Ford Explorer / Mercury Mountaineer 2001 thru 2005, repair e-manual (in Russian)

Content

Instruction manual

• Introduction
• Instrument panel
• Climate control system
• Lighting equipment
• Controls
• Locks and security
• Seats and auxiliary restraints
• Driving

Introduction

Regular care and maintenance

• Service schedule
• Introduction
• General recommendations for car care
• Checking the levels of fluids and lubricants
• Check of a condition and pressure of inflation of tires
• Replacement of engine oil and oil filter
• Rearrangement of wheels
• Inspection and replacement of wiper blades
• Inspection, maintenance and charging of the battery
• Inspection of the cooling system
• Seat belt inspection
• Inspection and replacement of hoses that are in the engine compartment
• Checking the technical condition of the braking system
• Checking the technical condition of the steering and suspension
• Checking the technical condition of the fuel system
• Checking the condition and replacing the air filter
• Checking the level of the transmission fluid in the manual transmission
• Checking the level of the transmission fluid in the transfer case
• Inspection of drive shaft covers
• Inspection of the technical condition of the exhaust system
• Replacing the fuel filter
• Maintenance of the cooling system (draining, flushing and filling)
• Brake fluid replacement
• Checking the condition and replacing the drive belt
• Changing the oil of a manual gearbox
• Checking the level and replacing the differential oil
• Checking the level of the transmission fluid in the manual transmission
• Checking the condition and replacing the valve of the crankcase ventilation system (PCV)
• Inspection and replacement of spark plugs
• Check of a condition of the coil of ignition (engines V8)
• Inspection and replacement of wires of spark plugs (V6 engines)

The V6 engine

• General information
• Car repair without removing the engine from the engine compartment
• The top dead center (TDC) of the piston of the first cylinder is the location
• Valve mechanism covers - removing and installing
• Rocker arms and compensators - removal, inspection and installation
• Intake manifold - removal and installation
• Exhaust manifolds - removal and installation
• Cylinder heads - removing and installing
• Pulley and front crankshaft seal - removal and installation
• Drive chain and sprockets - removal, inspection and installation
• Camshafts - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Handwheel / drive plate - removal and installation
• Rear main engine oil seal - replacement
• Engine mountings - inspection and replacement

The V8 engine

• General information
• Car repair without removing the engine from the engine compartment
• The top dead center (TDC) of the piston of the first cylinder is the location
• Valve mechanism covers - removing and installing
• Intake manifold - removal and installation
• Exhaust manifolds - removal and installation
• Pulley and front crankshaft seal - removal and installation
• Drive chain casing - removing and installing
• Drive chains, tensioners and asterisks - removal, inspection and installation
• Rocker arms and valve clearance adjusters - removal, inspection and installation
• Camshafts - removal, inspection and installation
• Cylinder heads - removing and installing
• Pallet - removal and installation
• Oil pump - removal and installation
• Drive disk - removal and installation
• Rear main engine oil seal - replacement
• Engine mountings - inspection and replacement

Major engine repairs

• General information - overhauling the engine
• Checking the oil pressure
• Compression check in cylinders
• Diagnosis with measurement of the degree of dilution
• Alternative methods of engine restoration
• Engine removal - methods and precautions
• Engine - removal and installation
• Engine overhauling - sequence of disassembly
• Intermediate and balancing shaft (V6) - removal, inspection and installation
• Pistons and connecting rods - removal and installation
• Crankshaft - removal and installation
• Engine overhaul - assembly sequence
• The first start-up and engine break-in after major overhaul

Cooling, heating and air conditioning systems

• General information
• Antifreeze - general information
• Thermostat - check of working capacity and replacement
• Cooling fan - performance check and replacement
• The expansion tank of the system - removal and installation
• Radiator - removal and installation
• Cooling pump - performance test
• Pump of cooling system - replacement
• Coolant temperature sensor - operation and replacement test
• Resistor and fan heater - replacement
• Control panel for heating / air conditioning - removal and installation
• Heater - replacement
• Air conditioning and heating systems - operation and maintenance check
• Air conditioning compressor - removal and installation
• Air conditioning system accumulator - removal and installation
• Condenser for air conditioning - removal and installation
• Compressor clutch loop switch and high pressure cutoff switch - replacement
• Air conditioning expansion tube - removing and installing

Fuel and exhaust system

• General information
• Pressure relief in the fuel system
• Fuel pump / fuel pressure check
• Fuel lines and their connectors - general information
• Fuel tank - removal and installation
• Fuel tank - cleaning and recovery
• Fuel pump / fuel level sensor - removing and installing
• Intake air duct and air cleaner - removal and installation
• Accelerator cable - removal and installation
• Multipoint fuel injection (MFI) - general information
• Fuel injection system - general condition check
• Throttle unit - inspection, removal and installation
• Fuel system by-pass valve - removal and installation
• Extinguisher of fuel pulsation - removal and installation
• Fuel receiver and nozzles - removal and installation
• Maintenance of the exhaust system - general information

Engine electrical systems

• General information, precautions and battery disconnection
• Battery - emergency start from external battery
• Battery - inspection and replacement
• Battery wires - inspection and replacement
• Ignition system - general information and precautions
• Ignition system - operation check
• Ignition coils - replacement
• Charging system - general information and precautions
• Charging system - operation check
• Generator - removal and installation
• Launch system - general information and precautions
• The starter and its electrical circuit - check without removal
• Starter - removal and installation

