engine FORD E SERIES 2015 4.G Repair Manual

If you drive in extremely hot climates:
•It may be necessary to have a Ford authorized dealer decrease the
coolant concentration to 40%.
•A coolant concentration of 40% will provide improved overheat
protection. Engine coolant concentrations below 40% will decrease the
corrosion/freeze protection characteristics of the engine coolant and
may cause engine damage.
Vehicles driven year-round in non-extreme climates should use
prediluted engine coolant for optimum cooling system and engine
protection.
What You Should Know About Fail-Safe Cooling
If the engine coolant supply is depleted, this feature allows the vehicle to
be driven temporarily before incremental component damage is incurred.
The fail-safe distance depends on ambient temperatures, vehicle load and
terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the engine coolant temperature gauge
will move to the red (hot) area and:
The coolant temperature warning light will illuminate.
The service engine soon indicator will illuminate.
If the engine reaches a preset over-temperature condition, the engine
will automatically switch to alternating cylinder operation. Each disabled
cylinder acts as an air pump and cools the engine.
When this occurs the vehicle will still operate. However:
•The engine power will be limited.
•The 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 restarted. Take
your vehicle to an authorized dealer as soon as possible to minimize
engine damage.
Maintenance175
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

When Fail-Safe Mode is Activated
WARNING:Fail-safe mode is for use during emergencies only.
Operate the vehicle in fail-safe mode only as long as necessary to
bring the vehicle to rest in a safe location and seek immediate repairs.
When in fail-safe mode, the vehicle will have limited power, will not be
able to maintain high-speed operation, and may completely shut down
without warning, potentially losing engine power, power steering assist,
and power brake assist, which may increase the possibility of a crash
resulting in serious injury.
WARNING:Never remove the coolant reservoir cap while the
engine is running or hot.
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 an authorized dealer.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
5. Restart the engine and take your vehicle to an authorized dealer.
Note:Driving the vehicle without repairing the engine problem increases
the chance of engine damage. Take your vehicle to an authorized dealer
as soon as possible.
176Maintenance
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

TRANSMISSION FLUID CHECK
Checking Automatic Transmission Fluid (If Equipped)
Refer to yourscheduled maintenance informationfor scheduled
intervals for fluid checks and changes. Your transmission does not
consume fluid. However, the fluid level should be checked if the
transmission is not working properly, i.e., if the transmission slips or
shifts slowly or if you notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 20 miles [30 kilometers]). If your vehicle has
been operated for an extended period at high speeds, in city traffic
during hot weather or pulling a trailer, the vehicle should be turned off
for about 30 minutes to allow fluid to cool before checking.
1. Drive the vehicle 20 miles (30 kilometers) or until it reaches normal
operating temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the engine running, parking brake engaged and your foot on the
brake pedal, move the gearshift lever through all of the gear ranges.
Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
Maintenance177
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

POWER STEERING FLUID CHECK
WARNING:For E-350 and E-450 vehicles with the Hydro-Boost
Brake System, do not press the brake pedal after the engine has
been turned off. Pressing the brake pedal after the engine has been
turned off will give a false power steering fluid level reading.
Note:Do not operate the vehicle with a low power steering pump fluid
level (if the fluid level is below the MIN line on the reservoir).
Note:Do not fill the power steering pump reservoir above the MAX line,
as this may result in leaks from the reservoir.
Check the power steering fluid at the appropriate intervals. Refer to the
scheduled maintenance information.
1. Start the engine and let it run until it reaches normal operating
temperature.
2. While the engine idles, turn the steering wheel left and right several
times.
3. Turn the engine off.
4. Check the fluid level in the reservoir. It should be between the MIN
and MAX lines on the reservoir. Do not add fluid if the level is in this
range.
5. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the range between the MIN and MAX lines. Be
sure to put the cap back on the reservoir. Refer to the technical
specifications table in theCapacities and Specificationschapter for the
proper fluid type.
FUEL FILTER
Your vehicle is equipped with a lifetime fuel filter that is integrated with
the fuel tank. Regular maintenance or replacement is not needed.
Maintenance185
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

Dual Batteries (If Equipped)
Your vehicle may be equipped with a frame-mounted battery located on
the passenger side frame rail, behind the front passenger door. This
battery is connected in parallel with the battery in the engine
compartment. Both batteries are used to start the vehicle.
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.
•Note: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.
188Maintenance
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

CHANGING THE WIPER BLADES
Replace wiper blades at least once per year for optimum performance.
To replace the wiper blades:
1. Fold back the wiper arm and
position the wiper blade at a right
angle to the wiper arm.
2. To remove the wiper blade, press
the retaining clip (A) to disengage
the wiper blade, then pull the blade
down toward the windshield to
remove it from the arm.
3. Install the new wiper blade on the arm and press it into place until a
click is heard.
Poor wiper quality can be improved by cleaning the wiper blades and
windshield. Refer toWindows and wiper bladesin theCleaning
chapter.
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.
AIR FILTER CHECK
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.
Note:Failure to use the correct air filter element may result in severe
engine damage. The customer warranty may be void for any damage to
the engine if the correct air filter element is not used.
When changing the air filter element, use only the air filter element
listed. SeeMotorcraft® Part Numbersin theCapacities and
Specificationschapter.
SeeScheduled Maintenance Informationfor the appropriate intervals
for changing the air filter element.
Note:Failure to use the correct air filter element may result in severe
engine damage. The customer warranty may be void for any damage to
the engine if the correct air filter element is not used.
A
190Maintenance
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

