brake FORD E SERIES 2019 Service Manual

Protected ComponentFuse RatingFuse or RelayNumber
Ignition switch feed.20A27
Audio mute (start).5A28
Cluster (except stripped chassis).5A29
Not used (spare).5A30
Not used (spare).10A31
Restraints module.10A32
Trailer brake controller.10A33
Not used (spare).5A34
Cutaway run/start.10A35
Passive anti-theft system radio frequencymodule.5A36
Climate control.10A37Stripped chassis #1 run/start.
Not used (spare).20A38
Radio.20A39
Not used (spare).20A40
Radio.15A41Switch illumination.Automatic dimming rear view mirror.Power inverter.
Auxiliary switch.10A42
Stripped chassis instrument panelconnector #1.10A43
Trailer tow battery charge relay.10A44
Wipers.5A45Stripped chassis engine connector 3.
Passenger airbag deactivation indicator.7.5A46
Windows accessory delay circuit breaker.30A47
Delayed accessory relay.—48
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GENERAL INFORMATION
Have your vehicle serviced regularly to helpmaintain its roadworthiness and resalevalue. There is a large network ofauthorized dealers that are there to helpyou with their professional servicingexpertise. We believe that their speciallytrained technicians are best qualified toservice your vehicle properly and expertly.They are supported by a wide range ofhighly specialized tools developedspecifically for servicing your vehicle.
If your vehicle requires professional service,an authorized dealer can provide thenecessary parts and service. Check yourwarranty information to find out whichparts and services are covered.
Use only recommended fuels, lubricants,fluids and service parts conforming tospecifications. Motorcraft® parts aredesigned and built to provide the bestperformance in your vehicle.
Precautions
•Do not work on a hot engine.
•Make sure that nothing gets caught inmoving parts.
•Do not work on a vehicle with theengine running in an enclosed space,unless you are sure you have enoughventilation.
•Keep all open flames and other burningmaterial (such as cigarettes) awayfrom the battery and all fuel relatedparts.
Working with the Engine Off
1. Set the parking brake and shift thetransmission to park (P).
2. Switch off the engine.
3. Block the wheels.
Working with the Engine On
WARNING: To reduce the risk ofvehicle damage and personal burninjuries, do not start your engine with theair cleaner removed and do not removeit while the engine is running.
1. Set the parking brake and shift thetransmission to park (P).
2. Block the wheels.
OPENING AND CLOSING THE
HOOD
1.Inside the vehicle, pull the hood releasehandle located under the bottom leftcorner of the instrument panel.
2.Go to the front of the vehicle and pushthe auxiliary latch, located in the centerof the top grille, to the left in order torelease the hood.
3. Lift the hood and secure it with theprop rod.
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UNDER HOOD OVERVIEW
Windshield washer fluid reservoir. See Washer Fluid Check (page 153).A
Engine oil filler cap. See Engine Oil Check (page 143).B
Automatic transmission fluid dipstick. See Automatic Transmission FluidCheck (page 149).C
Air filter assembly. See Changing the Engine Air Filter (page 159).D
Engine oil dipstick. See Engine Oil Dipstick (page 143).E
Brake fluid reservoir. See Brake Fluid Check (page 152).F
Engine coolant reservoir. See Engine Coolant Check (page 144).G
Engine compartment fuse box. See Changing a Fuse (page 139).H
Power steering fluid reservoir. See Power Steering Fluid Check (page 152).I
Battery. See Changing the 12V Battery (page 153).J
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ENGINE OIL DIPSTICK
MINA
MAXB
ENGINE OIL CHECK
To check the engine oil level consistentlyand accurately, do the following:
1.Make sure the parking brake is on. Makesure the transmission is in park (P) orneutral (N).
2. Run the engine until it reaches normaloperating temperature.
3. Make sure that your vehicle is on levelground.
4. Switch the engine off and wait 15minutes for the oil to drain into the oilpan. Checking the engine oil level toosoon after you switch the engine offmay result in an inaccurate reading.
5. Open the hood. See Opening andClosing the Hood (page 141).
6. Remove the dipstick and wipe it witha clean, lint-free cloth. See UnderHood Overview (page 142).
7. Replace the dipstick and remove itagain to check the oil level. SeeEngine Oil Dipstick (page 143).
8.Make sure that the oil level is betweenthe maximum and minimum marks. Ifthe oil level is at the minimum mark,add oil immediately. See Capacitiesand Specifications (page 203).
