light FORD EXPLORER 2002 3.G Repair Manual

Batteries normally produce explosive gases which can cause
personal injury. Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When working near the battery,
always shield your face and protect your eyes. Always provide proper
ventilation.
When lifting a plastic-cased battery, excessive pressure on the
end walls could cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
Lift the battery with a battery carrier or with your hands on opposite
corners.
Keep batteries out of reach of children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or clothing. Shield your eyes
when working near the battery to protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Battery posts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
Because your vehicle's engine is electronically controlled by a computer,
some control conditions are maintained by power from the battery. When
the battery is disconnected or a new battery is installed, the engine must
relearn its idle and fuel trim strategy for optimum driveability and
performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Drive the vehicle to complete the relearning process.
²The vehicle may need to be driven to relearn the idle and fuel trim
strategy.
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Repairs to correct the effects of using a fuel for which your vehicle was
not designed may not be covered by your warranty.
Octane recommendations
Do not be concerned if your engine
sometimes knocks lightly. However,
if it knocks heavily under most
driving conditions while you are
using fuel with the recommended
octane rating, see your dealer or a qualified service technician to prevent
any engine damage.
Unleaded Gasoline engines
Your vehicle is designed to use ªRegularº unleaded gasoline with an
(R+M)/2 octane rating of 87. We do not recommend the use of gasolines
labeled as ªRegularº that are sold with octane ratings of 86 or lower in
high altitude areas.
FFV engine (if equipped)
Your vehicle is designed to use Fuel Ethanol, ªRegularº unleaded gasoline
or any percentage of the two fuels combined.
U.S. government regulations require fuel ethanol dispensing
pumps to have a small, square, orange and black label with the
common abbreviation or the appropriate percentage for that
region. Use of other fuels such as Fuel Methanol may cause
powertrain damage, a loss of vehicle performance, and your
warranty may be invalidated.
Fuel quality
Many of the world's automakers
issued the World-wide Fuel Charter
that recommends gasoline
specifications to provide improved
performance and emission control
system protection for your vehicle.
Gasolines that meet the World-wide
Fuel Charter should be used when
available. Ask your fuel supplier
about gasolines that meet the
World-wide Fuel Charter. In Canada,
look for fuels that display theAuto Makers' Choiceylogo.
87(R+M)/2 METHOD
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²Idling for long periods of time (greater than one minute) may waste
fuel.
²Anticipate stopping; slowing down may eliminate the need to stop.
²Sudden or hard accelerations may reduce fuel economy.
²Slow down gradually.
²Driving at reasonable speeds (traveling at 88 km/h [55 mph] uses 15%
less fuel than traveling at 105 km/h [65 mph]).
²Revving the engine before turning it off may reduce fuel economy.
²Using the air conditioner or defroster may reduce fuel economy.
²You may want to turn off the speed control in hilly terrain if
unnecessary shifting between third and fourth gear occurs.
Unnecessary shifting of this type could result in reduced fuel
economy.
²Warming up a vehicle on cold mornings is not required and may
reduce fuel economy.
²Resting your foot on the brake pedal while driving may reduce fuel
economy.
²Combine errands and minimize stop-and-go driving.
Maintenance
²Keep tires properly inflated and use only recommended size.
²Operating a vehicle with the wheels out of alignment will reduce fuel
economy.
²Use recommended engine oil. Refer toLubricant Specifications.
²Perform all regularly scheduled maintenance items. Follow the
recommended maintenance schedule and owner maintenance checks
found in your vehicle scheduled maintenance guide.
Conditions
²Heavily loading a vehicle or towing a trailer may reduce fuel economy
at any speed.
²Carrying unnecessary weight may reduce fuel economy (approximately
0.4 km/L [1 mpg] is lost for every 180 kg [400 lb] of weight carried).
²Adding certain accessories to your vehicle (for example bug
deflectors, rollbars/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
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267

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.
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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.
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270

