ALLDATA Online - 1997 Ford Escort L4-122 2.0L SOHC - Engine - MIL ON/Misfire D. Page 1 of 4
Article No. 04-9-1 05/11/04 ^ DRIVEABILITY - ROUGH IDLE, LOW POWER AND/OR STALL AT IDLE WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0300-P0304 STORED IN MEMORY - VEHICLES EQUIPPED WITH 2.0L SPI ENGINE ONLY ^ ELECTRICAL - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0300-P0304 STORED IN MEMORY - VEHICLES EQUIPPED WITH 2.0L SPI ENGINE ONLY FORD: 1997-2002 ESCORT 2000-2002 FOCUS MERCURY: 1997-1999 TRACER This article supersedes TSB 02-09-01 to update the service and part information. ISSUE Some vehicles equipped with the 2.0L SPI engine may exhibit a malfunction indicator lamp (MIL) illuminated and diagnostic trouble codes (DTCs) P0300 through P0304 stored in memory. The vehicle may also have a rough idle or reduced power condition, and/or may stall at an idle. This may be caused by sticking exhaust valves due to excessive carbon build-up. ACTION Check for faulty fuel injectors and ignition wires. One or more exhaust valves may be temporarily sticking due to carbon build-up between the valve stem and guide. If the diagnostic checks point to a sticking exhaust valve, the cylinder head assembly may need to be replaced with a new level cylinder head assembly with revised valve guides, revised exhaust valves will also need to be installed to help prevent carbon build-up. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS PROCEDURE APPLIES ONLY TO THE 2.0L SPI ENGINE. This condition usually results in misfire when the engine returns to idle after running approximately 2000 RPM or higher. 1. Use the worldwide diagnostic system (WDS) to test for Power Balance with the engine at idle. Check for cylinder misfire. If misfire is occurring constantly, go to
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ALLDATA Online - 1997 Ford Escort L4-122 2.0L SOHC - Engine - MIL ON/Misfire D. Page 2 of 4
Step 3. If misfire is not occurring, attempt to induce misfire by performing the following step: a. Apply the parking brake and keep the transmission in Park or Neutral. Bring the engine to approximately 2800 RPM and hold for one (1) minute. Check the WDS Power Balance display while holding engine speed constant. Allow the engine to return to idle and watch the WDS Power Balance display for a misfiring cylinder. 2. If WDS Power Balance indicates a misfiring cylinder with the previous test, one or more exhaust valves may be intermittently sticking due to carbon build-up between the valve stem and guide. Replace the cylinder head with the new level cylinder head with revised valve guides. Once stock is exhausted of the loaded cylinder heads, the cylinder head will come bare so revised exhaust valves will need to be installed in place of the original valves. The revised valve guides and exhaust valves help prevent carbon build-up. Consult the appropriate model year Workshop Manual for removal and installation procedures for the Cylinder Head Assembly. 3. If WDS Power Balance did not indicate a misfiring cylinder with the previous test or a misfire is occurring constantly, the misfire may not be due to a sticking exhaust valve. Refer to the appropriate model year Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual for further diagnosis. Other possible causes may be, worn or arcing ignition wires, base engine compression, fuel injectors, fuel injector harness resistance or PCM injector driver signal. Perform diagnosis and repair as necessary. 4. After completing either Step 2 or Step 3, replace the PCV Valve (YS4Z-6A666AC) (Motorcraft EV-244) on model year 2000-2002 Focus or 2000-2002 Escort. Vacuum fluctuations from engine misfire may prematurely wear the PCV valve on those applications. NOTE THE CYLINDER HEAD ASSEMBLIES LISTED BELOW WILL BE BARE CASTINGS ONCE SUPPLY OF LOADED HEADS IS EXHAUSTED, IN MOST CASES IT WILL BE NECESSARY TO REPLACE ONLY THE PARTS LISTED BELOW, ALL OTHER PARTS CAN BE REUSED.
ALLDATA Online - 1997 Ford Escort L4-122 2.0L SOHC - Engine - MIL ON/Misfire D. Page 3 of 4

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ALLDATA Online - 1997 Ford Escort L4-122 2.0L SOHC - Engine - MIL ON/Misfire D. Page 4 of 4

ALLDATA Online - 1998 Ford Escort ZX2 L4-2.0L DOHC VIN 3 - Engine - Vibration.

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Article No. 03-15-15 08/04/03 ^ 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 FORD: 1997-2002 ESCORT 1998-2003 ESCORT ZX2 MERCURY: 1997-1999 TRACER This article supersedes TSB's 00-5-9 and 02-21-12. ISSUE This TSB article is being republished to assist in diagnosing idle vibration. ACTION Diagnose and repair idle vibration conditions by referring to the following idle vibration Service Procedures. 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 1. Neutralize engine mounts only. Refer to appropriate model year Noise, Vibration and Harshness (NVH) Workshop Manual Section 100-04. PROCEDURES FOR 1997-2002 ESCORT, ESCORT ZX2 AND TRACER 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).
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4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02.

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5. Remove the rear lower cross-member (attached with four (4) bolts (Figure 1)).

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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). NOTE DISCARD THE TWO ENGINE MOUNT # 1 FLAT WASHERS FOR VEHICLES BUILT PRIOR TO 12/03/2001 ONLY. NOTE STEP 7 MODIFICATIONS ARE FOR VEHICLES BUILT PRIOR TO 07/15/02 ONLY.
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).

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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). NOTE STEP 10 IS FOR VEHICLES BUILT PRIOR TO 05/26/2000 ONLY.

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10. Remove original front and rear engine support cross-member bushings (Figure 3).
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.).

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14. Install the Engine Mount # 1 and # 2 retaining nuts, do not tighten at this time. (Figure 8). 15. Lower the vehicle. NOTE THE ENGINE MOUNT REPLACEMENT DIRECTIVE APPLIES ONLY TO 1997-1999 MY VEHICLES BUILT PRIOR TO 01/29/1999. NOTE ENGINE MOUNT # 3 BRACKET REPLACEMENT DIRECTIVE APPLIES ONLY TO VEHICLES BUILT PRIOR TO 06/15/2002.

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16. Remove the # 3 Engine Mount and damper (Figure 5).
17. Vehicles built prior to 6/15/02, remove the # 3 Engine Mount bracket and replace with a new bracket (254Z-6028-AA) (Figure 10). Torque the retaining

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bolts to 16-22 N.m (12-17 lb-ft.). Do not paint bracket, install as received. Removal ^ Raise vehicle on hoist. ^ Remove power steering bracket bolt to frame. ^ Lower vehicle. ^ Remove power steering - A/C bracket nuts and power steering bracket bolt, and position aside. ^ Raise engine using 3-bar support. ^ Remove retainers for engine mount bracket and remove bracket.