light FORD E SERIES 2024 Workshop Manual

REDUCED ENGINE
PERFORMANCE
WARNING: If you continue to driveyour vehicle when the engine isoverheating, the engine could stopwithout warning. Failure to follow thisinstruction could result in the loss ofcontrol of your vehicle.
If the engine coolant temperature gaugeneedle moves to the upper limit position,the engine is overheating. See Gauges(page 58).
You must only drive your vehicle for a shortdistance if the engine overheats. Thedistance you can travel depends onambient temperature, vehicle load andterrain. The engine continues to operatewith limited power for a short period oftime.
If the engine temperature continues to rise,the fuel supply to the engine reduces. Theair conditioning switches off and the enginecooling fan operates continually.
1.Gradually reduce your speed and stopyour vehicle as soon as it is safe to doso.
2.Immediately switch the engine off toprevent severe engine damage.
3.Wait for the engine to cool down.
4.Check the coolant level. See EngineCoolant Check (page 165).
5.Have your vehicle checked as soon aspossible.
ECONOMICAL DRIVING
Fuel economy is affected by several thingssuch as how you drive, the conditions youdrive under and how you maintain yourvehicle.
There are some things to keep in mind thatmay improve fuel economy:
•Accelerate and slow down in a smooth,moderate fashion.
•Drive at reasonable and steady speeds.
•Anticipate stops.
•Minimize stop and go driving.
•Close the windows when driving athigher speed.
•Keep the tires properly inflated and useonly the recommended size.
•Use the recommended engine oil.
•Perform all regularly scheduledmaintenance.
Avoid these actions; they reduce fueleconomy:
•Sudden or hard accelerations.
•Revving the engine before turning it off.
•Idle for periods longer than one minute.
•Warm up your vehicle on coldmornings.
•Using air conditioning.
•Using speed control in hilly terrain.
•Resting your foot on the brake pedalwhile driving.
•Driving with the wheels out ofalignment.
Conditions:
•Adding certain accessories to yourvehicle may reduce fuel economy. Forexample, bug deflectors, rollbars, lightbars, running boards, ski racks orluggage racks.
•Using fuel blended with alcohol maylower fuel economy.
•Fuel economy may decrease with lowertemperatures during the first 5–10 mi(12–16 km) of driving.
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•Driving on flat terrain offers improvedfuel economy as compared to drivingon hilly terrain.
•Transmissions give their best fueleconomy when operated in the topcruise gear and with steady pressureon the gas pedal.
BREAKING-IN
You need to break in new tires forapproximately 300 mi (480 km). Duringthis time, your vehicle may exhibit someunusual driving characteristics.
Avoid driving too fast during the first1,000 mi (1,600 km). Vary your speedfrequently and change up through thegears early. Do not labor the engine.
Do not tow during the first 1,000 mi(1,600 km).
DRIVING THROUGH WATER
WARNING: Do not drive throughflowing or deep water as you may losecontrol of your vehicle.
Note:Driving through standing water cancause vehicle damage.
Note:Engine damage can occur if waterenters the air filter.
Before driving through standing water,check the depth. Never drive through waterthat is higher than the bottom of the wheelhubs.
When driving through standing water, drivevery slowly and do not stop your vehicle.Your brake performance and traction maybe limited. After driving through water andas soon as it is safe to do so:
•Lightly press the brake pedal to dry thebrakes and to check that they work.
•Check that the horn works.
•Check that the exterior lights work.
•Turn the steering wheel to check thatthe steering power assist works.
FLOOR MATS
WARNING: Use a floor matdesigned to fit the footwell of yourvehicle that does not obstruct the pedalarea. Failure to follow this instructioncould result in the loss of control of yourvehicle, personal injury or death.
WARNING: Pedals that cannotmove freely can cause loss of vehiclecontrol and increase the risk of seriouspersonal injury.
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HAZARD FLASHERS
Note:If used when the vehicle is notrunning, the battery loses charge. As a result,there may be insufficient power to restartyour vehicle.
The hazard flasher control is located onthe instrument panel. Use it when yourvehicle is creating a safety hazard for othermotorists.
•Press the flasher control and all frontand rear direction indicators flash.
•Press the flasher control again toswitch them off.
JUMP STARTING THE VEHICLE
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 correct ventilation.
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: Use only adequatelysized cables with insulated clamps.
Preparing Your Vehicle
Do not attempt to push-start yourautomatic transmission vehicle.
Note:Attempting to push-start a vehiclewith an automatic transmission may causetransmission damage.
Note:Use only a 12-volt supply to start yourvehicle.
