2002 Ford Taurus Service And Repair Manual

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Basic Information Identification Make: Ford Model: Taurus Year: 2002 Generation Generation Name: Fourth Generation (DG116) Codes Platform: Ford CDW27 Platform Introduction Market Position Segment: Mid-size Sedan Target Demographic: Families, commuters seeking reliable and comfortable transportation. Competitive Analysis Key Competitors 2002: Chevrolet Impala, Toyota Camry, Honda Accord, Nissan Altima, Buick LeSabre. Key Features Interior Space: Known for its spacious interior, offering ample legroom and headroom. Ride Comfort: Emphasized a comfortable and quiet ride, typical of Ford's large sedan offerings. Safety Features: Offered a range of safety features including airbags and ABS. Engine Options: Available with both V6 engines, providing a balance of power and efficiency. Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Specificity: Specific to 2002 Ford Taurus models, not generic Page Count Estimated Page Count: 1500-2000+ pages (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Manual Intended Audience: Professional Technicians, Dealership Service Departments Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, valve train, pistons, connecting rods, crankshaft, engine assembly, timing system, lubrication system, cooling system, fuel system, emission control systems. Engine Performance: Engine tune-up, diagnosis and testing, spark plugs, ignition coils, fuel injectors, sensors (MAF, TPS, O2, ECT), engine performance troubleshooting. Transmission Automatic: Removal/installation, internal components, torque converter, valve body, clutch packs, seals, bands, diagnosis, fluid service. Transmission Manual: If applicable, removal/installation, internal components, clutch, flywheel, diagnosis, fluid service. Drivetrain: Axles, drive shafts, CV joints, differential, wheel bearings. Brakes: Front and rear brake systems, calipers, rotors, pads, hydraulic lines, ABS system (components, diagnosis, bleeding), parking brake. Suspension: Front and rear suspension components, struts, shocks, springs, control arms, ball joints, bushings, steering linkage, alignment specifications. Steering: Power steering system, steering gear/rack and pinion, steering column, linkage, diagnosis, fluid service. Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, component testing. Body And Frame: Body panel removal/installation, doors, hood, trunk, bumpers, glass, interior trim, structural components, corrosion protection. HVAC: Air conditioning system, heater core, blower motor, climate control modules, refrigerant, diagnosis, repair. Comfort And Convenience: Power windows, power locks, mirrors, seats, sunroof, cruise control, remote keyless entry system. Safety Systems: Airbag system (components, SRS module, diagnosis), seat belts, passive restraint systems. Diagnostic Troubleshooting: Systematic diagnostic procedures, fault code interpretation (OBD-II), common problems and solutions. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, belt inspections, spark plug replacement, brake fluid flush, coolant flush. Repair And Replacement: Component-specific repair instructions, part replacement procedures, gasket and seal replacements, engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper replacement. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, electrical system diagnosis, engine performance issues, transmission problems. Specifications And Data: Torque specifications for all fasteners, fluid capacities, diagnostic parameters, alignment angles, electrical resistance values, engine timing specifications. Wiring Diagrams: Detailed electrical system wiring diagrams with component locations and wire colors. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and fluid changes to complete engine and transmission overhauls, complex electrical diagnostics, and body repair. Detail Level: In-depth step-by-step instructions with accompanying diagrams and illustrations. Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Typically searchable text within the PDF for quick information retrieval. Print Quality Quality: High-resolution scans of original documentation, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) Engine Specifications Primary Engine Engine Code: SOHC Duratec 3.0L V6 (G) Displacement: 3.0 Liters (182 cubic inches) Configuration: V6, SOHC (Single Overhead Camshaft), 24 Valves Bore X Stroke: 3.50 in x 3.27 in (89.0 mm x 83.0 mm) Compression Ratio: 9.7:1 Horsepower: 193 hp @ 5500 rpm Torque: 205 lb-ft @ 4250 rpm Engine Option 2 Engine Code: Vulcan 3.0L V6 (R) Displacement: 3.0 Liters (182 cubic inches) Configuration: V6, OHV (Overhead Valve), 12 Valves Horsepower: 155 hp @ 5000 rpm Torque: 185 lb-ft @ 3700 rpm Performance 0-60 Mph Estimate: Approximately 8.5-10.0 seconds depending on engine and drivetrain. Fuel System Induction: Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) for Duratec. Fuel Type: Unleaded gasoline Fuel Pump Type: In-tank electric fuel pump Transmission Standard Transmission Type: 4-Speed Automatic (4F50N) Drive Type: Front-Wheel Drive (FWD) Optional Optional Drive: All-Wheel Drive (AWD) available on select trims/engines. Features Features: Electronic control, torque converter lock-up for improved efficiency. Fluid Specifications Fluid Type: Mercon V Automatic Transmission Fluid Fluid Capacities Capacity Approximate: 9.5 quarts (9.0 liters) for a complete fluid change. Dimensions Exterior Length: 199.7 inches (5072 mm) Width: 73.1 inches (1857 mm) Height: 55.6 inches (1412 mm) Wheelbase: 112.7 inches (2863 mm) Front Track: 61.6 inches (1565 mm) Rear Track: 61.4 inches (1560 mm) Wheel Bolt Pattern: 5 x 108 mm Interior Passenger Volume: 104.1 cubic feet (2948 liters) Front Headroom: 39.3 inches...

