engine FORD E SERIES 2011 4.G Repair Manual

FORD AND LINCOLN MERCURY CAR CARE PRODUCTS
Your Ford or Lincoln Mercury authorized dealer has many quality
products available to clean your vehicle and protect its finishes. These
quality products have been specifically engineered to fulfill your
automotive needs; they are custom designed to complement the style
and appearance of your vehicle. Each product is made from high quality
materials that meet or exceed rigid specifications. For best results, use
the following products or products of equivalent quality:
MotorcraftBug and Tar Remover (ZC-42)
MotorcraftCustom Bright Metal Cleaner (ZC-15)
MotorcraftDetail Wash (ZC-3-A)
MotorcraftDusting Cloth (ZC-24)
MotorcraftEngine Shampoo and Degreaser (U.S. only) (ZC-20)
MotorcraftEngine Shampoo (Canada only) (CXC-66-A)
MotorcraftMulti-Purpose Cleaner (Canada only) (CXC-101)
MotorcraftPremium Glass Cleaner (Canada only) (CXC-100)
MotorcraftPremium Quality Windshield Washer Fluid (Canada only)
[CXC-37-(A, B, D or F)]
MotorcraftPremium Windshield Washer Concentrate (U.S. only)
(ZC-32-A)
MotorcraftProfessional Strength Carpet & Upholstery Cleaner (ZC-54)
MotorcraftSpot and Stain Remover (U.S. only) (ZC-14)
MotorcraftUltra-Clear Spray Glass Cleaner (ZC-23)
MotorcraftVinyl Cleaner (Canada only) (CXC-93)
MotorcraftWheel and Tire Cleaner (ZC-37-A)
Cleaning
253
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

SERVICE RECOMMENDATIONS
To help you service your vehicle, we providescheduled maintenance
informationwhich makes tracking routine service easy.
If your vehicle requires professional service, your authorized dealer can
provide the necessary parts and service. Check yourWarranty Guideto
find out which parts and services are covered.
Use only recommended fuels, lubricants, fluids and service parts
conforming to specifications. Motorcraftparts are designed and built to
provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE
•Do not work on a hot engine.
•Make sure that nothing gets caught in moving parts.
•Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
•Keep all open flames and other burning material (such as cigarettes)
away from the battery and all fuel related parts.
Working with the engine off
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Turn off the engine and remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
Working with the engine on
1. Set the parking brake and shift to P (Park).
2. Block the wheels.
WARNING:To reduce the risk of vehicle damage and/or
personal burn injuries, do not start your engine with the air
cleaner removed and do not remove it while the engine is running.
Maintenance and Specifications
254
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
1. Battery
2. Windshield washer fluid reservoir
3. Engine oil filler cap
4. Automatic transmission fluid dipstick
5. Air filter assembly
6. Engine oil dipstick
7. Power steering fluid reservoir
8. Brake fluid reservoir
9. Engine coolant reservoir
10. Power distribution box
13
4
567
89210
Maintenance and Specifications
256
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

To prolong the life of the wiper blades, it is highly recommended to
scrape off the ice on the windshield before turning on the wipers. The
layer of ice has many sharp edges and can damage the micro edge of the
wiper rubber element.
ENGINE OIL
Checking the engine oil
Refer to thescheduled maintenance informationfor the appropriate
intervals for checking the engine oil.
1. Make sure the vehicle is on level ground.
2. Turn the engine off and wait 15 minutes for the oil to drain into the
oil pan.
3. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
4. Open the hood. Protect yourself from engine heat.
5. Locate and carefully remove the
engine oil level dipstick.
6. Wipe the dipstick clean. Insert the dipstick fully, then remove it again.
•If the oil level isbetween the lower and upper holes or between
the MIN and MAX marks (depending on application),the oil
level is acceptable.DO NOT ADD OIL.
•If the oil level is below the lower hole or the MIN mark, add enough
oil to raise the level within the lower and upper holes or within the
MIN-MAX range.
•Oil levels above the upper hole or the MAX mark may cause engine
damage. Some oil must be removed from the engine by an authorized
dealer.
Maintenance and Specifications
258
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

