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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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Replacing of rear shock absorber assembly (for use on the Ford Explorer III model)

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