maintenance FORD EXCURSION 2004 1.G Owners Manual

Cleaning 213
Underbody preservation 217
Maintenance and Specifications 219
Hood 220
Engine compartment 221
Engine oil 222
Battery 225
Fuel information 233
Air filter(s) 248
Part numbers 254
Refill capacities 254
Lubricant specifications 257
Engine data 259
Vehicle dimensions 260
Accessories 263
Index 266
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Copyright © 2002 Ford Motor Company
Table of Contents
3

Notice to owners of diesel-powered vehicles
Read the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s
Guide Supplement for information regarding correct operation and
maintenance of your diesel-powered light truck.
Notice to owners of pickup trucks and utility type vehicles
Utility vehicles have a significantly higher rollover rate than
other types of vehicles.
Before you drive your vehicle, please read this Owner’s Guide carefully.
Your vehicle is not a passenger car. As with other vehicles of this type,
failure to operate this vehicle correctly may result in loss of control or an
accident.
Snowplowing
The Excursion is not recommended for snowplow installation. Ford
makes no representation as to the suitability of the Excursion for
snowplowing, in particular regarding the potential for exceeding vehicle
weight limits, airbag (SRS) deployment sensitivity, vehicle crash integrity,
or powertrain durability. The Snowplow Package Option is not available.
Middle East/North Africa vehicle specific information
For your particular global region, your vehicle may be equipped with
features and options that are different from the ones that are described
in this Owner Guide; therefore, a supplement has been supplied that
complements this book. By referring to the pages in the provided
supplement, you can properly identify those features, recommendations
and specifications that are unique to your vehicle.Refer to this Owner
Guide for all other required information and warnings.
Introduction
7

Light is blinking:
Engine misfire is occurring which could damage your catalytic converter.
You should drive in a moderate fashion (avoid heavy acceleration and
deceleration) and have your vehicle serviced at the first available
opportunity.
Under engine misfire conditions, excessive exhaust temperatures
could damage the catalytic converter, the fuel system, interior
floor coverings or other vehicle components, possibly causing a fire.
Check fuel cap (if equipped)
Illuminates when the fuel cap is not
installed correctly. Check the fuel
cap for proper installation. When
the fuel filler cap is properly
re-installed, the light(s) will turn off
after a period of normal driving.
Continuing to operate the vehicle with the check fuel cap light on, or a
mis-installed fuel cap can activate theService Engine Soon/Check
Enginewarning light.
It may take a long period of time for the system to detect an
improperly installed fuel filler cap.
For more information, refer toFuel filler capin theMaintenance and
specificationschapter.
Check gage
Illuminates when the engine coolant
temperature is high, the engine oil
pressure is low or the fuel gauge is
at or near empty. Refer toEngine
coolant temperature gauge, Engine oil pressure gaugeorFuel gauge
in this chapter for more information.
Brake system warning
To confirm the brake system warning
light is functional, it will momentarily
illuminate when the ignition is turned
to the ON position (alternatively for
some vehicles when the ignition is moved from the ON position to START
position, the light will momentarily illuminate prior to reaching the START
CHECK
GAGE
Instrument Cluster
11

Key-in-ignition warning chime
Sounds when the key is left in the ignition and the driver’s door is
opened.
Parking brake ON warning chime
Sounds when the parking brake is set, the engine is running and the
vehicle is driven more than 5 Km (3 mph).
GAUGES
Engine coolant temperature gauge
Indicates the temperature of the
engine coolant. At normal operating
temperature, the needle remains
within the normal area (the area
between the “H” and “C”). If it
enters the red section, the engine is
overheating. Stop the vehicle as
soon as safely possible, switch off
the engine immediately and let the
engine cool. Refer toEngine
coolantin theMaintenance and
specificationschapter.
Never remove the coolant reservoir cap while the engine is
running or hot. Steam and scalding liquid from a hot cooling
system can burn you badly.
This gauge indicates the temperature of the engine coolant, not the
coolant level. If the coolant is not at its proper level the gauge indication
will not be accurate.
Instrument Cluster
15

