Ford Focus 2.0 Zetec-E (What is this engine noise? See vid)
Discussion
I have mk1 99 v reg Ford Focus 2.0 Ghia hatchback with the zetec-e engine. I have owned the car since 2003 so know its history. It has been a great car and have managed to rack up 190,000 miles on it.
However, recently the piston rings need replacing as it was smoking when cold.
A friend who is an experienced mechanic with experience of numerous engine rebuilds and myself who is also quite confident with the spanners did the work, taking of the sump, crankcase, and cylinder head, popping out the pistons, honing the bores (not re-bore!) and re-ringing them. The engine and bores seemed to be in fairly good nick for the mileage. We also checked and cleaned components and replaced the big end bearings, big end bolts, timing belt and tensioners, head bolts as well as any gaskets that needed replacing.
The work has cured the smoking I have been running in the engine for the last 750-1000 miles and it is running nice and smooth. I didnt take her over 2000 rpm for the first 100 miles and and not over 3000 rpm until 500 miles.
However, not long after the rebuild (around 200 miles in) I noticed a noise when when the engine is revved in neutral when its warm.
Here is a youtube vid of the noise:
https://www.youtube.com/watch?v=BINEpp6I9A4
My first thoughts were that it was maybe valve shim clearances needed checking after having to remove the cams to get the head off but the sound did not sound "ticky" enough for it to be that.
I have checked and replaced the aux drivebelt and checked all pulley and pump/alternator brackets.
When driving, the noise is not that noticeable inside the car unless you use light throttle to maintain speed or light acceleration above 2000 rpm and upwards in 1st and 2nd gear so it seems that it happens when the engine is not under much load and when its warm.
After further investigation I found that disconnecting spark on cylinder 3 seems to stop the noise so I thought it was could be pre-ignition knock as compression would have increased after the re-ring. I have checked and doubled checked the timing and it spot on. I have also tried changing spark plugs and swapping injectors around in case it was a bad injector and it has made absolutely no difference.
I am now coming to the conclusion that it must be the big end knocking, piston slap or or the gudgeon pins?
There was no knocking before the rebuild so I would have expected the crankshaft to be fine so not sure why the the big end shells would be knocking. If it was big ends surely the engine would have munched itself by now after 1000 miles?
Also, I am driving her daily (about 25 miles a day) and the noise has not got any worse.
Could it be flywheel related?
All opinions welcome!!
However, recently the piston rings need replacing as it was smoking when cold.
A friend who is an experienced mechanic with experience of numerous engine rebuilds and myself who is also quite confident with the spanners did the work, taking of the sump, crankcase, and cylinder head, popping out the pistons, honing the bores (not re-bore!) and re-ringing them. The engine and bores seemed to be in fairly good nick for the mileage. We also checked and cleaned components and replaced the big end bearings, big end bolts, timing belt and tensioners, head bolts as well as any gaskets that needed replacing.
The work has cured the smoking I have been running in the engine for the last 750-1000 miles and it is running nice and smooth. I didnt take her over 2000 rpm for the first 100 miles and and not over 3000 rpm until 500 miles.
However, not long after the rebuild (around 200 miles in) I noticed a noise when when the engine is revved in neutral when its warm.
Here is a youtube vid of the noise:
https://www.youtube.com/watch?v=BINEpp6I9A4
My first thoughts were that it was maybe valve shim clearances needed checking after having to remove the cams to get the head off but the sound did not sound "ticky" enough for it to be that.
I have checked and replaced the aux drivebelt and checked all pulley and pump/alternator brackets.
When driving, the noise is not that noticeable inside the car unless you use light throttle to maintain speed or light acceleration above 2000 rpm and upwards in 1st and 2nd gear so it seems that it happens when the engine is not under much load and when its warm.
After further investigation I found that disconnecting spark on cylinder 3 seems to stop the noise so I thought it was could be pre-ignition knock as compression would have increased after the re-ring. I have checked and doubled checked the timing and it spot on. I have also tried changing spark plugs and swapping injectors around in case it was a bad injector and it has made absolutely no difference.
I am now coming to the conclusion that it must be the big end knocking, piston slap or or the gudgeon pins?
There was no knocking before the rebuild so I would have expected the crankshaft to be fine so not sure why the the big end shells would be knocking. If it was big ends surely the engine would have munched itself by now after 1000 miles?
Also, I am driving her daily (about 25 miles a day) and the noise has not got any worse.
Could it be flywheel related?
All opinions welcome!!
I had a Zetec SE 1.6 making this noise:
https://www.youtube.com/watch?v=0ikRF1X5ZuM
It turned out it was because of piston slap from a worn piston:
https://www.youtube.com/watch?v=Xc6mFSZGh-w
None of the other pistons moved like that. I swapped one of the pistons from the scrap engine I had and it's been running nicely for the last few thousand miles.
I'll leave it for you to decide if it's the same noise (I don't think it is) but that's what piston slap sounds like. It quietened down over about 3,500 rpm and got loudest around 2,000 rpm.
https://www.youtube.com/watch?v=0ikRF1X5ZuM
It turned out it was because of piston slap from a worn piston:
https://www.youtube.com/watch?v=Xc6mFSZGh-w
None of the other pistons moved like that. I swapped one of the pistons from the scrap engine I had and it's been running nicely for the last few thousand miles.
I'll leave it for you to decide if it's the same noise (I don't think it is) but that's what piston slap sounds like. It quietened down over about 3,500 rpm and got loudest around 2,000 rpm.
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