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Description

Basic Information
Identification
Make:	Ford
Model:	Taurus
Year:	2002
Generation
Generation Name:	Fourth Generation (DG116)
Codes
Platform:	Ford CDW27 Platform

Introduction
Market Position
Segment:	Mid-size Sedan
Target Demographic:	Families, commuters seeking reliable and comfortable transportation.
Competitive Analysis
Key Competitors 2002:	Chevrolet Impala, Toyota Camry, Honda Accord, Nissan Altima, Buick LeSabre.
Key Features
Interior Space:	Known for its spacious interior, offering ample legroom and headroom.
Ride Comfort:	Emphasized a comfortable and quiet ride, typical of Ford's large sedan offerings.
Safety Features:	Offered a range of safety features including airbags and ABS.
Engine Options:	Available with both V6 engines, providing a balance of power and efficiency.

Manual Details
Coverage Areas
Coverage Scope:	All Models & All Repairs A-Z
Specificity:	Specific to 2002 Ford Taurus models, not generic
Page Count
Estimated Page Count:	1500-2000+ pages (typical for comprehensive service manuals of this era)
Manual Type
Type:	Service and Repair Manual
Intended Audience:	Professional Technicians, Dealership Service Departments
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Engine removal/installation, cylinder head, valve train, pistons, connecting rods, crankshaft, engine assembly, timing system, lubrication system, cooling system, fuel system, emission control systems.
Engine Performance:	Engine tune-up, diagnosis and testing, spark plugs, ignition coils, fuel injectors, sensors (MAF, TPS, O2, ECT), engine performance troubleshooting.
Transmission Automatic:	Removal/installation, internal components, torque converter, valve body, clutch packs, seals, bands, diagnosis, fluid service.
Transmission Manual:	If applicable, removal/installation, internal components, clutch, flywheel, diagnosis, fluid service.
Drivetrain:	Axles, drive shafts, CV joints, differential, wheel bearings.
Brakes:	Front and rear brake systems, calipers, rotors, pads, hydraulic lines, ABS system (components, diagnosis, bleeding), parking brake.
Suspension:	Front and rear suspension components, struts, shocks, springs, control arms, ball joints, bushings, steering linkage, alignment specifications.
Steering:	Power steering system, steering gear/rack and pinion, steering column, linkage, diagnosis, fluid service.
Electrical System:	Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, component testing.
Body And Frame:	Body panel removal/installation, doors, hood, trunk, bumpers, glass, interior trim, structural components, corrosion protection.
HVAC:	Air conditioning system, heater core, blower motor, climate control modules, refrigerant, diagnosis, repair.
Comfort And Convenience:	Power windows, power locks, mirrors, seats, sunroof, cruise control, remote keyless entry system.
Safety Systems:	Airbag system (components, SRS module, diagnosis), seat belts, passive restraint systems.
Diagnostic Troubleshooting:	Systematic diagnostic procedures, fault code interpretation (OBD-II), common problems and solutions.
Procedures Included
Maintenance:	Oil changes, filter replacements, fluid checks and top-offs, tire rotations, belt inspections, spark plug replacement, brake fluid flush, coolant flush.
Repair And Replacement:	Component-specific repair instructions, part replacement procedures, gasket and seal replacements, engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper replacement.
Troubleshooting:	Diagnostic flowcharts, symptom-based troubleshooting guides, electrical system diagnosis, engine performance issues, transmission problems.
Specifications And Data:	Torque specifications for all fasteners, fluid capacities, diagnostic parameters, alignment angles, electrical resistance values, engine timing specifications.
Wiring Diagrams:	Detailed electrical system wiring diagrams with component locations and wire colors.
Technical Depth
Depth:	Comprehensive: Covers everything from basic maintenance and fluid changes to complete engine and transmission overhauls, complex electrical diagnostics, and body repair.
Detail Level:	In-depth step-by-step instructions with accompanying diagrams and illustrations.

