Exploring The 202 Explorer: Replacing The Fuel Filter

If you're looking to replace the fuel filter on your 2002 Explorer, you'll first need to locate it. The fuel filter is located on the passenger side, in front of the fuel tank, behind a shield or plate/cover. It should take around 20-30 minutes to replace. You'll need a ratchet, a 10mm socket, a 13mm socket, a Ford fuel tool, rags, a new filter, safety glasses, and possibly a rubber mallet. Before you begin, pull the fuel pump relay and start the truck—it may stall or not run at all. Block the rear wheels and raise the front end, then locate and remove the heat shield and plastic cover. You'll then need to remove the hose connections, being careful with the internal spring. Finally, remove the old filter and install the new one.

Locating the fuel filter

To locate the fuel filter on a 2002 Ford Explorer, look on the passenger side of the vehicle, under the door, near the front wheel well. It is behind a curved shield and a flat plate that is marked "fuel filter replace".

To access the fuel filter, you will need to remove the heat shield at the front of the fuel tank. There are two bolts retaining the shield to the right frame rail and two bolts retaining the shield to the cross member. Once the shield is removed, you will see the filter.

Be careful when removing the fuel lines, as they have locking clips that do not remove from the lines and can be damaged if you are not careful.

For a 2006-2010 Ford Explorer, the fuel filter is located on the passenger side of the vehicle, near the catalytic converter. There is a heat shield held in place by three 13mm bolts, two in the frame and one on the cross member. Remove these bolts and the heat shield, and you will see two 10mm nuts holding an additional shield in place. Remove these nuts, and the fuel filter will be visible.

Disconnecting the fuel lines

To disconnect the fuel lines, start by removing the two front connections on the fuel filter. These should be accessible and can be taken off without much difficulty. The problem often arises with the connection coming from the tank, which is in a tight space behind the catalytic converter. This makes it challenging to insert and manoeuvre tools, and there may not be enough room for two hands to work.

One possible solution is to cut the line behind the fitting and reattach it to the filter with a hose clamp. However, this is not an ideal workaround, and it may be necessary to consult a mechanic or a Ford dealer for advice on the best approach. It is important to exercise caution when working with fuel lines to avoid any potential safety hazards.

Replacing the fuel filter

Step 1: Locating the Fuel Filter

The first step in replacing the fuel filter on a 2002 Explorer is to locate it. The fuel filter is usually located near the gas tank.

Step 2: Identifying the Fuel Lines

There are two fuel lines connected to the fuel filter. The inner line is the feed line, running from the fuel pump to the fuel filter. The outer line is the return line, which goes back to the gas tank.

Step 3: Disconnecting the Fuel Lines

Disconnect the two front connections on the fuel filter. Be careful, as the fuel lines are often under pressure, and there may be some residual fuel in the lines. You may need a special tool to remove the fuel filter, especially if it is an in-line filter.

Step 4: Replacing the Fuel Filter

Once the fuel lines are disconnected, carefully remove the old fuel filter. Check that the new fuel filter you are installing is the correct replacement part for your vehicle. Install the new fuel filter, ensuring that the connections are secure.

Step 5: Reconnecting the Fuel Lines

Reconnect the two fuel lines to the new fuel filter, ensuring that the lines are securely attached. Again, be careful, as the fuel lines are under pressure.

Step 6: Testing

Start the engine and check for any leaks around the fuel filter connections. If there are no leaks, your new fuel filter is successfully installed!

Note: Always exercise caution when working with fuel systems, as fuel is highly flammable. Ensure you have the necessary tools and knowledge before attempting any repairs.

Reattaching the fuel lines

To reattach the fuel lines to your 2002 Explorer, you will need to identify the feed and return lines. The inner line is the feed line, and it runs from the fuel pump to the fuel filter. The outer line is the return line, which runs from the fuel filter back to the gas tank.

Once you have identified the lines, you can proceed to reattach them. Ensure that the connections are secure and tight to prevent any leaks. It is recommended to refer to a mechanic or a professional for advice if you are unsure about the process or if you encounter any issues.

If the fuel line is damaged or corroded, you may need to replace the entire line. In some cases, it may be possible to replace just the fitting on the end of the fuel filter line. However, if the line is damaged near the fitting, it may be challenging to get a new fitting to seal properly.

When reattaching the fuel lines, exercise caution and ensure that the area is well-ventilated. It is important to avoid any sparks or open flames as gasoline is highly flammable.

Testing the new fuel filter

Once you've installed your new fuel filter, it's important to test it to ensure it's working correctly. Here's a step-by-step guide on how to test a new fuel filter:

Depressurise the Fuel System:

Remove the fuel relay or fuse and start the engine to release any built-up pressure.

Locate the Fuel Filter:

Refer to your 202 Explorer's service manual to identify the exact location of the fuel filter. It's usually mounted near the engine.

Perform a Blow Test:

• Find the inlet part of the fuel filter, which is where the fuel flows into the filter. This is the part you'll be blowing into.
• Clean the inlet with a shop towel to remove any debris.
• Place a rag on your workbench for safety.
• Gently blow into the inlet. If the filter is clear, you should be able to blow into it with ease. If it's clogged, you'll struggle to blow, or it may be impossible.

Inspect for Leaks:

After testing, ensure there are no fuel leaks around the filter or the fuel lines.

Start the Engine:

Once you're satisfied that the new filter is installed correctly and functioning as it should, start the engine.

Test Drive the Vehicle:

Take the car for a short drive to ensure the engine is running smoothly. Listen for any unusual noises, and pay attention to how the car accelerates and idles.

By following these steps, you can be confident that your new fuel filter is working as intended, ensuring clean fuel is reaching your engine. Remember always to refer to your service manual and exercise caution when working with fuel systems.

Frequently asked questions