engine FORD EXPLORER SPORT TRAC 2002 Workshop Manual

Running out of fuel
Running out of fuel may have an adverse affect on powertrain
components.
•You 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.
•Your“Check Engine”indicator may come on.
Fuel filler cap
When fueling:
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.
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“Check Fuel Cap”indicator
illuminates and stays on after you
start the engine, the cap may not be
properly installed.
If you must replace the fuel
filler cap, replace it with a fuel filler cap that is designed for your
vehicle.
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 personal
injury.
Fuel filter
Refer to theScheduled Maintenance Guidefor the appropriate
replacement intervals. Replace the fuel filter with an authorized
Motorcraft part.
ESSENTIALS OF GOOD FUEL ECONOMY
We do not recommend taking fuel economy measurements during the
first 1,600 km (1,000 miles) of driving. You will get a more accurate
measurement after 3,000 km - 5,000 km (2,000 miles - 3,000 miles)
CHECK
FUEL
CAP
Maintenance and Specifications
170

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 this chapter.
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 100
total kilometers
•Miles traveled
gallons used
Maintenance and Specifications
171

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.
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.
Maintenance and Specifications
172

The following signs could indicate a problem with your emission control
system:
•Fluid leaks
•Strange odors
•Smoke
•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.
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:
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.
Maintenance and Specifications
173

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
The brake fluid should be checked
and refilled according to the service
maintenance schedule in the
Scheduled Maintenance Guide.
1. Clean the reservoir cap before
removal.
2. Check the fluid level.
3. If necessary, add brake fluid from
a clean, unopened container. Do not
fill above the MAX line.
Note:Use only a DOT 3 brake fluid
that meets Ford Motor Company
specifications.
DONOTOVERFILLPOWERSTEERINGFLUID
Maintenance and Specifications
174

Do not let the master
cylinder reservoir run dry.
This may cause your brakes to
fail.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical attention if
irritation persists. If taken internally, drink water and induce vomiting.
Seek medical attention immediately.
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.
MAX
Maintenance and Specifications
175

MOTORCRAFT PART NUMBERS
Component 4.0L SOHC V6 engine
Air filter element FA-1658
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.
REFILL CAPACITIES
Fluid Ford Part
NameApplication
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 85.2L (22.5
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
MERCONV
AT F5R55E
Automatic (4x2)9.5L (10.0
quarts)2
5R55E
Automatic (4x4)9.8L (10.3
quarts)2
Maintenance and Specifications
183

Fluid Ford Part
NameApplication
Capacity
Transfer case Motorcraft
MERCONAT F4WD 1.2L (1.3
quarts)
3
Engine coolant4Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
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)
Rear axle
lubricant
5Motorcraft SAE
80W-90
Premium Rear
Axle LubricantRefer to
Footnote 62.9-3.1L (5.5-5.8
pints)
Motorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle LubricantRefer to
Footnote 7
Windshield
washer fluidMotorcraft
Ultra-Clear
Windshield
Washer
ConcentrateAll 2.6L (2.7
quarts)
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONand MERCONV are not interchangeable. DO NOT
MIX MERCONand MERCONV. Refer to the scheduled maintenance
guide to determine the correct service interval.
Maintenance and Specifications
184

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
D0AZ-19584-AA
or
F5AZ-19G209-AAESB-M1C93-B or
ESR-M1C159-A
Hydraulic clutch
fluid and brake
fluidHigh
Performance
DOT 3 Motor
Vehicle Brake
FluidC6AZ-19542-ABESA-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 Engine
Coolant
(green-colored)VC-4–A (US) or
CXC-10
(Canada)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Engine oilMotorcraft SAE
5W-30 Super
Premium Motor
OilXO-5W30-QSPWSS-M2C205-A
with API
Certification
Mark
Automatic
transmission
(5R55E)
1
Motorcraft
MERCONV
AT FXT-5-QM MERCONV
Maintenance and Specifications
186

3Traction-Lok rear axles are filled with Motorcraft SAE 75W-140 High
Performance Synthetic Rear Axle Lubricant, part number F1TZ-19780-B,
Ford specification WSL-M2C192-A.
4Add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118–A to Traction-Lok
rear axles whenever the axle has been serviced.
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 4-Door mm (in.)
(1) Overall length 5 230 (205.9)
(2) Overall width 1 823 (71.8)
(3) Vehicle height/ Maximum
height*1 776 (69.9)/1 794 (70.6)*
(4) Wheelbase 3 198 (125.9)
(5) Front track /Rear track 1 486 (58.5)/1 480 (58.3)
*Denotes a 4x4 vehicle with 16”tires
Maintenance and Specifications
188