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 StandardFACTORY OEM SERVICE PROCEDURE
Gasoline Engines
- 1) Fuel System Visual Inspection
Visually inspect fuel system, including fuel lines, connections, injectors and electrical connections. Ensure Inertia Fuel Shutoff (IFS) switch is not tripped. Check condition of battery and fuses. Ensure fuel level in tank is sufficient. - 2) Check Fuel Pressure
Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). Release fuel system pressure. See FUEL PRESSURE RELEASE . Install fuel pressure gauge. Using scan tool, access OUTPUT TEST MODE. For additional information, see OUTPUT TEST MODE under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - EEC-V - CNG, FLEX-FUEL & GASOLINE article. Command fuel pump ON and run fuel pump to obtain maximum fuel pressure. Record fuel pressure. Compare measured fuel pressure to fuel pressure specification. See FUEL PRESSURE SPECIFICATIONS . If fuel pressure is within specification, go to next step. If fuel system pressure is not within specification, go to TEST HC, step 1) under SYSTEM TESTS in SELF-DIAGNOSTICS - EEC-V - CNG, FLEX-FUEL & GASOLINE article for fuel delivery system diagnosis. - 3) Check Fuel Pressure Leakdown
With fuel pressure gauge still installed, cycle ignition switch on and off several times. Record fuel pressure. After one minute with ignition off, fuel pressure should remain within 5 psi (34 kPa) of maximum fuel pressure. If fuel pressure remains within specification, system is capable of maintaining fuel pressure. If fuel pressure does not remain within specification, check for leaking fuel injectors or fuel pressure regulator.
WARNING:
ALWAYS relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. See FUEL PRESSURE RELEASE .
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.
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