engine FORD EXPLORER SPORT 2003 1.G Repair Manual

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:
•Turn the engine/ignition switch to the off position prior to refueling,
an error in the reading will result if the engine is left running.
•Use the same filling rate setting (low — medium — high) each time
the tank is filled.
•Allow no more than 2 automatic click-offs when filling.
•Always use fuel with the recommended octane rating.
•Use a known quality gasoline, preferably a national brand.
•Use the same side of the same pump and have the vehicle facing the
same direction each time you fill up.
•Have the vehicle loading and distribution the same every time.
Your results will be most accurate if your filling method is consistent.
Calculating fuel economy
1. Fill the tank and record the odometer reading.
2. Each time you fill up the tank, record the amount of fuel added.
3. After at least 3 fill-ups, fill the fuel tank and record the current
odometer reading.
4. Subtract your initial odometer reading from the current reading.
Use one of the following simple calculations to determine fuel economy:
•Liters x 100total kilometers
•Miles traveledgallons used
Keep a record for at least one month and record the type of driving (city
or highway). You can also keep records in summer and winter to
determine how temperature impacts fuel economy. Note that ethanol
decrease fuel economy.
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Improving fuel economy
To improve your fuel economy:
•Do not leave your vehicle idling for long periods of time.
•Drive at a moderate pace, with smooth acceleration and deceleration.
•Turn off speed control in hilly terrain.
•Follow the recommended maintenance schedule in yourScheduled
Maintenance Guide.
•Do not carry unnecessary weight.
EPA window sticker
The EPA window sticker should be your guide for fuel economy
comparisons. If you have any questions about this sticker, contact your
dealer.
EMISSION CONTROL SYSTEM
Your vehicle has emission control components and a catalytic converter
that enable your vehicle to comply with applicable exhaust emission
standards. To make sure that the emission control components work
properly:
•Use only unleaded fuel.
•Avoid running out of fuel.
•Do not turn off your ignition while the vehicle is moving.
•Follow yourScheduled Maintenance Guide.
•Use Ford Motor Company authorized parts for maintenance
replacements or for service.
Consult yourWarranty Guidefor emission warranty information.
Do not park, idle, or drive your vehicle in dry ground cover. The
emission system heats up the engine and exhaust system, which
could cause a fire.
The following signs could indicate a problem with your emission control
system:
•Fluid leaks
•Strange odors
•Smoke
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•Loss of engine power
•Illumination of the charging system, temperature, or “Check Engine”
light in the instrument panel.
Exhaust leaks may result in harmful and potentially lethal fumes
entering the passenger compartment.
It is unlawful 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.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When theCheck
Engine/Service Engine Soonlight illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause yourCheck
Engine/Service Engine Soonlight to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck Engine/Service Engine Soonlight should turn off.
(A driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck Engine/Service Engine Soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
It may be a legal requirement in your area to pass an I/M test of the
on-board diagnostics system. If the system or battery has just been
serviced, the on-board diagnostic system is reset to a “not ready for I/M
test” condition. To ready the system, allow the vehicle to sit for at least
eight hours without starting. Then, start the engine and complete the
following driving cycle:
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1. Drive on an expressway or highway for at least 10 minutes.
2. Drive in stop-and-go traffic for at least 20 minutes with a minimum of
four idle periods.
The engine must warm up to its normal operating temperature. Once
started, do not turn off the engine until the above drive cycle is
complete.
Note:If your “Check Engine” light is on, your vehicle may not pass an
I/M test.
CHECKING AND ADDING POWER STEERING FLUID
Check the fluid. Refer to the
Scheduled Maintenance Guidefor
service maintenance schedules.
1. Start the engine and let it run
until it reaches normal operating
schedules.
2. Turn the steering wheel left and
right several times.
3. Turn the engine off.
4. Check the fluid level.
5. If the fluid is below the MIN line,
add fluid in small amounts until it
reaches the correct level (between
the MIN and MAX lines).
Use only MERCONAT F.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the “MAX” line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
DONOTOVERFILLPOWERSTEERINGFLUID
M
AX
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TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
•Refer to yourScheduled Maintenance Guidefor scheduled check
and change intervals.
•Transmission does not consume fluid.
•Check fluid when transmission is not operating properly or if you see
a leak.
•Fluid level must be checked at normal operating temperature, 30 km
(20 miles) of driving.
To check and add fluid:
1. Drive the vehicle 30 km (20 miles) to reach normal operating
temperatures.
2. If driven in hot weather, city traffic, pulling a trailer, allow
transmission to cool for 30 minutes before checking.
3. Engage parking brake, start engine.
4. Put your foot on the brake pedal and move the gearshift lever slowly
through all of the gear ranges.
5. Shift to P (Park) and leave the engine running.
6. Remove the dipstick, wipe clean with a dry lint free rag.
7. Install and fully seat the dipstick into the filler tube.
8. Remove the dipstick and inspect
the fluid level. Level should be in
the cross-hatched area.