Manual Specifications
File Format
Format:	PDF (Portable Document Format)
Searchability:	Typically searchable text within the PDF for quick information retrieval.
Print Quality
Quality:	High-resolution scans of original documentation, ensuring clarity of text and diagrams.
Binding Type
Binding:	N/A (Digital PDF format)
Paper Type
Paper Quality:	N/A (Digital PDF format)

Engine Specifications
Primary Engine
Engine Code:	SOHC Duratec 3.0L V6 (G)
Displacement:	3.0 Liters (182 cubic inches)
Configuration:	V6, SOHC (Single Overhead Camshaft), 24 Valves
Bore X Stroke:	3.50 in x 3.27 in (89.0 mm x 83.0 mm)
Compression Ratio:	9.7:1
Horsepower:	193 hp @ 5500 rpm
Torque:	205 lb-ft @ 4250 rpm
Engine Option 2
Engine Code:	Vulcan 3.0L V6 (R)
Displacement:	3.0 Liters (182 cubic inches)
Configuration:	V6, OHV (Overhead Valve), 12 Valves
Horsepower:	155 hp @ 5000 rpm
Torque:	185 lb-ft @ 3700 rpm
Performance
0-60 Mph Estimate:	Approximately 8.5-10.0 seconds depending on engine and drivetrain.
Fuel System
Induction:	Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) for Duratec.
Fuel Type:	Unleaded gasoline
Fuel Pump Type:	In-tank electric fuel pump

Transmission
Standard
Transmission Type:	4-Speed Automatic (4F50N)
Drive Type:	Front-Wheel Drive (FWD)
Optional
Optional Drive:	All-Wheel Drive (AWD) available on select trims/engines.
Features
Features:	Electronic control, torque converter lock-up for improved efficiency.
Fluid Specifications
Fluid Type:	Mercon V Automatic Transmission Fluid
Fluid Capacities
Capacity Approximate:	9.5 quarts (9.0 liters) for a complete fluid change.

Dimensions
Exterior
Length:	199.7 inches (5072 mm)
Width:	73.1 inches (1857 mm)
Height:	55.6 inches (1412 mm)
Wheelbase:	112.7 inches (2863 mm)
Front Track:	61.6 inches (1565 mm)
Rear Track:	61.4 inches (1560 mm)
Wheel Bolt Pattern:	5 x 108 mm
Interior
Passenger Volume:	104.1 cubic feet (2948 liters)
Front Headroom:	39.3 inches (998 mm)
Front Legroom:	42.0 inches (1067 mm)
Rear Headroom:	38.1 inches (968 mm)
Rear Legroom:	39.4 inches (1001 mm)
Cargo
Cargo Volume Rear Seats Up:	16.0 cubic feet (453 liters)
Weights
Curb Weight Estimate:	3350-3600 lbs (1520-1633 kg) depending on configuration.
Gross Vehicle Weight Rating Gvwr Estimate:	4500-4750 lbs (2041-2155 kg)

