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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+
Component Replacement & Adjustment -> Passenger Cars -> Cabin Air Filter, Replace -> Continental -> Cougar -> Focus -> LS -> Sable & Taurus -> Thunderbird
Vehicle: 2001 Ford ZX2 2.0 L4 GAS
Cougar
- Ensure wiper motor is in park position.
- Lift covers, loosen mounting nuts and remove wiper arms.
- Open housing.
- Remove screw covers, mounting bolts, weatherseal and cowl grille.
- Remove cabin air filter.
- Reverse procedure to install. Torque wiper arm mounting nuts to 18 ft. lbs.
Continental
- Open hood and pull hood pad away from righthand cowl vent screen.
- Remove righthand cowl vent screen and water shield.
- Remove cabin air filter from filter, Fig. .
- Reverse procedure to install.
Focus
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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+.
Drum Brakes -> Escort, Tracer & ZX2 -> Brake Service -> Installation -> Removal
Vehicle: 2001 Ford ZX2 2.0 L4 GAS
Removal
- Raise and support vehicle, then remove wheel and tire assembly.
- Remove brake drum screws, then the brake drum.
- Remove wheel hub as outlined in "Escort, Tracer & ZX2" chassis chapter.
- Remove brake shoe retracting springs, Fig. , using screwdriver to push in and twist spring to disengage it from pin.
- Remove righthand anti-rattle spring.
- Push and turn brake shoe hold down springs, then remove them.
- Remove primary rear shoe and lining from backing plate, then the secondary shoe and lining.
Installation
- If rear shoes and linings are to be used again, inspect them to ensure they meet speci...
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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 Replacement -> Except 2002-05 Thunderbird, 2000-06 LS, 1984-87 Escort, Tracer, Tempo & Topaz 2.0L Diesel Engine & 1984-85 Continental & Mark VI 2.4L Diesel Engine
Vehicle: 2002 Ford ZX2 2.0 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
When installing the fuel filter, ensure the flow arrow is facing in the pro...
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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: 1999 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 -> Electronic Throttle Control ->
Vehicle: 2002 Ford ZX2 2.0 L4 GAS
Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...
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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: 1998 Ford ZX2 2.0 L4 GAS
Lower
- Drain cooling system into a suitable container.
- Raise and support vehicle.
- Remove two lefthand splash shield bolts.
- Reposition hose clamp from water pump inlet.
- Remove radiator outlet hose from water pump inlet.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator a...
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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: 2000 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+.
 HVAC Components Diagram for 2003 Ford ZX2 2.0 L4 GASComponents on diagram: |
 Power Steering System 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: |
 2001 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: A/C - IDENT OF NON-APPROVED REFRIGERANTS - REV Vehicle: 1999 Ford ZX2 2.0 L4 GAS Auto Systems: |
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Document: DRIVEABILITY SERVICE TIPS FOR OBDII VEHICLES ONLY Vehicle: 1998 Ford ZX2 2.0 L4 GAS Symptoms: |
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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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