Think my engine is very sick. Returned from MOT and could hear a slight rattle when on light throttle, and has got worse. Tried putting pre MOT ECU map back in and still same noise. Sounds like small end or piston. forget all that b*****ks about reliable Zetecs! Suspect reving to 7400rpm did'nt help! Still have picked up another engine for £300 from 77,000 mile Mondeo. Will swap over after SVA if original lump doesn't die on route to the test.

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Tried putting pre MOT ECU map back in

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Could it be external? Perhaps the engine mounts settled down - something making contact with the chassis. Perhaps a bolt's loose or even the exhaust manifold's cracked.

Who said Zetec's were reliable? If oil not changed regularly early in their life the cranks suffer terribly.

It'll not be a little end - there has never been a Zetec with little end failure. Could be a piston if it's been hot, more likely big ends.

Suspect it will turn out to be a piston...will take the head off once its out the car.

are you running carbs or standard injection?

I know a couple people who've blown up (race) zetecs (or rather the new 2ltr duratecs) due to the standard injection starving the engine of fuel, their solution was to use a header tank of fuel as they thought the injectors were running dry - perhaps fuel pump or rev related?

Anyways, hope you get it sorted ok.

Ned.

Possible due to running lean, I had the ECU set lean at tickover 500-1000 rpm for MOT but time spent at this engine speed was short. Don't mind wrecking an engine due to giving it some stick but doing the same just to keep MOT man happy not good!

well what do you expect......ford s**t thats wot i say,you know you cant beat a red top vauxhall.wink wink wink.