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
Section 873 (Engine System-General Information)
WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Specifications
- Description And Operation
- Diagnosis And Testing
- Engine
- Special Tool(s)
- Material
- Inspection and Verification
- Symptom Chart
- Component Tests
- Engine Oil Leaks
- Engine Oil Leaks - Fluorescent Oil Additive Method
- Leakage Points - Underhood
- Leakage Points - Under Engine - With Vehicle on Hoist
- Leakage Points - With Transmission and Flywheel Removed
- Compression Test - Compression Gauge Check
- Compression Test - Test Results
- Compression Pressure Limit Chart
- Compression Test - Interpreting Compression Readings
- Cylinder Leakage Detection
- Excessive Engine Oil Consumption
- Intake Manifold Vacuum Test
- Valve Train Analysis - Engine Off - Valve Cover Removed
- Notes
- Valve Train Analysis - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft
- Valve Train Analysis - Engine Off, Camshaft - Engines
- Valve Train Analysis - Valve Springs
- Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
- Valve Train Analysis - Engine Off, Valves and Cylinder Head
- Valve Train Analysis - Engine Running
- Engine
- General Procedures
- Sprockets
- Camshaft Bearing Journal Diameter
- Camshaft Journal - Clearance, Plastigage Method
- Camshaft End Play
- Camshaft Surface Inspection
- Camshaft Lobe Lift
- Camshaft Runout
- Crankshaft Main Bearing Journal Diameter
- Crankshaft Main Bearing Journal Taper and Out-of-Round
- Crankshaft Main Bearing Journal - Clearance
- Crankshaft End Play
- Crankshaft Runout
- Connecting Rod Bearing Journal Taper and Out-of-Round
- Cylinder Bore Taper
- Cylinder Bore Out-of-Round
- Piston Inspection
- Piston Pin to 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
- Piston Wrist Pin Side Clearance
- Connecting Rod - Bearing Journal Clearance
- Connecting Rod to Crankshaft Side Clearance
- Roller Follower Inspection
- 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 Cleaning
- Cylinder Block Core Plug Replacement
- Spark Plug Inspection
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
Factory Service Tools
Use the Manual With the Right Hardware
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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.