service FORD POSTAL EXPLORER 2001 2.G Owner's Manual

It should not be necessary to add any aftermarket products to your fuel
tank if you continue to use high quality fuel of the recommended octane
rating. Aftermarket products could cause damage to the fuel system.
Repairs to correct the effects of using an aftermarket product in your
fuel may not be covered by your warranty.
If you are experiencing starting, rough idle or hesitation driveability
problems during a cold start using only unleaded gasoline, try a different
brand of ªRegularº unleaded gasoline. ªPremiumº unleaded gasoline is
not recommended (particularly in the United States) because it may
cause these problems to become more pronounced. If the problems
persist, see your dealer or a qualified service technician.
Your FFV will operate well on ordinary ªRegularº unleaded gasoline, but
only the highest quality fuel ethanol will provide the same level of
protection and performance.
Standards for fuel ethanol have been developed to provide FFVs the best
possible performance, safety and durability. To assist alcohol fuel
providers in meeting these standards, guidelines have also been
developed which prescribe ªEthanol Fuel Compatibleº dispensing station
equipment. These standards and guidelines can be obtained from Ford
Motor Company. Fuel stations may apply to be certified as meeting these
standards. However, not all stations meet these standards at this time. To
ensure proper operation of your FFV on fuel ethanol, refuel at certified
stations.
If you are experiencing a rough or rolling idle after start-up with the
outside temperature above 27É C (80É F) using fuel ethanol, the idle
should improve within 10 to 30 seconds. If the problems persist below
this temperature, see your dealer or a qualified service technician.
Cleaner air
Ford endorses the use of reformulated ªcleaner-burningº gasolines to
improve air quality.
Running out of fuel
Avoid running out of fuel because this situation may have an adverse
affect on powertrain components.
Maintenance and care
76

If you have run out of fuel:
²You may need to cycle the ignition from OFF to ON several times after
refueling, to allow the fuel system to pump the fuel from the tank to
the engine.
²Your ªCheck Engineº indicator may come on. For more information on
the ªCheck Engineº indicator, refer to theInstrumentationchapter.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/8 turn on/off feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/8 of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/8 of a turn until it stops.
If the ªService Engine Soon/Check Engineº indicator comes on and stays
on after you start the engine, the fuel filler cap may not be properly
installed. Turn off the engine, remove the fuel filler cap, align the cap
properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Maintenance and care
77

Fuel Filter
Your vehicle is equipped with a fuel filter which is fuel ethanol
compatible. charging system warning light, Refer to the scheduled
maintenance guide for the appropriate intervals for changing the fuel
filter.
Replace the fuel filter with an authorized Motorcraft part. The
customer warranty may be void for any damage to the fuel system
if an authorized Motorcraft fuel filter is not used.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
²Use only the specified fuels listed.
²Avoid running out of fuel.
²Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
²Have the items listed in your scheduled maintenance guide performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
guide are essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the ªCheck Engineº light, charging system warning light
or the temperature warning light, fluid leaks, strange odors, smoke or
loss of engine power, could indicate that the emission control system is
not working properly.
Maintenance and care
78

Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle's emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult your ªWarranty Guideº for complete emission warranty
information.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your ªCheck Engine/Service Engine
Soonº light is on, refer to the description in theWarning Lights and
Chimessection of theInstrumentationchapter. Your vehicle may not
pass the I/M test with the ªCheck Engine/Service Engine Soonº light on.
If the vehicle's powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a ªnot ready for I/M testº
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
²First, at least 10 minutes of driving on an expressway or highway.
²Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four 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.
Maintenance and care
79

MOTORCRAFT PART NUMBERS
Component 4.0L SOHC V6 engine
Air filter element FA-1658
Fuel filter FG-1002
Battery BXT-65-650
Oil filter FL-820
PCV valve EV-245
Spark plugs* AGSF-22PP
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
Fluid Ford Part Name Capacity
Brake fluid High Performance DOT 3
Motor Vehicle Brake FluidFill to line on
reservoir.
Engine oil (including
filter change)Motorcraft SAE 5W-30
Super Premium Motor Oil4.7L (5.0 quarts)
Fuel tank N/A 78.7L
(20.8 gallons)
Power steering fluid Motorcraft MERCONt
AT FFill to MAX line on
reservoir.
Transmission fluid Motorcraft MERCONtV
AT F
19.5L
(10.0 quarts)2
Engine coolant3Premium Engine Coolant 13.2L
(14.0 quarts)
Rear axle lubricant
4,5Motorcraft SAE 80W-90
Premium Rear Axle
Lubricant2.9-3.1L
(5.5-5.8 pints)
Windshield washer
fluidUltra-Clear Windshield
Washer Concentrate2.6L (2.7 quarts)
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONtand MERCONtV are not interchangeable. DO NOT
mix MERCONtand MERCONtV. Refer to the scheduled maintenance
guide to determine the correct service interval.
Capacities and specifications
80

