maintenance FORD FREESTAR 2004 1.G User Guide

Always transport children 12 years old and under in the back
seat and always properly use appropriate child restraints.
The passenger occupant classification sensor can automatically turn off
the passenger front air bag and side air bag (if equipped). The system is
designed to help protect small (child size) occupants from air bag
deployments when they are improperly seated or restrained in the front
passenger seat contrary to proper child-seating or restraint usage
recommendations. Even with this technology, parents areSTRONGLY
encouraged to always properly restrain children in the rear seat. The
sensor also turns off the air bag(s) when the passenger seat is empty to
prevent unnecessary replacement of the air bag(s) after a collision.
Front safety belt usage sensors
The front safety belt usage sensors detect whether or not the driver and
front outboard passenger safety belts are fastened. This information
allows your Personal Safety System to tailor the air bag deployment and
safety belt pretensioner activation depending upon safety belt usage.
Refer toSafety beltsection in this chapter.
Front safety belt pretensioners
The safety belt pretensioners at the front outboard seating positions are
designed to tighten the safety belts firmly against the occupant’s body
during a frontal or near-frontal collision. This maximizes the effectiveness
of the safety belts and helps properly position the occupant relative to
the air bag to improve protection. The safety belt pretensioners can be
either activated alone or, if the collision is of sufficient severity, together
with the air bags.
Front safety belt energy management retractors
The front outboard safety belt energy management retractors allow
webbing to be pulled out of the retractor in a gradual and controlled
manner in response to the occupant’s forward momentum. This helps
reduce the risk of force-related injuries to the occupant’s chest by
limiting the load on the occupant. Refer toEnergy management feature
section in this chapter.
Determining if the Personal Safety System is operational
The Personal Safety System uses a warning light in the instrument
cluster or a back-up tone to indicate the condition of the system. Refer
to theWarning lightsection in theInstrument clusterchapter. Routine
maintenance of the Personal Safety System is not required.
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Seating and Safety Restraints
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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, replacing 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), 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 recommends that all safety belt assemblies in use 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,
except as described in theReplacing the front seat belt assemblies
after a collisionsection of this chapter. 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 toInteriorin theCleaningchapter.
Replacing the front seat belt assemblies after a collision
The front outboard safety belt assemblies have a special energy
management retractors designed to further reduce the risk of injury in
the event of a head-on collision. These retractors should be replaced if
they were used in any accident in which the front airbags deploy. If the
safety belt assemblies are not replaced, there may be increased risk of
injury in the event of a subsequent collision.
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.
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Children and air bags
Children must always be properly
restrained. Accident statistics
suggest that children are safer when
properly restrained in the rear
seating positions than in the front
seating position. Failure to follow
these instructions may increase the
risk of injury in a collision.
Air bags can kill or injure a
child in a child seat.
NEVERplace a rear-facing child
seat in front of an active air bag. If
you must use a forward-facing
child seat in the front seat, move
the seat all the way back.
Determining if the system is operational
The supplemental restraint system uses a warning indicator in the
instrument cluster or a back-up tone to indicate the condition of the
system. Refer to theWarning lightsection in theInstrument cluster
chapter. 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 (same light
for front and side air bag system)
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 supplemental
restraint system serviced at your dealership or by a qualified technician
immediately. Unless serviced, the system may not function properly in
the event of a collision.
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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 to theAir bag readiness
section in theInstrument Clusterchapter. Routine maintenance of the
air bag is not required.
Any difficulty with the system is indicated by one or more of the
following:
•The readiness light (same light as for front air bag system) 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 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
or rollover event.
Disposal of air bags and air bag equipped vehicles (including
pretensioners)
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 (generally children who are four years old
or younger and who weigh 18 kg [40 lbs] or less) ride in your vehicle,
you must put them in safety seats made especially for children. Many
states require that children use approved booster seats until they are
eight years old. Check your local and state or provincial laws for specific
requirements regarding the safety of children in your vehicle. When
possible, always place children under age 12 in the rear seat of your
vehicle. Accident statistics suggest that children are safer when properly
restrained in the rear seating positions than in the front seating position.
