maintenance FORD E SERIES 2008 4.G Owners Manual

Maintenance and Specifications 229
Engine compartment 231
Engine oil 233
Battery 236
Engine coolant 238
Fuel information 244
Air filter(s) 261
Part numbers 263
Maintenance product specifications and capacities 264
Engine data 268
Accessories 272
Index 274
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Copyright © 2007 Ford Motor Company
Table of Contents
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2008 Econoline(eco)
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SAFETY AND ENVIRONMENT PROTECTION
Warning symbols in this guide
How can you reduce the risk of personal injury to yourself or others? In
this guide, answers to such questions are contained in comments
highlighted by the warning triangle symbol. These comments should be
read and observed.
Warning symbols on your vehicle
When you see this symbol, it is
imperative that you consult the
relevant section of this guide before
touching or attempting adjustment
of any kind.
Protecting the environment
We must all play our part in
protecting the environment. Correct
vehicle usage and the authorized
disposal of waste, cleaning and
lubrication materials are significant
steps towards this aim. Information in this respect is highlighted in this
guide with the tree symbol.
BREAKING-IN YOUR VEHICLE
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed frequently in order to give the
moving parts a chance to break in.
Drive your new vehicle at least 1,000 miles (1,600 km) before towing a
trailer. For more detailed information about towing a trailer, refer to
Trailer towingin theTires, Wheels and Loadingchapter.
Do not add friction modifier compounds or special break-in oils since
these additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter for more information on oil
usage.
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Introduction
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Vehicle Modification Data Recording
Some aftermarket products may cause severe engine and/or transmission
damage; refer to theWhat is not coveredsection inThe new vehicle
limited warranty for your vehiclechapter of your vehicle’sWarranty
Guidefor more information. Some vehicles are equipped with
Powertrain Control Systems that can detect and store information about
vehicle modifications that increase horsepower and torque output; this
information cannot be erased and will stay in the system’s memory even
if the modification is removed. When a dealer or repair facility works on
your vehicle, it may be necessary for them to access the information in
the Powertrain Control System. This information will likely identify if any
unauthorized modifications have been made to the system and may be
used to determine if repairs will be covered by warranty.
Special instructions
For your added safety, your vehicle is fitted with sophisticated electronic
controls.
Please read the sectionAirbag supplemental restraint system
(SRS)in theSeating and Safety Restraintschapter. Failure to
follow the specific warnings and instructions could result in personal
injury.
Front seat mounted rear-facing child or infant seats should
NEVERbe placed in front of an active passenger airbag.
Notice to owners of diesel-powered vehicles
Read the6.0 and 6.4 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s GuideSupplement for information regarding correct operation
and maintenance of your Diesel-powered light truck.
Notice to owners of pickup trucks and utility type vehicles
Utility vehicles have a significantly higher rollover rate than
other types of vehicles.
Before you drive your vehicle, please read thisOwner’s Guidecarefully.
Your vehicle is not a passenger car. As with other vehicles of this type,
failure to operate this vehicle correctly may result in loss of vehicle
control, vehicle rollover, personal injury or death.
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Introduction
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WARNING LIGHTS AND CHIMES
Warning lights and gauges can alert you to a vehicle condition that may
become serious enough to cause expensive repairs. A warning light may
illuminate when a problem exists with one of your vehicle’s functions.
Many lights will illuminate when you start your vehicle to make sure the
bulb works. If any light remains on after starting the vehicle, refer to the
respective system warning light for additional information.
If your vehicle is equipped with a Diesel engine, it has a unique cluster,
refer toStarting the engine in your 6.0 Liter Power Stroke Direct
Injection Turbo Diesel Owner’s Guide Supplement.
Service engine soon:TheService
engine soonindicator light
illuminates when the ignition is first
turned to the ON position to check
the bulb and to indicate whether the vehicle is ready for
Inspection/Maintenance (I/M) testing. Normally, theService engine soon
light will stay on until the engine is cranked, then turn itself off if no
malfunctions are present. However, if after 15 seconds theService
engine soonlight blinks eight times, it means that the vehicle is not
ready for I/M testing. See theReadiness for Inspection/Maintenance
(I/M) testingin theMaintenance and Specificationschapter.