Safety Features
Ratings
NHTSA Front Impact Driver:	Good (2002 model year ratings for similar Ford vehicles).
NHTSA Front Impact Passenger:	Good (2002 model year ratings for similar Ford vehicles).
IIHS Front Crash Test Rating:	Acceptable (for models equipped with side airbags and tested in subsequent years for similar platforms).
Active Features
Antilock Brakes ABS:	Standard on most models.
Traction Control:	Available on some models/trims.
Passive Features
Airbags:	Frontal airbags for driver and passenger standard. Available side-impact airbags for front seats.
Seat Belts:	Three-point seat belts in all seating positions, pre-tensioners for front seats.
Child Seat Anchors:	LATCH (Lower Anchors and Tethers for Children) system.

Technology Features
Infotainment
Audio System:	AM/FM stereo with cassette player and optional CD player. Premium sound system options available.
Display:	Central dashboard display for climate control and audio functions.
Driver Assistance
Cruise Control:	Standard or optional depending on trim level.
Parking Assistance:	Rear parking assist sensors available on some models.
Connectivity
Remote Keyless Entry:	Available on higher trim levels.
Onboard Diagnostics:	OBD-II compliant system for emissions and powertrain diagnostics.

Maintenance
Service Intervals
Oil Change Interval:	Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions).
Engine Air Filter Replacement:	Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Cabin Air Filter Replacement:	Every 15,000-30,000 miles (24,000-48,000 km) or as needed.
Spark Plug Replacement Duratec:	Approximately 100,000 miles (160,000 km) using long-life iridium spark plugs.
Spark Plug Replacement Vulcan:	Approximately 30,000-60,000 miles (48,000-96,000 km) using platinum spark plugs.
Transmission Fluid Change:	Every 50,000-100,000 miles (80,000-160,000 km) or per severe service schedule. Manual specifies checking for condition.
Coolant Flush:	Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Type:	SAE 5W-20 (preferred for fuel economy and emissions) or SAE 5W-30 meeting Ford specification WSS-M2C153-H or equivalent.
Engine Oil Capacity:	4.5 quarts (4.3 liters) with filter for 3.0L Duratec; 4.0 quarts (3.8 liters) for 3.0L Vulcan.
Coolant Type:	Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B44-D.
Brake Fluid Type:	DOT 3
Power Steering Fluid Type:	Mercon V ATF or Ford Power Steering Fluid.
Known Issues
Common Problems:	Transmission internal failures (particularly the 4F50N transmission), EGR valve clogging, power steering pump leaks, rear main crankshaft seal leaks, front strut mount wear, ABS sensor failures.
Diagnostic Focus Areas:	The manual would detail diagnostic procedures for all common issues, including torque converter shudder, internal transmission component wear, and electronic control module (ECM) related faults.

Vehicle History
Brand Heritage
Brand Focus:	Ford Motor Company, an American automotive manufacturer with a long history of producing popular and durable vehicles.
Model Evolution
Introduction Year:	1983
Generation Context:	The 2002 Taurus represents the final model year of the fourth generation, which debuted for the 1996 model year. This generation was characterized by its distinctive 'New Edge' styling and significant redesigns from earlier generations.
Design Changes 2002:	Minor updates for the final year of the generation, typically focused on feature packaging and minor trim adjustments.
Production
Assembly Locations:	Chicago, Illinois, USA
Production Period:	1985-2007 (overall model lifespan)

Awards & Recognition
Recognitions
Previous Generation Awards:	While the fourth generation (including the 2002 model) did not achieve the same critical acclaim as earlier Taurus models, Ford Taurus was a consistent best-seller for many years and received various awards during its earlier generations.