FORD E SERIES 2002 4.G Owners Manual

²Five tire rotation
Replacing the tires
Replace the tires when the wear
band is visible through the tire
treads.
When replacing full size tires, never mix radial bias-belted, or
bias-type tires. Use only the tire sizes that are listed on the
Certification Label. Make sure that all tires are the same size, speed
rating, and load-carrying capacity. Use only the tire combinations
recommended on the label. If you do not follow these precautions,
your vehicle may not drive properly and safely.
Make sure that all replacement tires are of the same size, type,
load-carrying capacity and tread design (e.g., ªAll Terrainº, etc.),
as originally offered by Ford.
Maintenance and specifications
251

Do not replace your tires with ªhigh performanceº tires or larger
size tires.
Failure to follow these precautions may adversely affect the
handling of the vehicle and make it easier for the driver to lose
control and roll over.
Tires that are larger or smaller than your vehicle's original tires may also
affect the accuracy of your speedometer.
SNOW TIRES AND CHAINS
Snow tires must be the same size and grade as the tires you
currently have on your vehicle.
The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
tires and chains. If you need to use chains, it is recommended that steel
wheels (of the same size and specifications) be used as chains may chip
aluminum wheels.
Follow these guidelines when using snow tires and chains:
²Use only SAE Class S chains.
²Install chains securely, verifying that the chains do not touch any
wiring, brake lines or fuel lines.
²Drive cautiously. If you hear the chains rub or bang against your
vehicle, stop and re-tighten the chains. If this does not work, remove
the chains to prevent damage to your vehicle.
²If possible, avoid fully loading your vehicle.
²Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
²The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
Maintenance and specifications
252

MOTORCRAFT PART NUMBERS
Component14.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Air filter
elementFA-1634 FA-1634 FA-1634 FA-1634
Battery
(standard)BXT-65-750 BXT-65-750 BXT-65-750 BXT-65-750
Battery
(auxiliary)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-251 EV-233 EV-233 EV-233
Spark plugs
2AGSF-34EEM3AWSF-32PP4AGSF-22W AGSF-22W
1Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor Motorcraft diesel engine service part
numbers.
2Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
3If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2 and 3 have a ªEGMº suffix. Cylinders
No. 4, 5 and 6 have a ªEMº suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letter9EEM9as
shown on the engine decal.
4If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, 3 and 4 have a ªPGº suffix. Cylinders
No. 5, 6, 7 and 8 have a ªPº suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letter as shown
on the engine decal.
Maintenance and specifications
253

REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine
oil-gasoline
engine (includes
filter change)Motorcraft SAE
5W-20 Super
Premium Motor
OilAll 5.7L (6.0
quarts)
Engine oil-diesel
engine (includes
filter change)Refer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner's Guide Supplement.
Engine
coolant-gasoline
engine
1
Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)4.2L V6 engine 22.0L (23.3
quarts)
4.2L V6 engine
with aux rear
heat24.0L (25.4
quarts)
4.6L V8 engine 23.7L (25.0
quarts)
4.6L V8 engine
with aux rear
heat25.7L (27.2
quarts)
5.4L V8 engine 27.4L (29.0
quarts)
5.4L V8 engine
with aux rear
heat29.4L (31.0
quarts)
6.8L V10 engine 29.0L (30.6
quarts)
6.8L V10 engine
with aux rear
heat31.0L (32.8
quarts)
Maintenance and specifications
254

Fluid Ford Part
NameApplication Capacity
Engine
coolant-diesel
engineRefer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner's Guide Supplement.
1
Power steering
fluidMotorcraft
MERCONtAT FAll Keep in FULL
range on
dispstick
Rear axle
4Motorcraft SAE
75W-140
Synthetic rear
axle lubricantVisteon 8.8/9.75
inch
conventional and
Traction-Lok2.6-2.7L (5.5-5.8
pints)2
Motorcraft
80W-90
Premium rear
axle lubricantDana 9.75 inch
(M60-IU)3.0L (6.3 pints)3
Dana 10.5 inch
(M70-2U)3.1L (6.6 pints)3
Dana 10.5 inch
(M70-1HD)3.5L (7.5 pints)3
Maintenance and specifications
255

Fluid Ford Part
NameApplication Capacity
Fuel tank N/A All regular and
extended length
vans and wagons132.4L (35.0
gallons)
138 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
158 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
5
176 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
158 inch and
176 inch
wheelbase
(E-Super Duty)208.0L (55 .0
gallons)
Transmission
fluid
6Motorcraft
MERCONtV
AT FAutomatic
(4R70W)13.2L (13.9
quarts)7
Motorcraft
MERCONtAT FAutomatic
(4R100 except
E-Super Duty)16.1L (17.0
quarts)7
Automatic
(4R100 E-Super
Duty)16.7L (17.7
quarts)7
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateAll 4.0L (4.2
quarts)
1Add the coolant type originally equipped in your vehicle.
Maintenance and specifications
256

