brake FORD WINDSTAR 2002 2.G Service Manual

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
11 15A Electric Brake Controller, Brake
Shift Interlock Solenoid, Rear
Electronic Module
12 20A Center High-Mount Stop Lamp
13 10A Right Rear Turn Lamp, Left Stop
Lamp, Left Rear Park Lamp
14 10A Autolamp Sensor, Transmission
Overdrive Cancel Switch, Front
Electronic Module, Compass
Module, Electrochromatic Mirror,
Power Sliding Door Overhead
Console Switch
15 20A Console Power Point
16 10A Cluster
17 20A Cigar Lighter/Powerpoint, Datalink
Connector
18 15A LH Quarter Window Motor, RH
Quarter Window Motor, RH
Window Switch Backlighting, RH
Lock Switch Backlighting, Master
Control Switch (LH) Backlighting,
Radio, Video Cassette Player,
Liquid Crystal Display, Front
Electronic Module
19 10A Starter Interrupt Relay (coil)
20 Ð Not Used
21 Ð Not Used
22 10A LH Heated Mirror, RH Heated
Mirror
23 20A Body Powerpoint, Auxiliary
Blower Relay #1 and #2 Coils
24 Ð Not Used
25 10A Radio (Anti-theft)
Roadside Emergencies
207

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
101 40A** ABS Module or IVD Module
102 40A** ABS Module or IVD Module
103 40A** SSP4 Relay, SSP4 Relay (coil)
104 30A** LH Power Seat Motors (if
equipped), LH Power Lumbar
Motor (if equipped), Driver Seat
Memory Module (if equipped)
105 30A** Starter Motor Solenoid, Ignition
Switch
106 30A** Delayed Accessory Relay, Delayed
Accessory Relay (coil), Front
Electronic Module, RHF Window
Motor
107 50A** RH/LH Engine Cooling Fan
Motors, Cooling Fan Dropping
Resistor
108 Ð Not Used
109 30A** Heated Seat Modules (RH/LH)
110 50A** RH Power Sliding Door Module
111 40A** Fuse Junction Box
112 30A** Trailer Tow, Electric Brake
Controller
113 30A** Front Electronic Module (LH
Window Motor)
114 40A** SSP3 Relay, SSP3 Relay (coil)
115 50A** Fuse Junction Box Bus #2
116 30A** Heated Backlight Relay
117 40A** Auxiliary Blower Relay (coil),
Auxiliary Blower Motor
118 50A** LH Power Sliding Door Module
119 30A** Fuse Junction Box Bus #1
120 40A** Front Blower Relay (coil), Front
Blower Motor
Roadside Emergencies
211

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
121 20A** Ignition Switch, Rear Defrost
Relay (coil)
122 40A** RH Power Seat Motors, RH Power
Lumbar Motor
201 Ð Not Used
202 Ð Front Wiper ON/OFF Relay
203 Ð Rear Wiper Relay
204 Ð A/C Clutch Relay
205 Ð Horn Relay
206 Ð Not Used
207 Ð Fuel Pump Relay
208 Ð Not Used
209 Ð Front Wiper Hi/Low Relay
301 Ð Starter Interrupt Relay
302 Ð High Speed Engine Cooling Fan
Relay
303 Ð Low Speed Engine Cooling Fan
Relay
304 Ð Powertrain Control Module Relay
401 Ð Not Used
501 Ð Powertrain Control Module Diode
502 Ð Not Used
503 Ð Not Used
* Mini Fuses ** Maxi Fuses
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road. If your Low tire
warning light is on, refer toLow tire warningin theMaintenance and
specificationschapter.
Roadside Emergencies
212

Tire change procedure
When one of the front wheels is off the ground, the transaxle
alone will not prevent the vehicle from moving or slipping off the
jack, even if the vehicle is in P (Park).
To prevent the vehicle from moving when you change a tire, be
sure the parking brake is set, then block (in both directions) the
wheel that is diagonally opposite (other side and end of the vehicle) to
the tire being changed.
If the vehicle slips off the jack, you or someone else could be
seriously injured.
1. Park on a level surface, activate
hazard flashers and set parking
brake.
2. Place gearshift lever in P (Park),
turn engine OFF, and block the
diagonally opposite wheel.
3. Remove the spare tire, jack and
lug wrench.
4. If equipped with a wheel cover
that's bolted on, remove the outer
wheel cover from the wheel with the
tapered end of the wheel nut
wrench.
5. Loosen the five plastic nuts on
the center ornament with the wheel
nut wrench and remove.
Roadside Emergencies
215

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; also, the
catalytic conveter may become damaged.
Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its adaptive strategy. As a result of this, the
transmission may shift firmly. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation to its
optimum shift feel.
1.Use only a 12±volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle's electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Roadside Emergencies
218

