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.
2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE
General Specifications
WARNING: This page is about a different car, the 2003 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Lubricants and Sealants | |
| Motorcraft Premium Synthetic Blend SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent | WSS-M2C153-H |
| Metal Surface Cleaner F4AZ-19A536-RA | WSE-M5B392-A |
| Silicone Gasket and Sealant F7AZ-19554-EA | WSE-M4G323-A4 |
| Engine | |
| Displacement | 3.0L (4V) (182 CID) |
| Number of cylinders | 6 |
| Bore | 89.0 mm (3.5 in) |
| Stroke | 79.5 mm (3.13 in) |
| Firing order | 1-4-2-5-3-6 |
| Oil pressure (hot 1,500 rpm) | 138-310 kPa (20-45 psi) |
| Oil capacity (with filter change) | 6.5 L (6.9 qts) |
| Compression ratio | 10.5:1 |
| Cylinder Head and Valve Train | |
| Cylinder head gasket surface flatness | 0.12 mm (0.004 in) |
| Combustion chamber volume | 45.7 ± 1.5 cc |
| Valve arrangement (front to rear) | - |
| Valve clearance - intake | 0.175-0.225 mm (0.0069-0.0089 in) |
| Valve clearance - exhaust | 0.325-0.375 mm (0.0128-0.0148 in) |
| Valve guide bore diameter | - |
| Valve stem diameter (standard) - intake | 5.492-5.477 mm (0.216-0.215 in) |
| Valve stem diameter (standard) - exhaust | 5.479-5.464 mm (0.215 in) |
| Valve stem-to-guide clearance - intake | 0.022-0.067 mm (0.0008-0.0026 in) |
| Valve stem-to-guide clearance - exhaust | 0.035-0.080 mm (0.001-0.003 in) |
| Valve head diameter - intake | 35 mm (1.38 in) |
| Valve head diameter - exhaust | 30 mm (1.18 in) |
| Valve head diameter - gauge diameter | 33.5 and 28.0 mm (1.318 and 1.102 in) |
| Valve face runout | 0.02 mm (0.007 in) |
| Valve face angle | 45.5 degrees |
| Valve seat width - intake | 1.1-1.4 mm (0.043-0.055 in) |
| Valve seat width - exhaust | 1.4-1.7 mm (0.055-0.066 in) |
| Valve seat runout | 0.04 mm (0.001 in) |
| Valve seat angle | 89-90 degrees |
| Valve spring free length (approx.) | 44.2 mm (1.740 in) |
| Valve spring compression pressure (N @ spec, length) | 400 ± 22 at 24.5 mm (89.92 ± 4.94 at 0.964 in) |
| Valve spring installed pressure (N @ spec, length) | 175 ± 10 at 33.41 mm (39.34 ± 2.24 at 1.315 in) |
| Camshaft | |
| Theoretical valve lift @ 0 lash | - |
| Lobe lift - intake | 8.466 mm (0.333 in) |
| Lobe lift - exhaust | 9.461 mm (0.372 in) |
| Allowable lobe lift loss | - |
| Journal diameter | 26.929-26.936 mm (1.060 in) |
| Camshaft journal bore inside diameter | - |
| Camshaft journal-to-bearing clearance - standard | 0.025-0.076 mm (0.001-0.0029 in) |
| Camshaft journal-to-bearing clearance - service limit | 0.151 mm (0.005 in) |
| Runout | - |
| End play - standard | 0.07-0.15 mm (0.002-0.005 in) |
| End play - service limit | 0.277 mm (0.010 in) |
| Cylinder Block | |
| Cylinder bore diameter - grade 1 | 89.000-89.010 mm (3.503-3.504 in) |
| Cylinder bore diameter - grade 2 | 89.010-89.020 mm (3.504 in) |
| Cylinder bore diameter - grade 3 | 89.020-89.030 mm (3.504-3.505 in) |
| Cylinder bore maximum taper | 0.020 mm (0.0007 in) |
| Cylinder bore maximum out-of-round - limit | 0.015 mm (0.0005 in) |
| Cylinder bore maximum out-of-round - service limit | 0.020 mm (0.0007 in) |
| Main bearing bore inside diameter | 67.998-68.022 mm (2.677-2.6780 in) |
| Head gasket surface flatness | 0.025-0.050 mm (0.0009-0.0019 in) |
| Head gasket surface finish | 0.12 mm (0.004 in) |
| Crankshaft | |
| Main bearing journal diameter | 62.968-62.992 mm (2.467-2.479 in) |
| Main bearing journal maximum taper | - |
| Main bearing journal maximum out-of-round | - |