Note:Do not disconnect the battery of thedisabled vehicle as this could damage thevehicle electrical system.
Park the booster vehicle close to the hoodof the disabled vehicle, making sure thetwo vehicles do not touch.
Connecting the Jumper Cables
WARNING: Do not connect thenegative jumper cable to any other partof your vehicle. Use the ground point.
WARNING: Make sure that thecables are clear of any moving parts andfuel delivery system parts.
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WARNING: To reduce the risk ofpersonal injury, make sure the engine iscool before unscrewing the coolantpressure relief cap. The cooling systemis under pressure. Steam and hot liquidcan come out forcefully when you loosenthe cap slightly.
When the engine is cold, check theconcentration and level of the coolant atthe intervals listed in the scheduledmaintenance information. See ScheduledMaintenance (page 249).
Note:Make sure that the coolant level isbetween the MIN and MAX marks on thecoolant reservoir.
Note:Coolant expands when it is hot. Thelevel may extend beyond the MAX mark.
Maintain coolant concentration within48% to 50%, which equates to a freezepoint between -29°F (-34°C) and -35°F(-37°C). Use a refractometer to checkcoolant concentration. Do not usehydrometers or coolant test strips formeasuring coolant concentration.
Adding Coolant
WARNING: Do not add coolantwhen the vehicle is on or the coolingsystem is hot. Failure to follow thisinstruction could 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.
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 add coolantfurther than the MAX mark.
Note: Automotive fluids are notinterchangeable. Do not use coolant orwindshield washer fluid outside of itsspecified function and vehicle location.
Note:Do not use stop leak pellets, coolingsystem sealants, or non-specified additivesas they can cause damage to the enginecooling or heating systems. Resultingcomponent damage may not be covered bythe vehicle warranty.
Always use prediluted coolant approvedto the correct specification to avoidplugging the small passageways in theengine cooling system. See Capacitiesand Specifications (page 226). Do notmix different colors or types of coolant inyour vehicle. Mixing of engine coolants orusing an incorrect coolant may harm theengine or cooling system components andmay not be covered by the vehiclewarranty.
Note:If prediluted coolant is not available,use the approved concentrated coolantdiluting it to 50/50 with distilled water. SeeCapacities and Specifications (page 226).Using water that has not been deionizedmay contribute to deposit formation,corrosion and plugging of the small coolingsystem passageways.
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Note:Coolants marketed for all makes andmodels may not be approved to Fordspecifications and may damage the coolingsystem. Resulting component damage maynot be covered by the vehicle warranty.
If the coolant level is at or below theminimum mark, add prediluted coolantimmediately.
Top up the coolant level as follows:
1.Unscrew the cap slowly. Any pressureescapes as you unscrew the cap.
2.Add prediluted coolant approved tothe correct specification. SeeCapacities and Specifications (page226).
3.Add enough prediluted coolant toreach the correct level.
4.Replace the coolant reservoir cap. Turnthe cap clockwise until it contacts thehard stop.
5.Check the coolant level the next fewtimes you drive your vehicle. Ifnecessary, add enough predilutedengine coolant to bring the coolantlevel to the correct level.
If you have to add more than 1.1 qt (1 L) ofengine coolant per month, have yourvehicle checked as soon as possible.Operating an engine with a low coolantlevel can result in engine overheating andpossible engine damage.
Note:During normal vehicle operation, thecoolant may change color, and slightlydarken. As long as the coolant is clear anduncontaminated, this color change does notindicate the coolant has degraded nor doesit require the coolant to be drained, thesystem to be flushed, or the coolant to bereplaced.
In case of emergency, you can add a largeamount of water without coolant to reacha vehicle service location. In this instance,qualified personnel:
1.Must drain the cooling system.
2.Chemically clean the coolant system.
3.Refill with coolant that meets thecorrect specification. See Capacitiesand Specifications (page 226).
Water alone, without coolant, can causeengine damage from corrosion,overheating or freezing.
Do not use the following as a coolantsubstitute:
•Alcohol.
•Methanol.
•Brine.
•Any coolant mixed with alcohol ormethanol antifreeze.
Alcohol and other liquids can cause enginedamage from overheating or freezing.
Do not add extra inhibitors or additives tothe coolant. These can be harmful andcompromise the corrosion protection ofthe coolant.
Recycled Coolant
We do not recommend the use of recycledcoolant as an approved recycling processis not yet available.
Dispose of used engine coolant in anappropriate manner.
Follow your community's regulations andstandards for recycling and disposing ofautomotive fluids.
