warning FORD E SERIES 2019 Service Manual

GENERAL INFORMATION
WARNING: Extended idling at highengine speeds can produce very hightemperatures in the engine and exhaustsystem, creating the risk of fire or otherdamage.
WARNING: Do not park, idle ordrive your vehicle on dry grass or otherdry ground cover. The emission systemheats up the engine compartment andexhaust system, creating the risk of fire.
WARNING: Do not start the enginein a closed garage or in other enclosedareas. Exhaust fumes can be toxic.Always open the garage door before youstart the engine.
WARNING: Exhaust leaks mayresult in entry of harmful and potentiallylethal fumes into the passengercompartment. If you smell exhaustfumes inside your vehicle, have yourvehicle inspected immediately. Do notdrive if you smell exhaust fumes.
If you disconnect the battery, your vehiclemay exhibit some unusual drivingcharacteristics for approximately 5 mi(8 km) after you reconnect it. This isbecause the engine management systemmust realign itself with the engine. Youcan disregard any unusual drivingcharacteristics during this period.
The powertrain control system meets allCanadian interference-causing equipmentstandard requirements regulating theimpulse electrical field or radio noise.
When you start the engine, avoid pressingthe accelerator pedal before and duringoperation. Only use the accelerator pedalwhen you have difficulty starting theengine.
IGNITION SWITCH
A (accessory) - Allows the electricalaccessories, such as the radio, to operatewhile the engine is not running.
Note:Do not leave the ignition key in thisposition for too long. This could cause yourvehicle battery to lose charge.
B (lock) - Locks the gearshift lever andallows key removal.
C (off) - The ignition is off.
Note:When you switch the ignition off andleave your vehicle, do not leave your key inthe ignition. This could cause your vehiclebattery to lose charge.
D (on) - All electrical circuits areoperational and the warning lamps andindicators illuminate.
E (start) - Cranks the engine.
STARTING A GASOLINE
ENGINE
When you start the engine, the idle speedincreases, this helps to warm up theengine. If the engine idle speed does notslow down automatically, have yourvehicle checked by an authorized dealer.
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Starting and Stopping the EngineE161572
D
E
C
B
A

Before starting the engine check thefollowing:
•Make sure all occupants have fastenedtheir safety belts.
•Make sure the headlamps andelectrical accessories are off.
•Make sure the parking brake is on.
•Make sure the transmission is in park(P) or neutral (N).
•Turn the ignition key to the on position.
Note:Do not touch the accelerator pedal.
1. Fully press the brake pedal.
2. Turn the key to the start position tostart the engine. Release the key whenthe engine starts.
Note:The engine may continue crankingfor up to 15 seconds or until it starts.
Note:If you cannot start the engine on thefirst try, wait for a short period and try again.
Failure to Start
If you cannot start the engine after threeattempts, wait 10 seconds and follow thisprocedure:
1. Fully press the brake pedal.
2. Fully press the accelerator pedal andhold it there.
3. Start the engine.
Stopping the Engine When YourVehicle is Stationary
1. Shift into park (P) or neutral (N).
2. Turn the key to the off position.
3. Apply the parking brake.
Stopping the Engine When YourVehicle is Moving
WARNING: Switching off theengine when the vehicle is still movingwill result in a loss of brake and steeringassistance. The steering will not lock, buthigher effort will be required. When theignition is switched off, some electricalcircuits, including air bags, warning lampsand indicators may also be off. If theignition was turned off accidentally, youcan shift into neutral (N) and re-start theengine.
1. Put the transmission into neutral (N)and use the brakes to bring your vehicleto a safe stop.
2. When your vehicle has stopped, shiftinto park (P) or neutral (N) and switchthe ignition off.
3. Apply the parking brake.
Guarding Against Exhaust Fumes
WARNING: If you smell exhaustfumes inside your vehicle, have yourvehicle checked by your authorizeddealer immediately. Do not drive yourvehicle if you smell exhaust fumes.Carbon monoxide is present in exhaustfumes. Take precautions to avoid itsdangerous effects.
Important Ventilating Information
If you stop your vehicle and then leave theengine idling for long periods of time, werecommend that you do one of thefollowing:
•Open the windows at least 1 in (3 cm).
•Set your climate control to outside air.
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Starting and Stopping the Engine