If the bulb is accidentally touched, it should be cleaned with rubbing
alcohol before being used.
1. Install the new bulb in lamp assembly by pushing straight in and
turning to lock in position. You may need to turn the bulb slightly to
align the grooves in the plastic base with the tabs in the lamp assembly.
2. Connect the electrical connector to the bulb.
3. Install the headlamp on vehicle by aligning the lamp on the vehicle,
push rearward to fully seat the lamp assembly then push the two
retainer pins down.
4. Turn the headlamps on and make sure they work properly. If the
headlamp was correctly aligned before you changed the bulb, you should
not need to align it again.
Replacing front parking lamp/turn signal/sidemarker bulbs
1. Make sure headlamp switch is in
OFF position, then open the hood.
2. Remove screw from the lamp
assembly.
3. Disengage lamp assembly by
pulling forward.
4. Rotate bulb socket
counterclockwise and remove from
lamp assembly.
5. Carefully pull bulb straight out of
socket and push in the new bulb.
6. Install bulb socket in lamp
assembly by turning clockwise.
7. Align the parking lamp studs with
the plastic grommets on the vehicle and push rearward to snap in place.
8. Install screw on lamp assembly.
Replacing tail/brake/turn/backup lamp bulbs
The tail/brake//turn/backup bulbs are located in the tail lamp assembly,
one just below the other. Follow the same steps to replace either bulb:
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Replacing high-mount brake lamp bulbs
1. Remove the two screws and move
the lamp assembly away from the
liftgate.
2. Remove the bulb holder from the
lamp assembly by depressing the
snaps.
3. Pull the bulb straight out of the
socket and push in the new bulb.
To complete installation, follow the
removal procedure in reverse order.
USING THE RIGHT BULBS
Replacement bulbs are specified in the chart below. Headlamp bulbs
must be marked with an authorized ªD.O.T.º for North America and an
ªEº for Europe to assure lamp performance, light brightness and pattern
and safe visibility. The correct bulbs will not damage the lamp assembly
or void the lamp assembly warranty and will provide quality bulb burn
time.
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Function Number of bulbs Trade number
Park/turn lamps
(front)2
3157 AK (amber)
Headlamp high beam 2 9005
Headlamp low beam 2 9006
Rear stop/turn/tail
lamps2
3157K
Rear license plate
lamps2
168
Backup lamp 2 3156K
High-mount stop
lamps5
W5W
Fog lamp 2 9145
Cargo lamp 1 211-2
Interior overhead lamp 1 912 (906)
Front door courtesy
lamp1
168
Map lamps 2 168 (T10)
Ashtray lamp 1 161
All replacement bulbs are clear in color except where noted.
To replace all instrument panel lights - see your dealer.
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4. On the wall or screen you will
observe a light pattern with a
distinct horizonal edge of high
intensity light with a slight angle
towards the right. If this edge is not
at the horizontal reference line, the
beam will need to be adjusted.
5. Locate the vertical adjuster on
each headlamp, then usea4mm
socket/wrench to turn the adjuster either counterclockwise (to adjust
down) or clockwise (to adjust up) aligning the upper edge of the light
pattern up to the horizontal line.
6. HORIZONTAL AIM IS NOT REQUIRED FOR THIS VEHICLE AND IS
NON-ADJUSTABLE.
7. Close the hood and turn off the lamps.
CLEANING AND CARING FOR YOUR VEHICLE
Refer to the Customer Assistance chapter for a list of Ford-approved
cleaners, polishes and waxes.
Washing your vehicle
Wash your vehicle regularly with
cold or lukewarm water. Never use
strong detergents or soap. If your
vehicle is particularly dirty, use a
quality car wash detergent. Always
use a clean sponge, washing glove
or similar device and plenty of water
for best results. To avoid spots,
avoid washing when the hood is still
warm, immediately after or during
exposure to strong sunlight.
During winter months, it is especially important to wash the vehicle on a
regular basis. Large quantities of dirt and road salt are difficult to
remove and also cause damage to the vehicle.
Any gasoline spilled on the vehicle or deposits such as bird droppings
should be washed and sponged off as soon as possible. Deposits not
removed promptly can cause damage to the vehicle's paintwork.
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277

²Take care when using a power washer to clean the engine. The high
pressure fluid could penetrate the sealed parts and cause damage.
²Do not spray with cold water to avoid cracking the engine block or
other engine components.
²Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
²Cover the highlighted areas to prevent water damage when cleaning
the engine.
4.6L V8 Engine
4.0L SOHC V6 Engine
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