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Only use fluid that meets ourspecifications. See Capacities andSpecifications (page 226).
Brake Fluid Service Interval
Brake fluid absorbs water over time whichdegrades the effectiveness of the brakefluid. Change the brake fluid at thespecified intervals to prevent degradedbraking performance.
For detailed interval information, seeScheduled Maintenance in your Owner'sManual or your local maintenance guide.
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.
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 Hydraulic PowerSteering Fluid Capacity andSpecification (page 236).
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.
CHANGING THE 12V BATTERY
WARNING: This vehicle may havemore than one battery. Removing thebattery cables from only one batterydoes not disconnect your vehicleelectrical system. Make sure youdisconnect the battery cables from allbatteries when disconnecting power.Failure to do so may cause seriouspersonal injury or property 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 correct ventilation.
WARNING: When lifting aplastic-cased battery, excessive pressureon the end walls could cause acid to flowthrough the vent caps, resulting inpersonal injury and damage to thevehicle or battery. Lift the battery with abattery carrier or with your hands onopposite corners.
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1.Park the vehicle directly in front of awall or screen on a level surface,approximately 25 ft (7.6 m) away.
2.Measure the height of the headlampbulb center from the ground and markan 8 ft (2.4 m) horizontal reference lineon the vertical wall or screen at thisheight.
Note:To see a clearer light pattern foradjusting, you may want to block the lightfrom one headlamp while adjusting theother.
3.Turn on the low beam headlamps toilluminate the wall or screen and openthe hood.
4.On the wall or screen, you will observea flat zone of high intensity lightlocated at the top of the right handportion of the beam pattern. If the topedge of the high intensity light zone isnot at the horizontal reference line, youwill need to adjust the headlamp.
5.Locate the vertical adjuster on eachheadlamp. Using a Phillips #2screwdriver, turn the adjuster eitherclockwise or counterclockwise in orderto adjust the vertical aim of theheadlamp.
6.Repeat steps 3 through 5 to adjust theother headlamp.
7.Close the hood and switch off thelamps.
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 226).
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CLEANING THE EXTERIOR
Wash your vehicle regularly with cool orlukewarm water and a neutral pHshampoo, we recommend MotorcraftDetail Wash.
•Never use strong household detergentsor soap, for example dish washing orlaundry liquid. These products candiscolor and spot painted surfaces.
•Never wash your vehicle when it is hotto the touch, or during strong or directsunlight.
•Dry your vehicle with a chamois or softterry cloth towel to eliminate waterspotting.
•Immediately remove fuel spillages, birddroppings, insect deposits and road tar.These may cause damage to yourvehicle’s paintwork or trim over time.We recommend Motorcraft Bug andTar Remover.
•Remove any exterior accessories, forexample antennas, before entering acar wash.
•When filling with AdBlue®, remove anyresidue on painted surfacesimmediately.
Note:Suntan lotions and insect repellentscan damage painted surfaces. If thesesubstances come in contact with yourvehicle, wash the affected area as soon aspossible.
Cleaning the Exterior Precautions
Immediately remove fuel spillages, AdBlueresiduals, bird droppings, insect depositsand road tar. These may cause damage toyour vehicle’s paintwork or trim over time.
Remove any exterior accessories, forexample antennas, before entering a carwash.
Cleaning the Exterior Lamps
Note:Do not scrape the exterior lampslenses or use abrasives, alcoholic solventsor chemical solvents to clean them.
Note:Do not wipe the exterior lamps whenthey are dry.
Exterior Chrome Parts
•Apply a high quality-cleaning productto bumpers and other chrome parts.Follow the manufacturer’s instructions.We recommend Motorcraft CustomBright Metal Cleaner.
•Do not apply the cleaning product tohot surfaces. Do not leave the cleaningproduct on chrome surfaces longerthan the time recommended.
•Using non-recommended cleaners canresult in severe and permanentcosmetic damage.
Note:Never use abrasive materials, forexample steel wool or plastic pads as theycan scratch the chrome surface.
Note:Do not use chrome cleaner, metalcleaner or polish on wheels or wheel covers.
Exterior Plastic Parts
For routine cleaning we recommendMotorcraft Detail Wash. If tar or greasespots are present, we recommendMotorcraft Bug and Tar Remover.
Stripes or Graphics (If Equipped)
Hand washing your vehicle is preferredhowever, pressure washing may be usedunder the following conditions:
•Do not use water pressure higher than2,000 psi (14,000 kPa).
•Do not use water hotter than 179°F(82°C).
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•Use a spray with a 40 degree widespray angle pattern.