ENGINE BLOCK HEATER (IF
EQUIPPED)
WARNING: Failure to followengine block heater instructions couldresult in property damage or seriouspersonal injury.
WARNING: Do not use your heaterwith ungrounded electrical systems ortwo-pronged adapters. There is a risk ofelectrical shock.
WARNING: Do not fully close thehood, or allow it to drop under its ownweight when using the engine blockheater. This could damage the powercable and may cause an electrical shortresulting in fire, injury and propertydamage.
Note:The heater is most effective whenoutdoor temperatures are below 0°F(-18°C).
The heater acts as a starting aid bywarming the engine coolant. This allowsthe climate control system to respondquickly. The equipment includes a heaterelement (installed in the engine block) anda wire harness. You can connect thesystem to a grounded 120-volt ACelectrical source.
We recommend that you do the followingfor a safe and correct operation:
•Use a 16-gauge outdoor extension cordthat is product certified byUnderwriter’s Laboratory (UL) orCanadian Standards Association(CSA). This extension cord must besuitable for use outdoors, in cold
temperatures, and be clearly markedSuitable for Use with OutdoorAppliances. Do not use an indoorextension cord outdoors. This couldresult in an electric shock or become afire hazard.
•Use as short an extension cord aspossible.
•Do not use multiple extension cords.
•Make sure that when in operation, theextension cord plug and heater cordplug connections are free and clear ofwater. This could cause an electricshock or fire.
•Make sure your vehicle is parked in aclean area, clear of combustibles.
•Make sure the heater, heater cord andextension cord are firmly connected.
•Check for heat anywhere in theelectrical hookup once the system hasbeen operating for approximately 30minutes.
•Make sure the system is unplugged andproperly stowed before starting anddriving your vehicle. Make sure theprotective cover seals the prongs of theblock heater cord plug when not in use.
•Make sure the heater system ischecked for proper operation beforewinter.
Using the Engine Block Heater
Make sure the receptacle terminals areclean and dry prior to use. Clean them witha dry cloth if necessary.
The heater uses 0.4 to 1.0 kilowatt-hoursof energy per hour of use. The system doesnot have a thermostat. It achievesmaximum temperature afterapproximately three hours of operation.Using the heater longer than three hoursdoes not improve system performance andunnecessarily uses electricity.
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Starting and Stopping the Engine

SAFETY PRECAUTIONS
WARNING: Do not overfill the fueltank. The pressure in an overfilled tankmay cause leakage and lead to fuel sprayand fire.
WARNING: The fuel system maybe under pressure. If you hear a hissingsound near the fuel filler inlet, do notrefuel until the sound stops. Otherwise,fuel may spray out, which could causeserious personal injury.
WARNING: Fuels can causeserious injury or death if misused ormishandled.
WARNING: Fuel may containbenzene, which is a cancer-causingagent.
WARNING: When refueling alwaysshut the engine off and never allowsparks or open flames near the fuel tankfiller valve. Never smoke or use a cellphone while refueling. Fuel vapor isextremely hazardous under certainconditions. Avoid inhaling excess fumes.
Follow these guidelines when refueling:
•Extinguish all smoking materials andany open flames before refueling yourvehicle.
•Always switch the engine off beforerefueling.
•Automotive fuels can be harmful orfatal if swallowed. Fuel is highly toxicand if swallowed can cause death orpermanent injury. If fuel is swallowedimmediately call a physician, even if nosymptoms are immediately apparent.The toxic effects of fuel may not beapparent for hours.
•Avoid inhaling fuel vapors. Inhaling fuelvapor can lead to eye and respiratorytract irritation. In severe cases,excessive or prolonged breathing offuel vapor can cause serious illness andpermanent injury.
•Avoid getting fuel in your eyes. If yousplash fuel in your eyes, immediatelyremove contact lenses (if worn), flushwith water for 15 minutes and seekmedical attention. Failure to seekproper medical attention could lead topermanent injury.
•Fuels can be harmful if absorbedthrough the skin. If you splash fuel onyour skin, clothing or both, promptlyremove contaminated clothing andthoroughly wash your skin with soapand water. Repeated or prolonged skincontact causes skin irritation.
•Be particularly careful if you are takingAntabuse or other forms of Disulfiramfor the treatment of alcoholism.Breathing fuel vapors could cause anadverse reaction, serious personalinjury or sickness. Immediately call aphysician if you experience any adversereactions.
FUEL QUALITY - E85
Choosing the Right Fuel - Flex FuelVehicles
Flex fuel vehicles have one of the followingidentifiers:
•Yellow fuel filler cap.
•Yellow bezel around the fuel filler inlet.
•Yellow fuel filler housing.
•Yellow E85 label on the fuel tank fillerdoor.
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Fuel and Refueling

