engine FORD E SERIES 1998 4.G Workshop Manual

Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle's emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult your ªWarranty Guideº for complete emission warranty
information.
Readiness for inspection/maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostic (OBD-II) system. If your ªcheck engine/service
engine soonº light is on, reference the applicable light description in the
Warning Lights and Chimessection of your owners guide. Your vehicle
may not pass the I/M test with the ªcheck engine/service engine soonº
light on.
If the vehicle's powertrain system or its battery has just been serviced,
the OBD-II system is reset to a ªnot ready for I/M testº condition. To
ready the OBD-II system for I/M testing, a minimum of 30 minutes of city
and highway driving is necessary as described below:
²First, at least 10 minutes of driving on an expressway or highway.
²Next, at least 20 minutes driving in stop and go, city type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
EXTERIOR BULBS
Replacing exterior bulbs
Check the operation of the following lamps frequently:
²Headlamps
²Tail lamps
²Brakelamps
²High-mount brakelamp
Maintenance and care
122

²Turn signals
²Backup lamps
²License plate lamp
Do not remove lamp bulbs unless they will be replaced immediately. If a
bulb is removed for an extended period of time, contaminants may enter
the lamp housings and affect performance.
Replacing headlamp bulbs (aerodynamic)
Handle a halogen headlamp bulb carefully and keep out of
children's reach. Grasp the bulb only by its plastic base and do
not touch the glass. The oil from your hand could cause the bulb to
break the next time the headlamps are operated.
To remove the headlamp bulb:
1. Make sure headlamp switch is in OFF position.
2. Open the hood.
3. Push each clip tab toward the
engine compartment and lift upward
to the stop position.
4. Remove the headlamp assembly.
5. Disconnect the electrical
connector from the bulb by pulling
the connector rearward.
Maintenance and care
123

Cleaning the engine
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
²Take care when using a power washer to clean the engine. The high
pressure fluid could penetrate the sealed parts and cause damage.
²Do not spray with cold water to avoid cracking the engine block or
other engine components.
²Cover the highlighted areas to prevent water damage when cleaning
the engine.
²Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
Cleaning plastic exterior parts
Use vinyl cleaner for routine cleaning. Clean with a tar remover if
necessary. Do not clean plastic parts with thinners, solvents or
petroleum-based cleaners.
Maintenance and care
127

MOTORCRAFT PART NUMBERS
Component 4.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Air filter FA-1632 FA-1632 FA-1632 FA-1632
Battery
(standard)BXT-65-650 BXT-65-650 BXT-65-650 BXT-65-650
Battery (optional) BXT-65-750 BXT-65-750 BXT-65-750 BXT-65-750
Battery (auxilary) BH-65DC BH-65DC BH-65DC BH-65DC
Fuel filter FG-872 FG-872 FG-872 FG-872
Oil filter FL-400-S FL-820-S FL-820-S FL-820-S
PCV Valve EV-152 EV-233 EV-233 EV-233
Spark plugs* AGSF-34EE AWSF-32PP AWSF-22E AWSF-22E
* Refer to Vehicle Emissions Control Information (VECI) decal for
spark plug gap information.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine oil
(includes
filter change)Motorcraft
5W30 Super
Premium Motor
OilAll 5.7L (6.0 quarts)
Engine
coolantFord Extended
Life Engine
Coolant
(DEX-COOL)4.2L V6 engine 22.0L (23.2 quarts)
4.6L V8 engine 23.7L (25.0 quarts)
5.4L V8 engine 27.4L (29.0 quarts)
6.8L V10 engine 29.0L (30.6 quarts)
Power
steering fluidMotorcraft
MERCONtAT FAll Keep in FULL range
on dispstick
Capacities and specifications
129

