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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 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). 4. Raise vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. 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). 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). 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. 10. Remove original front and rear engine support cross-member bushings (Figure 3).

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DESCRIPTION Some vehicles may experience a body vibration when driving approximately 55mph. This symptom is due to the characteristics of the No. 3 & No. 4 engine mounts. Modified No. 3 & No. 4 engine mounts have been established for service only. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE IMPORTANT NOTE: • This repair should only be performed if all tires and rims are confirmed to be in balance and all suspension components are in proper working condition. • Notify customers that use of the modified mounts will reduce vibration at cruising speed but may increase vibration at idle. NOTE: Because idle vibration may increase, it is highly recommended to continue using mass production mounts for all other service concerns. 1. Verify concern. 2. Replace the No. 3 & 4 engine mounts with service parts according to the appropriate Workshop Manual section 01-10 ENGINE REMOVAL/INSTALLATION. 3. Center the new engine mounts as outlined in ENGINE MOUNT CENTERING PROCEDURE. 4. Verify repair. ENGINE MOUNT CENTERING PROCEDURE No. 1, No. 3 and No. 4 Engine Mount Adjustment 1. Warm up the engine. 2. Raise and support vehicle on a hoist. 3. Remove engine under cover. 4. Lower the vehicle until the front tires lightly touch the ground. 5. Secure the engine and transaxle using an engine jack and attachment as instructed in No.3 Engine Mount And No.4 Engine Mount Rubber Installation Note in appropriate Workshop Manual, section 01-10 MECHANICAL. 6. Remove two bolts from No. 3 engine mount bracket. REMOVE THE BOLTS 7. Lift engine using jack until No.3 engine mount is lifted slightly from vehicle body. NOTE: • Do not raise engine too much or A/C pipe damage may occur. 8. Move the engine mount rubber or engine until installation hole on the vehicle body aligns with hole in the engine mount bracket. ENGINE MOUNT BRACKET 1532c SHOWN BEFORE ALIGNING THE HOLES SHOWN AFTER ALIGNING THE HOLES 9. Lower the jack and tighten bolts on No. 3 engine mount bracket. Tightening torque: 55.0-77.3 ft-lbf (74.5-04.9 N.m) NOTE: 10. With engine supported as described in STEP 5, remove four (4) nuts and two (2) bolts from No. 4 engine mount top plate. Remove top plate. NOTE: 11. Lift engine again using jack until No.4 engine mount is lifted slightly from vehicle body. NOTE: 12. With top plate of No. 4 engine mount removed, move engine mount bottom plate or engine until all four (4) installation studs on the vehicle align with the engine mount holes. • Do not allow the engine mount bracket to be misaligned. • To access the mount, remove battery box. • Do not raise engine too much or A/C pipe damage may occur. ALIGN THE 4 STUDS IN THE PLATE HOLES 13. Place top plate back on and tighten No. 4 engine mount bracket nuts and bolts to torque indicated. Tightening torque: A.32.5-45.0 ft-lbf (44.0-61.0 N.m) B.61.1-86.7 in-lbf (6.9-9.8 N.m) TIGHTEN BOLTS IN SEQUENCE SHOWN 1532e 14. Lift engine again using jack and loosen the two bolts on the No. 1 engine mount rubber until slightly loose on the No. 1 engine mount rubber.

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Engine Runs Hot and/or Engine Oil Mixed with Engine Coolant in Engine Coolant Recovery Reservoir (Replace Cylinder Head Assembly) This bulletin is revised to provide updated claim information as well as parts information about the release of a remanufactured cylinder head. This bulletin supercedes bulletin 96-T-65A, which should be discarded. MODELS AFFECTED: 1991-1997 Saturn vehicles equipped with SOHC (LK0-1991-1994, L24-1995-1997) engines. CONDITION: Engine may run hot and/or have engine oil mixed with engine coolant. This condition may be noticeable when checking coolant recovery reservoir level. CAUSE: Some 1991-1997 SOHC engines may develop a crack on or near the camshaft journals and surrounding casting areas allowing engine oil to mix with engine coolant. CORRECTION: Refer to the following procedure to locate the area where the engine oil is leaking into engine coolant passages. PROCEDURE: IMPORTANT: When required, refer to the appropriate year service manuals when performing the following procedures. 1. Remove camshaft from cylinder head. 2. Pressure test cooling system.

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Model(s): 1994-95 Buick Regal 1994-97 Buick Skylark 1994-98 Buick Century 1994-95 Chevrolet Beretta Corsica, Lumina, Monte Carlo 1996-98 Chevrolet Venture 1997-98 Chevrolet Malibu 1993-97 Oldsmobile Cutlass Supreme 1994-96 Oldsmobile Cutlass Ciera 1994-97 Oldsmobile Achieva 1996-98 Oldsmobile Silhouette 1997-98 Oldsmobile Cutlass 1994-98 Pontiac Grand Am, Grand Prix 1996-98 Pontiac Trans Sport with 3100, 3400 V6 Engine (VINs M, E – RPOs ticking type noise that begins shortly after cold engine start-up and gradually diminishes as the engine warms up. In most cases, the noise is gone after five (5) minutes. In severe cases, the noise may not disappear when lhe engine is hot. Under normal design tolerances when the piston pin bore is produced at the maximum tolerance and the piston pin is produced at the minimum tolerance (min-max tolerance) trace noise levels can occur. This level of noise does not affect the reliability or durability of the product. If piston-to-pin noise is detected and the customer desires the condition to be corrected, replace all six pistons with pin assemblies. The new piston sets have a minimal piston-to-pin clearance. Remember, piston-to-pin noise occurs in both park and drive at engine idle rpm and it varies in intensity depending on the number of pistons involved. A ticking sound means one piston is affected whereas a rattle or diesel type sound indicates more than one piston affected. The following should also be checked: 1. On W-Cars, make sure the right side engine splash shield is not contacting the engine crankshaft balancer. This condition usually happens cold and is caused by the shield curling when cold. 2. Reference Service Bulletin 57-71-06 for transmission rattle noise often confused for engine rattle noise. 3. Reference Service Bulletin 47-61-36 for Accessory Drive Belt Tensioner noise. 4. Check cylinder bore diameter and piston diameter as outlined in the Service Manual.

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ENGINE – 4.0L OHV – CARBON KNOCK ON ACCELERATION NOISE – CARBON KNOCK ON ACCELERATION – VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use Motorcraft Carburetor Tune-up Cleaner PM-3. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter.