This factory service and repair manual for the 2002 Ford E-150 covers the three-door standard passenger van in its single XL trim, built around a choice of two gasoline engines. The 4.2L overhead-valve V6 of 256 cubic inches is the smaller of the pair, and the 5.4L overhead-cam V8 of 330 cubic inches sits above it, both naturally aspirated. Procedures, specifications, torque values, wiring diagrams and diagnostics are laid out system by system for both, so a shop can move between a six-cylinder van and a V8 van without changing books.
Engines covered
- 4.2L V6 (256 cu in) — OHV, naturally aspirated, gasoline
- 5.4L V8 (330 cu in) — SOHC, naturally aspirated, gasoline
Body styles covered
- 3-door standard passenger van
Trims covered
- XL
Known issues on the 2002 E-150. One recall is on federal record for this model year, recorded under vehicle speed control on a campaign that reached across a long list of Ford vans, trucks and wagons. Owners have filed 37 complaints with NHTSA. Speed control on this van runs through the engine management and the body wiring, so the wiring diagrams, diagnostics and specifications for those circuits are the sections most likely to be needed, alongside the ordinary service procedures for the 4.2L V6 and the 5.4L V8.
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXP
BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ
HEADLIGHT ADJUSTMENT NEEDED. *KB
VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT
MALFUNCTION INDICATOR LAMP ON WITH DIAGNOSTIC TROUBLE CODE P1131 AND/OR P1151 - 4.2L ENGINE. *TT
HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT
INTERMITTENT CLUNK ON 3-2 DOWNSHIFT DURING COASTDOWN/TIP-IN. OASIS. TO INCLUDE 2005 F-150, E-SERIES AND EXPEDITION. *TT
FRONT BRAKE PAD WEAR. *TT
CLUNK FROM FRONT SUSPENSION. *TT
Showing the 8 most recent of 13 technical service bulletins on file with NHTSA.
AS THE RESULT OF A HEAD-ON COLLISION, THE AIRBAGS FAILED TO DEPLOY. THE COLLISION WAS SLIGHTLY OFF-CENTER TO THE DRIVERS SIDE OF THE VEHICLE. SUBJECT VEHICLE WAS TRAVELING AT APPRO
The contact owns a 2002 Ford E-150. The contact stated while driving at approximately 75 MPH, he smelled a burning odor in the passenger cabin. The contact stated that he turned th
Showing the 2 most serious of 37 complaints filed with NHTSA.
