Service Procedure
2002-2003 4 DOOR EXPLORER/MOUNTAINEER4.0L
Vehicles Built 1/14/02 Through 12/02/2002
At latest level for engine calibration.
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
Vehicles Built Before 1/14/02
1. Verify that WDS is at the latest level, B21.0 or higher.
2. Reprogram the PCM with the latest calibration.
3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit.
4. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
5. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE THE CONVERTER.
2002-2003 4 DOOR EXPLORER/MOUNTAINEER
4.6L
Vehicles Built Prior To 12/02/2002
1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit.
2. Refer to Drive Sequence heading to purge stored sulfur from catalyst.
3. See Contributing Factors Heading for additional information.
NOTE
CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY.
2001-2002 2 DOOR EXPLORER SPORT 4.0L
7/24/00 Through 3/4/02 With 5R55E Transmission
1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration only.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L
Vehicles Built After 3/27/02
At latest level for engine calibration and converter, no service action will improve the situation.
1. See Contributing Factors Heading for additional information.
3/4/02 Through 3/27/02
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 2 DOOR EXPLORER SPORT/SPORT TRAC
4.0L M5R4 MANUAL TRANSMISSION
11/2/01 Through 3/4/02 With Manual Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only.
2. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE.
2002 SPORT TRAC 4.0L 5R55E TRANSMISSION
11/2/01 Through 3/4/02 With 5R55E Transmission
1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA.
2. Verify that WDS is at the latest level, B21.0 or higher.
3. Reprogram the PCM with the latest calibration.
4. See Contributing Factors Heading for additional information.
NOTE
DO NOT REPLACE CONVERTER MORE THAN ONCE.
DRIVE SEQUENCE AFTER REPAIRS COMPLETED
Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system.
CONTRIBUTING FACTORS TO SULFUR SMELL
Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor.
For example:
^ Extended Idle - Increase sulfur odor
^ Stop and go driving - Increase sulfur odor
^ Trailer Towing - Decrease sulfur odor
^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor
^ Abrupt accel/decel - Decrease sulfur odor
^ Hotter driving conditions - Decrease sulfur odor
^ Hilly terrain - Decrease sulfur odor
^ Canceling Overdrive - Decrease sulfur odor
Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor.
Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation.
To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time.
PCM Calibration Information
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-16-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
022106A Install Exhaust Wrap And 1.4 Hrs.
Perform Drive Sequence.
2002-2003
Explorer/Mountaineer 4.0L
Vehicles Built 1-14-02
Through 12-02-02, 4.6L
Built Prior To 12-02-02
022106B Install Exhaust Wrap, 1.6 Hrs.
Reprogram Powertrain
Control Module And
Perform Drive Sequence.
2002-2003
Explorer/Mountaineer 4.0L
Built Prior To 1-14-02
022106C Replace Catalytic 0.8 Hr.
Converter And Reprogram
Powertrain Control Module.
2001-2002 Explorer Sport
Vehicles Built 7-24-00
Through 3-4-02, 2002
Sport Trac 11-02-01
Through 3-4-02
022106D Replace Catalytic 0.6 Hr.
Converter Only. 2002
Explorer Sport/Sport Trac
3-4-02 Through 3-27-02
With Automatic
Transmission, 11-02-01
Through 3-4-02 With
Manual Transmission
DEALER CODING
CONDITION
BASIC PART NO. CODE
5F250 42
OASIS CODES: 403000, 499000
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