LUBRICANT SPECIFICATIONS
Item Ford part name Ford part
numberFord
specification
Brake fluid High Performance
DOT 3 Motor Vehicle
Brake FluidC6AZ-
19542-ABESA-
M6C25-A and
DOT 3
Door
weatherstripsSilicone Lubricant C0AZ-19553-AA
and
D7AZ-19553-AAESR-M13P4-A
Engine
coolantFord Premium
Cooling System FluidEFZ-19549-AA ESE-M97B44-A
Engine oil
(gasoline)Motorcraft 5W-30
Super Premium
Motor OilXO-
5W30-QSPWSS-M2C153-G
with API
Certification
Mark
Engine oil
(diesel)Consult separate diesel engine owner's guide
supplement
Hinges,
latches,
Striker plates,
fuel filler door
hinge, and
seat tracksMulti-Purpose
GreaseD0AZ-
19584-AA or
F5AZ-
19G209-AAESB-
M1C93-B or
ESR-
M1C159-A
Lock cylinders Penetrating
LubricantE8AZ-
19501-Bnone
Power
steering fluidMotorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
transmission
(E4OD)Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
tranmission
(4R70W)Motorcraft
MERCONtVATFXT-5-QM MERCONtV
Disc brake
caliper railsSilicone Brake
Caliper and
Dielectric compoundD7AZ-19A331-A
WA-10ESE-M1C171-A
Capacities and specifications
132

ENGINE DATA
Engine 4.2L V6 engine
Cubic inches 256
Horsepower 200 @ 4800 rpm
Torque 250 lbs.ft. @ 2800 rpm
Required fuel grade 87 octane
Firing order 1-4-2-5-3-6
Spark plug gap 1.3-1.4 mm (0.052-.056 inch
Ignition system EDIS
Compression ratio 9.0:1
Engine 4.6L V8 engine
Cubic inches 281
Horsepower 215 @ 4450 rpm
Torque 290 lbs.ft. @ 3250 rpm
Required fuel grade 87 octane
Firing order 1-3-7-2-6-5-4-8
Spark plug gap 1.3-1.4 mm (0.052-.056 inch
Ignition system EDIS
Compression ratio 9.0:1
Engine 5.4L V8 engine
Cubic inches 330
Horsepower 235 @ 4450 rpm
Torque 335 lbs.ft. @ 3000 rpm
Required fuel grade 87 octane
Firing order 1-3-7-2-6-5-4-8
Spark plug gap 1.3-1.4 mm (0.052-.056 inch
Ignition system EDIS
Compression ratio 9.0:1
Capacities and specifications
134

Engine 6.8L V10 engine
Cubic inches 415
Horsepower 265 @ 4250 rpm
Torque 405 lbs.ft. @ 2750 rpm
Required fuel grade 87 octane
Firing order 1-6-5-10-2-7-3-8-4-9
Spark plug gap 1.3-1.4 mm (0.052-.056 inch
Ignition system EDIS
Compression ratio 9.0:1
VEHICLE DIMENSIONS
Van/wagon models
E-150 E-250 E-350
(1) Overall height 2 054.8 mm (80.9
in)2 118.4 mm
(83.4)2 136.1
(84.1 in)
(2) Track front/rear 1 762.8 mm (69.4 in)/ 1 701.8 mm (67.0 in)
(3) Overall width
(excluding mirrors)2 014.2 mm (79.3 in)
(4) Wheelbase 3 505 mm (138 in)
(5) Overall length Regular van, 5 379.7 mm (211.8 in) Supervan, 5
892.8 mm (232.0 in)
Capacities and specifications
135