2If your vehicle's rear axle is filled with a synthetic rear axle lubricant it
is considered lubricated for life. These lubricants do not need to be
checked or changed unless a leak is suspected, service is required or the
axle assembly has been submerged in water. The axle lubricant should
be changed any time the rear axle has been submerged in water.
Fill 6 mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole.
Add 118 ml (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118±A, for complete refill
of 8.8 inch and 9.75 inch Traction-Lok axles.
3Fill Dana rear axles to 6 mm to 19 mm (1/4 inch to 3/4 inch) below
bottom of fill hole.
4Visteon conventional and Traction-Lok axles require 118 ml (4 oz.) of
Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford
specification EST-M2C118±A. Dana conventional and limited-slip axles
(E250/350/450) require 237ml (8 oz.) of Additive Friction Modifier
C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.
5Optional fuel tank 208L (55 gallon).
6Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONtand MERCONtV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONttype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONtV type fluid.
MERCONtand MERCONtV type fluids are not interchangeable.
DO NOT mix MERCONtand MERCONtV. Use of a transmission
fluid that indicates dual usage (MERCONtand MERCONtV) in
an automatic transmission application requiring MERCONtmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
7Approximate dry fill capacity including transmission fluid cooling
system, actual refill capacities will vary based on vehicle application and
transmission fluid cooling system (i.e. coolers size, cooling lines. auxiliary
cooler capacities). The amount of transmission fluid and fluid level
should be set by the indication on the dipstick's normal operating range.
Maintenance and specifications
257

LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantF7AZ-19G208-BA
and
F5AZ-19553-AAESR-M13P4-A
Engine coolant Motorcraft
Premium Engine
Coolant
(green-colored)VC-4±A (in
Canada,
Motorcraft
CXC-10)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7±A WSS
-M97B51-A1
Engine
oil-gasoline
engineMotorcraft SAE
5W-20 Super
Premium Motor
OilXO-5W20-QSP WSS-M2C153-H
with API
Certification
Mark
Engine oil-diesel
engineRefer to the7.3 Liter Power Stroke Direct
Injection Turbo Diesel Owner's Guide Supplement.
Hinges, latches,
Striker plates,
fuel filler door
hinge, and seat
tracksMotorcraft
Multi-Purpose
GreaseXG±4 or
F5AZ-19G209-AAESR-M1C159-A
Lock cylinders Motorcraft
Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONtAT FXT-2-QDX MERCONt
Maintenance and specifications
258

Item Ford part
nameFord part
numberFord
specification
Automatic
transmission
(4R100)
1
Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
tranmission
(4R70W)
1
Motorcraft
MERCONtV
AT FXT-5-QM MERCONtV
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-4 ESE-M1C171-A
Parking brake
assembly
(E-Super Duty)Motorcraft
MERCONt
Automatic
Transmission
FluidXT-2-QDX MERCONt
Visteon
conventional and
Traction-Lok
axles (E-150)
2
Motorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle LubricantXY-75W140±QL WSL-M2C192-A
Dana 9.75 inch
(M60±1U) 10.5
inch (M70±2U)
(M70±1HD)
(E-250/350/450)
3
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantXY-80W90-QL WSP-M2C197-A
Windshield
washer fluidUltra-clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
Maintenance and specifications
259

correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONtand MERCONtV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONttype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONtV type fluid.
MERCONtand MERCONtV type fluids are not interchangeable.
DO NOT mix MERCONtand MERCONtV. Use of a transmission
fluid that indicates dual usage (MERCONtand MERCONtV) in
an automatic transmission application requiring MERCONtmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
2Add 118 ml (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118-A for complete refill
of Visteon Traction-Lok rear axles.
3Add 237 ml (8 oz.) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118-A for complete refill
of Dana Traction-Lok rear axles.
ENGINE DATA
Engine*4.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Cubic inches 256 281 330 415
Required
fuel87 octane 87 octane 87 octane 87 octane
Firing order1-4-2-5-3-6 1-3-7-2-6
-5-4-81-3-7-2-6
-5-4-81-6-5-10-2-7
-3-8-4-9
Spark plug
gap1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)
Ignition
systemEDIS EDIS Coil on plug Coil on plug
Compression
ratio9.3:1 9.37:1 9.0:1 9.0:1
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor diesel engine information.
Maintenance and specifications
260