engine FORD E SERIES 2005 4.G Service Manual

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
6 10A Brake-shift interlock, Daytime
Running Lamps (DRL) module
7 10A Multi-function switch, Turn signals
8 30A Radio capacitor(s), Ignition coil,
Powertrain Control Module (PCM)
diode, PCM power relay
9 5A Wiper control module
10 20A Main light switch, Park lamps,
License lamp (external lamps),
Multi-function switch
(flash-to-pass)
11 15A Multi-function switch (hazards),
Brake lamp switch, Brake lamps
12 15A Back-up lamps, Auxiliary battery
relay (gasoline engine only),
Trailer tow relay
13 15A Blend door actuator, Function
selector switch
14 5A Instrument cluster
15 5A Trailer battery charge relay,
Cluster
16 30A Power seats
17 5A Power mirrors
18 — Not used
19 — Not used
20 10A Restraints
21 — Not used
22 15A Memory power radio, Rear seat
video control unit, Battery saver
relay, Instrument cluster, Courtesy
lamp relay, Accessory delay relay
23 20A Power locks w/RKE
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Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
24 — Not used
25 10A Left headlamp (low beam)
26 20A Cigar lighter, Diagnostics
27 5A Radio
28 — Not used
29 — Not used
30 15A Headlamps (high beam indicator)
31 10A Right headlamp (low beam)
32 20A Power point #1 (instrument
panel)
33 10A Start relay
34 — Not used
35 — Not used
36 5A Instrument illumination
37 — Not used
38 — Not used
39 10A Trailer tow electric brake, Center
High-Mounted Stop Lamp
(CHMSL), Brake lamps
40 20A Power point #2 (2nd row seating
position - driver side)
41 30A Modified vehicle
42 20A circuit
breakerPower windows
43 — Not used
44 20A circuit
breakerWiper/washer
Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle’s main electrical systems from overloads.
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
7 60A** Ignition switch, Fuse panel,
Accessory delay
8 40A** Trailer battery charge relay
9 50A** Modified vehicle power
10 30A** Electric brake controller
11 60A** 4-Wheel Anti-lock Brake System
(4WABS)
12 60A** I/P fuses 29, 34, 35, 40 and 41
13 20A** Fuel pump relay
14 50A** Auxiliary blower relay
15 30A** Main light switch
16 — Not used
17 50A** Blower motor relay (blower
motor)
18 60A** Engine compartment fuses 3, 5,
23 and 26, Instrument panel fuses
26 and 32, Start relay
19 50A** IDM relay (Diesel engine only)
20 60A** Auxiliary battery relay (gasoline
engine only), PDB fuses 8 and 24
21 30A** PCM power relay, PDB fuse 27
22 60A** I/P fuses 4, 5, 10, 11, 16, 17, 22
and 23, Circuit breaker 44
23 — Not used
24 20A* Trailer tow running lamps and
back-up lamp relays
25 — Not used
26 20A* Trailer tow turn signals
27 10A* PCM
28 — Not used
A — Fuel pump relay
B — Horn relay
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Engine compartment relay module
The engine compartment relay module is located in one of two places
depending on which type of engine your vehicle is equipped with:
•Gasoline engine: driver side of the engine compartment above the
brake master cylinder.
•Diesel engine: passenger side of the engine compartment behind the
power distribution box.
Have a certified technician or your dealer service this module, if
required.
The relays are coded as follows:
Relay location Description
1 PCM back-up lamp
2 A/C control
3 Trailer tow right turn
4 Trailer tow left turn
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JUMP STARTING YOUR VEHICLE
The following procedure is for vehicles equipped with a gasoline engine;
if your vehicle is equipped with a diesel engine, refer to the6.0L Power
Stroke Direct Injection Turbo Diesel Owner’s Guide Supplementfor
the proper jump starting procedure.
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which can burn skin, eyes and
clothing, if contacted.
Do not attempt to push-start your vehicle. Automatic
transmissions do not have push-start capability; doing so may
damage the catalytic converter.
Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its shift strategy. As a result, the transmission
may have firm and/or soft shifts. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation.
1.Use only a 12–volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
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3. Connect the negative (-) cable to the negative (-) terminal of the
assisting battery.
4. Make the final connection of the negative (-) cable to an exposed
metal part of the stalled vehicle’s engine, away from the battery and the
carburetor/fuel injection system.Do notuse fuel lines, engine rocker
covers or the intake manifold asgroundingpoints.
Do not connect the end of the second cable to the negative (-)
terminal of the battery to be jumped. A spark may cause an
explosion of the gases that surround the battery.
5. Ensure that the cables are clear of fan blades, belts, moving parts of
both engines, or any fuel delivery system parts.
+–+–
+–+–
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Jump starting
1. Start the engine of the booster vehicle and run the engine at
moderately increased speed.
2. Start the engine of the disabled vehicle.
3. Once the disabled vehicle has been started, run both engines for an
additional three minutes before disconnecting the jumper cables.
Removing the jumper cables
Remove the jumper cables in the reverse order that they were
connected.
1. Remove the jumper cable from thegroundmetal surface.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
2. Remove the jumper cable on the negative (-) connection of the
booster vehicle’s battery.
+–+–
+–+–
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3. Remove the jumper cable from the positive (+) terminal of the booster
vehicle’s battery.
4. Remove the jumper cable from the positive (+) terminal of the
disabled vehicle’s battery.
After the disabled vehicle has been started and the jumper cables
removed, allow it to idle for several minutes so the engine computer can
relearnits idle conditions.
+–+–
+–+–
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The use of leaded fuel in your vehicle without proper conversion may
damage the effectiveness of your emission control system and may cause
engine knocking or serious engine damage. Ford Motor Company/Ford of
Canada is not responsible for any damage caused by use of improper
fuel.
In the United States, using leaded fuel may also result in difficulty
importing your vehicle back into the U.S.
If your vehicle must be serviced while you are traveling or living in
Central or South America, the Caribbean, or the Middle East, contact the
nearest Ford dealership. If the dealership cannot help you, write or call:
FORD MOTOR COMPANY
WORLDWIDE DIRECT MARKET OPERATIONS
1555 Fairlane Drive
Fairlane Business Park #3
Allen Park, Michigan 48101
U.S.A.
Telephone: (313) 594-4857
FAX: (313) 390-0804
If you are in another foreign country, contact the nearest Ford
dealership. If the dealership employees cannot help you, they can direct
you to the nearest Ford affiliate office.
If you buy your vehicle in North America and then relocate outside of
the U.S. or Canada, register your vehicle identification number (VIN) and
new address with Ford Motor Company Worldwide Direct Market
Operations.
ORDERING ADDITIONAL OWNER’S LITERATURE
To order the publications in this portfolio, contact Helm, Incorporated at:
HELM, INCORPORATED
P.O. Box 07150
Detroit, Michigan 48207
Or call:
For a free publication catalog, order toll free: 1-800-782-4356
Monday-Friday 8:00 a.m. - 6:00 p.m. EST
Helm, Incorporated can also be reached by their website:
www.helminc.com.
(Items in this catalog may be purchased by credit card, check or
money order.)
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Customer Assistance
189

ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
•Cover the highlighted areas to prevent water damage when cleaning
the engine.
•Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
PLASTIC (NON-PAINTED) EXTERIOR PARTS
Use only approved products to clean plastic parts. These products are
available from your dealer.
•For routine cleaning, use Motorcraft Detail Wash (ZC-3–A).
•If tar or grease spots are present, use Motorcraft Bug and Tar
Remover (ZC-42).
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Cleaning
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