Exhaust gas control and engine control systems

• General information
• On-board diagnostic system (OBD) and DTCs
• The brake pedal position sensor (RRP) is a replacement
• The camshaft position sensor (CMP) is a replacement
• Crankshaft position sensor (TFR) - replacement
• Cylinder Head Temperature Sensor (VT) (V8) - replacement
• Selector position sensor (DTR) - replacement and adjustment
• Coolant temperature sensor (ECT) (V6) - replacement
• Supply air temperature sensor (IAT) - replacement
• The sensor of the intermediate shaft revolution (ISS) is a replacement
• Detonation sensor - replacement
• Airflow meter (MAF) - replacement
• The sensor of rotation of the secondary shaft (OSS) - replacement
• Oxygen sensors - general information and replacement
• Throttle Position (TP) Sensor - replacement
• Turbine shaft speed sensor (TSS) - replacement
• Engine control unit (PCM) - removal and setting
• Idle valve (IAC) - replacement
• Catalytic converters - general information, inspection and replacement
• Fuel vapor recovery system (EVAP) - general description and replacement of elements
• The EGR system is a general description and replacement of elements
• Crankcase ventilation system (PCV)

Manual transmission

• General information
• Gear lever - removal and installation
• The stuffing box located in the shell extension is a replacement
• Transmission support - inspection and replacement
• Manual gearbox - removing and installing
• Mechanical transmission repair - general information

Automatic transmission

• General information
• Diagnosis - general information
• Selector lever - replacement
• Selector cable - replacement and adjustment
• Switching mechanism switch cable - replacement and adjustment
• Transmission control switch - inspection and replacement
• Transmission oil cooler - removing and installing
• Automatic gearbox - removal and installation
• Automatic transmission repair - general information

Transfer case

• General information
• Transfer case control box (A4WD) - replacement
• Switching servo motor (A4WD) - replacement
• Drive shaft oil seal for transfer case - removing and installing
• Mode switch (A4WD) - replacement
• Transfer case - removal and installation

Clutch and transmission

• General information
• Clutch - description and verification
• Clutch master cylinder - removal and installation
• Clutch slave cylinder - removing and installing
• Hydraulic clutch system - pumping
• Releaser - removal and installation
• Clutch elements - removal, inspection and installation
• Drive shafts - removal and installation
• Drive shaft cover - replacement
• Drive shaft - removal and installation
• Omentums of the differential - replacement
• Differential - removal and installation
• Cardan joints - general description and inspection
• Cardan joints - replacement

Brake system

• General information
• Anti-lock braking system (ABS) - general information
• Disc brake pads - replacement
• Disc brake caliper - removal and installation
• Brake disc - inspection, removal and installation
• Brake shoes - replacement
• Master cylinder - removal and installation
• Hoses and pipes of brake system - inspection and replacement
• Hydraulic braking system - pumping
• Vacuum brake booster - performance check, removal and installation
• Handbrake cable - Removing and installing
• Stop light sensor - replacement

Suspension and steering

• General Information
• Shock absorber / spring (front suspension) - removing, replacing parts and installing
• Stabilizer of lateral stability (front) and its bushings - removal and installation
• Rotary cam (front) - removal and installation
• The top lever of a forward suspension bracket - removal and installation
• The lower lever of a forward suspension bracket - removal and installation
• Front hub and bearing - removal and installation
• Shock absorber / spring (rear suspension) - removal, replacement of parts and installation
• Stabilizer of lateral stability (rear) and its bushings - removal and installation
• The top lever of a back suspension bracket - removal and installation
• The bottom lever of a back suspension bracket - removal and installation
• Lateral pull - removal and installation
• Rear wheel trunnion - removal and installation
• Rear hub and bearing - replacement
• Suspension hinges - inspection and replacement
• Steering wheel - removal and installation
• Steering column - removal and installation
• Tips of steering rods - removal and installation
• Power steering pads - replacement
• Steering gear - removal and installation
• Power steering pump - removal and installation
• Hydraulic power steering system - pumping
• Hydraulic power steering fluid cooler - removal and installation
• Wheels and tires - general information
• Wheel alignment angles - general information

Car body

• General information
• Body - service
• Vinyl cladding - maintenance
• Upholstery and carpets - maintenance
• Body repair - minor damage
• Body repair - serious damage
• Loops and locks - maintenance
• Wind and fixed glass - replacement
• Hood and tailgate support hinges - removal and installation
• Hood cover - removal, installation and adjustment
• Latch and bonnet bonnet cable - removal and installation
• Radiator grille and bonnet panel - removal and installation
• Bumpers - removal and installation
• Front wing - removal and installation
• Facing panels of doors - removal and installation
• Door - removal, installation and adjustment
• Latch, lock cylinder and door handles - removal and installation
• Glasses of door windows - removal and installation
• Lift - removal and installation
• Mirrors - removal and installation
• Rear hinged door - removal, installation and adjustment
• The lock of the rear hinged door - removal and installation
• Central console - removal and installation
• Dashboard panel trim - removal and installation
• Dashboard paneling - removal and installation
• Covers of a casing of a steering column - removal and installation
• Air intake housing - removal and installation
• Seats - removal and installation
• Instrument panel - removal and installation

Electrical equipment of a car

• General information
• Determining the causes of faults in electrical circuits - general information
• Fuses and inserts - general information
• Circuit breakers - general information
• Relay - general information and validation
• Circuit breaker / warning light interrupter - operation and replacement test
• Switches located on the steering column-change
• Switch and ignition lock cylinder - replacement
• Switches located on the dashboard - replacement
• Instrument panel - removal and installation
• Windscreen wiper motor - replacement
• Car radio and speakers - removing and installing
• Antenna and its cable replacement
• Rear window heater - performance check and repair
• Headlamp bulbs - replacement
• Headlights - adjustment
• Headlights - replacement
• Signal replacement
• Replacement of lighting fixtures
• Side mirrors with electric drive - description
• Speed-keeping system - description
• Power windows - description
• Automatic door locks - description
• Daylight-saving lighting (DRL) - general information
• Airbag system - general information
• Wiring diagrams

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