power steering FORD E SERIES 2002 4.G Owners Manual

Introduction 4
Congratulations 4
Safety and environment protection 5
Symbol glossary 10
Instrument cluster 12
Warning and control lights 12
Gauges 16
Entertainment systems 20
AM/FM stereo 20
AM/FM stereo cassette 20
AM/FM stereo cassette with CD 31
AM/FM stereo with CD 41
Climate controls 78
Heater only 78
Manual heating and air conditioning 79
Lights 85
Headlamps 85
Bulb replacement 88
Driver controls 94
Windshield wiper/washer control 94
Steering wheel adjustment 95
Power windows 96
Mirrors 97
Locks and security 108
Keys 108
Locks 108
Anti-theft system 109
Table of contents
1

Vehicle Symbol Glossary
Child Safety Door
Lock/Unlock
Interior Luggage
Compartment Release
Symbol
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
11

Never adjust the steering wheel when the vehicle is moving.
AUXILIARY POWER POINT
Power outlets are designed for
accessory plugs only. Do not
hang any type of accessory or
accessory bracket from the plug.
Improper use of the power
outlet can cause damage not
covered by your warranty.
The auxiliary power point is located
on the instrument panel.
A second power point (if equipped)
is located behind the driver's seat on
the upper trim panel.
Do not plug optional electrical
accessories into the cigarette lighter.
Use the power point.
POWER WINDOWS (IF EQUIPPED)
Press and hold the rocker switches to open and close windows.
²Press the top portion of the
rocker switch to close.
Driver controls
96

STARTING
Positions of the ignition
1. ACCESSORY, allows the electrical
accessories such as the radio to
operate while the engine is not
running.
2. LOCK, locks the steering wheel,
automatic transmission gearshift
lever and allows key removal.
3. OFF, shuts off the engine and all
accessories without locking the
steering wheel.
4. ON, all electrical circuits operational. Warning lights illuminated. Key
position when driving.
5. START, cranks the engine. Release the key as soon as the engine
starts.
Preparing to start your vehicle
Engine starting is controlled by the powertrain control system. This
system meets all Canadian Interference-Causing Equipment standard
requirements regulating the impulse electrical field strength of radio
noise.
When starting a fuel-injected engine, avoid pressing the accelerator
before or during starting. Only use the accelerator when you have
difficulty starting the engine. For more information on starting the
vehicle, refer toStarting the enginein this chapter.
Extended idling at high engine speeds can produce very high
temperatures in the engine and exhaust system, creating the risk
of fire or other damage.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
3
1
2
5
4
Driving
148

STEERING
Your vehicle is equipped with power steering. Power steering uses energy
from the engine to help steer the vehicle.
To prevent damage to the power steering pump:
²Never hold the steering wheel to the extreme right or the extreme left
for more than a few seconds when the engine is running.
²Do not operate the vehicle with a low power steering pump fluid level
(below the MIN mark on the reservoir).
If the power steering system breaks down (or if the engine is turned
off), you can steer the vehicle manually, but it takes more effort.
If the steering wanders or pulls, the condition could be caused by any of
the following:
²underinflated tire(s) on any wheel(s)
²uneven vehicle loading
²high crown in center of road
²high crosswinds
²wheels out of alignment
²loose or worn suspension components
TRACTION-LOK AXLE (IF EQUIPPED)
This axle provides added traction on slippery surfaces, particularly when
one wheel is on a poor traction surface. Under normal conditions, the
Traction-Lok axle functions like a standard rear axle.
Extended use of other than the manufacturer's specified size tires on a
Traction-Lok rear axle could result in a permanent reduction in
effectiveness. This loss of effectiveness does not affect normal driving
and should not be noticeable to the driver.
To avoid injury, never run the engine with one wheel off the
ground, such as when changing a tire.
Driving
155

Fuse/ Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
14 5A Instrument Cluster (Air Bag and
Charge Indicator)
15 5A Trailer Battery Charge Relay
16 30A Power Seats
17 Ð Not Used
18 Ð Not Used
19 10A Air Bag Diagnostic Monitor
20 5A Overdrive Cancel Switch
21 30A Power Windows*
22 15A Memory Power Radio, E Traveler
Radio, E Traveler Console
23 20A Cigar Lighter, Data Link
Connector (DLC)
24 Ð Not Used
25 10A Left Headlamp (Low Beam)
26 20A Rear Power Point
27 5A Radio
28 20A Power Plug
29 Ð Not Used
30 15A Headlamps (High Beam
Indicator), DRL10A
31 10A Right Headlamp (Low Beam),
DRL
32 5A Power Mirrors
33 20A E Traveler Power Point #2
34 10A Transmission Range (TR) Sensor
35 30A RKE Module
36 5A (Cluster, A/C, Illumination,
Radio), Steering Column
Assembly
37 20A Power Plug
38 10A Air Bag Diagnostic Monitor
Roadside emergencies
180

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
H Ð Blower Motor Relay
J Ð Horn Relay
K Ð Fuel Pump Relay
* Mini Fuses ** Maxi Fuses
Relays
Relays are located in the power distribution box and should be replaced
by qualified technicians.
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road.
Spare tire information
The spare tire for your vehicle is stowed under the rear of your vehicle
(except cutaway and stripped chassis models).
To remove the spare tire:
1. Open both rear doors and remove
thumb screw and anti-theft bracket.
If finger pressure will not remove
the thumb screw, use the lug
wrench to loosen the screw.
2. Remove the access cover from
the rubber strip behind the left
door.
Roadside emergencies
184

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
Engine compartment component locations
Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor diesel engine component locations.
1. Windshield washer fluid reservoir
2. Engine oil filler cap (except 4.2L V6 engine)
3. Automatic transmission fluid dipstick
4. Air filter assembly
5. Engine oil dipstick
6. Engine oil filler cap (4.2L V6 engine only)
7. Power steering fluid reservoir
8. Brake fluid reservoir
9. Engine coolant reservoir
10. Battery
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910
Maintenance and specifications
216

When this occurs the vehicle will still operate. However:
²The engine power will be limited.
²The air conditioning system will be disabled.
Continued operation will increase the engine temperature and the engine
will completely shut down, causing steering and braking effort to
increase.
Once the engine temperature cools, the engine can be re-started. Take
your vehicle to a service facility as soon as possible to minimize engine
damage.
When fail-safe mode is activated
You have limited engine power when in the fail-safe mode, so drive the
vehicle with caution. The vehicle will not be able to maintain high-speed
operation and the engine will run rough. Remember that the engine is
capable of completely shutting down automatically to prevent engine
damage, therefore:
1. Pull off the road as soon as safely possible and turn off the engine.
2. Arrange for the vehicle to be taken to a service facility.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
Never remove the coolant reservoir cap while the engine is
running or hot.
5. Re-start the engine and take your vehicle to a service facility.
Driving the vehicle without repairing the engine problem
increases the chance of engine damage. Take your vehicle to a
service facility as soon as possible.
Maintenance and specifications
232

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.
CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCONtAT F.
Check the fluid level when it is at ambient temperature, 20É ± 80É F (-7É
± 25É C):
1. Check the fluid level on the dipstick. It should be between the arrows
in the FULL COLD range. Do not add fluid if the level is within this
range.
2. If the fluid level is low, start the engine.
3. While the engine idles, turn the steering wheel left and right several
times.
4. Turn the engine off.
FULL COLD
Maintenance and specifications
243