Common Specifications & Procedures

EXPLORER COMMON SPECIFICATIONS & PROCEDURES

System			Specification/Procedure
Air Conditioning
Service
	EMTC System		SPECIFICATIONS
	DATC System		SPECIFICATIONS
Torque
	EMTC System		TORQUE SPECIFICATIONS
	DATC System		TORQUE SPECIFICATIONS
Axle Nut/Hub Nut			350 N.m (258 Ft. Lbs.)
Battery			SPECIFICATIONS
Brakes
Bleeding Sequence			BRAKE SYSTEM BLEEDING
Front Disc Brakes w/Torque			TORQUE SPECIFICATIONS
Rear Disk Brakes w/Torque			TORQUE SPECIFICATIONS
Charging
Generator w/Torque
	2.0L GTDI		Generator Upper Bolt: 62 lb.in (7 Nm) Generator Bracket Stud: 62 lb.in (7 Nm)
	3.5L Ti-VCT, 3.7L Ti-VCT		Generator Bolt:47 Nm (35 lb-ft) Generator Stud Nut: 47 Nm (35 lb-ft) Generator Stud: 8 Nm (71 lb-in)
Drive Belts
Adjustment			SPECIFICATIONS
Belt Routing
	2.0L GTDI		ACCESSORY DRIVE BELT -- 2.0L GTDI
	3.5L GTDI		ACCESSORY DRIVE BELT -- 3.5L GTDI
	3.5L Ti-VCT, 3.7L Ti-VCT		ACCESSORY DRIVE BELT -- 3.5L TI-VCT
Engine Cooling
General Service Specifications			GENERAL SPECIFICATIONS
Pressure Relief Cap			95 kPa (13.8 psi) -125 kPa (18.1 psi)
	Thermostat R & I
	2.0L GTDI		THERMOSTAT HOUSING -- 2.0L GTDI
	3.5L GTDI		THERMOSTAT -- 3.5L GTDI
	3.5L Ti-VCT, 3.7L Ti-VCT		THERMOSTAT -- 3.5L TI-VCT or THERMOSTAT HOUSING -- 3.5L TI-VCT
Water Pump R & I
	2.0L GTDI		COOLANT PUMP -- 2.0L GTDI
	3.5L GTDI		COOLANT PUMP -- 3.5L GTDI
	3.5L Ti-VCT, 3.7L Ti-VCT		COOLANT PUMP -- 3.5L TI-VCT
Engine Mechanical
2.0L GTDI
Compression			SPECIFICATIONS
Oil Pressure @ 2, 000 RPM (engine at normal operating temperature)			29-60 psi (200-414 kPa)
Overhaul			SPECIFICATIONS
Torque			TORQUE SPECIFICATIONS
3.5L GTDI
	Compression		SPECIFICATIONS
	Oil Pressure @ 1, 500 RPM (engine at normal operating temperature)		Minimum 30 psi
	Overhaul		SPECIFICATIONS
	Torque		TORQUE SPECIFICATIONS
3.5L Ti-VCT, 3.7L Ti-VCT
Compression			SPECIFICATIONS
Oil Pressure @1, 500 RPM (engine at normal operating temperature)			Minimum 30 psi (205 kPa)
Overhaul			SPECIFICATIONS
Torque			TORQUE SPECIFICATIONS
Fluid Specifications			See FLUIDS under MAINTENANCE tab. From within Manager or Service Writer, click the "30/60/90 Interval" or "Maint." button.
Flex Plate Torque
	2.0L GTDI		FLEXPLATE Stage 1: Tighten to 50 Nm (37 lb-ft) Stage 2: Tighten to 80 Nm (59 lb-ft) Stage 3: Tighten to 120 Nm (89 lb-ft)
	3.5L Ti-VCT, 3.7L Ti-VCT		FLEXPLATE 80 Nm (59 lb-ft)
	3.5L GTDI		FLEXPLATE 80 Nm (59 lb-ft)
Fuel System
Fuel Filter Location			Vehicle has a lifetime fuel filter which is serviced as part of the Fuel Pump (FP) module.
Fuel Filter R & I			FUEL PUMP ASSEMBLY
Pressure Release Procedure			FUEL SYSTEM PRESSURE RELEASE
Pressure Specification			SPECIFICATIONS
Fuel Pressure Test Procedure			FUEL SYSTEM PRESSURE TEST
Ignition
	Firing Order & Cylinder Identification		FIRING ORDER & CYLINDER IDENTIFICATION
Ignition Wires			Engine has coil-on-plug ignition.
Spark Plugs
2.0L GTDI
Type			Motorcraft CYFS -12Y-2
Gap			.028-.031 In. (0.7-0.8 mm)
Torque			106 In. Lbs. (12 N.m)
3.5L GTDI
	Type		Motorcraft CYFS 12 YT3
	Gap		.032-.038 In. (0.81-0.97 mm)
	Torque		133 In. Lbs. (15 N.m)
3.5L Ti-VCT
Type			Motorcraft CYFS-12F-5
Gap			.049-.053 In. (1.25-1.35 mm)
Torque			133 In. Lbs. (15 N.m)
3.7L Ti-VCT
	Type		Motorcraft CYFS-12F-5
	Gap		.051 In. (1.30 mm)
	Torque		133 In. Lbs. (15 N.m)
Starting
Starter w/Torque
	2.0L GTDI		2 Stud Bolts: 48 Nm (35 lb-ft).
		3.5L GTDI STARTER MOTOR -- 3.5L GTDI
	3.5L Ti-VCT, 3.7L Ti-VCT		2 Starter Motor Stud Bolt: 48 Nm (35 lb-ft)
		3.7L TI-VCT STARTER MOTOR -- 3.7L TI-VCT
Wheel Alignment
Adjustment Specifications			SPECIFICATIONS
Torque			TORQUE SPECIFICATIONS
Wheel & Tire
Wheel Lug Nut Torque (All Except Police Vehicles)			100 Ft. Lbs. (135 N.m)
	Wheel Lug Nut Torque (Police Vehicles)		110 Ft. Lbs. (149 N.m)