light FORD E SERIES 1996 4.G Repair Manual

289
*
[SV07025( ALL)05/95]
NOTE: If you replace your fuel cap with an
aftermarket fuel filler cap, the customer
warranty may be void for any damage
to the fuel tank and/or fuel system.
*
[SV07050( ALL)05/95]
RWARNING
If the fuel cap is venting vapor or if you
hear a hissing sound, wait until it stops
before completely removing the cap.
*
[SV07060(BEF )11/89]
A venting fuel tank is not an abnormal
condition. It may be caused by:
*
[SV07061(BEF )03/90]
q
Too volatile a fuel for the weather conditions.
The service stations sometimes sell winter
grade fuel in the summer.
*
[SV07062(BEF )11/89]
q
Pulling a heavy load on hot days, or at high
altitudes.
*
[SV07063(BEF )11/89]
q
Extended periods of idling with the engine
RPM increased above the normal idle range.
*
[SV07064(BEF )11/89]
q
Parking vehicle in full sunlight for extended
periods on extremely hot days.
*
[SV07500( ALL)06/95]
Choosing the Right Fuel
*
[SV07550( EF )05/94]
NOTE: Read the7.3L Diesel Engine Owner
Guide Supplementfor information
regarding correct fuel requirements for
your diesel-powered vehicle.
*
[SV07600( ALL)06/95]
Use only UNLEADED FUEL in your vehicle.
Using leaded fuel is prohibited by federal law.
Your warranty may not apply if your vehicle is
damaged because you used the wrong fuel.
*
[SV07700( ALL)06/95]
Vehicle inspection programs may detect
misfueling. Under these circumstances, you may
be required by law to make costly repairs at
your own expense.
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Update:Wed Apr 17 08:40:13 1996

290 %
*
[SV08710( ALL)04/95]
Octane recommendations
*
[SV08725( ALL)06/95]
Your engine is designed to use regular
unleaded fuel with an octane rating of 87.In
most cases, it is not necessary to use a fuel with
an octane rating higher than 87. At service
stations, the octane rating is displayed on a label
on the pumps.
*
[SV08900( ALL)06/95]
one inch art:0060001-C
Typical octane rating label
*
[SV09050( ALL)06/95]
In some parts of the country, ªregularº grade
fuels are sold with octane ratings of 86 or even
less, especially in high altitude areas. We
recommend that you do not use these fuels.
Always use a fuel with an octane rating of 87,
even if it is sold as a ªmidgradeº or ªpremium.º
%*
[SV09200( ALL)06/95]
Do not be concerned if your vehicle sometimes
knocks lightly when you drive up a hill or when
you accelerate. However, see your dealer or a
qualified service technician if persistent, heavy
knocking occurs because this can damage the
engine.
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298
*
[SV13730( EF )01/93]
For vehicles with 4.9L, 5.0L or 7.5L engines
[SV13740( ALL)04/95]
Engine oils with anSAE 10W-30viscosity are
PREFERREDfor your vehicle which provide the
best engine protection for all climates down to
-5ÊF (-20ÊC). SAE5W-30 enigne oils may also be
used down to-15ÊF (-25ÊC).
[SV13745( ALL)02/95]
Synthetic engine oils which are CERTIFIED and
of the preferred viscosity may be used in your
engine. The engine oil and oil filter must still be
changed according to the maintenance schedule.
*
[SV13775( ALL)01/95]
Checking and Adding Engine Oil
*
[SV13800( ALL)03/95]
Since the proper amount of engine oil is
important for safe engine operation, check the oil
using the dipstick each time you put fuel in
your vehicle. Remember the engine must be off,
the oil must be warm and the vehicle must be
parked on level ground.
*
[SV13900( ALL)03/95]
Checking the engine oil level:
*
[SV14000( ALL)02/95]
1. Turn the engine off after it has warmed up
and allow a few minutes for the engine oil
to drain back into the oil pan.
*
[SV14075( E M)03/95]
2. Set the parking brake, making sure the
gearshift is securely latched in P (Park).
*
[SV14100( ALL)02/95]
3. Open the hood. Protect yourself from engine
heat.