Engine oil pressure gauge
Indicates engine oil pressure. At
normal operating temperature, the
needle will be in the normal range
(the area between the “L” and “H”);
if the needle goes below the normal
range, stop the vehicle as soon as
safely possible and switch off the
engine immediately. Check the oil
level. Add oil if needed (refer to
Engine oilin theMaintenance
and specificationschapter). If the
oil level is correct, have your vehicle
checked at your dealership or by a qualified technician.
Transmission fluid temperature gauge
If the gauge is in the:
White area(normal) - the
transmission fluid is within the
normal operating temperature
(between “H” and “C”).
Yellow area(warning) — the
transmission fluid is higher than
normal operating temperature. This
can be caused by special operation
conditions (i.e. towing or off road
use). Refer toSpecial Operating
Conditionsin the scheduled
maintenance guide for instructions.
Operating the transmission for
extended periods of time with the
gauge in the yellow area may cause
internal transmission damage.
Altering the severity of the driving conditions is recommended to lower
the transmission temperature into the normal range.
Instrument Cluster
16

Failure to follow these instructions will affect the performance of
the safety belts and increase the risk of personal injury.
Safety belt pretensioner (if equipped)
Your vehicle is equipped with safety belt pretensioners at the driver and
front outboard passenger seating positions.
The Seat Integrated Restraints (SIR) seat is equipped with a buckle
pretensioner. Do NOT place objects between the seats, this could
interfere with the functioning of the pretensioner.
The safety belt pretensioners are designed to activate only during certain
frontal or near-frontal collisions with sufficient longitudinal deceleration.
A safety belt pretensioner is a device which tightens the webbing of the
lap and shoulder belts in such a way that they fit more snugly against
the body.
The driver and front outboard passenger safety belt system (including
retractors, buckles and height adjusters) must be replaced if the vehicle
is involved in a collision that results in the activation of the safety belt
pretensioners. Refer to theSafety belt maintenancesection in this
chapter.
Failure to replace the safety belt assembly under the above
conditions could result in severe personal injuries in the event of
a collision.
Front and second row safety belt height adjustment
Your vehicle has safety belt height
adjustments for the driver, front
passenger and second row outboard
passengers. Adjust the height of the
shoulder belt so the belt rests
across the middle of your shoulder.
To lower the shoulder belt height,
push the button down and slide the
height adjuster down. To raise the
height of the shoulder belt, slide the
height adjuster up. Pull down on the
height adjuster to make sure it is locked in place.
Seating and Safety Restraints
133

8. Confirmation of enabling BeltMinder is provided by flashing the safety
belt warning light four times per second for three seconds, followed by
three seconds with the safety belt warning light off, then followed by
flashing the safety belt warning light four times per second for three
seconds again.
9. After receiving confirmation, the deactivation/activation procedure is
complete.
Safety belt extension assembly
If the safety belt is too short when fully extended, there is a 20 cm (8
inch) safety belt extension assembly that can be added (part number
611C22). This assembly can be obtained from your dealer at no cost.
Use only extensions manufactured by the same supplier as the safety
belt. Manufacturer identification is located at the end of the webbing on
the label. Also, use the safety belt extension only if the safety belt is too
short for you when fully extended.
Do not use extensions to change the fit of the shoulder belt across the
torso.
Safety belt maintenance
Inspect the safety belt systems periodically to make sure they work
properly and are not damaged. Inspect the safety belts to make sure
there are no nicks, tears or cuts. Replace if necessary. All safety belt
assemblies, including retractors, buckles, front seat belt buckle
assemblies, buckle support assemblies (slide bar-if equipped), shoulder
belt height adjusters (if equipped), shoulder belt guide on seatback (if
equipped), child safety seat tether bracket assemblies (if equipped),
LATCH child seat tether anchors and lower anchors (if equipped), and
attaching hardware, should be inspected after a collision. Ford Motor
Company recommends that all safety belt assemblies used in vehicles
involved in a collision be replaced. However, if the collision was minor
and a qualified technician finds that the belts do not show damage and
continue to operate properly, they do not need to be replaced. Safety
belt assemblies not in use during a collision should also be inspected and
replaced if either damage or improper operation is noted.
Failure to inspect and if necessary replace the safety belt
assembly under the above conditions could result in severe
personal injuries in the event of a collision.
Refer toCleaning and maintaining the safety beltsin theCleaning
chapter.
Seating and Safety Restraints
139

