ignition FORD EXPLORER 2002 3.G Workshop Manual

The fuel pump shut-off switch is
located in the passenger's foot well,
by the kick panel.
Use the following procedure to reset the fuel pump shut-off switch.
1. Turn the ignition to the OFF position.
2. Check the fuel system for leaks.
3. If no fuel leak is apparent, reset the fuel pump shut-off switch by
pushing in on the reset button.
4. Turn the ignition to the ON position. Pause for a few seconds and
return the key to the OFF position.
5. Make a further check for leaks in the fuel system.
FUSES AND RELAYS
Fuses
If electrical components in the
vehicle are not working, a fuse may
have blown. Blown fuses are
identified by a broken wire within
the fuse. Check the appropriate
fuses before replacing any electrical
components.
15
Roadside emergencies
207

The high-current fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
1 60A** PJB
2 20A** Door Locks
3 20A** GCC Pusher Fan (export only)
4 30A** Heated Backlight
5 40A** ABS
6 60A** Circuit Breaker
7 20A** Power Point #2
8 Ð Not Used
9 20A** Power Point #1
10 20A** ABS Module
11 40A** PTEC
12 50A** Ignition Relay
13 30A** Trailer Tow Battery
14 10A* Fog Lamps
15 5A* Memory
16 15A* Headlamp Switch
17 20A*4 x 4 (v-batt 2)
18 20A*4 x 4 (v-batt 1)
19 20A** High Beam Relay
20 30A** Electric Brake
21 Ð Not Used
22 20A** Autolmap; Low Beam
23 30A** Ignition Switch
24 10A* Rear Fog Lamps
25 20A* Security Module (horns)
26 15A* Fuel Pump
27 20A* Trailer Tow Lamps
28 10A* Daytime Running Lamps (DRL)
29 60A** PJB
30 Ð Not Used
31 Ð Not Used
32 Ð Not Used
33 30A** Auxiliary Blower Motor
Roadside emergencies
214

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
34 30A** Power Seats
35 Ð Not Used
36 40A** Blower Motor
37 15A* A/C Clutch
38 15A* Coil On Plug
39 15A* High Beam
40 15A* PTEC Power
41 15A* HEGO, UMV, CMS, PTEC
42 10A* Right Low Beam
43 10A* Left Low Beam
44 10A* High Beam Relay
45 7.5A* Right High Beam (export only)
46 15A* Injectors
47 Ð Daytime Running Lamps Relay,
GCC Pusher Fan (export)
48 Ð Fuel Pump Relay
49 Ð High Beam Relay
50 Ð Fog Lamp Relay
51 Ð Autolamp Relay
52 Ð A/C Clutch Relay
53 Ð Park Lamp Relay (export)
54 Ð Wiper Run / Park Relay
55 Ð Blower Motor Relay
56 Ð Starter Relay
57 Ð PTEC Relay
58 Ð Ignition Relay
59 Ð Wiper High/Low Relay
60 Ð PCM Diode
61 Ð A/C Clutch Diode
67 30A CB Delayed accessory
* Mini Fuses ** Maxi Cartridge Fuses
Roadside emergencies
215

If you have run out of fuel:
²You may need to cycle the ignition from OFF to ON several times after
refueling, to allow the fuel system to pump the fuel from the tank to
the engine.
²Your ªCheck Engineº indicator may come on. For more information on
the ªCheck Engineº indicator, refer to theInstrumentationchapter.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/8 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/8 of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/8 of a turn until it stops.
If the ªCheck Fuel Capº indicator comes on and stays on after you start
the engine, the fuel filler cap may not be properly installed. Turn off the
engine, remove the fuel filler cap, align the cap properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Maintenance and care
264

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

²Using fuel blended with alcohol may lower fuel economy.
²Fuel economy may decrease with lower temperatures during the first
12±16 km (8±10 miles) of driving.
²Driving on flat terrain offers improved fuel economy as compared to
driving on hilly terrain.
²Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
²Four-wheel-drive operation (if equipped) is less fuel efficient than
two-wheel-drive operation.
²Close windows for high speed driving.
EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
dealer if the window sticker is not supplied with your vehicle. The EPA
window sticker should be your guide for the fuel economy comparisons
with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of L/100 km (MPG)
expected on the vehicle under optimum conditions. Your fuel economy
may vary depending upon the method of operation and conditions.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
²Use only the specified fuel listed.
²Avoid running out of fuel.
²Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
²Have the items listed in your scheduled maintenance guide performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
guide are essential to the life and performance of your vehicle and to its
emissions system.
Maintenance and care
268

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

odometer ...................................15
speedometer .............................14
tachometer ................................16
trip odometer ............................15
GAWR
(Gross Axle Weight Rating) .....194
calculating ...............................196
definition .................................194
driving with a heavy load ......194
location ....................................194
GVWR (Gross
Vehicle Weight Rating) .............194
calculating .......................194, 196
definition .................................194
driving with a heavy load ......194
location ....................................194
H
Hazard flashers .........................206
Head restraints .................131, 136
Headlamps ...................................28
aiming ......................................276
autolamp system .......................30
bulb specifications ..................274
daytime running lights .............28
flash to pass ..............................29
high beam ...........................11, 29
replacing bulbs .......................271
turning on and off ....................28
warning chime ..........................13
Heating ........................................33
heating and air
conditioning system .................33
HomeLink universal
transceiver (see
Garage door opener) ........103±107
Hood ..........................................231I
Ignition .................................89, 287
Infant seats
(see Safety seats) .....................163
Inspection/maintenance
(I/M) testing ..............................270
Instrument panel
cleaning ...................................281
cluster ..................................8, 281
lighting up
panel and interior .....................29
location of components ..............8
J
Jack ....................................217±218
positioning .......................217, 219
storage .....................217±218, 222
Jump-starting your vehicle ......222
K
Keyless entry system ...............121
autolock ...................................124
keypad .....................................121
locking and unlocking doors ..122
programming entry code .......121
Keys ...........................127±128, 130
key in ignition chime ...............13
positions of the ignition ...........89
L
Lamps
autolamp system .......................30
bulb replacement
specifications chart ................274
cargo lamps ...............................29
daytime running light ...............28
Index
307