9. If necessary, add fluid in 250ml (1/2 pint) increments through the filler
tube until the level is correct at normal operating temperatures. Refer to
theLubricant Specificationssection in this chapter for the correct fluid
type. The use of any other non-approved fluid may cause internal
transmission damage.
10. Fluid can be checked at ambient
temperatures between 10–30°C
(50–95°F). DO NOT ADD fluid until
the transmission is at normal
operating temperatures or the transmission will be overfilled.
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SNOW TIRES AND TRACTION DEVICES
Snow tires must be the same size and grade as the original tires.
Your tires have all-weather treads to provide traction in the rain and
snow. In some climate, using snow tires or traction devices may be
necessary. For Motor Company offers tire cables as a Ford approved
accessory and recommends use of these or SAE class “S” cables. See
your dealer for more information.
Follow these guidelines:
•Do not use tire cables or chains with P255/70R16 size tires.
•Cables or chains should only be used on the rear wheels.
•If you need to use chains, it is recommended that steel wheels (of the
same size and specification) be used, as chains may chip aluminum
wheels.
•Install cables or chains securely, verifying that they do not touch any
wiring, brake lines or fuel lines.
•Avoid overloading your vehicle.
•Do not use cables or chains on dry roads.
•Do not exceed 48 km/h (30 mph).
•Drive cautiously.
Remove the cables or chains when they are no longer needed.
MOTORCRAFT PART NUMBERS
Component 4.0L SOHC V6 engine
Air filter element FA-1744
Fuel filter FG-1036
Battery BXT-65-650
Oil filter FL-820S
PCV valve EV-243
Spark plugs* AGSF-22PP
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
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REFILL CAPACITIES
Fluid Ford Part Name Application Capacity
Brake and clutch
fluidMotorcraft 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
OilAll 4.7L
(5.0 quarts)
Fuel tank N/A All 63.6 L
(16.8 gallons)
Power steering
fluidMotorcraft
MERCONAT FAll Fill to line on
reservoir
Transmission
fluid
1Motorcraft
MERCONAT F4-speed manual 2.6L
(5.6 pints)8
Motorcraft
MERCONVATF5R55E Automatic
(4x2)9.5L
(10.0 quarts)2
5R55E Automatic
(4x4)9.8L
(10.3 quarts)2
Transfer case Motorcraft
MERCONAT F4WD 1.2L
(1.3 quarts)3
Engine coolant4Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)4.0L SOHC V6
engine13.2L
(14.0 quarts)
Front axle
lubricantMotorcraft SAE
80W-90 Premium
Rear Axle
Lubricant4x4 vehicles 1.7L (1.8 quarts)
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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
GreaseD0AZ-19584-AA
or XL-5ESB-M1C93-B or
ESR-M1C159-A
Hydraulic clutch
fluid and brake
fluidMotorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1ESA-M6C25-A
and DOT 3
Driveshaft, slip
spline, universal
jointsPremium Long
Life GreaseXG-1-C or
XG-1-T or
XG-1-KESA-M1C75-B
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Engine oilMotorcraft SAE
5W-30 Super
Premium Motor
Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)XO-5W30-QSP
(US)
CXO-5W20–LSP12
(Canada)WSS-M2C205-A
with API
Certification
Mark
Automatic
transmission
(5R55E)
1
Motorcraft
MERCONVATFXT-5-QM MERCONV
4–speed manual
transmissionMotorcraft
MERCON
Multi-Purpose
AT FXT-2-QDX MERCON
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ENGINE DATA
Engine 4.0L SOHC V6 engine
Cubic inches 245
Required fuel 87 octane
Firing order 1-4-2-5-3-6
Spark plug gap 1.3-1.4 mm (0.052-0.056 inch)
Ignition system EDIS
Compression ratio 9.7:1
VEHICLE DIMENSIONS
Dimensions 2 Door 4x2 XL model
mm (in.)2 Door 4x4 Sport
model mm (in.)
(1) Overall length 4608 (181.4) 4608 (181.4)
(2) Overall width 1783 (70.2) 1783 (70.2)
(3) Maximum
height*1704 (67.1) 1779 (70.0)*
(4) Wheelbase 2585 (101.8) 2585 (101.8)
(5) Front track /
rear1486 (58.5)/1486 (58.5) 1486 (58.5)/1486 (58.5)
* Height includes roof rack & P255 tire
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IDENTIFYING YOUR VEHICLE
Certification label
The National Highway Traffic Safety
Administration Regulations require
that a Certification label be affixed
to a vehicle and prescribe where the
Certification label may be located.
The Certification label is located on
the front door latch pillar on the
driver’s side.
Vehicle identification number (VIN)
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel. (Please note that
in the graphic XXXX is
representative of your vehicle
identification number.)
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block, transmission, frame and
transfer case (if equipped).
XXXXXXXXXXXXXXXXX
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