If your vehicle runs out of fuel:
•Normally, adding 1.3 gal (5 L) of fuel isenough to restart the engine. If yourvehicle is on a steep grade, more fuelmay be required.
•You may need to cycle the ignition fromoff to on several times after refuelingto allow the fuel system to pump thefuel from the tank to the engine. Onrestarting, cranking time will take a fewseconds longer than normal.
Filling a Portable Fuel Container
WARNING: Flow of fuel througha fuel pump nozzle can produce staticelectricity. This can cause a fire if you arefilling an ungrounded fuel container.
Use the following guidelines to avoidelectrostatic charge build-up, which canproduce a spark, when filling anungrounded fuel container:
•Only use an approved fuel container totransfer fuel to your vehicle. Place thecontainer on the ground when filling.
•Do not fill a fuel container while it isinside your vehicle (including the cargoarea).
•Keep the fuel pump nozzle in contactwith the fuel container while filling.
•Do not use a device that holds the fuelpump nozzle lever in the fill position.
REFUELING
WARNING: Fuel vapor burnsviolently and a fuel fire can cause severeinjuries.
WARNING: Read and follow allthe instructions on the pump island.
WARNING: Turn off your enginewhen you are refueling.
WARNING: Do not smoke if youare near fuel or refueling your vehicle.
WARNING: Keep sparks, flamesand smoking materials away from fuel.
WARNING: Stay outside yourvehicle and do not leave the fuel pumpunattended when refueling your vehicle.This is against the law in some places.
WARNING: Keep children awayfrom the fuel pump; never let childrenpump fuel.
WARNING: Do not use personalelectronic devices while refueling.
WARNING: Wait at least 10seconds before removing the fuel pumpnozzle to allow any residual fuel to draininto the fuel tank.
WARNING: Stop refueling afterthe fuel pump nozzle automaticallyshuts off for the second time. Failure tofollow this will fill the expansion spacein the fuel tank and could lead to fueloverflowing.
WARNING: Do not remove the fuelpump nozzle from its fully insertedposition when refueling.
Use the following guidelines to avoidelectrostatic charge build-up when fillingan ungrounded fuel container:
•Place approved fuel container on theground.
•Do not fill a fuel container while it is inthe vehicle (including the cargo area).
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Fuel and Refueling

•Keep the fuel pump nozzle in contactwith the fuel container while filling.
•Do not use a device that would holdthe fuel pump handle in the fill position.
Fuel Filler Cap
WARNING: The fuel system maybe under pressure. If you hear a hissingsound near the fuel filler door, do notrefuel until the sound stops. Otherwise,fuel may spray out, which could causeserious personal injury.
WARNING: If you do not use theproper fuel filler cap, excessive pressureor vacuum in the fuel tank may damagethe fuel system or cause the fuel cap todisengage in a collision, which may resultin possible personal injury.
Note:If you must replace the fuel filler cap,replace it with a fuel filler cap that isdesigned for your vehicle. The customerwarranty may be void for any damage to thefuel tank or fuel system if the correctgenuine Ford, Motorcraft or other certifiedfuel filler cap is not used.
Your fuel tank filler cap has an indexeddesign with a 1/4th turn on and off feature.When fueling your vehicle:
1. Put your vehicle in park (P).
2. Switch the engine off.
3. Carefully turn the filler capcounterclockwise until it spins off.
4. Pull to remove the cap from the fuelfiller pipe.
5.To install the cap, align the tabs on thecap with the notches on the filler pipe.
6. Turn the filler cap clockwise 1/4 of aturn clockwise until it clicks at leastonce.
If the Check Fuel Cap light or a Check FuelCap message appears in the instrumentcluster and stays on after you start theengine, you may not have installed the fuelfiller properly.
If the fuel cap light remains on, at the nextopportunity, safely pull off of the road,remove the fuel filler cap, align the capproperly and reinstall it. The check fuel caplight or Check fuel cap message may notreset immediately. It may take severaldriving cycles for the indicators to turn off.A driving cycle consists of an enginestart-up (after four or more hours with theengine off) followed by normal city andhighway driving.
FUEL CONSUMPTION
Advertised Capacity
The advertised capacity is the maximumamount of fuel that you can add to the fueltank after running out of fuel. Included inthe advertised capacity is an emptyreserve. The empty reserve is anunspecified amount of fuel that remainsin the fuel tank when the fuel gaugeindicates empty.
Note:The amount of fuel in the emptyreserve varies and should not be relied uponto increase driving range.
Fuel Economy
Your vehicle calculates fuel economyfigures through the trip computer averagefuel function. See General Information(page 58).
The first 1,000 mi (1,500 km) of driving isthe break-in period of the engine. A moreaccurate measurement is obtained after2,000 mi (3,000 km).
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Fuel and Refueling