Solid illumination after the engine is started indicates the On Board
Diagnostics System (OBD-II) has detected a malfunction. Refer toOn
board diagnostics (OBD-II)in theMaintenance and Specifications
chapter. If the light is blinking, engine misfire is occurring which could
damage your catalytic converter. Drive in a moderate fashion (avoid
heavy acceleration and deceleration) and have your vehicle serviced
immediately by your authorized dealer.
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Instrument Cluster
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Under engine misfire conditions, excessive exhaust temperatures
could damage the catalytic converter, the fuel system, interior
floor coverings or other vehicle components, possibly causing a fire.
Electronic throttle control:
Illuminates when the engine has
defaulted to a “limp-home”
operation. Report the fault to a
dealer at the earliest opportunity.
Check fuel cap:Illuminates when
the fuel cap may not be properly
installed. Continued driving with
this light on may cause the Service
Engine Soon warning light to come
on, refer toFuel filler capin the
Maintenance and Specificationchapter.
Brake system warning light:To
confirm the brake system warning
light is functional, it will
momentarily illuminate when the
ignition is turned to the ON position
when the engine is not running, or in a position between ON and START,
or by applying the parking brake when the ignition is turned to the ON
position. If the brake system warning light does not illuminate at this
time, seek service immediately from your authorized dealer. Illumination
after releasing the parking brake indicates low brake fluid level and the
brake system should be inspected immediately by your authorized dealer.
Driving a vehicle with the brake system warning light on is
dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle
checked by your authorized dealer. Driving extended distances with
the parking brake engaged can cause brake failure and the risk of
personal injury.
P!
BRAKE
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Instrument Cluster
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Anti-lock brake system:If the
ABS light stays illuminated or
continues to flash, a malfunction has
been detected, have the system
serviced immediately by your
authorized dealer. Normal braking is still functional unless the brake
warning light also is illuminated.
Airbag readiness:If this light fails
to illuminate when the ignition is
turned to ON, continues to flash or
remains on, have the system
serviced immediately by your authorized dealer. A chime will also sound
when a malfunction in the supplemental restraint system has been
detected.
Safety belt:Reminds you to fasten
your safety belt. A Belt-Minder

chime will also sound to remind you
to fasten your safety belt. Refer to
theSeating and safety restraints
chapter to activate/deactivate the Belt-Minder
chime feature.
Engine oil pressure:Illuminates
when the oil pressure falls below the
normal range, refer toEngine oilin
theMaintenance and
Specificationschapter.
Engine coolant temperature:
Illuminates when the engine coolant
temperature is high. Stop the
vehicle as soon as possible, switch off the engine and let cool. Refer to
Engine coolantin theMaintenance and Specificationschapter.
Never remove the coolant reservoir cap while the engine is
running or hot.
ABS
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Instrument Cluster
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Trip odometer:Registers the miles
(kilometers) of individual journeys.
Press the SELECT/RESET control
once to switch from the odometer to
the trip odometer. Press the control again to select Trip A and Trip B
features. To reset the trip, press and hold the control again until the trip
reading is 0.0 miles.
Tachometer:Indicates the engine
speed in revolutions per minute.
Driving with your tachometer
pointer continuously at the top of
the scale may damage the engine.
Battery voltage gauge:
Indicates
the battery voltage when the ignition
is in the ON position. If the pointer
moves and stays outside the normal
operating range, have the vehicle’s
electrical system checked by your
authorized dealer as soon as possible.
Engine oil pressure gauge:
Indicates engine oil pressure. The
needle should stay in the normal
operating range (between “L” and
“H”). If the needle falls below the
normal range, stop the vehicle, turn
off the engine and check the engine
oil level. Add oil if needed. If the oil level is correct, have your vehicle
checked by your authorized dealer.
Fuel gauge:Indicates
approximately how much fuel is left
in the fuel tank (when the ignition
is in the ON position). The fuel
gauge may vary slightly when the
vehicle is in motion or on a grade.
The FUEL icon and arrow indicates
which side of the vehicle the fuel filler door is located.