If the air bag has deployed,the air bag will not function
again and must be replaced immediately.
If the air bag is not
replaced, the unrepaired area will increase the risk of injury in a collision.
Determining if the system is operational
The SRS uses a readiness light in the instrument cluster or a tone to
indicate the condition of the system. Refer toAir bag readinesssection
in theInstrument clusterchapter. Routine maintenance of the air bag is
not required.
A difficulty with the system is indicated by one or more of the following:
•The readiness light will either
flash or stay lit.
•The readiness light will not
illuminate immediately after
ignition is turned on.
•A series of five beeps will be heard. The tone pattern will repeat
periodically until the problem and/or light are repaired.
If any of these things happen, even intermittently, have the SRS serviced at
your dealership or by a qualified technician immediately. Unless serviced,
the system may not function properly in the event of a collision.
Disposal of air bags and air bag equipped vehicles (including
pretensioners)
For disposal of air bags or air bag equipped vehicles, see your local
dealership or qualified technician. Air bags MUST BE disposed of by
qualified personnel.
SAFETY RESTRAINTS FOR CHILDREN
See the following sections for directions on how to properly use safety
restraints for children. Also seeAir bag supplemental restraint system
(SRS)in this chapter for special instructions about using air bags.
Important child restraint precautions
You are required by law to use safety restraints for children in the U.S.
and Canada. If small children ride in your vehicle (generally children who
are four years old or younger and who weigh 18 kg [40 lbs] or less), you
must put them in safety seats made especially for children. Check your
local and state or provincial laws for specific requirements regarding the
safety of children in your vehicle.
Seating and Safety Restraints
144

Have the exhaust and body ventilation systems checked whenever:
•the vehicle is raised for service.
•the sound of the exhaust system changes.
•the vehicle has been damaged in a collision.
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. In addition, certain fluids contained in vehicles and
certain products of component wear contain or emit chemicals known
to the State of California to cause cancer and birth defects or other
reproductive harm.
Important ventilating information
If the engine is idling while the vehicle is stopped in an open area for
long periods of time, open the windows at least 2.5 cm (one inch).
Adjust the heating or air conditioning (if equipped) to bring in fresh air.
Improve vehicle ventilation by keeping all air inlet vents clear of snow,
leaves and other debris.
BRAKES
Your service brakes are self-adjusting. Refer to the scheduled
maintenance guide for scheduled maintenance.
Occasional brake noise is normal and often does not indicate a
performance concern with the vehicle’s brake system. In normal
operation, automotive brake systems may emit occasional or intermittent
squeal or groan noises when the brakes are applied. Such noises are
usually heard during the first few brake applications in the morning;
however, they may be heard at any time while braking and can be
aggravated by environmental conditions such as cold, heat, moisture,
road dust, salt or mud. If a “metal-to-metal,” “continuous grinding” or
“continuous squeal” sound is present while braking, the brake linings
may be worn-out and should be inspected by a qualified service
technician.
If you are driving down a long or steep hill, shift to a lower gear.
Do not apply your brakes continuously, as they may overheat
and become less effective.
Driving
156

Parking
On some 4WD vehicles, when the transfer case is in the N (Neutral)
position, the engine and transmission are disconnected from the rest of
the driveline. Therefore, the vehicle is free to roll even if the automatic
transmission is in P (Park) or the manual transmission is in gear. Do not
leave the vehicle unattended with the transfer case in N (Neutral)
position. Always set the parking brake fully and turn off the ignition
when leaving the vehicle.
4WD Systems
4WD (when you select a 4WD mode), uses all four wheels to power the
vehicle. This increases traction, enabling you to drive over terrain and
road conditions that a conventional two-wheel drive vehicle can’t.
Power is supplied to all four wheels
through a transfer case. On 4WD
vehicles, the transfer case allows
you to select 4WD when necessary.
Information on transfer case
operation and shifting procedures
can be found in theDriving
chapter. Information on transfer
case maintenance can be found in theMaintenance and specifications
chapter. You should become thoroughly familiar with this information
before you operate your vehicle.
Normal characteristics
On some 4WD models, the initial shift from two-wheel drive to 4x4 while
the vehicle is moving can cause some momentary clunk and ratcheting
sounds. This is the front drivetrain coming up to speed and the
automatic locking hubs engaging and is not cause for concern.
Sand
When driving over sand, try to keep all four wheels on the most solid
area of the trail. Avoid reducing the tire pressures but shift to a lower
gear and drive steadily through the terrain. Apply the accelerator slowly
and avoid spinning the wheels.
If you must reduce the tire pressure for whatever reason in sand, make
sure you re-inflate the tires as soon as possible.
Avoid excessive speed because vehicle momentum can work against you
and cause the vehicle to become stuck to the point that assistance may
be required from another vehicle. Remember, you may be able to back
out the way you came if you proceed with caution.
Driving
172