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Ford ZX2 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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 Ford ZX2 AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Ford ZX2 cars and light trucks from 1990+
Computer Relearn Procedures -> Ford Motor Co. -> 1999-2002 -> 2003-04 -> Automatic Data Transfer -> Except 1999-2002 -> Manual Data Entry -> Powertrain Control Module (PCM)
Vehicle: 2002 Ford ZX2 2.0 L4 GAS
Powertrain Control Module (PCM)
Except 1999-2002
Disconnect negative battery cable for a minimum of five minutes. After clearing memory, it is required to drive vehicle a minimum of 10 miles to allow PCM time to relearn operating strategy.
1999-2002
Automatic Data Transfer
- Prior to removing old PCM, connect a suitably programmed scan tool to Data Link Connector (DLC).
- Follow scan tool manufacturers' instructions to download data from old PCM.
- Install new PCM and connect scan tool to DLC.
- Follow scan tool manufactur...
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BRAKE SERVICE PROCEDURES FOR Ford ZX2 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Ford ZX2 cars and light trucks from 1990+.
Disc Brakes -> Front Disc Brakes -> Brake System Bleed -> System Priming -> Wheel Bleeding Sequence
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
Pressure bleeding is recommended for all hydraulic disc brake systems.
Do not reuse brake fluid drained from the hydraulic system when bleeding the brakes. Ensure disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated.
Do not shake the pressure bleeder tank while air is being added or after it has been pressurized. This will prevent air from the tank getting into the lines. Do not move the tank during the bleeding operation. The tank should be kept at least one third full.
On models equipped with power brakes, exhaust the...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Ford ZX2 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Ford ZX2 cars and light trucks sold in the U.S. for 1980+.
Ford Motor Co. Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1998-03 Escort, ZX2, LN7, Lynx & Tracer -> Normal Service -> Severe Service
Vehicle: 1999 Ford ZX2 2.0 L4 GAS
Normal Service
Replac...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Ford ZX2 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Ford ZX2 cars and light trucks from 1990+.
CV AXLE SHAFT, Replace
Vehicle: 2000 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 Ford ZX2 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Ford ZX2 cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1998 Ford ZX2 2.0 L4 GAS
- Disconnect battery ground cable
- Remove alternator drive belt.
- Remove coolant tank reservoir.
- Disconnect electrical connectors.
- Remove alternator mounting bolts.
- Remove alternator...
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MAINTENANCE LAMP RESET PROCEDURES FOR Ford ZX2 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Ford ZX2 cars and light trucks sold in the U.S. from 1990+.
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 Ford ZX2 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Ford ZX2 cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1998 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 thermostat housing.
- Remove hose from thermostat housing.
- Remove hose from vehicle.
- Reverse procedure to instal...
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SERPENTINE BELT SERVICE PROCEDURES FOR Ford ZX2 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Ford ZX2 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1998 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 Ford ZX2 AUTOMOBILES
Component location diagrams for most Ford ZX2 cars and light trucks sold in the U.S. from 1990+.
 Instrument Panel Component Location Views Diagram for 2002 Ford ZX2 2.0 L4 GASComponents on diagram: |
 Exterior Lighting Diagram for 2002 Ford ZX2 2.0 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Ford ZX2 AUTOMOBILES
OEM drawn wiring diagrams for most Ford ZX2 cars and light trucks sold in the U.S.
 2003 Ford ZX2 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 1999 Ford ZX2 2.0 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Ford ZX2 AUTOMOBILES
OEM TSB listings for most Ford ZX2 cars and light trucks sold in the U.S. from 1985+.
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Document: CUSTOMER ASSISTANCE - TIRE COMPANY PHONE #'S - REV Vehicle: 1998 Ford ZX2 2.0 L4 GAS Auto Systems: |
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Document: A/C - IDENT OF NON-APPROVED REFRIGERANTS - REV Vehicle: 1998 Ford ZX2 2.0 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Ford ZX2 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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