engine FORD THUNDERBIRD 2004 11.G Repair Manual

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 Warranty Guidefor complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine ’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When the Check
Engine/Service Engine Soon light illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause your Check
Engine/Service Engine Soon light to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, the Check Engine/Service Engine Soon light should turn off.
(A driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If the Check Engine/Service Engine Soon light remains on, have your
vehicle serviced at the first available opportunity.
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 “Check Engine/Service Engine
Soon ”light is on, refer to the description in the Warning lights and
chimes section of the Instrument cluster chapter. Your vehicle may not
pass the I/M test with the “Check Engine/Service Engine Soon ”light on.
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If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test ”
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:
• First, at least 10 minutes of driving on an expressway or highway.
• Next, 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.
POWER STEERING FLUID
Refer to the scheduled maintenance guide for the service interval
schedules. If adding fluid is necessary, use only MERCON AT F.
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.
M AX
M I
N
M AX
M IN
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BRAKE FLUID RESERVOIR
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 your brake
system could be compromised, seek service from your dealer
immediately.
TRANSMISSION FLUID
Checking automatic transmission fluid
The 5R55S transmission does not have a transmission fluid dipstick.
Refer to your scheduled maintenance guide for 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.
Transmission fluid should be checked and, if required, fluid
should be added by a qualified technician.
Before adding any fluid, make sure the correct type is used. Use only
MERCON V automatic transmission fluid. The type of fluid used is
indicated on the transmission fluid pan, extension housing and also in
the Lubricant specifications section in this chapter.
Use of a non-approved automatic transmission fluid may cause
internal transmission component damage and void the warranty.
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 MAINTENANCE
Refer to the scheduled maintenance guide for the appropriate intervals
for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer to Motorcraft Part Numbers .
Note: Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
MAX
MIN
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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 unmetered air to enter the engine if not properly
seated.
6. Replace the air filter housing
cover and secure the clamps. Be
sure all of the tabs on front edge are
correctly aligned as shown.
Note:If you encounter any difficulty in replacing your air filter element,
have your vehicle serviced at your local dealer.
INFORMATION ABOUT UNIFORM TIRE QUALITY GRADING
New vehicles are fitted with tires
that have a rating on them called
Tire Quality Grades. The Quality
grades can be found where
applicable on the tire sidewall
between tread shoulder and
maximum section width. For
example:
• Treadwear 200 Traction AA Temperature A
These Tire Quality Grades are determined by standards that the United
States Department of Transportation has set.
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The use of snow cables is not recommended for this vehicle, as damage
to your vehicle may occur under extreme handling or rough road
conditions. However, if you choose to operate the vehicle with snow
cables, avoid these conditions and follow the manufacturer’s
recommendations.
Do not use any type of tire chains, as this will likely cause damage to
your vehicle.
MOTORCRAFT PART NUMBERS
Component 3.9L-4V V8 engine
Air filter element FA-1679
Fuel filter FG-1011
Battery BXT-66-650
Oil filter FL-218
PCV valve N/A
Spark plugs* AGSP-32F
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug information.
REFILL CAPACITIES
Fluid Ford Part NameApplication Capacity
Brake fluid Motorcraft High Performance
DOT 3 Motor
Vehicle Brake
Fluid
1
All Fill to MAX lineon reservoir
Engine oil
(includes filter
change)
6
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) 3.9L-4V V8
engine
6.2L (6.5
quarts)
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Fluid Ford PartNameApplication Capacity
Engine coolant
2Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) 3.9L-4V V8
engine
11.3L (11.9
quarts)
Power steering
fluid Motorcraft
MERCON
AT F All Fill to MAX line
on reservoir
Rear axle
3Motorcraft SAE
75W-90 Fuel
Efficient High
Performance
Synthetic Rear
Axle Lubricant All 1.2
–1.3L
(2.5 –2.7 pints)
Fuel tank N/A All 68.2L (18.0 gallons)
Transmission
fluid
4Motorcraft
MERCON V
AT F Automatic
(5R55S)
11.2L (11.9
quarts)5
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll Fill to line on
reservoir
1Use only brake fluids certified to meet Ford specifications. Refer to
Lubricant Specifications in this chapter. DOT 3 fluid is recommended.
However, if DOT 3 is not available, DOT 4 fluid can be used.
