Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE
Engine System-General Information
- Specifications
- Description And Operation
- Diagnosis And Testing
- General Procedures
- Sprockets
- Camshaft Journal - Diameter
- Camshaft Journal - Clearance
- Camshaft Journal - to Bearing Clearance
- Camshaft - End Play
- Camshaft - Lobe Surface
- Camshaft - Lobe Lift
- Camshaft - Runout
- Crankshaft Main Bearing Journal - Diameter
- Crankshaft Main Bearing Journal - Taper
- Crankshaft Main Bearing Journal - Clearance
- Crankshaft - End Play
- Crankshaft - Runout
- Crankshaft - Connecting Rod Journal Diameter
- Crankshaft - Connecting Rod Journal Taper
- Cylinder Bore - Taper
- Cylinder Bore - Out-of-Round
- Piston - Inspection
- Piston - Pin Bore Diameter
- Piston - Diameter
- Piston - to Cylinder Bore Clearance
- Piston - Selection
- Piston - Ring End Gap
- Piston - Ring-to-Groove Clearance
- Piston - Pin Diameter
- Connecting Rod - Cleaning
- Connecting Rod - Large End Bore
- Connecting Rod - Bushing Diameter
- Connecting Rod - Bend
- Connecting Rod - Twist
- Connecting Rod - Piston Pin Side Clearance
- Connecting Rod - Bearing Journal Clearance
- Connecting Rod - Side Clearance
- Roller Follower - Inspection
- Valve Tappet - Inspection
- Valve Tappet - Leakdown Test, Hydraulic
- Valve - Stem Diameter
- Valve - Stem -to-Valve Guide Clearance
- Valve - Inspection
- Valve - Guide Inner Diameter
- Valve - Guide Reaming
- Valve - Spring Installed Length
- Valve - Spring Free Length
- Valve - Spring Squareness
- Valve - Spring Strength
- Valve - Seat Inspection
- Valve - Seat Width
- Valve - Seat Runout
- Cylinder Head - Distortion
- Cylinder Bore - Honing
- Cylinder Bore - Cleaning
- Cylinder Block-Distortion
- Cylinder Block - Repair
- Cylinder Block - Core Plug Replacement
- Spark Plug -Inspection
- Exhaust Manifold - Inspection
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
Rather have a pro handle this?
A certified mobile mechanic comes to your home or office. They bring the tools, you stay comfortable. No tow truck, no waiting room, no surprises.
Comes to youSame-day available12-month warranty
Get a Free QuoteNo obligation. See pricing before you book.