9. If the oil level is correct, replace thedipstick and make sure it is fully seated.
Note:Do not remove the dipstick when theengine is running.
Note: If the oil level is between themaximum and minimum marks, the oil levelis acceptable. Do not add oil.
Note:The oil consumption of new enginesreaches its normal level after approximately3,100 mi (5,000 km).
Adding Engine Oil
WARNING: Do not remove thefiller cap when the engine is running.
Do not use supplemental engine oiladditives because they are unnecessaryand could lead to engine damage that maynot be covered by the vehicle Warranty.
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AB E142732

Only use oils certified for gasoline enginesby the American Petroleum Institute (API).An oil with this trademark symbolconforms to the current engine andemission system protection standards andfuel economy requirements of theInternational Lubricants SpecificationAdvisory Committee (ILSAC).
To top up the engine oil level do thefollowing:
1. Clean the area surrounding the engineoil filler cap before you remove it.
2. Remove the engine oil filler cap. SeeUnder Hood Overview (page 142).Turn it counterclockwise and removeit.
3. Add engine oil that meets Fordspecifications. See Capacities andSpecifications (page 203). You mayhave to use a funnel to pour the engineoil into the opening.
4. Recheck the oil level.
5. If the oil level is correct, replace thedipstick and make sure it is fully seated.
6. Replace the engine oil filler cap. Turnit clockwise until you feel a strongresistance.
Note: Do not add oil further than themaximum mark. Oil levels above themaximum mark may cause engine damage.
Note:Make sure you install the oil filler capcorrectly.
Note:Soak up any spillage with anabsorbent cloth immediately.
OIL CHANGE INDICATOR
RESET
Resetting the Oil Life MonitoringSystem
Only reset the oil life monitoring systemafter changing the engine oil and oil filter.
To reset the oil life monitoring system dothe following:
1.Switch the ignition on. Do not start theengine.
2. Fully press the accelerator and brakepedals at the same time.
3.Keep the accelerator and brake pedalsfully pressed.
4. After three seconds, a messagedisplays confirming the reset procedureis in progress.
5. After 25 seconds, a message displaysconfirming the reset procedure iscomplete.
6. Release the accelerator and brakepedals.
7. Switch the ignition off.
ENGINE COOLANT CHECK
WARNING: Do not remove thecoolant reservoir cap when the engine ison or the cooling system is hot. Wait 10minutes for the cooling system to cooldown. Cover the coolant reservoir capwith a thick cloth to prevent thepossibility of scalding and slowly removethe cap. Failure to follow this instructioncould result in personal injury.
WARNING: Do not put coolant inthe windshield washer reservoir. Ifsprayed on the windshield, coolant couldmake it difficult to see through thewindshield.
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Severe Climates
If you drive in extremely cold climates:
•It may be necessary to increase thecoolant concentration above 50%.
•A coolant concentration of 60%provides improved freeze pointprotection. Coolant concentrationsabove 60% decrease the overheatprotection characteristics of thecoolant and may cause enginedamage.
If you drive in extremely hot climates:
•You can decrease the coolantconcentration to 40%.
•Coolant concentrations below 40%decrease the freeze and corrosionprotection characteristics of thecoolant and may cause enginedamage.
Vehicles driven year-round in non-extremeclimates should use prediluted coolant foroptimum cooling system and engineprotection.
Coolant Change
At specific mileage intervals, as listed inthe scheduled maintenance information,the coolant should be changed. Addprediluted coolant approved to the correctspecification. See Capacities andSpecifications (page 198).
Fail-Safe Cooling
Fail-safe cooling allows you to temporarilydrive your vehicle before any incrementalcomponent damage occurs. The fail-safedistance depends on ambienttemperature, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, thecoolant temperature gauge moves towardthe red zone:
A warning lamp illuminates anda message may appear in theinformation display.
If the engine reaches a presetover-temperature condition, the engineautomatically switches to alternatingcylinder operation. Each disabled cylinderacts as an air pump and cools the engine.
When this occurs, your vehicle stilloperates, however:
•Engine power is limited.
•The air conditioning system turns off.
Continued operation increases the enginetemperature, causing the engine tocompletely shut down. Your steering andbraking effort increases in this situation.
When the engine temperature cools, youcan re-start the engine. Have your vehiclechecked as soon as possible to minimizeengine damage.