2Add the coolant type originally equipped in your vehicle.3Your vehicle ’s rear axle is filled with a synthetic rear axle lubricant and
is considered lubricated for life. These lubricants do not need to be
checked or changed unless a leak is suspected, service is required or the
axle assembly has been submerged in water. The axle lubricant should
be changed any time the rear axle has been submerged in water. Fill 6
mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole.
4Ensure the correct automatic transmission fluid is used. MERCON and
MERCON V are not interchangeable. DO NOT MIX MERCON and
MERCON V. Refer to the scheduled maintenance guide to determine
the correct service interval.
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5Approximate dry capacity, includes cooler and tubes. Fluid level should
be checked by a qualified service technician.
6Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C153 –H and the API Certification mark.
LUBRICANT SPECIFICATIONS
Item Ford part nameFord part
number Ford
specification
Brake fluid Motorcraft High Performance
DOT 3 Motor
Vehicle Brake
Fluid
1
PM-1 ESA-M6C25-A and DOT 3
Door
weatherstrips Silicone
LubricantXL-6 ESR-M13P4-A
Door latch,
hood latch,
auxiliary hood
latch, door
hinges, striker
plates, seat
tracks and fuel
filler door hinge Multi-Purpose
Grease
XL-4 or XL-5 ESB-M1C93-B
or
ESR-M1C159-A
Engine coolant Motorcraft Premium Gold
Engine Coolant
(yellow-colored)VC-7-A (VC-7
–B
in Oregon) WSS-M97B51-A1
Engine oil Motorcraft SAE 5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)XO-5W20-QSP
(US)
CXO-5W20
–LSP12
(Canada) WSS-M2C153-H
with API
Certification
Mark
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ENGINE DATA
Engine 3.9L-4V V8 engine
Displacement 3 949 cc (241 cid)
Required fuel 91 octane
Firing order 1-5-4-2-6-3-7-8
Spark plug gap 0.99-1.09 mm (0.039-0.043 inch)
Ignition system Coil on plug
Compression ratio 10.75:1
VEHICLE DIMENSIONS
Vehicle dimensions mm (in)
(1) Overall length 4732mm (186.3 in)
(2) Overall width 1829mm (72.0 in)
(3) Overall height 1323 mm (52.1 in)
(4) Wheelbase 2722 mm (107.2 in)
(5) Track - Front 1537 mm (60.5 in)
(5) Track - Rear 1529 mm (60.2 in)
4
1
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Vehicle identification number (VIN)
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel. (Please note that
in the graphic XXXX is
representative of your vehicle
identification number.)
1. World manufacturer identifier
2. Brake type and gross vehicle
weight rating (GVWR)
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block, transmission, frame and
transfer case (if equipped).
XXXXXXXXXXXXXXXXX
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FORD ACCESSORIES FOR YOUR VEHICLE
A wide selection of genuine Ford accessories are available for your
vehicle through your local authorized Ford or Ford of Canada dealer.
These quality accessories have been specifically engineered to fulfill your
automotive needs; they are custom designed to complement the style
and aerodynamic appearance of your vehicle. In addition, each accessory
is made from high quality materials and meets or exceeds Ford’s rigorous
engineering and safety specifications. Ford Motor Company will repair or
replace any properly dealer-installed Ford accessory found to be
defective in factory-supplied materials or workmanship during the
warranty period, as well as any component damaged by the defective
accessory. The accessory will be warranted for whichever provides you
the greatest benefit:
• 12 months or 20,000 km (12,000 miles) (whichever occurs first), or
• the remainder of your new vehicle limited warranty.
This means that genuine Ford accessories purchased along with your new
vehicle and installed by the dealer are covered for the full length of your
New Vehicle ’s Limited Warranty —3 years or 60,000 km (36,000 miles)
(whichever occurs first). Contact your dealer for details and a copy of the
warranty.
Not all accessories are available for all models.
Following is a list of several Ford Genuine Accessory products. Not all
accessories are available for all models. To find out what accessories are
available for your vehicle, please contact your dealer or visit our online
store at: www.fordaccessoriesstore.com.
Exterior style
Bug shields
Deflectors
Exterior trim kits
Front end covers
Grille inserts
Headlamps, fog lights and Daytime Running Lamps (DRLS)
Splash guards
Wheels
Interior style
Cell phone holders
Electrochromatic compass/temperature interior mirrors
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Accessories
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