*
[SV14200( ALL)03/95]
4. Locate the engine oil dipstick (highlighted in
yellow) and carefully pull it out of the
engine.
*
[SV14300( ALL)01/95]
5. Wipe the dipstick clean and put it back into
position, making sure it is fully seated.
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299
*
[SV14400( ALL)06/95]
quarter page art:0010364-D
Engine oil dipstick
*
[SV14500( ALL)02/95]
6. Carefully, pull the dipstick out again. If the
oil level is below the ªADD 1 QT.º line, add
engine oil as necessary. If the oil level is
beyond the letter ªFº in FULL, engine
damage or high oil consumption may occur
and some oil must be removed from the
engine.
*
[SV14600( ALL)01/95]
7. Put the dipstick back in and make sure it is
fully seated.
*
[SV14800( ALL)01/95]
It may be necessary to add some oil between oil
changes. Make sure you use a CERTIFIED
engine oil of the preferred viscosity. Your
vehicle's warranty coverage may not apply if
engine damage is caused by the use of improper
engine oil.
*
[SV15000( ALL)03/95]
Add engine oil through the oil filler cap
highlighted in yellow. To add oil, remove the
filler cap and use a funnel to pour oil into the
opening. Be careful not to overfill the engine.
Recheck the oil level after you finish adding oil.
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313 [SV26650( E )03/93]
For E-250 (over 8500 GVWR [3855 kg]), and
E-350 vehicles, rotate the tires at 5,000 miles
(8,000 km), then at 15,000 miles (24,000 km), and
then every 15,000 miles (24,000 km) thereafter.
*
[SV26660( EF )03/94]
If your light truck has dual rear wheels, you can
rotate the front tires side to side without
disturbing the rear tires.
*
[SV26700(BEF )07/92]
Rotate the tires according to the following
diagram. If you notice that the tires wear
unevenly, have them checked. If your light truck
has a temporary spare tire, do not include it in
the tire rotation pattern.
*
[SV26750(BEF )03/90]
In situations where the tires differ from front to
rear (snow/traction), simply rotate using a side
to side pattern.
*
[SV26800(BEF )06/93]
half page art:0020364-A
Tire rotation pattern
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326 %
*
[SV35800( ALL)03/91]
Driveline Universal Joint and
Slip Yoke
*
[SV36000(BEF )06/93]
The universal joints that come standard with
your vehicle do not require lubrication. If your
original equipment universal joints are replaced
with universal joints equipped with grease
fittings, lubrication will be necessary at the
intervals shown in theMaintenance Schedule and
Recordbooklet.
*
[SV36300( ALL)03/95]
Brake Fluid
*
[SV36350( ALL)05/90]
Your vehicle is equipped with a brake fluid level
indicator in the master cylinder which lights the
BRAKE warning light on the instrument panel
when the brake fluid level is low.
*
[SV36400( ALL)04/95]
Under normal circumstances, your vehicle
should not use up brake fluid rapidly. However,
expect the level of the brake fluid to slowly fall
as you put more mileage on your vehicle and
the brake lining wears.
*
[SV36500( ALL)10/89]
Check the brake fluid at least once a year. You
can do this by looking at the fluid level in the
plastic reservoir on the master cylinder. The
fluid level should be at or near the MAX mark.
*
[SV36550( ALL)05/95]
RWARNING
Brake fluid is toxic.
*
[SV36560( ALL)06/95]
If brake fluid contacts eyes, flush eyes with
running water for 15 minutes. Get medical
attention if irritation persists. If taken internally,
drink water and induce vomiting. Get medical
attention immediately.
%*
[SV36600( ALL)02/95]
If the fluid is low, carefully clean and remove
the filler cap from the reservoir. Fill the
reservoir to the MAX line with Ford High
Performance DOT 3 Brake Fluid C6AZ-19542-AA
or DOT 3 equivalent fluid meeting Ford
specification ESA-M6C25-A.
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328
*
[SV37600( ALL)03/95]
Power Steering Fluid
*
[SV37700( ALL)01/95]
Check the level of the power steering fluid at
least twice a year (i.e., every Spring and Fall).