When Fail-Safe Mode Is Activated
WARNING: Fail-safe mode is foruse during emergencies only. Operateyour vehicle in fail-safe mode only aslong as necessary to bring your vehicleto rest in a safe location and seekimmediate repairs. When in fail-safemode, your vehicle will have limitedpower, will not be able to maintainhigh-speed operation, and maycompletely shut down without warning,potentially losing engine power, powersteering assist, and power brake assist,which may increase the possibility of acrash resulting in serious injury.
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1. Pull off the road as soon as safelypossible and shift the transmission intopark (P).
2. Leave the engine running until thecoolant temperature gauge needlereturns to the normal position. If thetemperature does not drop afterseveral minutes, follow the remainingsteps.
3.Switch the engine off and wait for it tocool. Check the coolant level.
4. If the coolant level is at or below theminimum mark, immediately addprediluted coolant.
5. If the coolant level is normal, restartthe engine and continue driving.
AUTOMATIC TRANSMISSION
FLUID CHECK
Have an authorized dealer check andchange the transmission fluid and filter atthe correct service interval. SeeScheduled Maintenance (page 276).
Do not use supplemental transmissionfluid additives, treatments or cleaningagents. The use of these materials mayaffect transmission operation and resultin damage to internal transmissioncomponents.
Checking Automatic TransmissionFluid
For scheduled intervals of the fluid checksand changes, See ScheduledMaintenance (page 276). Yourtransmission does not consume fluid.However, the fluid level should be checkedif the transmission is not working properly,i.e., if the transmission slips or shifts slowlyor if you notice some sign of fluid leakage.
Automatic transmission fluid expandswhen warmed. To obtain an accurate fluidcheck, drive the vehicle until it is at normaloperating temperature (approximately19 mi (30 km)). Verify that thetransmission fluid temperature gauge,located on the instrument cluster, is withinnormal range.
1. Drive the vehicle 19 mi (30 km) until itreaches normal operating temperature.
2.Park the vehicle on a level surface andengage the parking brake.
3.With the engine running, parking brakeengaged and your foot on the brakepedal, move the gearshift lever throughall of the gear ranges. Allow sufficienttime for each gear to engage.
4. Put the transmission in park (P) andleave the engine running.
5. Remove the dipstick, wiping it cleanwith a clean, dry lint free rag. Ifnecessary, refer to the Under HoodOverview in this chapter for thelocation of the dipstick.
6.Install the dipstick making sure it is fullyseated in the filler tube.
7. Remove the dipstick and inspect thefluid level. The fluid should be in thedesignated area for normal operatingtemperature or ambient temperature.
Low Fluid Level
Type A
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Do not use supplemental transmissionfluid additives, treatments or cleaningagents. The use of these materials mayaffect transmission operation and resultin damage to internal transmissioncomponents.
Automatic Transmission FluidFilter
Your automatic transmission is equippedwith a serviceable transmission fluid filterlocated inside the transmission bottompan. For service intervals for the automatictransmission fluid and transmission filter,See Scheduled Maintenance (page 276).
For transmission filter maintenance, seeyour authorized dealer.
BRAKE FLUID CHECK
WARNING: Do not use any fluidother than the recommended brake fluidas this will reduce brake efficiency. Useof incorrect fluid could result in the lossof vehicle control, serious personal injuryor death.
WARNING: Only use brake fluidfrom a sealed container. Contaminationwith dirt, water, petroleum products orother materials may result in brakesystem damage or failure. Failure toadhere to this warning could result in theloss of vehicle control, serious personalinjury or death.
WARNING: Do not allow the fluidto touch your skin or eyes. If thishappens, rinse the affected areasimmediately with plenty of water andcontact your physician.
WARNING: A fluid level betweenthe MAX and MIN lines is within thenormal operating range and there is noneed to add fluid. A fluid level not in thenormal operating range couldcompromise the performance of thesystem. Have your vehicle checkedimmediately.
To avoid fluid contamination, the reservoircap must remain in place and fully tight,unless you are adding fluid.
Only use fluid that meets Fordspecifications. See Capacities andSpecifications (page 198).
POWER STEERING FLUID
CHECK
WARNING: A fluid level betweenthe MAX and MIN lines is within thenormal operating range and there is noneed to add fluid. A fluid level not in thenormal operating range couldcompromise the performance of thesystem.
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WARNING: For E-350 and E-450vehicles with the Hydro-Boost BrakeSystem, do not press the brake pedalafter the engine has been turned off.Pressing the brake pedal after the enginehas been turned off will give a falsepower steering fluid level reading.
Only use fluid that meets Fordspecifications. See Capacities andSpecifications (page 203).