EMISSION LAW
WARNING: Do not remove or alterthe original equipment floor covering orinsulation between it and the metal floorof the vehicle. The floor covering andinsulation protect occupants of thevehicle from the engine and exhaustsystem heat and noise. On vehicles withno original equipment floor coveringinsulation, do not carry passengers in amanner that permits prolonged skincontact with the metal floor. Failure tofollow these instructions may result infire or personal injury.
U.S. federal laws and certain state lawsprohibit removing or rendering inoperativeemission control system components.Similar federal or provincial laws mayapply in Canada. We do not approve of anyvehicle modification without firstdetermining applicable laws.
Tampering with emissionscontrol systems includingrelated sensors or the DieselExhaust Fluid system can result in reducedengine power and the illumination of theservice engine soon light.
Tampering With a Noise ControlSystem
Federal laws prohibit the following acts:
•Removal or rendering inoperative byany person other than for purposes ofmaintenance.
•Repair or replacement of any device orelement of the design incorporated intoa new vehicle for the purpose of noisecontrol prior to its sale or delivery tothe ultimate purchaser or while it is inuse.
•The use of the vehicle after any personremoves or renders inoperative anydevice or element of the design.
The U.S. Environmental Protection Agencymay presume to constitute tampering asfollows:
•Removal of hood blanket, fender apronabsorbers, fender apron barriers,underbody noise shields or acousticallyabsorptive material.
•Tampering or rendering inoperative theengine speed governor, to allow enginespeed to exceed manufacturerspecifications.
If the engine does not start, runs rough,experiences a decrease in engineperformance, experiences excess fuelconsumption or produces excessiveexhaust smoke, check for the following:
•A plugged or disconnected air inletsystem hose.
•A plugged engine air filter element.
•Water in the fuel filter and waterseparator.
•A clogged fuel filter.
•Contaminated fuel.
•Air in the fuel system, due to looseconnections.
•An open or pinched sensor hose.
•Incorrect engine oil level.
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Engine Emission Control

•Incorrect fuel for climatic conditions.
•Incorrect engine oil viscosity forclimactic conditions.
Note:Some vehicles have a lifetime fuelfilter that is integrated with the fuel tank.Regular maintenance or replacement is notneeded.
Note:If these checks do not help youcorrect the concern, have your vehiclechecked as soon as possible.
Noise Emissions Warranty,Prohibited Tampering Acts andMaintenance
On January 1, 1978, Federal regulationbecame effective governing the noiseemission on trucks over 10,000 lb(4,536 kg) Gross Vehicle Weight Rating(GVWR). The preceding statementsconcerning prohibited tampering acts andmaintenance, and the noise warrantyfound in the Warranty Guide, areapplicable to complete chassis cabs over10,000 lb (4,536 kg) GVWR.
CATALYTIC CONVERTER
WARNING: Do not park, idle ordrive your vehicle on dry grass or otherdry ground cover. The emission systemheats up the engine compartment andexhaust system, creating the risk of fire.
WARNING: The normal operatingtemperature of the exhaust system isvery high. Never work around or attemptto repair any part of the exhaust systemuntil it has cooled. Use special care whenworking around the catalytic converter.The catalytic converter heats up to a veryhigh temperature after only a shortperiod of engine operation and stays hotafter the engine is switched off.
WARNING: Exhaust leaks mayresult in entry of harmful and potentiallylethal fumes into the passengercompartment. If you smell exhaustfumes inside your vehicle, have yourvehicle inspected immediately. Do notdrive if you smell exhaust fumes.
Your vehicle has various emission controlcomponents and a catalytic converter thatenables it to comply with applicableexhaust emission standards.
To make sure that the catalytic converterand other emission control componentscontinue to work properly:
•Do not crank the engine for more than10 seconds at a time.
•Do not run the engine with a spark pluglead disconnected.
•Do not push-start or tow-start yourvehicle. Use booster cables. See JumpStarting the Vehicle (page 121).
•Use only the specified fuel listed.
•Do not switch the ignition off when yourvehicle is moving.
•Avoid running out of fuel.
•Have the items listed in scheduledmaintenance information performedaccording to the specified schedule.
Note:Resulting component damage maynot be covered by the vehicle Warranty.
The scheduled maintenance items listedin scheduled maintenance information areessential to the life and performance ofyour vehicle and to its emissions system.
If you use anything other than Ford,Motorcraft or Ford-authorized parts formaintenance replacements or for serviceof components affecting emission control,such non-Ford parts should be equivalentto genuine Ford Motor Company parts inperformance and durability.
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Engine Emission Control