| Main bearing journal-to-cylinder block clearance | - |
| Connecting rod journal diameter | 49.970-49.990 mm (1.967-1.968 in) |
| Connecting rod journal maximum taper | - |
| Connecting rod journal maximum out-of-round | - |
| Crankshaft maximum end play | 0.110-0.232 mm (0.004-0.009 in) |
| Piston and Connecting Rod | |
| Piston diameter - coded grade 1 | 88.990-89.010 mm (3.5035-3.5043 in) |
| Piston diameter - coded grade 2 | 88.998-89.022 mm (3.5039-3.5048 in) |
| Piston diameter - coded grade 3 | 89.010-89.030 mm (3.5043-3.5051 in) |
| Piston-to-cylinder bore clearance | 0.012-0.022 mm (0.0005-0.0009 in) |
| Piston ring end gap - compression.(top, gauge diameter) | 0.100-0.250 mm (0.0039-0.0098 in) |
| Piston ring end gap - compression (bottom, gauge diameter) | 0.27-0.42 mm (0.0106-0.0165 in) |
| Piston ring end gap - oil ring (steel-rail, gauge diameter) | 0.15-0.65 mm (0.0059-0.0255 in) |
| Piston ring end gap - compression (top, service limit) | 0.50 mm (0.0196 in) max. |
| Piston ring end gap - compression (bottom, service limit) | 0.65 mm (0.0255 in) max. |
| Piston ring end gap - oil ring (steel rail, service limit) | 0.90 mm (0.0354 in) max. |
| Piston ring groove width - compression (top) | 1.230-1.245 mm (0.0484-0.0490 in) |
| Piston ring groove width - compression (bottom) | 1.530-1.545 mm (0.0602-0.0608 in) |
| Piston ring groove width - oil ring | 3.030-3.055 mm (0.1192-0.0120 in) |
| Piston ring width | - |
| Piston ring-to-groove clearance | - |
| Piston pin bore diameter | 21.017-21.031 mm (0.827-0.828 in) |
| Piston pin diameter | 21.011-21.013 mm (0.8272 in) |
| Piston pin length | 60.51-60.08 mm (2.382-2.365 in) |
| Piston pin-to-piston fit | -0.005 to +0.001 mm (0.0001-0.00003 in) |
| Piston-to-connecting rod clearance | - |
| Connecting rod-to-pin clearance - standard | 0.004-0.020 mm (0.0001-0.0007 in) |
| Connecting rod-to-pin clearance - service limit | 0.035 mm (0.0013 in) |
| Connecting rod pin bore diameter | - |
| Connecting rod length (center-to-center) | 138.06-138.14 mm (5.435-5.38 in) |
| Connecting rod maximum allowed bend | 0.038 mm per 25.0 mm (0.0014 in per 0.984 in) |
| Connecting rod maximum allowed twist | 0.050 mm per 25.0 mm (0.0019 in per 0.984 in) |
| Connecting rod bearing bore diameter | - |
| Connecting rod bearing-to-crankshaft clearance | 0.028-0.045 mm (0.0011-0.0017 in) |
| Connecting rod side clearance (assembled to crank) - standard | 0.100-0.30 mm (0.0039-0.0118 in) |
| Connecting rod side clearance (assembled to crank) - service limit | 0.35 mm (0.0137 in) max. |
TORQUE SPECIFICATIONS
| Description | Nm | lb-ft | lb-in | ||||
|---|---|---|---|---|---|---|---|
| Ignition coil bolts | 6 | - | 53 | ||||
| Valve cover studs and bolts | 10 | - | 89 | ||||
| Upper intake manifold bolts | 10 | - | 89 | ||||
| Front intake manifold support nut | 10 | - | 89 | ||||
| Lower intake manifold bolts | 10 | - | 89 | ||||
| Coolant outlet tube bolts | 10 | - | 89 | ||||
| Coolant inlet tube bolts | 25 | 18 | - | ||||
| Crankshaft position sensor bolts | 10 | - | 89 | ||||
| Camshaft journal cap bolts(1) | - | - | - | ||||
| Camshaft position sensor bolt | 10 | - | 89 | ||||
| Crankshaft pulley bolt (1) | - | - | - | ||||
| Exhaust manifold nuts" | 20 | 15 | - | ||||
| Oil level indicator tube stud bolt | 10 | --89 | |||||
| Oil filter(2) | - | - | - | ||||
| Oil pan bolt | 25 | 18 | - | ||||
| Oil pressure switch | 14 | 10 | - | ||||
| Oil pump bolts | 10 | - | 89 | ||||
| Oil separator bolts | 10 | - | 89 | ||||
| Oil pump screen tube bolts | 10 | - | 89 | ||||