7. Put the dipstick back in and ensure it is fully seated.
Adding engine oil
1. Check the engine oil. For instructions, refer toChecking the engine
oilin this chapter.
2. If the engine oil level is not within the normal range, add only certified
engine oil of the recommended viscosity. Remove the engine oil filler cap
and use a funnel to pour the engine oil into the opening.
3. Recheck the engine oil level. Make sure the oil level is not above the
normal operating range on the engine oil level dipstick.
4. Install the dipstick and ensure it is fully seated.
5. Fully install the engine oil filler cap by turning the filler cap clockwise
1/4 of a turn until three clicks are heard or until the cap is fully seated.
To avoid possible oil loss, DO NOT operate the vehicle with the
engine oil level dipstick and/or the engine oil filler cap removed.
Engine oil and filter recommendations
Look for this certification
trademark.
Use SAE 5W-20 engine oil
Only use oils certified for gasoline engines by the American Petroleum
Institute (API). An oil with this trademark symbol conforms to the
current engine and emission system protection standards and fuel
economy requirements of the International Lubricant Standardization and
Approval Committee (ILSAC), comprised of U.S. and Japanese
automobile manufacturers.
To protect your engine and engine’s warranty, use MotorcraftSAE
5W-20 or an equivalent SAE 5W-20 oil meeting Ford specification
WSS-M2C930-A.SAE 5W-20 oil provides optimum fuel economy and
durability performance meeting all requirements for your
Maintenance and Specifications
259
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

vehicle’s engine.Refer toMaintenance product specifications and
capacitieslater in this chapter for more information.
Do not use supplemental engine oil additives, cleaners or other engine
treatments. They are unnecessary and could lead to engine damage that
is not covered by Ford warranty.
Change your engine oil and filter according to the appropriate schedule
listed in thescheduled maintenance information.
Ford production and Motorcraftreplacement oil filters are designed for
added engine protection and long life. If a replacement oil filter is used
that does not meet Ford material and design specifications, start-up
engine noises or knock may be experienced.
It is recommended you use the appropriate Motorcraftoil filter or
another with equivalent performance for your engine application.
BATTERY
Your vehicle is equipped with a
Motorcraftmaintenance-free
battery which normally does not
require additional water during its
life of service.
WARNING:This vehicle may be equipped with more than one
battery, removal of cable from only one battery does not
disconnect the vehicle electrical system. Be sure to disconnect cables
from all batteries when disconnecting power. Failure to do so may
cause serious personal injury or property damage.
If your battery has a cover/shield, make sure it is reinstalled
after the battery has been cleaned or replaced.
For longer, trouble-free operation, keep the top of the battery clean and
dry. Also, make certain the battery cables are always tightly fastened to
the battery terminals.
If you see any corrosion on the battery or terminals, remove the cables
from the terminals and clean with a wire brush. You can neutralize the
acid with a solution of baking soda and water.
Maintenance and Specifications
260
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

Auxiliary battery (if equipped)
Your vehicle may be equipped with a frame-mounted auxiliary battery
located on the passenger side frame rail, behind the front passenger
door. This auxiliary battery is connected to the auxiliary battery relay, so
it is not used to start the vehicle.
Battery relearn
Because your vehicle’s engine is electronically controlled by a computer,
some control conditions are maintained by power from the battery. When
the battery is disconnected or a new battery is installed, the engine must
relearn its idle and fuel trim strategy for optimum driveability and
performance. Flexible fuel vehicles (FFV) must also relearn the ethanol
content of the fuel for optimum driveability and performance. To begin
this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Release the parking brake. With your foot on the brake pedal and with
the A/C on, put the vehicle in D (Drive) and allow the engine to idle for
at least one minute.
7. Drive the vehicle to complete the relearning process.
•The vehicle may need to be driven 10 miles (16 km) or more to
relearn the idle and fuel trim strategy along with the ethanol content
for flexible fuel vehicles.
•If you do not allow the engine to relearn its idle trim, the idle quality
of your vehicle may be adversely affected until the idle trim is
eventually relearned.
•For flexible fuel vehicles, if you are operating on E85, you may
experience poor starts or an inability to start the engine and
driveability problems until the fuel trim and ethanol content have been
relearned.
If the battery has been disconnected or a new battery has been installed,
the clock and radio settings must be reset once the battery is
reconnected.
Maintenance and Specifications
262
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

•Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center
to find out more about recycling
automotive batteries.
ENGINE COOLANT
Checking engine coolant
The concentration and level of engine coolant should be checked at the
intervals listed inscheduled maintenance information.The coolant
concentration should be maintained at 50/50 coolant and distilled water,
which equates to a freeze point of -34°F (-36°C). Coolant concentration
testing is possible with a hydrometer or antifreeze tester. The level of
coolant should be maintained at the FULL COLD level or within the
COLD FILL RANGE in the coolant reservoir. If the level falls below, add
coolant per the instructions in theAdding engine coolantsection.
Your vehicle was factory-filled with a 50/50 engine coolant and water
concentration. If the concentration of coolant falls below 40% or above
60%, the engine parts could become damaged or not work properly.A
50/50 mixture of coolant and water provides the following:
•Freeze protection down to -34°F (-36°C).
•Boiling protection up to 265°F (129°C).
•Protection against rust and other forms of corrosion.
•Proper function of calibrated gauges.
LEAD
RETURN
RECYCLE
Maintenance and Specifications
263
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

When the engine is cold, check the
level of the engine coolant in the
reservoir.
•The engine coolant should be at the FULL COLD level, or within the
COLD FILL or MIN / MAX range as listed on the engine coolant
reservoir (depending upon application).
•Refer toscheduled maintenance informationfor service interval
schedules.
If the engine coolant has not been checked at the recommended interval,
the engine coolant reservoir may become low or empty. If the reservoir is
low or empty, add engine coolant to the reservoir. Refer toAdding
engine coolantin this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant/antifreeze or windshield washer fluid outside of its specified
function and vehicle location.
Adding engine coolant
When adding coolant, make sure it is a 50/50 mixture of engine coolant
and distilled water. Add the mixture to the coolant reservoir,when the
engine is cool,until the appropriate fill level is obtained. If coolant is
filled to the COLD FILL RANGE or FULL COLD level when the engine is
not cool, the system will remain underfilled.
Maintenance and Specifications
264
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)

WARNING:Do not add engine coolant when the engine is hot.
Steam and scalding liquids released from a hot cooling system
can burn you badly. Also, you can be burned if you spill coolant on hot
engine parts.
WARNING:Do not put engine coolant in the windshield washer
fluid container. If sprayed on the windshield, engine coolant
could make it difficult to see through the windshield.
•DO NOT MIXdifferent colors or types of coolant in your vehicle.
Make sure the correct coolant is used.DO NOT MIXrecycled coolant
and new (unused) coolant together in the vehicle. Mixing of engine
coolants may harm your engine’s cooling system. The use of an
improper coolant may harm engine and cooling system components
and may void the warranty. Refer toMaintenance product
specifications and capacitiesin this chapter.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
•Do not use alcohol, methanol, brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
For vehicles with overflow coolant systems with a non-pressurized cap
on the coolant recovery system, add coolant to the coolant recovery
reservoir when the engine is cool. Add the proper mixture of coolant and
distilled water to the FULL COLD level. For all other vehicles which have
a coolant degas system with a pressurized cap, or if it is necessary to
remove the coolant pressure relief cap on the radiator of a vehicle with
an overflow system, follow these steps to add engine coolant.
WARNING:To reduce the risk of personal injury, make sure the
engine is cool before unscrewing the coolant pressure relief cap.
The cooling system is under pressure; steam and hot liquid can come
out forcefully when the cap is loosened slightly.
Maintenance and Specifications
265
2011 Econoline(eco)
Owners Guide, 1st Printing
USA(fus)