Changing the Air Filter Element
1. Disconnect the fresh air inlet
tube from the radiator support.
2. Open the clamp that secures the
two halves of the air filter housing
together.
3. Carefully separate the two
halves of the air filter housing.
4. Remove the air filter element
from the housing.
5. Install a new air filter element. Be careful not to crimp the filter
element edges between the air filter housing. This could cause filter
damage and allow unfiltered air to enter the engine if not properly
seated.
6. Replace the two halves of the air filter housing and secure the clamp.
7. Connect the fresh air inlet tube to the radiator support.
ADJUSTING THE HEADLAMPS
The headlamps on your vehicle are properly aimed at the assembly plant.
If your vehicle has been in an accident, an authorized dealer should
check the alignment of your headlamps.
Maintenance191
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

GENERAL INFORMATION
Your Ford or Lincoln authorized dealer has many quality products
available to clean your vehicle and protect its finishes.
CLEANING PRODUCTS
For best results, use the following products or products of equivalent
quality:
Motorcraft Bug and Tar Remover (ZC-42)
Motorcraft Custom Bright Metal Cleaner (ZC-15)
Motorcraft Detail Wash (ZC-3-A)
Motorcraft Dusting Cloth (ZC-24)
Motorcraft Engine Shampoo and Degreaser (United States only) (ZC-20)
Motorcraft Engine Shampoo (Canada only) (CXC-66-A)
Motorcraft Multi-Purpose Cleaner (Canada only) (CXC-101)
Motorcraft Premium Glass Cleaner (Canada only) (CXC-100)
Motorcraft Premium Quality Windshield Washer Fluid (Canada only)
[CXC-37-(A, B, D or F)]
Motorcraft Premium Windshield Wash Concentrate with Bitterant (United
States only) (ZC-32-B2)
Motorcraft Professional Strength Carpet & Upholstery Cleaner (ZC-54)
Motorcraft Premium Leather and Vinyl Cleaner (ZC-56)
Motorcraft Spot and Stain Remover (United States only) (ZC-14)
Motorcraft Ultra-Clear Spray Glass Cleaner (ZC-23)
Motorcraft Wheel and Tire Cleaner (ZC-37-A)
CLEANING THE EXTERIOR
Wash your vehicle regularly with cool or lukewarm water and a neutral
pH shampoo, such as Motorcraft® Detail Wash.
•Never use strong household detergents or soap, such as dish washing
or laundry liquid. These products can discolor and spot painted
surfaces.
•Never wash a vehicle that is hot to the touch or during exposure to
strong, direct sunlight.
•Dry the vehicle with a chamois or soft terry cloth towel in order to
eliminate water spotting.
Vehicle Care201
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

CLEANING THE ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal.
When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser on all parts that
require cleaning and pressure rinse clean. In Canada, use Motorcraft
Engine Shampoo.
•Never wash or rinse the engine while it is hot or running; water in the
running engine may cause internal damage.
•Never wash or rinse any ignition coil, spark plug wire or spark plug
well, or the area in and around these locations.
•Cover the battery, power distribution box, and air filter assembly to
prevent water damage when cleaning the engine.
CLEANING THE WINDOWS AND WIPER BLADES
The windows and wiper blades should be cleaned regularly. If the wipers
do not wipe properly, substances on the vehicle’s glass or the wiper
blades may cause squeaking or chatter noise from the blades, and
streaking and smearing of the windshield. To clean these items, follow
these tips:
•The windows may be cleaned with a non-abrasive cleaner such as
Motorcraft® Ultra-Clear Spray Glass Cleaner (U.S.) or Motorcraft
Premium Glass Cleaner (Canada).
•The wiper blades can be cleaned with isopropyl (rubbing) alcohol or
Motorcraft Premium Windshield Washer Concentrates in the U.S., or
Motorcraft Premium Quality Windshield Washer Fluid in Canada.
Replace your wiper blades when they appear worn or do not function
properly.
•Do not use abrasive materials, as they may cause scratches.
•Do not use fuel, kerosene, or paint thinner to clean any parts.
204Vehicle Care
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)

CLEANING THE ALLOY WHEELS
Note:Do not use chrome cleaner, metal cleaner or polish on wheels and
wheel covers.
A clearcoat paint finish coats aluminum wheels and wheel covers. In
order to maintain their condition:
•Clean weekly with Motorcraft Wheel and Tire Cleaner. Use a sponge to
remove heavy deposits of dirt and brake dust accumulation. Rinse
thoroughly with a strong stream of water when you have completed
the cleaning process.
•To remove tar and grease, use Motorcraft Bug and Tar Remover.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers.
•Industrial-strength (heavy-duty) cleaners, or cleaning chemicals, in
combination with brush agitation to remove brake dust and dirt, could
wear away the clearcoat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•If you intend on parking your vehicle for an extended period after
cleaning the wheels with a wheel cleaner, drive your vehicle for a few
minutes before doing so. This reduces the risk of increased corrosion
of the brake discs.
VEHICLE STORAGE
If you plan on storing your vehicle for an extended period of time
(30 days or more), read the following maintenance recommendations to
make sure your vehicle stays in good operating condition.
All motor vehicles and their components were engineered and tested for
reliable, regular driving. Long-term storage under various conditions may
lead to component degradation or failure unless specific precautions are
taken to preserve the components.
General
•Store all vehicles in a dry, ventilated place.
•Protect from sunlight, if possible.
•If vehicles are stored outside, they require regular maintenance to
protect against rust and damage.
208Vehicle Care
2015 Econoline(eco)
Owners Guide gf, 1st Printing, June 2014
USA(fus)