service FORD EXPLORER 2002 3.G Service Manual

Fuel Filter
For fuel filter replacement, see your dealer or a qualified service
technician. Refer to the scheduled maintenance guide for the appropriate
intervals for changing the fuel filter.
Replace the fuel filter with an authorized Motorcraft part. The
customer warranty may be void for any damage to the fuel system
if an authorized Motorcraft fuel filter is not used.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
possible. Fuel expense, frequency of fillups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1 600 km (1 000
miles) of driving (engine break-in period). You will get a more accurate
measurement after 3 000 km±5 000 km (2 000 miles-3 000 miles).
Filling the tank
The advertised fuel capacity of the fuel tank on your vehicle is equal to
the rated refill capacity of the fuel tank as listed in theRefill Capacities
section of theCapacities and specificationschapter.
The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.
The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.
For consistent results when filling the fuel tank:
²Turn the engine/ignition switch to the off position prior to refueling,
an error in the reading will result if the engine is left running.
²Use the same filling rate setting (low Ð medium Ð high) each time
the tank is filled.
Maintenance and care
265

If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the ªCheck Engineº light, charging system warning light
or the temperature warning light, fluid leaks, strange odors, smoke or
loss of engine power, could indicate that the emission control system is
not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle's emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult your ªWarranty Guideº for complete emission warranty
information.
Maintenance and care
269

Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your ªCheck Engine/Service Engine
Soonº light is on, refer to the description in theWarning Lights and
Chimessection of theInstrumentationchapter. Your vehicle may not
pass the I/M test with the ªCheck Engine/Service Engine Soonº light on.
If the vehicle's powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a ªnot ready for I/M testº
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
²First, at least 10 minutes of driving on an expressway or highway.
²Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
BULBS
Replacing exterior bulbs
Check the operation of the following lamps frequently:
²Headlamps
²Foglamps
²High-mount brakelamp
²Brakelamps
²Turn signals
²License plate lamp
²Tail lamps
²Back-up lamps
Do not remove lamp bulbs unless they can be replaced immediately with
new ones. If a bulb is removed for an extended period of time,
contaminants may enter the lamp housings and affect lamp performance.
Maintenance and care
270

MOTORCRAFT PART NUMBERS
Component 4.0L SOHC V6 engine 4.6L V8 engine
Air filter element FA-1695 FA-1695
Fuel filter FG-986B FG-986B
Battery BXT-65-650 BXT-65-650
Oil filter FL-820S FL-820S
PCV valve EV-243 F6ZE-6C324-CA
Spark plugs* AGSF-22PP ** AWSF-32P
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. If a spark plug needs to be replaced, use only spark plugs
with the service number suffix letter as shown on the engine decal.
REFILL CAPACITIES
Fluid Ford Part Name Application Capacity
Brake fluid and
Clutch fluid (if
equipped)High Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine oil
(including filter
change)Motorcraft SAE
5W-30 Super
Premium Motor Oil4.0L 4.7L
(5.0 quarts)
Motorcraft SAE
5W-20 Super
Premium Motor Oil4.6L 5.7L
(6.0 quarts)
Fuel tank N/A All 85.2L
(22.5 gallons)
Power steering
fluidMotorcraft
MERCONtAT FAll Fill between
the MIN and
MAX lines on
reservoir
Transmission
fluid
1Motorcraft
MERCONtAT F5-speed manual 2.4L
(5.1 pints)2
Motorcraft
MERCONtVATFAutomatic
transmissions
only.12.0L
(12.7 quarts)3
Capacities and specifications
283

Fluid Ford Part Name Application Capacity
Transfer case Motorcraft
MERCONtAT F4WD 1.4L
(1.5 quarts)
Engine coolant
4Premium Engine
Coolant4.0L SOHC V6
enginewithout
auxiliary
climate control15.4L
(16.3 quarts)
4.0L SOHC V6
enginewith
auxiliary
climate control17.2L
(18.2 quarts)
4.6L V8 engine
without
auxiliary
climate control17.6L
(18.6 quarts)
4.6L V8 engine
withauxiliary
climate control19.0L
(20.1 quarts)
Front axle
lubricantMotorcraft SAE
80W-90 Premium
Rear Axle
Lubricant4x4 vehicles 1.7L
(1.8 quarts)
Rear axle
lubricant
5Motorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle LubricantConventional
Axle61.7L (3.5 pints)
Limited slip
axle
61.5L
(3.25 pints)
Windshield
washer fluidUltra-Clear
Windshield Washer
ConcentrateAll 4.0L
(4.2 quarts)
1Ensure the correct automatic transmission fluid is used. MERCONtand
MERCONtV are not interchangeable. DO NOT mix MERCONtand
MERCONtV. Refer to your scheduled maintenance guide to determine
the correct service interval.
2Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface.
3Indicates only approximate dry-fill capacity. Some applications may
vary based on cooler size and if equipped with an in-tank cooler. The
amount of transmission fluid and fluid level should be checked by a
qualified technician.
Capacities and specifications
284

4Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford
Extended Life Engine Coolant (orange in color). Refer toAdding engine
coolant, in the Maintenance and Care chapter.
5All rear axles are filled with Motorcraft SAE 75W-140 High Performance
Synthetic Rear Axle Lubricant, part number F1TZ-19780±B or equivalent
meeting Ford Specification WSL-M2C192±A.
6Limited Slip differentials must add 118ml (4 oz) of Additive Friction
Modifier C8AZ-19B546±A or equivalent meeting Ford Specification
EST-M2C118±A to the rear axle whenever the axle has been serviced.
LUBRICANT SPECIFICATIONS
ItemFord Part
Name or
equivalentFord Part
NumberFord
Specification
Body hinges,
latches, door
striker plates
and rotors, seat
tracks, fuel filler
door hinge and
spring, hood
latch, auxiliary
latch, seat
tracksMulti-Purpose
Grease or
Multi-Purpose
Grease SprayD0AZ-19584-AA
or
F5AZ-19G209-AAESB-M1C93-B or
ESR-M1C159-A
Hydraulic brake
fluidHigh
Performance
DOT 3 Motor
Vehicle Brake
FluidC6AZ-19542-ABESA-M6C25-A,
DOT 3
Driveshaft, slip
spline, universal
jointsPremium Long
Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Engine coolant
1Motorcraft
Premium Engine
Coolant
(green-colored
or
yellow-colored)VC-4-A (in
Canada CXC-10)ESE-M97B44-A
or
WSS-M97B51-A
Capacities and specifications
285

1DO NOT USE Ford Extended Life Engine Coolant F6AZ-19544-AA,
meeting Ford specification WSS-M97B44-D (orange in color) Refer to
Adding engine coolant,in theMaintenance and Carechapter.
2Ensure the correct automatic transmission fluid is used. MERCONtand
MERCONtV are not interchangeable. DO NOT mix MERCONtand
MERCONtV. Refer to your scheduled maintenance guide to determine
the correct service interval.
3All rear axles are filled with Motorcraft SAE 75W-140 High Performance
Synthetic Rear Axle Lubricant, part number F1TZ-19780-B or equivalent
meeting Ford specification WSL-M2C192-A.
4Limited slip differentials must add 118 ml (4 oz) of Additive Friction
Modifier C8AZ-19B546-A or equivalent meeting Ford specification
EST-M2C118±A to the rear axle whenever the axle has been serviced.
ENGINE DATA
Engine 4.0L SOHC V6
engine4.6L V8 engine
Cubic inches 245 281
Required fuel 87 octane 87 octane
Firing order 1-4-2-5-3-6 1-3-7-2-6-5-4-8
Spark plug gap 1.3-1.4 mm
(0.052-
0.056 inch)1.3-1.4 mm
(0.052-
0.056 inch)
Ignition system EDIS EDIS
Compression ratio 9.7:1 9.4:1
VEHICLE DIMENSIONS
Dimensions 4-Door 4x2 or 4x4 XLT Model mm
(in.)
(1) Overall length 4 813 (189.5)
(2) Overall width 1 832 (72.1)
(3) Maximum height* 1 827 (71.9)
(4) Wheelbase 2 889 (113.7)
(5) Track width, front 1 547 (60.9)
(5) Track width, rear 1 554 (61.2)
* Height includes roof rack and P235 tire
Capacities and specifications
287