| Oil filter adapter bolts | 25 | 18 | - | ||||
| Oil filter adapter bolts (large single)(1) | - | - | - | ||||
| EGR-to-exhaust manifold tube | 40 | 30 | - | ||||
| EGR bolts | 25 | 18 | - | ||||
| Upper intake support bolt | 10 | - | 89 | ||||
| Upper intake support bracket nuts | 6 | - | 53 | ||||
| Oil cooler bolt | 57 | 42 | - | ||||
| Spark plugs | 15 | 11 | - | ||||
| Upper intake support bracket nuts | 10 | - | 89 | ||||
| LH and RH engine mount nuts | 63 | 46 | - | ||||
| Power steering pump bolts | 25 | 18 | - | ||||
| A/C manifold bolt | 21 | 15 | - | ||||
| A/C line bracket | 10 | - | 89 | ||||
| Cylinder head bolts(1) | - | - | - | ||||
| Lower cylinder block bolts(1) | - | - | - | ||||
| Generator mounting bolts | 48 | 35 | - | ||||
| A/C compressor mounting bracket bolts | 25 | 18 | - | ||||
| Engine mount bolts | 63 | 46 | - | ||||
| Engine mount nuts | 63 | 46 | - | ||||
| Engine mount bracket bolts | 25 | 18 | - | ||||
| Flywheel bolts | 80 | 59 | - | ||||
| Connecting rod cap nuts(1) | - | - | - | ||||
| Front cover bolts and studs | 25 | 18 | - | ||||
| Crankshaft damper bolts(1) | - | - | - | ||||
| Belt tensioner bolt | 50 | 37 | - | ||||
| Belt idler pulley bolt | 25 | 18 | - | ||||
| Transmission cooler line bracket bolt | 11 | - | 8 | ||||
| Torque converter nuts | 35 | 25 | - | ||||
| Cylinder head temperature (CHT) sensor | 15 | 11 | - | ||||
| Timing chain guide bolts | 25 | 18 | - | ||||
| Timing chain tensioner bolts | 25 | 18 | - | ||||
| Variable camshaft timing (VCT) oil filter plug | 25 | 18 | - | ||||
| Exhaust manifold heat shield bolts | 10 | - | 89 | ||||
| Power steering reservoir bolts | 12 | 9 | - | ||||
| Power steering pump bolts | 25 | 18 | - | ||||
| Power steering line bracket bolt | 10 | - | 89 | ||||
| Coolant pump bolts and studs | 25 | 18 | - | ||||
| Cross vehicle support bolts | 20 | 15 | - | ||||
| Ground strap-to-body bolt | 10 | - | 89 | ||||
| Ground strap-to-engine stud bolt and nut | 10 | - | 89 | ||||
| Steering shaft clamp bolt | 25 | 18 | - | ||||
| Starter studs and bolt | 25 | 18 | - | ||||
| Transmission oil cooler lines | 20 | 15 | - | ||||
| Engine-to-transmission bolts | 45 | 35 | - | ||||
| Radio ignition interference capacitor bolts | 10 | - | 89 | ||||
| Knock sensor bolts | 25 | 18 | - | ||||
| Front crossmember bolts | 103 | 76 | - | ||||
| Center crossmember bolts | 103 | 76 | - | ||||
| Lower strut mount bolts | 175 | 129 | - | ||||
| Description | Nm | lb-ft | lb-in | ||||
| Upper ball joint nuts | 90 | 66 | - | ||||
| Lower stabilizer link nut | 55 | 41 | - | ||||
| Front brake caliper bolts | 103 | 76 | - | ||||
| Upper radiator support bracket bolts | 10 | - | 89 | ||||
| Fuel pressure sensor shield bolts (M6) | 10 | - | 89 | ||||
| Fuel pressure sensor shield bolts | 6 | - | 53 | ||||
| Wiring harness-to-valve cover bracket nuts | 6 | - | 53 | ||||
| Fuel line bracket bolt | 10 | - | 89 | ||||
| Appearance cover bracket nuts | 6 | - | 53 | ||||
| Transmission-to-oil pan bolts | 45 | 35 | - | ||||
| Transmission cooler line bracket nut | 10 | - | 89 | ||||
| Cross vehicle support bolts | 20 | 15 | - | ||||
| A/C compressor bolts | 25 | 18 | - | ||||
| Subframe bolts | 104 | 77 | - | ||||
| Steering gear nuts | 103 | 76 | - | ||||
| Engine mount nuts (upper) | 40 | 30 | - | ||||
| Main engine wiring harness connector bolt | 10 | - | 89 | ||||
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Factory Service Tools
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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.