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If your vehicle has the optional trailer tow package it comes with heavy
duty cooling fans, auxiliary transmission fluid cooler, an auxiliary engine
oil cooler (4.2L engine only), heavy duty battery, trailer tow wiring
(including fuses and relays to isolate the vehicle lighting circuitry from
the trailer lighting) and a kit (in a cardboard box) that includes an
adapter wiring harness that contains the standard 4-pin trailer plug.
Trailer towing puts additional loads on your vehicle’s engine,
transmission, axle, brakes, tires, and suspension. For your safety and to
maximize vehicle performance, be sure to use the proper equipment
while towing.
Follow these guidelines to ensure safe towing procedure:
•Stay within your vehicle’s load limits. If exceeded, cargo should be
removed from the trailer and/or the vehicle until all weights are within
specified limits.
•Thoroughly prepare your vehicle for towing. Refer toPreparing to
towin this chapter.
•Use extra caution when driving while trailer towing. Refer toDriving
while you towin this chapter.
•Service your vehicle more frequently if you tow a trailer. Refer to
Special Operating Conditionsin the scheduled maintenance guide.
•Do not tow a trailer until your vehicle has been driven at least 800 km
(500 miles).
•Refer to the instructions included with towing accessories for the
proper installation and adjustment specifications.
Vehicle towing capability/Trailer
hitch requirementTrailer
Model/
EngineGCWR -
kg (lbs)Hitch type
requiredTrailer Weight
range - kg
(lbs)Tongue load
Van, 3.9L
3175
(7000)
Class I
Non-Equalizing
Weight
Carrying
0 - 907
(0 - 2000)10–15% of TW
(91 kg [200
lbs.] maximum) Wagon,
3.9L
Wagon,
4.2L3266
(7200)
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Driving
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Trailer brakes
Be sure your trailer conforms to all applicable local and Federal
Regulations regarding trailer braking. If your trailer is equipped with
electronically controlled brakes you will need to have an electronic brake
controller with associated wiring installed to your vehicle by a qualified
technician.
Do not connect a trailer’s hydraulic brake system directly to your
vehicle’s brake system. Your vehicle may not have enough
braking power and your chances of having a collision greatly increase.
The braking system of the tow vehicle is rated for operation at the
GVWR not GCWR.
Trailer lamps
Trailer lamps are required on most towed vehicles. Make sure all running
lights, brake lights, turn signals and hazard lights are working.
Do not splice into the vehicle lamp wiring for trailer lamps. Your
vehicle uses an advanced electronic module to control and
monitor your vehicle lamps. Splicing into the wiring or attaching
wiring to the vehicle bulbs may DISABLE the rear vehicle lamps
or cause them not to function properly. Your lamp outage feature
may also be disabled or provide incorrect information.
See your dealer or trailer rental agency for proper instructions and
equipment for hooking up trailer lamps.
Driving while you tow
When towing a trailer:
•Turn off the speed control. The speed control may shut off
automatically when you are towing on long, steep grades.
•Consult your local motor vehicle speed regulations for towing a trailer.
•To eliminate excessive shifting, use a lower gear. This will also assist
in transmission cooling. (For additional information, refer to the
Understanding the positions of the 4–speed automatic
transmissionsection in this chapter.
•Anticipate stops and brake gradually.
•Do not exceed the GCWR rating or transmission damage may occur.
Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
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Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
The cover for the power distribution box can be removed by releasing
the tab on the back left corner of the cover, then pulling the cover up.
The high-current fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
1 — Not used
2 30A** Right cooling fan
3 30A** Left cooling fan
4 30A** Starter solenoid
5 30A** Right-hand power sliding door
6 30A** SJB accessory #2 (driver power
window)
7 30A** Auxiliary blower motor
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Roadside Emergencies
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CHANGING A FLAT TIRE
If you get a flat tire while driving:
•do not brake heavily.
•gradually decrease the vehicle’s speed.
•hold the steering wheel firmly.
•slowly move to a safe place on the side of the road.
•If your low tire warning light is on, refer toLow tire warningin the
Maintenance and specificationschapter.
The use of tire sealants is not recommended and may damage
your tires. The use of tire sealants may also damage your tire
pressure monitoring system (if equipped).
