warning FORD E SERIES 2016 4.G Manual PDF

Should your vehicle shut off after a
collision, you may restart your vehicle. For
vehicles equipped with a key system:
1. Switch off the ignition.
2. Switch on the ignition.
3. Repeat Steps 1 and 2 to re-enable the
fuel pump.
Note: When you try to restart your vehicle
after a fuel shutoff, the vehicle makes sure
that various systems are safe to restart.
Once your vehicle determines that the
systems are safe, then the vehicle will allow
you to restart.
Note: In the event that your vehicle does
not restart after your third attempt, contact
an authorized dealer.
JUMP STARTING THE VEHICLE WARNINGS
Batteries normally produce explosive
gases which can cause personal
injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When working near
the battery, always shield your face and
protect your eyes. Always provide correct
ventilation. Keep batteries out of reach of
children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or
clothing. Shield your eyes when working
near the battery to protect against possible
splashing of acid solution. In case of acid
contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Use only adequately sized cables
with insulated clamps. Preparing Your Vehicle
Do not attempt to push-start your
automatic transmission vehicle.
Note:
Attempting to push-start a vehicle
with an automatic transmission may cause
transmission damage.
Note: Use only a 12-volt supply to start your
vehicle.
Note: Do not disconnect the battery of the
disabled vehicle as this could damage the
vehicle electrical system.
Park the booster vehicle close to the hood
of the disabled vehicle, making sure the
two vehicles do not touch.
Connecting the Jumper Cables WARNINGS
Do not attach the cables to fuel lines,
engine rocker covers, the intake
manifold or electrical components
as grounding points. Stay clear of moving
parts. To avoid reverse polarity
connections, make sure that you correctly
identify the positive (+) and negative (-)
terminals on both the disabled and booster
vehicles before connecting the cables. Do not attach the end of the positive
cable to the studs or L-shaped eyelet
located above the positive (+)
terminal of your vehicle ’s battery. High
current may flow through and cause
damage to the fuses. Do not connect the end of the
second cable to the negative (-)
terminal of the battery to be jumped.
A spark may cause an explosion of the
gases that surround the battery. Note:
In the illustration, the bottom vehicle
represents the booster vehicle.
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FUSE SPECIFICATION CHART
Power Distribution Box
WARNINGS
Always disconnect the battery before
servicing high current fuses.
To reduce risk of electrical shock,
always replace the cover to the
power distribution box before
reconnecting the battery or refilling fluid
reservoirs. Note:
If your vehicle is equipped with dual
batteries, disconnecting the primary
under-hood battery does not remove power
from all circuits.
The power distribution box is located in
the engine compartment. It has
high-current fuses that protect your
vehicle's main electrical systems from
overloads.
If the battery has been disconnected and
reconnected, you will need to reset some
features. See Changing the 12V Battery
(page 145). Protected components
Fuse amp rating
Fuse or relay number
Powertrain control module relay.
—
1
Starter solenoid relay.
—
2
Wiper relay.
—
3
Trailer tow battery charge.
—
4
Fuel pump relay.
—
5
Trailer tow park lamp relay.
—
6
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Protected components
Fuse amp rating
Fuse or relay number
Vehicle power 4.
15A*
78
Engine ignition coil relay coil.
Vehicle power 5.
10A*
79
Transmission.
Cluster run/start (stripped chassis).
10A*
80
Not used.
—
81
Not used.
—
82
Fuel pump diode.
—
83
Not used.
—
84
Auxiliary switch #1 relay.
—
85
*Mini fuses.
**A1S fuses.
Passenger Compartment Fuse
Panel WARNING
Always disconnect the battery before
servicing high current fuses. Note:
If your vehicle is equipped with dual
batteries, disconnecting the primary
under-hood battery does not remove power
from all circuits.
The fuse panel is located to the left of the
brake pedal and mounted onto the lower
left cowl panel. Remove the fuse panel
cover to access the fuses.
To remove a fuse, use the fuse puller tool
provided on the inside of the fuse panel
cover.
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Protected components
Fuse amp rating
Fuse or relay number
Cutaway run/start.
10A
35
Passive anti-theft system radio frequency
module.
5A
36
Climate control.
10A
37
Stripped chassis #1 run/start.
Not used (spare).
20A
38
Radio.
20A
39
Not used (spare).
20A
40
Radio.
15A
41
Switch illumination.
Automatic dimming rear view mirror.
Power inverter.
Auxiliary switch.
10A
42
Stripped chassis instrument panel
connector #1.
10A
43
Trailer tow battery charge relay.
10A
44
Wipers.
5A
45
Stripped chassis engine connector 3.
Passenger airbag deactivation indicator.
7.5A
46
Windows accessory delay circuit breaker.
30A
47
Delayed accessory relay.