A
Air cleaner filter .........................80
Antifreeze
(see Engine coolant) ..................57
Anti-lock brake system
(see Brakes) ..........................23±24
Automatic transmission
driving an automatic
overdrive ...................................27
fluid, adding ..............................62
fluid, checking ..........................62
fluid, refill capacities ................80
fluid, specification ....................82
Axle
lubricant specifications ......81±82
refill capacities ..........................80
B
Battery .........................................65
acid, treating emergencies .......65
charging system warning light ..9
jumping a disabled battery ......43
maintenance-free ......................65
replacement, specifications .....80
servicing ....................................65
voltage gauge ............................11
Brakes ..........................................23
anti-lock ...............................23±24
anti-lock brake system
(ABS) warning light .............8, 24
brake warning light ....................7
fluid, checking and adding ......56
fluid, refill capacities ................80
fluid, specifications .............81±82
lubricant specifications ......81±82
shift interlock ............................26
Break-in period .............................3C
Capacities for refilling fluids ......80
Coolant
checking and adding ................57
refill capacities ....................61, 80
specifications ......................81±82
D
Dipstick
automatic transmission fluid ...62
engine oil ...................................54
Doors
lubricant specifications ............81
Driveline universal
joint and slip yoke ......................64
Driving under special
conditions ....................................32
mud ......................................31±32
sand ...........................................32
snow and ice .......................31, 33
through water ...........................32
E
Emergencies, roadside
jump-starting ............................43
Emission control system ............78
Engine ..........................................82
check engine/
service engine soon light ...........6
coolant .......................................57
idle speed control .....................65
lubrication specifications ...81±82
refill capacities ..........................80
service points ............................53
starting after a collision ...........34
Engine oil ....................................54
Index
84

headlamps, flash to pass ..........14
instrument panel, dimming .....13
Lane change indicator
(see Turn signal) ........................16
Lights, warning and indicator ......6
anti-lock brakes (ABS) ........8, 24
brake ............................................7
charging system ..........................9
high beam ...................................8
overdrive off ................................8
safety belt ...................................7
service engine soon ....................6
turn signal indicator ...................8
Lubricant specifications .......81±82
M
Manual transmission
fluid capacities ..........................80
lubricant specifications ............82
Motorcraft parts ....................78, 80
O
Octane rating ..............................75
Odometer .....................................10
Oil (see Engine oil) ....................54
Overdrive .....................................16
P
Parking brake ..............................24
Parts (see Motorcraft parts) ......80
Power distribution box
(see Fuses) .................................37Power steering ............................25
fluid, checking and adding ......62
fluid, refill capacity ..................80
fluid, specifications .............81±82
R
Relays ....................................34, 39
S
Safety defects, reporting ............83
Safety restraints
warning light and chime ........7, 9
Servicing your vehicle ................52
Spark plugs, specifications ...80, 82
Special notice ................................3
utility-type vehicles ....................3
Specification chart,
lubricants ...............................81±82
Speedometer .................................9
Starting your vehicle ............18±21
jump starting ............................43
Steering wheel
tilting .........................................15
T
Tires .................................40, 67±69
changing ....................................40
checking the pressure ..............69
replacing ....................................70
rotating ......................................69
snow tires and chains ..............71
tire grades .................................68
treadwear ..................................68
Towing .........................................69
wrecker ......................................49
Index
86

Item Information
Required fuel Refer to9Octane
recommendations9in the
Maintenance and carechapter.
Fuel tank capacity 78.7L (20.8 gallons)
Engine oil capacity (includes filter
change)4.7L (5.0 quarts). Use Motorcraft
SAE 5W-30 Super Premium Motor
Oil, Ford
specificationWSS-M2C153-G.
Tire size and pressure Refer to the Certification Label on
inside of driver's door.
Hood release Pull handle under the instrument
panel.
Coolant capacity
113.2L (14.0 quarts)
Power steering fluid capacity Fill to MAX line on reservoir. Use
Motorcraft MERCONtAT F.
Automatic transmission fluid
capacity
29.5L (10.0 quarts). Use Motorcraft
MERCONtV ATF.3
1
Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford
Extended Life Engine Coolant (orange in color). Refer toAdding engine
coolant, in the Maintenance and Care chapter.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONtand MERCONtV are not interchangeable. DO NOT
mix MERCONtand MERCONtV. Refer to your scheduled maintenance
guide to determine the correct service interval.
3Approximate dry capacity, includes cooler and tubes. Fluid level should
be checked by a qualified service technician.
Filling station information
88