•Keep the nozzle at a 12 in (305 mm)distance and 90 degree angle to yourvehicle's surface.
Note:Holding the pressure washer nozzleat an angle to the vehicle's surface maydamage graphics and cause the edges topeel away from the vehicle's surface.
Underbody
Regularly clean the entire underside of yourvehicle. This includes the chassis, bodyfloor sheet metal and wheel wells usingfresh water. Keep body and door drainholes free of debris or foreign material.
Under Hood
For removing black rubber marks fromunder the hood we recommend MotorcraftWheel and Tire Cleaner or Motorcraft Bugand Tar Remover.
WAXING
Regular waxing is necessary to protect yourcar's paint from the elements. Werecommend that you wash and wax thepainted surface once or twice a year.
When washing and waxing, park yourvehicle in a shaded area out of directsunlight. Always wash your vehicle beforeapplying wax.
•Use a quality wax that does not containabrasives.
•Follow the manufacturer’s instructionsto apply and remove the wax.
•Apply a small amount of wax in aback-and-forth motion, not in circles.
•Do not allow wax to come in contactwith any non-body (low-gloss black)colored trim. The wax will discolor orstain the parts over time.
•Roof racks.
•Bumpers.
•Grained door handles.
•Side moldings.
•Mirror housings.
•Windshield cowl area.
•Do not apply wax to glass areas.
•After waxing, your car's paint shouldfeel smooth, and be free of streaks andsmudges.
CLEANING THE ENGINE
Engines are more efficient when they areclean because grease and dirt buildup keepthe engine warmer than normal.
When washing:
•Take care when using a power washerto clean the engine. The high-pressurefluid could penetrate the sealed partsand cause damage.
•Do not spray a hot engine with coldwater to avoid cracking the engineblock or other engine components.
•Spray Motorcraft Engine Shampoo andDegreaser on all parts that requirecleaning and pressure rinse clean. InCanada, use Motorcraft EngineShampoo.
Note:If your vehicle has an engine coverremove the cover before application ofMotorcraft Engine Shampoo and Degreaser.Immediately rinse away any over spray.
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•Never wash or rinse the engine while itis hot or running; water in the runningengine may cause internal damage.
•Never wash or rinse any ignition coil,spark plug wire or spark plug well, orthe area in and around these locations.
•Cover the battery, power distributionbox, and air filter assembly to preventwater damage when cleaning theengine.
CLEANING THE WINDOWS AND
WIPER BLADES
Car wash chemicals and environmentalfallout can result in windshield and wiperblade contamination. Dirty windshield andwipers will result in poor windshield wiperoperation. Keep the windshield and wiperblades clean to maintain windshield wiperperformance.
To clean the windshield and wiper blades:
•Clean the windshield with anon-abrasive glass cleaner. Whencleaning the interior of the windshield,avoid getting any glass cleaner on theinstrument panel or door panels. Wipeany glass cleaner off these surfacesimmediately.
•For windshields contaminated withtree sap, chemicals, wax or bugs, cleanthe entire windshield using steel wool(no greater than 0000 grade) in acircular motion and rinse with water.
•Clean the wiper blades with isopropylrubbing alcohol or windshield washerconcentrate.
Note: Do not use razor blades or othersharp objects to clean or remove decalsfrom the inside of the heated rear window.The vehicle warranty does not coverdamage caused to the heated rear windowgrid lines.
CLEANING THE INTERIOR
WARNING: Do not use cleaningsolvents, bleach or dye on the vehicle'sseatbelts, as these actions may weakenthe belt webbing.
WARNING: On vehicles equippedwith seat-mounted airbags, do not usechemical solvents or strong detergents.Such products could contaminate theside airbag system and affectperformance of the side airbag in a crash.
For fabric, carpets, cloth seats and seatsequipped with side airbags:
•Remove dust and loose dirt with avacuum cleaner.
•Remove light stains and soil withMotorcraft Professional StrengthCarpet & Upholstery Cleaner.
•If grease or tar is present on thematerial, spot-clean the area first withMotorcraft Spot and Stain Remover. InCanada, use Motorcraft Multi-PurposeCleaner.
•If a ring forms on the fabric after spotcleaning, clean the entire areaimmediately (but do not oversaturate)or the ring will set.
•Do not use household cleaningproducts or glass cleaners, which canstain and discolor the fabric and affectthe flame retardant abilities of the seatmaterials.
Mirrors
Do not clean the housing or glass of anymirror with harsh abrasives, fuel or otherpetroleum or ammonia-based cleaningproducts.
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