Temporary spare tire information
Your vehicle may have a temporary spare tire. The temporary spare tire
for your vehicle is labeled as such. It is smaller than a regular tire and is
designed for emergency use only. Replace this tire with a full-size tire as
soon as possible.
Note:The Low Tire Warning system
will detect the temporary spare tire
and illuminate the low tire warning
light until the spare tire is replaced
with a proper full-size tire. To reset
the system, refer toServicing your tiresin theMaintenance and
specificationschapter.
If you use the temporary spare tire continuously or do not follow
these precautions, the tire could fail, causing you to lose control
of the vehicle, possibly injuring yourself or others.
When driving with the temporary spare tiredo not:
•use more than one temporary spare tire at a time
•exceed 80 km/h (50 mph) or drive further than 3,200 km (2,000
miles) total under any circumstances
•load the vehicle beyond maximum vehicle load rating listed on the
Safety Compliance Label
•tow a Class III trailer
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5. Repeat this tightness check procedure when servicing the spare tire
pressure (every six months, per scheduled maintenance guide), or at any
time that the spare tire is disturbed through service of other
components.
6. If removed, install the spare tire lock (if equipped) into the bumper
drive tube with the spare tire lock key (if equipped) and jack handle.
Wheel lug nut torque specifications
Retighten the lug nuts to the specified torque at 800 km (500 miles)
after any wheel disturbance (rotation, flat tire, wheel removal, etc.).
Bolt size Wheel lug nut torque*
Nm Lb-ft
12x 20 113-153 85-115
* Torque specifications are for nut and bolt threads free of dirt and
rust. Use only Ford recommended replacement fasteners.
When a wheel is installed, always remove any corrosion, dirt or
foreign materials present on the mounting surfaces of the wheel
or the surface of the front disc brake hub and rotor that contacts the
wheel. Installing wheels without correct metal-to-metal contact at the
wheel mounting surfaces can cause the wheel nuts to loosen and the
wheel to come off while the vehicle is in motion, resulting in loss of
control.
JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which can burn skin, eyes and
clothing, if contacted.
Do not attempt to push-start your vehicle. Automatic
transmissions do not have push-start capability; doing so may
damage the catalytic converter.
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In the United States, a warranty dispute must be submitted to the
Dispute Settlement Board before taking action under the Magnuson-Moss
Warranty Act, or to the extent allowed by state law, before pursuing
replacement or repurchase remedies provided by certain state laws. This
dispute handling procedure is not required prior to enforcing state
created rights or other rights which are independent of the
Magnuson-Moss Warranty Act or state replacement or repurchase laws.
FORD EXTENDED SERVICE PLAN
You can get more protection for your new car or light truck by
purchasing Ford Extended Service Plan (Ford ESP) coverage. Ford ESP
is an optional service contract which is backed by Ford Motor Company
or Ford Motor Service Company (in the U.S.) and Ford of Canada (in
Canada). It provides the following:
•Benefits during the warranty period depending on the plan you
purchase (such as: reimbursement for rentals; coverage for certain
maintenance and wear items).
•Protection against covered repair costs after your Bumper-to-Bumper
Warranty expires.
You may purchase Ford ESP from any participating Ford and Lincoln
Mercury and Ford of Canada dealer. There are several plans available in
various time, distance and deductible combinations which can be tailored
to fit your own driving needs. Ford ESP also offers reimbursement
benefits for towing and rental coverage.
When you buy Ford ESP, you receive Peace-of-Mind protection
throughout the United States and Canada, provided by a network of
more than 5,000 participating Ford or Lincoln Mercury and Ford of
Canada dealers.
If you did not take advantage of the Ford Extended Service Plan at the
time of purchasing your vehicle, you may still be eligible. Since this
information is subject to change, please ask your dealer for complete
details about Ford Extended Service Plan coverage options, or visit the
Ford ESP website at www.ford-esp.com.
THE DISPUTE SETTLEMENT BOARD (U.S. ONLY)
The Dispute Settlement Board is:
•an independent, third-party arbitration program for warranty disputes.
•available free to owners and lessees of qualifying Ford Motor Company
vehicles.
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Customer Assistance
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