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2003 Ford ZX2 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 Ford ZX2 car and truck
repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Ford ZX2 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> ZX2 -> Symptom Based Diagnosis & Testing
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Hydraulic Brake Systems -> Component Service -> Assemble -> Disassemble -> Inspection -> Master Cylinder Overhaul -> Overhaul -> Wheel Cylinders
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
Master Cylinder Overhaul
Disassemble
- Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
- Remove stop bolt and pressure control valves, if equipped.
- Pry up on reservoir and remove it from master cylinder body.
- Remove fluid control valve, if equipped.
- Depress primary piston and remove snap ring from retaining groove at open end of bore.
- Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.
Inspection
When disassembled, wash all parts in clean brake...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Ford Motor Co. Passenger Cars -> Fuel Shutoff Switch Location -> 1999-03 Escort, Escort ZX2, EXP, Lynx, LN7 & Tracer
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
The...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
- Raise and support vehicle.
- Remove lug nuts and remove front tire and wheel.
- Raise staked portion of front axle wheel hub retainer using a small cape chisel.
- Remove and discard front axle wheel hub retainer.
- Remove cotter pin and tie rod end nut.
- Use a suitable tool to separate tie rod end from front wheel knuckle.
- Remove stabilizer bar link.
- Remove nut and ball joint pinch bolt.
- Pry down on front suspension lower arm separating front suspension lower arm ball joint from front wheel knuckle.
- Pull outward on front wheel knuckle then pull front wheel driveshaft and joint from front w...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Alternator, Replace
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
- Disconnect battery ground cable.
- Remove alternator drive belt.
- Remove cover and disconnect electrical connectors.
- Remove alternator mounting bolt and secure coolant expansion tank aside.
- Secure power steering reservoir aside.
- Remove mounting bolt and secure engine wiring loom bracket aside.
- Disconnect ground ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Ford Motor Co. Cars -> Check Fuel Cap Lamp ->
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. If the lamp remains...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Drain cooling system into a suitable container.
- Reposition heater hose outlet clamp at heater core.
- Disconnect heater ou...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Ford ZX2 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Ford ZX2 AUTOMOBILES
Component location diagrams for most 2003 Ford ZX2 cars and light trucks sold in the U.S. from 1990+.
 Instrument Panel Component Location Views Diagram for 2003 Ford ZX2 2.0 L4 GASComponents on diagram: |
 Shift Linkage Diagram for 2003 Ford ZX2 2.0 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Ford ZX2 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Ford ZX2 cars and light trucks sold in the U.S.
 2003 Ford ZX2 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 2003 Ford ZX2 2.0 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Ford ZX2 AUTOMOBILES
OEM TSB listings for most 2003 Ford ZX2 cars and light trucks sold in the U.S. from 1985+.
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Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 2003 Ford ZX2 2.0 L4 GAS Auto Systems: |
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Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 2003 Ford ZX2 2.0 L4 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Ford ZX2 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Ford ZX2 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 Ford ZX2 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 Ford ZX2 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 Ford ZX2 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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