—
48
CHANGING A FUSE
Fuses WARNING
Always replace a fuse with one that
has the specified amperage rating.
Using a fuse with a higher amperage
rating can cause severe wire damage and
could start a fire. 134
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GENERAL INFORMATION
Have your vehicle serviced regularly to help
maintain its roadworthiness and resale
value. There is a large network of
authorized dealers that are there to help
you with their professional servicing
expertise. We believe that their specially
trained technicians are best qualified to
service your vehicle properly and expertly.
They are supported by a wide range of
highly specialized tools developed
specifically for servicing your vehicle.
If your vehicle requires professional service,
an authorized dealer can provide the
necessary parts and service. Check your
warranty information to find out which
parts and services are covered.
Use only recommended fuels, lubricants,
fluids and service parts conforming to
specifications. Motorcraft® parts are
designed and built to provide the best
performance in your vehicle.
Precautions
•
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 shift to park
(P). 2. Switch off the engine.
3. Block the wheels.
Working with the Engine On 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. 1.
Set the parking brake and shift to park
(P).
2. Block the wheels.
OPENING AND CLOSING THE
HOOD 1.
Inside the vehicle, pull the hood release
handle located under the bottom left
corner of the instrument panel.
2. Go to the front of the vehicle and push
the auxiliary latch, located in the center
of the top grille, to the left in order to
release the hood.
3. Lift the hood and secure it with the prop rod.
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To reset the oil life monitoring system do
the following:
1.
Switch the ignition on. Do not start the
engine.
2. Fully press the accelerator and brake pedals at the same time.
3. Keep the accelerator and brake pedals
fully pressed.
4. After three seconds, a message displays confirming the reset procedure
is in progress.
5. After 25 seconds, a message displays confirming the reset procedure is
complete.
6. Release the accelerator and brake pedals.
7. Switch the ignition off.
ENGINE COOLANT CHECK WARNINGS
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, spilling
coolant on hot engine parts can burn you. 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. 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 you loosen the cap
slightly. Do not add coolant further than the
MAX mark. Checking the Engine Coolant
When the engine is cold, check the
concentration and level of the engine
coolant at the intervals listed in the
scheduled maintenance information. See
Scheduled Maintenance (page 268).
Note: Make sure that the coolant level is
between the MIN and MAX marks on the
coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the MAX mark.
Note: If the level is at the MIN mark, below
the MIN mark, or empty, add coolant
immediately. See
Adding Engine Coolant
in this chapter.
Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C).
Note: For best results, coolant
concentration should be tested with a
refractometer such as Robinair® Coolant
and Battery Refractometer 75240. We do
not recommend the use of hydrometers or
coolant test strips for measuring coolant
concentrations.
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
Note: Do not use stop leak pellets, cooling
system sealants or additives as they can
cause damage to the engine cooling or
heating systems. Your warranty may not
cover these damages.
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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 outside temperatures, vehicle
load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the engine
coolant temperature gauge moves to the
red (hot) area and:
A high engine temperature
message appears in the
information display.
The service engine soon
indicator appears in the
information display.
If the engine reaches a preset
over-temperature condition, the engine
automatically switches to alternating
cylinder operation. Each disabled cylinder
acts as an air pump and cools the engine.
If this occurs, your vehicle still operates.
However:
• The engine power becomes limited.
• The air conditioning system becomes
disabled.
Continued operation increases the engine
temperature and the engine completely
shuts down, causing steering and braking
effort to increase.
Once the engine temperature cools, the
engine can be re-started. Take your vehicle
to an authorized dealer as soon as possible
to minimize engine damage. When Fail-Safe Mode Is Activated WARNINGS
Fail-safe mode is for use during
emergencies only. Operate your
vehicle in fail-safe mode only as long
as necessary to bring your vehicle to rest
in a safe location and seek immediate
repairs. When in fail-safe mode, your
vehicle has limited power, does not
maintain high-speed operation and may
completely shut down without warning.
Potentially losing power steering assist,
and power brake assist, which may
increase the possibility of a crash resulting
in serious injury. Never remove the coolant reservoir
cap while the engine is running or hot.
Your vehicle has limited engine power,
drive your vehicle with caution. Your vehicle
does not maintain high-speed operation
and the engine operates poorly.
Remember that the engine is capable of
automatically shutting down to prevent
engine damage. In this situation:
1. Pull off the road as soon as safely
possible and switch off the engine.
2. Tow your vehicle 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 add if low.
5. Re-start the engine and drive your vehicle to an authorized dealer.
Note: Driving your vehicle without repair
increases the chance of engine damage. See
an authorized dealer as soon as possible.
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POWER STEERING FLUID
CHECK
WARNINGS
A fluid level between the MAX and
MIN lines is within the normal
operating range and there is no need
to add fluid. A fluid level not in the normal
operating range could compromise the
performance of the system. 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. Only use fluid that meets Ford
specifications. See Capacities and
Specifications (page 197).