Ford Extended Service Plan
You can get more protection for your new car or light truck by
purchasing Ford Extended Service Plan (Ford ESP) coverage. Ford ESP
is an optional service contract which is backed by Ford Motor Company
or Ford Motor Service Company (in the U.S.) and Ford of Canada (in
Canada). It provides the following:
²benefits during the warranty period depending on the plan you
purchase (such as: reimbursement for rentals; coverage for certain
maintenance and wear items)
²protection against repair costs after your Bumper to Bumper Warranty
expires
You may purchase Ford ESP from any participating Ford and Lincoln
Mercury and Ford of Canada dealer. There are several plans available in
various time, distance and deductible combinations which can be tailored
to fit your own driving needs. Ford ESP also offers reimbursement
benefits for towing and rental coverage. (In Hawaii, rules vary. See your
dealer for details.)
When you buy Ford ESP, you receive Peace-of-Mind protection
throughout the United States and Canada, provided by a network of
more than 5,000 participating Ford or Lincoln Mercury and Ford of
Canada dealers.
If you did not take advantage of the Ford Extended Service Plan at the
time of purchasing your vehicle, you may still be eligible. Please contact
your dealer for further information. Since this information is subject to
change, please ask your dealer for complete details about Ford Extended
Service Plan coverage options, or visit the Ford ESP website at
www.ford-esp.com.
Getting the service you need
At home
Ford Motor Company and Ford of Canada have authorized dealerships to
service your vehicle. When you need warranty repairs your selling dealer
would like you to return to it for that service, but you may also take your
vehicle to another Ford Motor Company or Ford of Canada dealership
authorized for warranty repairs. Certain warranty repairs require special
training though, so not all dealers are authorized to perform all warranty
repairs. That means that depending on the warranty repair needed, the
vehicle may need to be taken to another dealer. If a particular dealership
can not assist you, then contact the Customer Relationship Center.
Customer assistance
291

If you have questions or concerns, or are unsatisfied with the service you
are receiving, follow these steps:
1. Contact your Sales Representative or Service Advisor at your
selling/servicing dealership.
2. If your inquiry or concern remains unresolved, contact the Sales
Manager or Service Manager at the dealership.
3. If the inquiry or concern cannot be resolved at the dealership level,
please contact the Ford Customer Relationship Center.
Ford Motor Company and Ford of Canada dealerships also carry quality
parts and accessories, providing you with equipment reliability.
Away from home
If you own a Ford or Mercury vehicle and are away from home when
your vehicle needs service, or if you need more help than the dealership
could provide, after following the steps described above, contact the
Ford Customer Relationship Center to find an authorized dealership to
help you. In the United States:
Ford Motor Company
Customer Relationship Center
16800 Executive Plaza Drive
P.O. Box 6248
Dearborn, Michigan 48121
1-800-392-3673 (FORD)
(TDD for the hearing impaired: 1-800-232-5952)
In Canada:
Customer Relationship Centre
Ford Motor Company of Canada, Limited
P.O. Box 2000
Oakville, Ontario L6J 5E4
1-800-565-3673 (FORD)
Customer assistance
292

If you own a Lincoln vehicle and are away from home when your vehicle
needs service, or if you need more help than the dealership could
provide, after following the steps described above, contact the Ford
Customer Relationship Center to find an authorized dealership to help
you. In the United States:
Ford Motor Company
Customer Relationship Center
16800 Executive Plaza Drive
P.O. Box 6248
Dearborn, Michigan 48121
1-800-521-4140
(TDD for the hearing impaired: 1-800-232-5952)
In Canada:
Customer Relationship Centre
Ford Motor Company of Canada, Limited
P.O. Box 2000
Oakville, Ontario L6J 5E4
1-800-565-3673 (FORD)
In order to help you service your Ford or Lincoln Mercury vehicle, please
have the following information available when contacting a Customer
Relationship Center:
²Your telephone number (home and business)
²The name of the dealer and the city where the dealership is located
²The year and make of your vehicle
²The date of vehicle purchase
²The current odometer reading
²The vehicle identification number (VIN)
If you still have a complaint involving a warranty dispute, you may wish
to contact the Dispute Settlement Board (U.S.) or the Canadian Motor
Vehicle Arbitration Plan (CAMVAP), available in all of Canada (except
Quebec).
In some states (in the U.S.) you must directly notify Ford in writing
before pursuing remedies under your state's warranty laws. Ford is also
allowed a final repair attempt in some states.
In the United States, a warranty dispute must be submitted to the
Dispute Settlement Board before taking action under the Magnuson-Moss
Warranty Act, or to the extent allowed by state law, before pursuing
Customer assistance
293