maintenance FORD FLEX 2009 1.G Workshop Manual

If theService engine soonindicator remains on, have your vehicle
serviced at the first available opportunity. Although some malfunctions
detected by the OBD-II may not have symptoms that are apparent,
continued driving with theService engine soon
indicator on can
result in increased emissions, lower fuel economy, reduced engine and
transmission smoothness, and lead to more costly repairs.
Readiness for Inspection/Maintenance (I/M) testing
Some state/provincial and local governments may have
Inspection/Maintenance (I/M) programs to inspect the emission control
equipment on your vehicle. Failure to pass this inspection could prevent
you from getting a vehicle registration. Your vehicle may not pass the I/M
test if theService engine soon
indicator is on or not working
properly (bulb is burned out), or if the OBD-II system has determined
that some of the emission control systems have not been properly
checked. In this case, the vehicle is considered not ready for I/M testing.
If theService engine soon
indicator is on or the bulb does not
work, the vehicle may need to be serviced. Refer to the On board
diagnostics (OBD-II) description in this chapter.
If the vehicle’s engine or transmission has just been serviced, or the
battery has recently run down or been replaced, the OBD-II system may
indicate that the vehicle is not ready for I/M testing. To determine if the
vehicle is ready for I/M testing, turn the ignition key to the on position
for 15 seconds without cranking the engine. If theService engine
soon
indicator blinks eight times, it means that the vehicle is not
ready for I/M testing; if theService engine soon
indicator stays on
solid, it means that the vehicle is ready for I/M testing.
The OBD-II system is designed to check the emission control system
during normal driving. A complete check may take several days. If the
vehicle is not ready for I/M testing, the following driving cycle consisting
of mixed city and highway driving may be performed:
15 minutes of steady driving on an expressway/highway followed by
20 minutes of stop-and-go driving with at least four 30-second idle
periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete. If
the vehicle is still not ready for I/M testing, the above driving cycle will
have to be repeated.
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Owners Guide (post-2002-fmt)
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POWER STEERING FLUID
Refer to thescheduled maintenance informationfor the service
interval schedules.
1. Start the engine and let it run
until it reaches normal operating
temperature (the engine coolant
temperature gauge indicator will be
near the center of the normal area
between H and C).
2. While the engine idles, turn the
steering wheel left and right several
times.
3. Turn the engine off.
4. Check the fluid level in the reservoir. It should be between the MIN
and MAX lines. Do not add fluid if the level is in this range.
5. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the range between the MIN and MAX lines. Be
sure to put the cap back on the reservoir. Refer toMaintenance
product specifications and capacitiesin this chapter for the proper
fluid type.
BRAKE FLUID
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels between the “MIN” and
“MAX” lines are within the normal
operating range; there is no need to
add fluid. If the fluid levels are
outside of the normal operating
range the performance of the
system could be compromised; seek
service from your authorized dealer
immediately.
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Owners Guide (post-2002-fmt)
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TRANSMISSION FLUID
Checking automatic transmission fluid
Refer to yourscheduled maintenance informationfor scheduled
intervals for fluid checks and changes. Your transmission does not
consume fluid. However, the fluid level should be checked if the
transmission is not working properly, i.e., if the transmission slips or
shifts slowly or if you notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is warmed up
(approximately 20 miles [30 km]). If your vehicle has been
operated for an extended period at high speeds, in city traffic
during hot weather or pulling a trailer, the vehicle should be
turned off for about 30 minutes to allow fluid to cool before
checking.
1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated areas for normal operating temperature.
Low fluid level
Do not drive the vehicle if the fluid
level is in the add range or does not
show at all on the dipstick.
Correct fluid level
The transmission fluid should be checked at normal operating
temperature 149°F (65°C) on a level surface. The normal operating
temperature can be reached after approximately 20 miles (30 km) of
driving.
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Owners Guide (post-2002-fmt)
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Maintenance and Specifications
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The transmission fluid should be
within the cross-hatch area if at
normal operating temperature 149°F
(65°C).
High fluid level
Fluid levels above the safe range
may result in transmission failure.
An overfill condition of transmission
fluid may cause shift and/or
engagement concerns and/or possible damage.
High fluid levels can be caused by an overheating condition.
Adjusting automatic transmission fluid levels
Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick and also in the
Maintenance product specifications and capacitiessection in this
chapter.
Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.
If necessary, add fluid in 1/2 pint
(250 ml) increments through the
filler tube until the level is correct.
If an overfill occurs, excess fluid
should be removed by an authorized
dealer.
An overfill condition of
transmission fluid may cause shift and/or engagement concerns
and/or possible damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
AIR FILTER
Refer toscheduled maintenance informationfor the appropriate
intervals for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer toMotorcraft part numbersin this chapter.
2009 Flex(471)
Owners Guide (post-2002-fmt)
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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.
Changing the air filter element
1. Release the clamps that secure
the air filter housing cover.
2. Carefully separate the two halves
of the air filter housing.
3. Remove the air filter element
from the air filter housing.
4. Wipe the air filter housing and
cover clean to remove any dirt or
debris and to ensure good sealing.