To top up the power steering fluid level do
the following.
1. Start the engine and let it run until it reaches normal operating temperature.
2. Make sure the fluid is within the
MIN
and MAX range.
3. If the fluid level is low, add fluid to be within the
MIN and MAX range. Do not
overfill.
4. While the engine idles, turn the steering
wheel left and right several times.
5. Recheck the fluid level in the reservoir.
Note: Do not operate the vehicle with a low
power steering pump fluid level. WASHER FLUID CHECK WARNING
If you operate your vehicle in
temperatures below 40°F (5°C), use
washer fluid with antifreeze
protection. Failure to use washer fluid with
antifreeze protection in cold weather could
result in impaired windshield vision and
increase the risk of injury or accident. Add fluid to fill the reservoir if the level is
low. Only use a washer fluid that meets
Ford specifications. See
Capacities and
Specifications (page 191).
State or local regulations on volatile
organic compounds may restrict the use
of methanol, a common windshield washer
antifreeze additive. Washer fluids
containing non-methanol antifreeze
agents should be used only if they provide
cold weather protection without damaging
the vehicle ’s paint finish, wiper blades or
washer system.
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.
CHANGING THE 12V BATTERY WARNINGS
This vehicle may be fitted 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.
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WARNINGS
Batteries normally produce explosive
gases which can cause personal
injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When working near
the battery, always shield your face and
protect your eyes. Always provide proper
ventilation. When lifting a plastic-cased battery,
excessive pressure on the end walls
could cause acid to flow through the
vent caps, resulting in personal injury
and/or damage to the vehicle or battery.
Lift the battery with a battery carrier or
with your hands on opposite corners. Keep batteries out of reach of
children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or
clothing. Shield your eyes when working
near the battery to protect against possible
splashing of acid solution. In case of acid
contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash hands after
handling. Note:
If your vehicle battery has a cover,
make sure it is reinstalled after the battery
has been cleaned or replaced.
Note: Electrical or electronic accessories
or components added to the vehicle by the
dealer or the owner may adversely affect
battery performance and durability.
Your vehicle is fitted with a Motorcraft®
maintenance-free battery which normally
does not require additional water during
its life of service. 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.
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.
Reconnecting the Battery
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. Switch off all accessories and start the
engine.
2. Run the engine until it reaches normal operating temperature.
3. Allow the engine to idle for at least one
minute.
4. Turn the A/C on and allow the engine to idle for at least one minute.
5. Fully press the foot brake. Release the parking brake. Shift the gearshift lever
to Drive (D) and allow the engine to
idle for at least one minute.
6. Drive the vehicle for approximately 10 mi (16 km) to complete the
relearning process.
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3.
Disconnect the electrical connector by
squeezing the release tab and pushing
the connector forward, then pulling it
rearward.
4. Remove the headlamp.
To install the new lamp, follow the
removal procedures in reverse order.
Sealed Beam Headlamps
1. Make sure the headlamp switch is in the off position, then open the hood. 2. Remove the four screws from the
headlamp assembly and carefully
remove the lamp/bezel.
3. Remove the four screws and the retaining ring.
4. Disconnect the electrical connector from the lamp and remove the lamp.
To install the new lamp, follow the
removal procedures in reverse order.
CHANGING A BULB
Lamp Assembly Condensation
Exterior lamps are vented to
accommodate normal changes in pressure.
Condensation can be a natural by-product
of this design. When moist air enters the
lamp assembly through the vents, there is
a possibility that condensation can occur when the temperature is cold. When
normal condensation occurs, a thin film of
mist can form on the interior of the lens.
The thin mist eventually clears and exits
through the vents during normal operation.
Clearing time may take as long as 48 hours
under dry weather conditions.
Examples of acceptable condensation are:
•
Presence of thin mist (no streaks, drip
marks or droplets).
• Fine mist covers less than 50% of the
lens.
Examples of unacceptable moisture
(usually caused by a lamp water leak) are:
• Water puddle inside the lamp.
• Large water droplets, drip marks or
streaks present on the interior of the
lens.
Take your vehicle to a dealer for service if
any of the above conditions of
unacceptable moisture are present.
Replacing Headlamp Bulbs
(Aerodynamic) WARNING
Handle a halogen headlamp bulb
carefully and keep out of children
’s
reach. Grasp the bulb by only its
plastic base and do not touch the glass.
The oil from your hand could cause the
bulb to break the next time the headlamps
are operated. Note:
If the bulb is accidentally touched,
clean it with rubbing alcohol before use.
1. Make sure the headlamp switch is in the off position, then open the hood.
2. Remove the headlamp. See Removing a Headlamp (page 150).
3. Disconnect the electrical connector by
squeezing the release tab and pushing
the connector forward, then pulling it
rearward.
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