Illumination of the service engine soonindicator, charging system warning light orthe temperature warning light, fluid leaks,strange odors, smoke or loss of enginepower could indicate that the emissioncontrol system is not working properly.
An improperly operating or damagedexhaust system may allow exhaust toenter the vehicle. Have a damaged orimproperly operating exhaust systeminspected and repaired immediately.
Do not make any unauthorized changes toyour vehicle or engine. By law, vehicleowners and anyone who manufactures,repairs, services, sells, leases, tradesvehicles, or supervises a fleet of vehiclesare not permitted to intentionally removean emission control device or prevent itfrom working. Information about yourvehicle’s emission system is on the VehicleEmission Control Information Decallocated on or near the engine. This decalalso lists engine displacement.
Please consult your warranty informationfor complete details.
On-Board Diagnostics (OBD-II)
Your vehicle has a computer known as theon-board diagnostics system (OBD-II) thatmonitors the engine’s emission controlsystem. The system protects theenvironment by making sure that yourvehicle continues to meet governmentemission standards. The OBD-II systemalso assists a service technician in properlyservicing your vehicle.
When the service engine soonindicator illuminates, the OBD-IIsystem has detected amalfunction. Temporary malfunctions maycause the service engine soon indicator toilluminate. Examples are:
1. Your vehicle has run out of fuel—theengine may misfire or run poorly.
2. Poor fuel quality or water in thefuel—the engine may misfire or runpoorly.
3. The fuel fill inlet may not have closedproperly. See Refueling (page 80).
4. Driving through deep water—theelectrical system may be wet.
You can correct these temporarymalfunctions by filling the fuel tank withgood quality fuel, properly closing the fuelfill inlet or letting the electrical system dryout. After three driving cycles without theseor any other temporary malfunctionspresent, the service engine soon indicatorshould stay off the next time you start theengine. A driving cycle consists of a coldengine startup followed by mixed city andhighway driving. No additional vehicleservice is required.
If the service engine soon indicator remainson, have your vehicle serviced at the firstavailable opportunity. Although somemalfunctions detected by the OBD-II maynot have symptoms that are apparent,continued driving with the service enginesoon indicator on can result in increasedemissions, lower fuel economy, reducedengine and transmission smoothness andlead to more costly repairs.
Readiness for Inspection andMaintenance (I/M) Testing
Some state and provincial and localgovernments may haveInspection/Maintenance (I/M) programsto inspect the emission control equipmenton your vehicle. Failure to pass thisinspection could prevent you from gettinga vehicle registration.
If the service engine soonindicator is on or the bulb doesnot work, your vehicle may needservice. See On-Board Diagnostics.
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Engine Emission Control

AUTOMATIC TRANSMISSION
WARNING: Always fully apply theparking brake. Make sure you shift intopark (P) for vehicles with an automatictransmission. Switch the ignition off andremove the key whenever you leave yourvehicle.
Putting your vehicle in or out ofgear:
1. Fully press down the brake pedal.
2. Move the gearshift lever into thedesired gear.
3.When you are finished driving, come toa complete stop.
4. Move the gearshift lever and securelylatch it in park (P).
Park (P)
This position locks the transmission andprevents the wheels from turning.
Reverse (R)
With the transmission in reverse (R), yourvehicle moves backward. Always come toa complete stop before shifting into andout of reverse (R).
Neutral (N)
With the transmission in neutral (N), youcan start your vehicle and it is free to roll.Hold the brake pedal down when in thisposition.
Drive (D)
Drive (D) is the normal driving position forthe best fuel economy. The overdrivefunction allows automatic upshifts anddownshifts through gears one through six.
Fourth (4)
Transmission operates in fourth (4) gearonly. Used for improved traction onslippery roads.
Second (2)
Transmission operates in second (2) gearonly. Use second (2) gear to start-up onslippery roads.
First (1)
•Transmission operates in first (1) gearonly.
•Provides maximum engine braking.
•Allows upshifts by moving gearshiftlever.
•Does not downshift into first (1) gearat high speeds; allows for first (1) gearwhen vehicle reaches slower speeds.
Forced downshifts
•Allowed in drive (D) with the tow/haulfeature on or off.
•Press the accelerator to the floor.
•Allows transmission to select anappropriate gear.
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TransmissionE198819