may occur. Relieve the tension on the timing belt tensioner pulley.

1998 Ford Escort ZX2 L4-2.0L DOHC Diagnose and repair idle vibration conditions by referring to the following idle vibration Service Procedures

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PROCEDURE FOR 2003 ESCORT ZX2 PROCEDURES FOR 1997-2002 ESCORT, ESCORT ZX2 AND TRACER ^DRIVEABILITY – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY ^ENGINE – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY 1. Neutralize engine mounts only. Refer to appropriate model year Noise, Vibration and Harshness (NVH) Workshop Manual Section 100-04. 1. Shift the transaxle into Neutral and apply the parking brake. 2. Remove battery and battery tray. 3. Support engine with Three-Bar Engine Support Tool (Rotunda 303-D063) and Lifting Brackets (Rotunda 303-050). 4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. Zoom Sized for Print 5. Remove the rear lower cross-member (attached with four (4) bolts (Figure 1)) 6. Remove the engine support cross-member that runs from front to rear of the engine (Belly Band). This can be accomplished by removing the front two (2) attaching bolts, the rear two (2) attaching nuts and the four (4) Engine Mount # 1 and # 2 nuts (Figure 1). 7. Modify the Belly Band on the two rear attaching Engine Mount # 1 holes by slotting the holes approximately 1/4″ (6 mm) in a front to rear direction. Use a Drill Bit (Figure 7). 8. Loosen the center bolt on the # 1 (rear) lower Engine Mount (Figure 4). 9. Loosen the center bolt on the # 2 (front) lower Engine Mount (Figure 4) 10. Remove original front and rear engine support cross-member bushings (Figure 3). Zoom Sized for Print a. Modify two (2) new Front-Upper Engine Support Cross-Member Bushings only (F7CZ-6A061-AA) by removing approximately 1/4″ (6 mm) of material from two (2) sides of the upper bushing. Use a utility knife or hack saw to achieve desired shape (Figure 2). b. Reinstall front attaching point of engine support cross-member with the original two (2) bolts, two (2) new Lower Bushings (F7CZ-6A061-BA), and two (2) new Upper Bushings (F7CZ-6A061-AA) that were modified in Step A (Figure 3). Apply 2-3 drops of threadlocker (EOAZ-19554-AA) to the bolts. c. Reinstall rear attaching point of engine support cross-member using new Bushings (F7CZ-6A061-BA and F7CZ-6A061-AA) and original nuts (Figure 3). Both rear position upper bushings must be installed in “AS IS” condition (UNMODIFIED). d. Torque the retaining nuts and bolts to 64-89 N.m (47-65 lb-ft.). 11. Reinstall the front attaching points of the Belly Band with the original two (2) bolts. Apply 2-3 drops of threadlocker (EOAZ-19554-AA) to the bolts (Figure 1). 12. Reinstall rear-attaching points of the Belly Band with original two (2) nuts (Figure 1). 13. Torque the retaining nuts and bolts to 64-89 N-m (47-65 lb-ft.)

1998 Ford Escort Diagnose and repair idle vibration conditions by referring to the following idle vibration Service Procedures

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PROCEDURE FOR 2003 ESCORT ZX2 PROCEDURES FOR 1997-2002 ESCORT, ESCORT ZX2 AND TRACER ^DRIVEABILITY – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY ^ENGINE – IDLE VIBRATION – VEHICLES EQUIPPED WITH 2.0L SPI OR ZETEC ENGINE ONLY 1. Neutralize engine mounts only. Refer to appropriate model year Noise, Vibration and Harshness (NVH) Workshop Manual Section 100-04. 1. Shift the transaxle into Neutral and apply the parking brake. 2. Remove battery and battery tray. 3. Support engine with Three-Bar Engine Support Tool (Rotunda 303-D063) and Lifting Brackets (Rotunda 303-050). 4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. Zoom Sized for Print 5. Remove the rear lower cross-member (attached with four (4) bolts (Figure 1)) 6. Remove the engine support cross-member that runs from front to rear of the engine (Belly Band). This can be accomplished by removing the front two (2) attaching bolts, the rear two (2) attaching nuts and the four (4) Engine Mount # 1 and # 2 nuts (Figure 1) 7. Modify the Belly Band on the two rear attaching Engine Mount # 1 holes by slotting the holes approximately 1/4″ (6 mm) in a front to rear direction. Use a Drill Bit (Figure 7). 8. Loosen the center bolt on the # 1 (rear) lower Engine Mount (Figure 4). 9. Loosen the center bolt on the # 2 (front) lower Engine Mount (Figure 4) a. Modify two (2) new Front-Upper Engine Support Cross-Member Bushings only (F7CZ-6A061-AA) by removing approximately 1/4″ (6 mm) of material from two (2) sides of the upper bushing. Use a utility knife or hack saw to achieve desired shape (Figure 2). b. Reinstall front attaching point of engine support cross-member with the original two (2) bolts, two (2) new Lower Bushings (F7CZ-6A061-BA), and two (2) new Upper Bushings (F7CZ-6A061-AA) that were modified in Step A (Figure 3). Apply 2-3 drops of threadlocker (EOAZ-19554-AA) to the bolts. c. Reinstall rear attaching point of engine support cross-member using new Bushings (F7CZ-6A061-BA and F7CZ-6A061-AA) and original nuts (Figure 3). Both rear position upper bushings must be installed in “AS IS” condition (UNMODIFIED). d. Torque the retaining nuts and bolts to 64-89 N.m (47-65 lb-ft.). 11. Reinstall the front attaching points of the Belly Band with the original two (2) bolts. Apply 2-3 drops of threadlocker (EOAZ-19554-AA) to the bolts (Figure 1). 12. Reinstall rear-attaching points of the Belly Band with original two (2) nuts (Figure 1). 13. Torque the retaining nuts and bolts to 64-89 N-m (47-65 lb-ft.).

1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil