service FORD E SERIES 2011 4.G Repair Manual

WARNING:Exhaust leaks may result in entry of harmful and
potentially lethal fumes into the passenger compartment.
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 also lists engine displacement.
Please consult yourWarranty Guidefor complete emission warranty
information.
On-board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the
on-board diagnostics system (OBD-II). The OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists your
authorized dealer in properly servicing your vehicle. When the service
engine soon
indicator illuminates, the OBD-II system has detected
a malfunction. Temporary malfunctions may cause the service engine
soon
indicator to illuminate. Examples are:
1. The vehicle has run out of fuel—the engine may misfire or run poorly.
2. Poor fuel quality or water in the fuel—the engine may misfire or run
poorly.
3. The fuel cap may not have been securely tightened. SeeFuel filler
capin this chapter.
4. Driving through deep water—the electrical system may be wet.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel, properly tightening the fuel cap or letting the
electrical system dry out. After three driving cycles without these or any
other temporary malfunctions present, the service engine soon
indicator should stay off the next time the engine is started. A driving
cycle consists of a cold engine startup followed by mixed city/highway
driving. No additional vehicle service is required.
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If the service engine soonindicator remains on, have your vehicle
serviced at the first available opportunity. Although some malfunctions
detected by the OBD-II may not have symptoms that are apparent,
continued driving with the service engine soon
indicator on can
result in increased emissions, lower fuel economy, reduced engine and
transmission smoothness, and lead to more costly repairs.
Readiness for Inspection/Maintenance (I/M) testing
Some state/provincial and local governments may have
Inspection/Maintenance (I/M) programs to inspect the emission control
equipment on your vehicle. Failure to pass this inspection could prevent
you from getting a vehicle registration. Your vehicle may not pass the I/M
test if the service engine soon
indicator is on or not working
properly (bulb is burned out), or if the OBD-II system has determined
that some of the emission control systems have not been properly
checked. In this case, the vehicle is considered not ready for I/M testing.
If the service engine soon
indicator is on or the bulb does not
work, the vehicle may need to be serviced. Refer toOn-board
diagnostics (OBD-II)in this chapter.
If the vehicle’s engine or transmission has just been serviced, or the
battery has recently run down or been replaced, the OBD-II system may
indicate that the vehicle is not ready for I/M testing. To determine if the
vehicle is ready for I/M testing, turn the ignition key to the on position
for 15 seconds without cranking the engine. If the service engine
soon
indicator blinks eight times, it means that the vehicle is not
ready for I/M testing; if the service engine soon
indicator stays on
solid, it means that the vehicle is ready for I/M testing.
The OBD-II system is designed to check the emission control system
during normal driving. A complete check may take several days. If the
vehicle is not ready for I/M testing, the following driving cycle consisting
of mixed city and highway driving may be performed:
15 minutes of steady driving on an expressway/highway followed by
20 minutes of stop-and-go driving with at least four 30-second 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. If
the vehicle is still not ready for I/M testing, the above driving cycle will
have to be repeated.
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BRAKE FLUID
•E-150/E-250/E-350 Single Rear
Wheel
•E-350/E-450 Dual Rear Wheel
The fluid level will drop slowly as the brakes wear, and will rise when the
brake components are replaced. Fluid levels between the MIN and MAX
lines are within the normal operating range; there is no need to add
fluid. If the fluid levels are outside of the normal operating range, the
performance of the system could be compromised; seek service from
your authorized dealer immediately.
DRIVELINE UNIVERSAL JOINT AND SLIP YOKE
Your vehicle may be equipped with universal joints that require
lubrication. Refer to thescheduled maintenance informationfor
maintenance intervals. If the original universal joints are replaced with
universal joints equipped with grease fittings, lubrication will also be
necessary.
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Automatic transmission fluid filter
The Torqshiftautomatic
transmission is equipped with a
serviceable transmission fluid filter
located inside the transmission
bottom pan.
Refer toscheduled maintenance
informationfor service intervals for
automatic transmission fluid and
transmission filter.
For transmission filter maintenance,
see your authorized dealer.
AIR FILTER
Refer toscheduled maintenance informationfor the appropriate
intervals for changing the air filter element.
When changing the air filter element, use only the air filter element
listed. Refer toMotorcraftpart numbersin this chapter.
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.
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Item Capacity Ford part nameFord part number /
Ford specification
Fuel tank–158 inch and
176 inch wheelbase
(E-Super Duty)55.0 gallons
(208.0L)
1Add the coolant type originally equipped in your vehicle.2Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.3Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size, if
equipped with an in-tank cooler, if equipped with an oil to air cooler and if equipped with a remote
filter assembly. The amount of transmission fluid and fluid level should be set by the indication on
the dipstick’s normal operating range.4Automatic transmissions that require MERCONLV should only use MERCONLV fluid. Refer to
scheduled maintenance informationto determine the correct service interval. Use of any fluid
other than the recommended fluid may cause transmission damage.5Dana limited-slip axle (M60) requires 6 oz. (177 ml) of Additive Friction Modifier XL-3 or
equivalent meeting Ford specification EST-M2C118-A.6If 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.7Fill Dana rear axles to 1/4 inch to 9/16 inch (6 mm to 14 mm) below bottom of fill hole.8Optional fuel tank 55.0 gallons (208.0L).
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•Vehicle tracking and recovery*•Hitch mounted parking sensor*
•Bumper mounted parking sensors*
*Ford Licensed Accessories (FLA) are warranted by the accessory
manufacturer’s warranty. Ford Licensed Accessories are fully designed
and developed by the accessory manufacturer and have not been
designed or tested to Ford Motor Company engineering requirements.
Contact your Ford dealer for details regarding the manufacturer’s limited
warranty and/or a copy of the FLA product limited warranty offered by
the accessory manufacturer.
For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
•When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacity of the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
Compliance Certification label). Consult your authorized dealer for
specific weight information.
•The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems — such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use.
•To avoid interference with other vehicle functions, such as anti-lock
braking systems, amateur radio users who install radios and antennas
onto their vehicle should not locate the Amateur Radio Antennas in
the area of the driver’s side hood.
•Electrical or electronic accessories or components that are added to
the vehicle by the authorized dealer or the owner may adversely affect
battery performance and durability.
Accessories
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FORD ESP EXTENDED SERVICE PLANS (U.S. ONLY)
More than 30 million Ford, Lincoln, and Mercury owners have discovered
the powerful protection of Ford ESP. It is the only extended service plan
backed by Ford Motor Company, and provides “peace of mind”
protection beyond the New Vehicle Limited Warranty coverage.
Up to 500+ Covered Vehicle Components
There are four, new-vehicle Extended Service Plans with different levels
of coverage. Ask your dealer for details.
PremiumCare –Our most comprehensive coverage. With over 500
covered components, this plan is so complete that we generally only
discuss what’s not covered!
ExtraCare –Covers 113 components, and includes many high-tech
items.
BaseCare –Covers 84 components.
PowertrainCare –Covers 29 critical components.
Ford ESP is honored by all Ford, Lincoln and Mercury Dealers in
the U.S. and CanadaIt’s the only extended service plan authorized and
backed by Ford Motor Company. That means you get:
•Reliable, quality service anywhere you go.
•Factory-trained technicians.
•Genuine Ford and MotorcraftParts.
Rental car reimbursement
If your vehicle is kept overnight for covered repairs,you are
eligible for rental car coverage, including Bumper-to-Bumper warranty
repairs, or manufacturer’s recalls.
Transferable coverage
If you sell your vehicle before your Ford ESP coverage expires, you can
transfer any remaining coverage to the new owner. Whenever you’re
ready to sell your car, prospective buyers may feel better about taking a
risk on your used vehicle. Ford ESP may add resale value!
Plus,exclusive 24/7 roadside assistance,including:
•Towing, flat-tire change and battery jump starts.
•Out-of-fuel and lock-out assistance.
•Travel expense reimbursement for lodging, meals and rental car.
•Destination assistance for taxi, shuttle, rental car coverage and
emergency transportation.
Ford Extended Service Plan
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Ford ESP Can Quickly Pay for Itself
One service bill – the cost of parts and labor – can easily exceed the
price of your Ford ESP Service Contract. With Ford ESP, you minimize
your risk for unexpected repair bills and rising repair costs.
Avoid the rising cost of properly maintaining your vehicle!
Ford ESP also offers a Premium Maintenance Plan that covers items that
routinely wear out.
The coverage is prepaid, so you never have to worry about affording
your vehicle maintenance. It covers regular checkups, routine
inspections, preventive care and replacement of items that require
periodic attention fornormal “wear”:
•Wiper blades•Brake pads and linings
•Spark plugs (except
California)•Shock absorbers
•Clutch disc•Belts and hoses
Contact your selling Ford, Lincoln, or Mercury dealership today so they
can customize a Ford Extended Service Plan that fits your driving
lifestyle and budget.
Interest free finance options available
Take advantage of our installment payment plan, just a 10% down
payment will provide you with an affordable no interest, no-fee payment
opportunity.
Ford Extended Service Plan
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Ford Extended Service Plan
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FORD ESP EXTENDED SERVICE PLANS (CANADA ONLY)
You can get more protection for your vehicle by purchasing a Ford
Extended Service Plan (ESP). Ford ESP is the only service contract
backed by Ford Motor Company. Depending on the plan you purchase,
Ford ESP provides benefits such as:
•Rental reimbursement
•Coverage for certain maintenance and wear items
•Protection against repair costs after your New Vehicle Limited
Warranty Coverage expires
•Roadside Assistance benefits
You may purchase Ford ESP from any participating Ford Motor Company
dealership. There are several Ford ESP plans available in various time,
distance and deductible combinations. Each plan is tailored to fit your
own driving needs, including reimbursement for towing and rental.
When you purchase Ford ESP, you receive peace-of-mind protection
throughout Canada and the United States, provided by a network of Ford
Motor Company dealers.
For more information, visit your local Ford of Canada dealer or
www.ford.ca to find the Ford Extended Service Plan that is right for you.
NOTE:Repairs performed outside of Canada and the United States are
not eligible for Ford ESP coverage. This information is subject to change.
Ford Extended Service Plan
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