service FORD WINDSTAR 2002 2.G Workshop Manual

²If possible, avoid fully loading your vehicle.
²Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
²The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
MOTORCRAFT PART NUMBERS
Component 3.8L OHV V6 engine
Air filter element FA-1616
Fuel filter FG-986B
Battery (standard) BXT-65-650
Battery (optional) BXT-65-750
Oil filter FL-400S
PCV valve EV-152
Spark plugs* AWSF-42EE***
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
*** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, and 3 have a ªEGº suffix. Cylinders No.
4, 5, and 6 have a ªEº suffix. If a spark plug needs to be replaced, use
only spark plugs with the service part number suffix letter ªEEº as
shown on the engine decal.
Maintenance and Specifications
277

Item Ford part
nameFord part
numberFord
specification
Automatic
transaxle
(4F50N)Motorcraft
MERCONtV
AT F
2
XT-5-QM MERCONtV
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-3 ESE-M1C171-A
Constant
velocity jointsMotorcraft CV
Joint Grease
(High Temp.)XG-2 ESP-M1C207-A
Windshield
washer fluidUltra-clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
1Use only brake fluids certified to meet Ford specifications. DOT 3 fluid
is recommended. However, if DOT 3 is not available, DOT 4 fluid can be
used.
2Ensure the correct automatic transmission fluid is used MERCONtand
MERCONtV are not interchangeable. DO NOT MIX MERCONtand
MERCONtV. Refer to the scheduled maintenance guide to determine the
correct service interval.
ENGINE DATA
Engine 3.8L OHV V6 engine
Cubic inches 232
Required fuel 87 octane
Firing order 1-4-2-5-3-6
Spark plug gap 1.3-1.4 mm (0.052-0.056 inch)
Ignition system EDIS
Compression ratio 9.36:1
Maintenance and Specifications
280

For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
²When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacity of the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
compliance certification label). Consult your dealer for specific weight
information.
²The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems - such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
²Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use or are not properly installed. When operated, such systems may
cause the engine to stumble or stall or cause the transmission to be
damaged or operate improperly. In addition, such systems may be
damaged or their performance may be affected by operating your
vehicle. (Citizens band [CB] transceivers, garage door openers and
other transmitters with outputs of five watts or less will not ordinarily
affect your vehicle's operation.)
²Ford cannot assume responsibility for any adverse effects or damage
that may result from the use of such equipment.
Accessories
286

in rear seat ......................165, 167
tether anchorage
hardware .................................168
Cleaning your vehicle
engine compartment ..............237
exterior ....................................241
instrument cluster lens ..........239
instrument panel ....................239
interior .....................................239
plastic parts ............237±238, 240
safety belts ..............................240
washing ....................................235
waxing .....................................235
wheels ......................................236
windows ..................................240
wiper blades ............................238
woodtone trim ........................238
Clock ..........................22, 31, 37, 48
Compass, electronic ............88, 107
Console ........................................94
overhead ....................................82
Controls
power seat ...............................130
Coolant
checking and adding ..............252
refill capacities ................256, 278
specifications ..................279±280
Cruise control
(see Speed control) ....................90
Cupholder(s) .............................134
Customer Assistance ................200
Ford accessories for your
vehicle .....................................241
Ford Extended Service
Plan ..........................................227
Getting assistance outside
the U.S. and Canada ..............231Getting roadside
assistance ................................200
Getting the service
you need .................................225
Ordering additional
owner's literature ...................232
The Dispute Settlement
Board .......................................228
Utilizing the Mediation/
Arbitration Program ...............231
D
Daytime running lamps
(see Lamps) ................................67
Defrost
rear window ..............................66
Dipstick
automatic transmission
fluid ..........................................269
engine oil .................................246
Doors
door ajar warning .....................14
lubricant specifications ..........279
power sliding ............................83
Driving under special
conditions
through water .........................192
E
Emergencies, roadside
jump-starting ..........................218
Emission control system ..........265
Engine ................................280±281
check engine/service engine
soon light ..................................10
cleaning ...................................237
coolant .....................................252
Index
288

idle speed control ...................249
lubrication
specifications ..................279±280
refill capacities ........................278
service points ..........................244
starting after a collision .........201
Engine block heater .................178
Engine oil ..................................246
change oil soon warning,
message center .......................246
checking and adding ..............246
dipstick ....................................246
filter, specifications ........248, 277
recommendations ...................248
refill capacities ........................278
specifications ..................279±280
Exhaust fumes ..........................178
F
Floor mats ...................................96
Fluid capacities .........................278
Fuel ............................................257
calculating fuel economy .......262
cap .....................................11, 259
capacity ...................................278
choosing the right fuel ...........260
comparisons with EPA fuel
economy estimates .................265
detergent in fuel .....................261
filling your vehicle
with fuel ..................257, 259, 262
filter, specifications ........262, 277
fuel pump shut-off switch .....201
gauge .........................................17
improving fuel economy ........262
low fuel warning light ..............14
octane rating ...........260, 280±281
quality ......................................261
running out of fuel .................261safety information relating
to automotive fuels ................257
Fuses ..................................203±204
G
Garage door opener ..............82, 96
Gas cap (see Fuel cap) ......11, 259
Gas mileage
(see Fuel economy) .................262
Gauges .........................................16
engine coolant temperature
gauge .........................................16
fuel gauge ..................................17
odometer ...................................17
speedometer .............................17
tachometer ................................18
trip odometer ............................18
GAWR (Gross Axle Weight
Rating) .......................................193
calculating ...............................194
definition .................................193
driving with a heavy load ......193
location ....................................193
GVWR (Gross Vehicle Weight
Rating) .......................................193
calculating .......................193±194
definition .................................193
driving with a heavy load ......193
location ....................................193
H
Hazard flashers .........................201
Head restraints .................129, 133
Headlamps ...................................67
aiming ..................................69±70
autolamp system .......................67
bulb specifications ....................73
Index
289