To top up the power steering fluid level dothe following.
1. Start the engine and let it run until itreaches normal operating temperature.
2. Make sure the fluid is within the MINand MAX range.
3. If the fluid level is low, add fluid to bewithin the MIN and MAX range. Do notoverfill.
4.While the engine idles, turn the steeringwheel left and right several times.
5. Recheck the fluid level in the reservoir.
Note:Do not operate the vehicle with a lowpower steering pump fluid level.
WASHER FLUID CHECK
WARNING: If you operate yourvehicle in temperatures below 40°F(5°C), use washer fluid with antifreezeprotection. Failure to use washer fluidwith antifreeze protection in coldweather could result in impairedwindshield vision and increase the riskof injury or accident.
Add fluid to fill the reservoir if the level islow. Only use a washer fluid that meetsFord specifications. See Capacities andSpecifications (page 198).
State or local regulations on volatileorganic compounds may restrict the useof methanol, a common windshield washerantifreeze additive. Washer fluidscontaining non-methanol antifreezeagents should be used only if they providecold weather protection without damagingthe vehicle’s paint finish, wiper blades orwasher system.
CHANGING THE 12V BATTERY
WARNING: This vehicle may befitted with more than one battery,removal of cable from only one batterydoes not disconnect the vehicleelectrical system. Be sure to disconnectcables from all batteries whendisconnecting power. Failure to do somay cause serious personal injury orproperty damage.
WARNING: Batteries normallyproduce explosive gases which cancause personal injury. Therefore, do notallow flames, sparks or lightedsubstances to come near the battery.When working near the battery, alwaysshield your face and protect your eyes.Always provide proper ventilation.
WARNING: When lifting aplastic-cased battery, excessive pressureon the end walls could cause acid to flowthrough the vent caps, resulting inpersonal injury and/or damage to thevehicle or battery. Lift the battery with abattery carrier or with your hands onopposite corners.
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WARNING: Keep batteries out ofreach of children. Batteries containsulfuric acid. Avoid contact with skin,eyes or clothing. Shield your eyes whenworking near the battery to protectagainst possible splashing of acidsolution. In case of acid contact with skinor eyes, flush immediately with water fora minimum of 15 minutes and get promptmedical attention. If acid is swallowed,call a physician immediately.
WARNING: Battery posts,terminals and related accessoriescontain lead and lead compounds. Washhands after handling.
Note:If your vehicle battery has a cover,make sure it is reinstalled after the batteryhas been cleaned or replaced.
Note:Electrical or electronic accessoriesor components added to the vehicle by thedealer or the owner may adversely affectbattery performance and durability.
Your vehicle is fitted with a Motorcraft®maintenance-free battery which normallydoes not require additional water duringits life of service.
For longer, trouble-free operation, keep thetop of the battery clean and dry. Also,make certain the battery cables are alwaystightly fastened to the battery terminals.
If you see any corrosion on the battery orterminals, remove the cables from theterminals and clean with a wire brush. Youcan neutralize the acid with a solution ofbaking soda and water.
Always dispose of automotive batteries ina responsible manner. Follow your localauthorized standards for disposal. Call yourlocal authorized recycling center to findout more about recycling automotivebatteries.
Reconnecting the Battery
Because your vehicle’s engine iselectronically controlled by a computer,some control conditions are maintainedby power from the battery. When thebattery is disconnected or a new batteryis installed, the engine must relearn its idleand fuel trim strategy for optimumdriveability and performance. Flexible fuelvehicles (FFV) must also relearn theethanol content of the fuel for optimumdriveability and performance.
To begin this process.
1.Switch off all accessories and start theengine.
2. Run the engine until it reaches normaloperating temperature.
3.Allow the engine to idle for at least oneminute.
4. Turn the A/C on and allow the engineto idle for at least one minute.
5. Fully press the foot brake. Release theparking brake. Shift the gearshift leverto Drive (D) and allow the engine toidle for at least one minute.
6. Drive the vehicle for approximately10 mi (16 km) to complete therelearning process.
Note:If you do not carry out the aboveprocess, the idle quality of your vehicle maybe adversely affected until the idle trim iseventually relearned.
Flexible fuel vehicles operating on E85 mayexperience poor starts and driveabilityproblems until the fuel trim and ethanolcontent have been relearned.
When the battery is disconnected or a newbattery installed, the transmission mustlearn its adaptive strategy. As a result ofthis, the transmission may shift firmly. Thisoperation is considered normal and fullyupdates transmission operation to its
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