Engine - Exchange Program
Article No.94-19-10
09/21/94
ENGINE - 2.0L ZETEC AND 2.5L DURATEC - EXCHANGE PROGRAM
FORD:
1995 CONTOUR
LINCOLN-MERCURY:
1995 MYSTIQUE
This TSB is being republished in its entirety to describe the engine exchange program.
ISSUE:
An engine exchange program is being offered to provide early concern identification and to assure high product quality and customer satisfaction.
ACTION:
This exchange program is provided to dealers at NO COST. Refer to the following service/diagnosis procedures.
Generally, engines requiring replacement of the block and other major base repairs, including selected engine oil and coolant leaks, may qualify for a replacement assembly. Plant personnel will make the final decision whether to provide the exchange.
Before performing any type of repair, service personnel are requested to perform the diagnostics listed below on the original engine and record their findings.
NOTE:
DO NOT DISASSEMBLE THE ENGINE PRIOR TO CALLING THE TOLL-FREE NUMBER (LISTED AT THE END OF THIS ARTICLE).
1. Check and record engine fluid level and condition. If low, fill to the proper level and check for leaks.
2. Confirm customer concern and proceed to the following diagnostic steps.
DRIVEABILITY
1. Perform EEC-IV diagnostic quick test and record all codes. If codes are present, perform the required pinpoint test in the Powertrain Control/Emission Diagnosis Service Manual and repair all concerns.
2. Perform additional test to assure other engine sub-systems such as fuel delivery and ignition are performing within specifications.
3. If lack of compression is the suspected cause of a base engine concern, perform compression test both wet and dry. Confirm that compression is within the specification outlined in the 1995 Contour/Mystique Service Manual.
Prior to performing any repairs, call:
^ Chihuahua Engine Plant for the 2.0L Zetec 4-cylinder
^ Cleveland Engine Plant # 2 for the 2.5L Duratec V-6 at the phone numbers listed at the end of this article.
OIL LEAKS
1. If the source of oil leak is not obvious, determine source of the leak using Rotunda Oil Dye (112-ROO15, or equivalent) and Rotunda Black Light (164-RO753, or equivalent).
Prior to performing any repairs, call:
^ Chihuahua Engine Plant for the 2.OL Zetec 4-cylinder
^ Cleveland Engine Plant # 2 for the 2.5L Duratec V-6 at the phone numbers listed at the end of this article.
OIL CONSUMPTION
1. Confirm the engine has been driven for at least 1,000 miles (1,600 km).
2. Start an oil consumption test to confirm oil consumption rate. Request the customer return to the dealership when the oil level is 1/2 quart/litre low. The test will be complete when one (1) quart/litre has been added.
3. If the oil consumption is less than one (1) quart per 900 miles (one (1) litre per 1,500 km) (Ford standard), inform the customer the engine is operating properly.
4. If oil consumption is greater than one (1) quart per 900 miles (1,500 km), call (prior to performing any repairs):
^ Chihuahua Engine Plant for the 2.0L Zetec 4-cylinder
^ Cleveland Engine Plant # 2 for the 2.5L Duratec V-6 at the phone numbers listed at the end of this article.
ENGINE NOISE
1. Attempt to isolate the source of the noise by removing the Front End Accessory Drive (FEAD) belt.
2. If this does not assist you in identifying the source of the noise, re-install the FEAD belt and attempt to identify the noise by shorting the cylinders and/or using a technician stethoscope.
Prior to performing any repairs, call:
^ Chihuahua Engine Plant for the 2.0L Zetec 4-cylinder
^ Cleveland Engine Plant # 2 for the 2.5L Duratec V-6 at the phone numbers listed at the end of this article.
PREPARING REPLACEMENT 2.0L ZETEC AND 2.5L DURATEC ENGINES
^ The replacement 2.0L 4-cylinder engine will be shipped complete including the exhaust manifold but less FEAD components.
^ The replacement 2.5L V-6 engine will be shipped complete Including the FEAD belt and the exhaust manifold but less the left exhaust manifold.
Transfer the necessary components from the original engine to the replacement engine as required. Replacement engines will be shipped full of engine oil and precautions should be taken to avoid spillage during installation.
NOTE:
CORRECT FLUID LEVEL SHOULD BE VERIFIED AFTER INSTALLATION. REFER TO THE FLUID LEVEL CHECK PROCEDURES IN THE 1995 CONTOUR/MYSTIOUE SERVICE MANUAL.
Follow installation procedures found in the 1995 Contour/Mystique Service Manual. Special instructions will be included with the engine as required.
RETURNING THE ORIGINAL ENGINE
Do not disassemble the original engine beyond what is required to perform an exchange. The engine core must be reassembled prior to return.
NOTE:
BEFORE SHIPPING THE ORIGINAL 2.OL ZETEC OR THE 2.5L DURATEC ENGINE, DRAIN ALL FLUIDS (OIL, COOLANT, GASOLINE) COMPLETELY AND INSERT THE SHIPPING PLUGS FROM THE REPLACEMENT ASSEMBLY.
PLANT PHONE INFORMATION
Call the appropriate plant and provide the information requested. The plant can also provide technical assistance.
^ CHIHUAHUA ENGINE PLANT
^ Phone Number: 1-800-252-0951
^ Operating 8:00 AM to 8:00 PM Eastern Time, Monday through Friday (excluding Ford-observed holidays)
^ CLEVELAND ENGINE PLANT # 2
^ Phone Number: 1-800-DURATEC (387-2832)
^ Operating 7:00 AM to 7:00 PM Eastern Time, Monday through Friday (excluding Ford-observed holidays)
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 94-17-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 497000, 702000