Aiming headlamps ....................125
Air bag supplemental
restraint system ..........................46
and child safety seats ..............47
description ................................46
disposal ......................................49
indicator light ...........................48
passenger air bag .....................47
Air conditioning
manual heating and air
conditioning system .......16,17,18
Anti-lock brake system (ABS)
description ................................64
Battery .......................................108
voltage gauge ............................12
Brake fluid
checking and adding ..............100
Brakes ..........................................63
anti-lock .....................................63
anti-lock brake system (ABS)
warning light .............................63
fluid, checking and adding ....100
Brake-shift interlock ...................65
Break-in period .............................2
Bulbs, replacing ........................122
headlamps ...............................123
specifications ..........................125
Changing a tire ...........................85
Child safety seats ........................51
Chime
headlamps on ..............................9
Cleaning your vehicle ...............125
engine compartment ..............127
fabric ........................................128
instrument panel ....................128
plastic parts ............................127
safety belts ..............................128
tail lamps .................................128
washing ....................................126
waxing .....................................126
wheels ......................................126
windows ..................................128Controls .......................................20
Emission control system ..........121
Engine ........................................134
check engine temperature
warning, message center .........96
service points ............................96
Engine block heater ...................61
Engine coolant
checking and adding .......101,102
disposal ....................................103
refill capacities ........................103
Engine oil ...............................97,99
changing oil and oil filter .........99
checking and adding ...........97,99
Exhaust fumes ............................62
Fail safe cooling ........................103
Fuel
calculating fuel economy .......120
improving fuel economy ..........76
octane rating ...........................119
quality ......................................120
running out of fuel .................120
safety information relating
to automotive fuels ................118
Fuel gauge ...................................10
Fuel pump shut-off switch .........77
Fuse panels
instrument panel ......................79
power distribution box .............82
Fuses ............................................79
Gauges, Mechanical ....................10
engine coolant temperature
gauge .........................................11
Hazard flashers ...........................77
Headlamps ...................................13
daytime running lights .............13
flashing ......................................14
high beam .................................13
Heating ........................................14
High beams
indicator light .............................9
Index
140

Hood
release lever ..............................96
Ignition
positions of the ignition ...........21
Instrument panel
lighting up panel and interior .14
Jump-starting your vehicle ...91,93
attaching cables ........................92
disconnecting cables ................93
Keys
key in ignition chime .................9
Lamps
interior lamps ....................28,124
Lights, warning and indicator
air bag ..........................................8
anti-lock brakes (ABS) ..............6
brake ............................................6
charging system ..........................8
engine oil pressure .....................9
safety belt ...................................8
service engine soon .................6,7
turn signal indicator ...................8
Load limits
trailer towing ............................69
Lubricant specifications ...........132
Mirrors
side view mirrors (power) .......30
Odometer .....................................12
Overdrive .....................................27
Panic alarm feature, remote
entry system ................................31
Parking brake ..............................64
Parts (see Motorcraft parts) ....129
Power door locks ........................29
Power steering
fluid, checking and adding ....105
Refill capacities for fluids ........129
Relays .....................................79,84
Remote entry system .................30
illuminated entry .................33,34
locking/unlocking doors ......30,31replacement/additional
transmitters ...............................32
replacing the batteries .............31
Reporting safety defects ..........139
Safety restraints
extension assembly ..................44
for children ...............................49
lap and shoulder belts ...40,41,42
maintenance ..............................45
proper use .................................39
warning light and chime ..9,44,45
Safety seats for children
attaching with tether straps ....54
tether anchorage
hardware .........................54,55,57
Seats
adjusting the seat, manual .......34
adjusting the seat, power ........35
bench seat ............................36,37
lumbar support .........................36
quick release rear captain's
chair ......................................38,39
Servicing your vehicle ................95
precautions when servicing .....95
Snowplowing .................................3
Special notice
ambulance conversions ..............3
diesel-powered vehicles .............3
Speed control ..............................22
canceling a set speed ...............25
resuming a set speed ...............25
tap up/tap down ..................23,24
turning off .................................22
Speedometer ...............................10
Starting your vehicle .............59,61
Tilt steering wheel ......................26
Tires ....................................114,115
changing ...............................85,86
checking the pressure ............115
replacing .............................88,117
rotating ....................................115
snow tires and chains ............117
Index
141

Fuel informationUnleaded only - 87 octane
Fuel tank capacityRefer toRefill capacitiesin theCapacities
and specificationschapter.
Engine oil
specificationsUse only oil displaying the American
Petroleum Institute Certification Mark SAE
5W-30
Tire size and
pressureSee Safety Compliance Certification Label on
inside of driver door
Hood release
locationBottom left of driver side instrument panel
Fuel filler locationLeft rear of vehicle
Filling station information
144