Refer toFilling the tankin theMaintenance and Specifications
chapter for more information.
H
L
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Instrument Cluster
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•This will enable the Belt-Minder
feature for that seating position if it
is currently disabled. As confirmation, the safety belt warning light will
flash four times per second for three seconds, followed by three
seconds with the light off, then followed by the safety belt warning
light flashing four times per second for three seconds again.
5. After receiving confirmation, the deactivation/activation procedure is
complete.
Safety belt extension assembly
If the safety belt is too short when fully extended, there is a 9 inch (23
cm) or 12 inch (31 cm) safety belt extension assembly that can be added
(part number 611C22). This assembly can be obtained from an
authorized dealer.
Use only extensions manufactured by the same supplier as the safety
belt. Manufacturer identification is located at the end of the webbing on
the label. Also, use the safety belt extension only if the safety belt is too
short for you when fully extended.
Use the shortest extender assembly that will provide adequate fit.
Do not use extensions to change the fit of the shoulder belt
across the torso.
Safety belt maintenance
Inspect the safety belt systems periodically to make sure they work
properly and are not damaged. Inspect the safety belts to make sure
there are no nicks, tears or cuts. Replace if necessary. All safety belt
assemblies, including retractors, buckles, front safety belt buckle
assemblies, buckle support assemblies (slide bar-if equipped), shoulder
belt height adjusters (if equipped), shoulder belt guide on seatback (if
equipped), child safety seat LATCH and tether anchors, and attaching
hardware, should be inspected after a collision. Ford Motor Company
recommends that all safety belt assemblies in use in vehicles involved in
a collision be replaced. However, if the collision was minor and an
authorized dealer finds that the belts do not show damage and continue
to operate properly, they do not need to be replaced. Safety belt
assemblies not in use during a collision should also be inspected and
replaced if either damage or improper operation is noted.
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Seating and Safety Restraints
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Determining if the system is operational
The SRS uses a readiness light in the instrument cluster or a tone to
indicate the condition of the system. Refer toAirbag readinesssection
in theInstrument Clusterchapter. Routine maintenance of the airbag is
not required.
A difficulty with the system is indicated by one or more of the following:
•The readiness light will either
flash or stay lit.
•The readiness light will not
illuminate immediately after ignition is turned on.
•A series of five beeps will be heard. The tone pattern will repeat
periodically until the problem and/or light are repaired.
If any of these things happen, even intermittently, have the SRS serviced
at an authorized dealer immediately. Unless serviced, the system may not
function properly in the event of a collision.
Disposal of airbags and airbag equipped vehicles (including
pretensioners)
See your authorized dealer. Airbags MUST BE disposed of by qualified
personnel.
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Seating and Safety Restraints
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Improper or inadequate vehicle maintenance can cause tires to wear
abnormally. Inspect all your tires, including the spare, frequently, and
replace them if one or more of the following conditions exist:
Tire wear
When the tread is worn down to
1/16th of an inch (2 mm), tires must
be replaced to help prevent your
vehicle from skidding and
hydroplaning. Built-in treadwear
indicators, or “wear bars”, which
look like narrow strips of smooth
rubber across the tread will appear
on the tire when the tread is worn
down to 1/16th of an inch (2 mm).
When the tire tread wears down to
the same height as these “wear bars”, the tire is worn out and must be
replaced.
Damage
Periodically inspect the tire treads and sidewalls for damage (such as
bulges in the tread or sidewalls, cracks in the tread groove and
separation in the tread or sidewall). If damage is observed or suspected
have the tire inspected by a tire professional. Tires can be damaged
during off-road use, so inspection after off-road use is also
recommended.
Age
Tires degrade over time depending on many factors such as
weather, storage conditions, and conditions of use (load, speed,
inflation pressure, etc.) the tires experience throughout their lives.
In general, tires should be replaced after six years regardless of tread
wear. However, heat caused by hot climates or frequent high loading
conditions can accelerate the aging process and may require tires to be
replaced more frequently.
You should replace your spare tire when you replace the road tires or
after six years due to aging even if it has not been used.
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Tires, Wheels and Loading
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