*
[SV37800( ALL)03/95]
To check the level of your power steering fluid:
*
[SV37900( ALL)02/95]
1. Start the engine and let it run until the
power steering fluid reaches normal
operating temperature. The power steering
fluid will be at the right temperature when
the engine coolant temperature gauge in the
instrument cluster is near the center of the
NORMAL operating temperature range.
*
[SV38000( ALL)01/95]
2. While the engine idles, turn the steering
wheel back and forth several times. Make
sure that the cap assembly is installed at this
time.
*
[SV38100(BEF )05/95]
3. Turn the engine off.
[SV38150( E)10/95]
All vehicles except E-Super Duty:
%*
[SV38200( ALL)03/94]
4. Check the fluid level on the dipstick (which
is highlighted in yellow in your vehicle). The
fluid level should be between the arrows in
the FULL HOT range, which is marked on
the side of the dipstick, opposite the side
marked FULL COLD. Do not add fluid if the
level is within the FULL HOT range.
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Update:Wed Apr 17 08:40:13 1996

336 [SV41300( ALL)06/95]Power Distribution Box
*
[SV41400( ALL)10/92]
The high current fuses contained in the Power
Distribution Box protect your vehicle's main
electrical systems from overloads; these fuses
provide the connection between the battery and
your vehicle's electrical systems.
*
[SV41500( ALL)10/92]
The high current fuses are coded as follows: 30
amp -light green, 40 amp - orange, 50 amp - red,
60 amp -blue.
*
[SV41600( ALL)05/95]
RWARNING
Always disconnect the battery before
servicing high current fuses.
*
[SV41620( ALL)05/95]
Ford recommends that high current fuses be
replaced by a qualified technician.
*
[SV41700( ALL)03/93]
RWARNING
Always replace the cover to the Power
Distribution Box before reconnecting the
battery or refilling fluid reservoirs.
*
[SV41800( ALL)04/95]
A blown high current fuse may be replaced but
will continue to blow until the cause of the
overload condition is corrected.
*
[SV41900( ALL)05/95]
RWARNING
Always replace a fuse with one that has
the specified amperage rating. Using a
fuse with a higher amperage rating can
cause severe wire damage and could start
a fire.
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Update:Wed Apr 17 08:40:13 1996

340
*
[SV44600(BEF )03/95]
Lights and Bulb Replacement
*
[SV44700(BEF )01/95]
It is a good idea to check the operation of the
following lights frequently:
*
[SV44800(BEF )01/95]
q
headlamps
*
[SV44900(BEF )01/95]
q
tail lamps
*
[SV45000(BEF )01/95]
q
brakelamps
*
[SV45050(BEF )02/95]
q
high-mount brakelamp
*
[SV45100(BEF )01/95]
q
hazard flasher
*
[SV45200(BEF )01/95]
q
turn signals
*
[SV45300(BEF )01/95]
q
license plate lamp
%*
[SV45400(BEF )01/95]
The alignment of your headlamps should be
checked if:
*
[SV45500(BEF )01/95]
q
oncoming motorists frequently signal you to
turn off your vehicle's high beams when you
do not have the high beams on
*
[SV45600(BEF )01/95]
q
the headlamps do not seem to give you
enough light to see clearly at night
*
[SV45700(BEF )01/95]
q
the headlamp beams are pointed substantially
away from a position slightly down and to
the right
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342
*
[SV46300(BEF )03/95]
Removing the headlamp bulb
*
[SV46400(BEF )01/95]
1. Make sure that the headlamp switch on the
instrument panel is in the OFF position.
[SV46550( E )04/95]
2. Lift the hood and fix in up position using
prop rod.
[SV46600( E )04/95]
3. Bend back slightly and lift up on the two
metal tabs while holding the lamp to vehicle.
This will release the lamp from the installed
position.
[SV46650( E )05/91]
one third page art:0020844-B
Removing/Installing the headlamp bulb
[SV46750( E )04/95]
4. Remove the bulb retaining ring by turning it
1/8 of a turn to free it from the socket. Then
slide the ring off the plastic base. Keep the
ring. You must use it again to hold the new
bulb in place.
[SV46850( E )04/95]
5. Carefully remove the bulb assembly from its
socket by gently pulling it rearward without
turning.
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996