5. Install a new air filter element. Be
careful not to crimp the filter element edges between the air filter
housing and cover. This could cause filter damage and allow unfiltered
air to enter the engine if not properly seated.
6. Replace the air filter housing
cover and secure the clamps. Be
sure that the air cleaner cover tabs
are engaged into the slots of the air
cleaner housing.
Note:Failure to use the correct air filter element may result in severe
engine damage. The customer warranty may be void for any damage to
the engine if the correct air filter element is not used.
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Owners Guide (post-2002-fmt)
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MOTORCRAFT PART NUMBERS
Component 3.5L V6 Engine
Engine air filter element FA-1884
Battery BXT-65–750
Oil filter FL-400-S
PCV valve EV-257
1
Spark plugs SP-4112
1
The PCV valve is a critical emission component. It is one of the items
listed inscheduled maintenance informationand is essential to the
life and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your authorized dealer. Refer to
scheduled maintenance informationfor the appropriate intervals for
changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.
2For spark plug replacement, see your authorized dealer. Refer to
scheduled maintenance informationfor the appropriate intervals for
changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
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Owners Guide (post-2002-fmt)
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MAINTENANCE PRODUCT SPECIFICATIONS AND CAPACITIES
Items CapacityFord Part Name or
equivalentFord Part Number /
Ford Specification
Brake fluidBetween MAX and
MIN on reservoirMotorcraft High
Performance DOT 3
Motor Vehicle Brake
FluidPM-1-C /
WSS-M6C62-A or
WSS-M6C65-A1
Door latch, hood latch,
auxiliary hood latch,
seat tracks, trunk and
liftgate latches— Multi-Purpose GreaseXG-4 or XL-5 /
ESA-M1C93-B
Lock cylinders —Motorcraft Penetrating
and Lock LubricantXL-1 /
None
Automatic transmission
fluid10.0 quarts
(9.5L)
1
Motorcraft
MERCON
VATF
2
XT-5-QM /
MERCON
V
Rear differential fluid
(AWD)2.4 pints (1.15L)Motorcraft SAE 80W-90
Premium Rear Axle
LubricantXY-80W90-QL /
WSP-M2C197-A
Power Transfer Unit
(PTU) fluid (AWD)
5
18 ounces (0.53L)Motorcraft SAE 75W-140
Synthetic Rear Axle
LubricantXY-75W140-QL /
WSL-M2C192-A
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Items CapacityFord Part Name or
equivalentFord Part Number /
Ford Specification
Engine oil 5.5 quarts (5.2L)Motorcraft SAE 5W-20
Premium Synthetic
Blend Motor Oil (US)
Motorcraft SAE 5W-20
Super Premium Motor
Oil (Canada)
4
XO-5W20-QSP (US)
CXO-5W20-LSP12
(Canada) /
WSS-M2C930-A and API
Certification Mark
Engine coolant (with
rear heater)13.2 quarts
(12.5L)Motorcraft Premium
Gold Engine Coolant
with bittering agent
(yellow-colored)
3
VC-7-B /
WSS-M97B51-A1
Power steering fluidBetween MAX and
MIN on reservoirMotorcraft
MERCON
VATFXT-5-QM /
MERCON
V
Fuel tank18.6 gallons
(70.4 L)——
Windshield washer fluidTop- off fluid as
neededMotorcraft Premium
Windshield Washer
ConcentrateZC-32-A /
WSB-M8B16-A2
1Approximate dry fill capacity. Actual amount may vary during fluid changes.2Automatic transmissions that require MERCON
V should only use MERCON
V fluid. Refer to
scheduled maintenance informationto determine the correct service interval. Use of any fluid
other than the recommended fluid may cause transmission damage.3Add the coolant type originally equipped in your vehicle.4Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.5See your authorized dealer for fluid level checking or filling.
2009 Flex(471)
Owners Guide (post-2002-fmt)
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Maintenance and Specifications
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ENGINE DATA
Engine 3.5L DOHC V6 engine
Displacement 3.5L
Required fuel 87 octane
Firing order 1–4–2–5–3–6
Spark plug gap 0.052–0.056 inch (1.32–1.42 mm)
Ignition system Coil on plug
Compression ratio 10.3:1
Engine drivebelt routing
1. Short drivebelt is on first pulley groove closest to engine.
2. Long drivebelt is on second pulley groove farthest from engine.
2009 Flex(471)
Owners Guide (post-2002-fmt)
USA(fus)
Maintenance and Specifications
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IDENTIFYING YOUR VEHICLE
Safety Compliance Certification Label
The National Highway Traffic Safety
Administration Regulations require
that a Safety Compliance
Certification Label be affixed to a
vehicle and prescribe where the
Safety Compliance Certification
Label may be located. The Safety
Compliance Certification Label is
located on the structure (B-Pillar)
by the trailing edge of the driver’s
door or the edge of the driver’s
door.
Vehicle identification number (VIN)
The vehicle identification number is
located on the driver side
instrument panel.
Please note that in the graphic,
XXXX is representative of your
vehicle identification number.
XXXXXXXXXXXXXXXXX
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