REPAIRING PAINT CHIPS
Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
Minor scratches or paint damage from road debris may be repaired using
the Ultra Touch Prep and Finishing Kit (F7AZ-19K507±BA), which is
available at your authorized Ford, Lincoln or Mercury dealer. This kit
contains:
²Lacquer Touch-Up Paint (ALBZ-19500±XXXXA)
²Exterior Acrylic Spray Lacquer (ALAZ-19500±XXXXA)
Please note that the part numbers (shown as XXXX above) will vary with
your vehicle's specific coloring.Carefully observe the application
instructions on the products.
CLEANING THE WHEEL RIMS AND COVERS
Aluminum wheel rims or covers are coated with a clearcoat paint
finish.
Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Chemical-strength cleaners, or cleaning chemicals,
in combination with brush agitation to remove brake dust and dirt, could
wear away the clearcoat finish over time.
Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergents for
soiled wheel rims and covers.
Never apply any cleaning chemical to hot or warm wheel rims or covers.
Clean wheel rims and covers with Detail Wash (ZC-3±A), which is
available from your authorized Ford, Lincoln or Mercury dealer. Spray
cleaner on cool wheel rims or covers and allow to set for 2±5 minutes.
Agitate the area with a sponge and rinse off with plenty of water.
Use Extra Strength Tar and Road Oil Removal (B7A-19520±AA),
available from your authorized Ford, Lincoln or Mercury dealer, in order
to remove tar and grease from wheel rims and covers.
Cleaning
236

SERVICE RECOMMENDATIONS
To help you service your vehicle:
²We highlight do-it-yourself items in the engine compartment for easy
location.
²We provide a scheduled maintenance guide which makes tracking
routine service easy.
If your vehicle requires professional service, your dealership can provide
the necessary parts and service. Check yourWarranty Guideto find out
which parts and services are covered.
Use only recommended fuels, lubricants, fluids and service parts
conforming to specifications. Motorcraft parts are designed and built to
provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE
Be especially careful when inspecting or servicing your vehicle.
²Do not work on a hot engine.
²When the engine is running, make sure that loose clothing, jewelry or
long hair does not get caught up in moving parts.
²Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
²Keep all lit cigarettes, open flames and other lit material away from
the battery and all fuel related parts.
If you disconnect the battery, the engine must ªrelearnº its idle
conditions before your vehicle will drive properly, as explained inBattery
in this chapter.
Working with the engine off
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Turn off the engine and remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
Working with the engine on
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Block the wheels to prevent the vehicle from moving unexpectedly.
Maintenance and Specifications
242

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
3.8L OHV V6 engine
1. Brake fluid reservoir
2. Air filter assembly
3. Power distribution box
4. Battery
5. Automatic transmission fluid dipstick
6. Engine oil dipstick
7. Engine oil filler cap
8. Windshield washer fluid reservoir
9. Engine coolant reservoir
10. Power steering fluid reservoir
345678
91012
Maintenance and Specifications
244

ENGINE OIL
Checking the engine oil
Refer to the scheduled maintenance guide for the appropriate intervals
for checking the engine oil.
1. Make sure the vehicle is on level ground.
2. Turn the engine off and wait a few minutes for the oil to drain into the
oil pan.
3. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
4. Open the hood. Protect yourself from engine heat.
5. Locate and carefully remove the
engine oil level indicator (dipstick).
6. Wipe the indicator clean. Insert the indicator fully, then remove it
again.
²If the oil level isbetween the MIN and MAX marks,the oil level is
acceptable.DO NOT ADD OIL.
MAX MIN
Maintenance and Specifications
246

Because your vehicle's engine is electronically controlled by a computer,
some control conditions are maintained by power from the battery. When
the battery is disconnected or a new battery is installed, the engine must
relearn its idle and fuel trim strategy for optimum driveability and
performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. With your foot on the brake pedal and with the A/C on, put the
vehicle in D (Drive) and allow the engine to idle for at least one minute.
7. Drive the vehicle to complete the relearning process.
²The vehicle may need to be driven 16 km (10 miles) or more to
relearn the idle and fuel trim strategy.
²If you do not allow the engine to relearn its idle trim, the idle
quality of your vehicle may be adversely affected until the idle
trim is eventually relearned.
If the battery has been disconnected or a new battery has been installed,
the clock and the preset radio stations must be reset once the battery is
reconnected.
If the battery has been discharged, disconnected or a new battery has
been installed, the power sliding door may need to be reset. Refer to
Power Sliding Door-Resetting the PSDin theControls and Features
chapter.
²Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center
to find out more about recycling
automotive batteries.
LEAD
RETURN
RECYCLE
Maintenance and Specifications
251