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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+
Module Configuration Procedure -> Ford Motor Company -> 1999-2003 -> Calibration Update -> Programmable Module Installation (PMI) -> Programmable Parameters
Vehicle: 2002 Ford ZX2 2.0 L4 GAS
Some modules will need to be programmed as part of a repair procedure, Fig. . If not the module will not function properly and may set a number of diagnostic trouble codes including B2477 or P1639 indicating necessary data has not been programmed into the new module.
Module parameters and values are unique to each vehicle, therefore modules should not be exchanged from vehicle to vehicle.
There are two types of configuration data. The first type is used by the module so that it can interact with the vehicle correctly. The second type is customer preference driven. These ...
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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 -> Description -> Dual Piston Calipers -> Single Piston Calipers
Vehicle: 1998 Ford ZX2 2.0 L4 GAS
Single Piston Calipers
The caliper assembly consists of a pin sliding caliper housing, inner and outer shoe and lining assemblies and a single piston, Figs. through . The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the i...
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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 -> Component Locations -> 1997-03 Escort & ZX2
Vehicle: 2001 Ford ZX2 2.0 L4 GAS
Refer to ...
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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: 2001 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+.
Starter, Replace
Vehicle: 2003 Ford ZX2 2.0 L4 GAS
- Disconnect Mass Air Flow sensor.
- Disconnect breather pipe.
- Disconnect air cleaner outlet tube from throttle body and remove air cleaner.
- Remove starter motor upper mounting bolts
- Raise and support vehicle.
- Disconnect starter motor electrical connector.
- Remove lowe...
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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 -> Powertrain Malfunction Indicator ->
Vehicle: 1998 Ford ZX2 2.0 L4 GAS
This lamp should light when the ignition is turned On. After engine starts, the lamp should go off, unless a fault condition is detected in the powertrain system. If the lamp remains On a diagnostic trouble code is stored in the PCM. Following diagnosis and repair, the Powertrain Malfunction Indicator will automatically reset when stored diagnostic trouble codes are cleared from PCM memory. The PCM reset procedure allows the scan tool to command the PCM to clear all diagnostic trouble codes.
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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+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 Ford ZX2 2.0 L4 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator and from vehicle.
- Reverse procedure to in...
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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: 1999 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+.
 Fuel Components Diagram for 2002 Ford ZX2 2.0 L4 GASComponents on diagram: |
 Sedan Body Diagram for 1998 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.
 1998 Ford ZX2 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 2002 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: REAR WINDOW DEFROSTER GRID / INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR - REVISED Vehicle: 2000 Ford ZX2 2.0 L4 GAS Symptoms: |
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Document: WIRING HARNESS - TERMINAL REPAIR KIT - REV6 Vehicle: 2000 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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