This DIY repair and service manual, covers all 2002-2010 Ford Explorer and 2002-2010 Mercury Mountaineer models.
Note: This manual does not include Sport Trac model info.
Detailed chapters cover all major systems, with hundreds of close-up and detailed photos, including:
Book Excerpt: 2002-2010 Ford Explorer, Mercury Mountaineer Repair Manual
- Tune-Up and Routing Maintenance
- 4.0L V6 Engine
- 4.6L V8 Engine (2-Valve and 3-Valve)
- Engine Overhaul
- Cooling, Heating, and Air Conditioning Systems
- Engine Electrical
- Manual and Automatic Transmissions
- Transfer Case (4x4)
- Clutch, Driveline and Brakes
- Suspension and Steering
- Wiring Diagrams
- And much more!
GENERAL ENGINE OVERHAUL PROCEDURES
CYLINDER COMPRESSION CHECK
CHAPTER 1 - TUNE-UP AND ROUTINE MAINTENANCE
Refer to illustration 3.6
- A compression check will tell you what mechanical condition the upper end of your engine (pistons, rings, valves, head gaskets) is in. Specifically, it can tell you if the compression is down due to leakage caused by worn piston rings, defective valves and seats or a blown head gasket.
Note: The engine must be at normal operating temperature and the battery must be fully charged for this check.
- Begin by cleaning the area around the spark plugs before you remove them (compressed air should be used, if available). The idea is to prevent dirt from getting into the cylinders as the compression check is being done.
- Remove all of the spark plugs from the engine. (see Chapter 1).
- Block the throttle wide open.
- Disconnect the primary (low voltage) wires from the coil pack (V6 models) or the connectors at the ignition coils (V8 models)(see Chapter 5). Remove the fuel pump relay (see Chapter 4, Section 2).
- Install a compression gauge in the spark plug hole (see illustration).
- Crank the engine over at least seven compression strokes and watch the gauge. The compression should build up quickly in a healthy engine.
Low compression on the first stroke, followed by gradually increasing pressure on successive strokes, indicates worn piston rings.
A low compression reading on the first stroke, which doesn't build up during successive strokes, indicates leaking valves or a blown head gasket (a cracked head could also be the cause).
Deposits on the undersides of the valve heads can also cause low compression. Record the highest gauge reading obtained.
- Repeat the procedure for the remaining cylinders and compare the results to this Chapter's Specifications.
POWER STEERING FLUID
Refer to illustrations 4.25 and 4.28
- Check the power steering fluid level periodically to avoid steering system problems, such as damage to the pump.
Caution: DO NOT hold the steering wheel against either stop (extreme left or right turn) for more than five seconds. If you do, the power steering pump could be damaged.
- The power steering reservoir, located at the right side of the engine compartment (see illustration), has MIN and MAX fluid level marks on the side.
The fluid level can be seen without removing the reservoir cap.
- Park the vehicle on level ground and apply the parking brake.
- Run the engine until it has reached normal operating temperature. With the engine at idle, turn the steering wheel back and forth about 10 times to get any air out of the steering system.
Shut the engine off with the wheels in the straight-ahead position.
I bought the Haynes 2002 thru 2010 repair manual for the Ford Explorer. Now you can buy these books any place, they are the best repair manual you can get, except from the auto maker, and we all know how much they are!
For one the book is right on the money. It gives step by step instructions, and the best part, if they don't think you should try to fix something they say so.
Now the Motor Book Store has great prices and good service, that is why I bought from them and they have just about any manual you would need.
Jack Sparks | Nevada
Subject: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Ford Explorer and Mercury Mountaineer service, maintenance, repair. ISBN-10: 1563928116 | ISBN-13: 9781563928116 | Haynes 36025