maintenance FORD WINDSTAR 2002 2.G Owners Manual

Maintenance and Specifications 242
Hood 243
Engine compartment 244
Engine oil 246
Battery 249
Fuel information 257
Low tire warning system 272
Part numbers 277
Refill capacities 278
Lubricant specifications 279
Engine data 280
Vehicle dimensions 281
Accessories 284
Index 287
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Copyright 2001 Ford Motor Company
Table of Contents
3

These temporary malfunctions can be corrected by filling the fuel tank
with high quality fuel of the recommended octane and/or properly
installing and securely tightening the fuel cap. After three driving cycles
without these or any other temporary malfunctions present, the 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 light remains on, have your vehicle serviced at the first available
opportunity.
Light is blinking:
Engine misfire is occurring which could damage your catalytic converter.
You should drive in a moderate fashion (avoid heavy acceleration and
deceleration) and have your vehicle serviced at the first available
opportunity.
Under engine misfire conditions, excessive exhaust temperatures
could damage the catalytic converter, the fuel system, interior
floor coverings or other vehicle components, possibly causing a fire.
Check fuel cap
Illuminates when the fuel cap is not
installed correctly. Check the fuel
cap for proper installation. When
the fuel filler cap is properly
re-installed, the light(s) will turn off
after a period of normal driving. Continuing to operate the vehicle with
the check fuel cap light on, can activate theService Engine Soon/Check
Enginewarning light.
It may take a long period of time for the system to detect an
improperly installed fuel filler cap.
For more information, refer toFuel filler capin theMaintenance and
specificationschapter.
CHECK
FUEL
CAP
Instrument Cluster
11

Engine oil pressure
Illuminates when the oil pressure
falls below the normal range. Check
the oil level and add oil if needed.
Refer toEngine oilin the
Maintenance and specifications
chapter.
Traction ControlYactive (if equipped)
Illuminates when the Traction
Controlysystem is active. It will be
lit for a minimum of four seconds or
for the duration of the Traction
Controlyevent.
For more information, refer to theDrivingchapter.
Traction ControlYoff light (if equipped)
Illuminates when the Traction
Controlysystem has been disabled
(by the driver or as a result of a
system failure). For more
information, refer to theDrivingchapter.
Low tire warning
Illuminates while the low tire
warning system is enabled. If the
light remains on while driving, the
tire pressures should be checked,
refer toLow tire warningin the
Maintenance and specificationschapter.
Bulb Warning
Illuminates when one of the exterior
bulbs has burned out.
TRAC
ACTIVE
TRAC
OFF
Instrument Cluster
13

GAUGES
Engine coolant temperature gauge
Indicates the temperature of the
engine coolant. At normal operating
temperature, the needle remains
within the normal area (the area
between the ªHº and ªCº). If it
enters the red section, the engine is
overheating. Stop the vehicle as
soon as safely possible, switch off
the engine immediately and let the
engine cool. Refer toEngine coolantin theMaintenance and
specificationschapter.
Never remove the coolant reservoir cap while the engine is
running or hot. Steam and scalding liquid from a hot cooling
system can burn you badly.
This gauge indicates the temperature of the engine coolant, not the
coolant level. If the coolant is not at its proper level the gauge indication
will not be accurate.
40
4080
120
160
20020
12345
6
760
80100
120MPH RPMX1000 THEFT
TRAC
ACTIVE TRAC
OFFTEMP
H
FFUEL
E
km/h
BRAKE
mi
O/D
OFFCHECK
FUEL
CAP
TEMP
H
Instrument Cluster
16

LIFTGATE AJAR.Displayed when the liftgate is not completely closed.
CHECK CHARGING SYSTEM.Displayed when the electrical system is
not maintaining proper voltage. If you are operating electrical accessories
when the engine is idling at a low speed, turn off as many of the
electrical loads as soon as possible. If the warning stays on or comes on
when the engine is operating at normal speeds, have the electrical
system checked as soon as possible.
LOW FUEL LEVEL.Displayed as an early reminder of a low fuel
condition.
CHECK TRANSMISSION.Indicates the transmission is not operating
properly. If this warning stays on, contact your dealer as soon as
possible.
TRANSMISSION OVERHEATED.Indicates the transmission is
overheating. This warning may appear when towing heavy loads or when
driving in a low gear at a high speed for an extended period of time.
Stop the vehicle as soon as safely possible, turn off the engine and let it
cool. Check the transmission fluid and level. Refer toTransmission
fluidin theMaintenance and specificationschapter. If the warning
stays on or continues to come on, contact your dealer for transmission
service as soon as possible.
CHECK BRAKE LAMPS. Displayed when the brake lamps are
activated and at least one is burned out. Check the lamps as soon as
possible and have the burned out lamp replaced. The center high-mount
brakelamp is not monitored.
CHECK HEADLAMPS. Displayed when the headlamps are activated
and at least one is burned out. Check the lamps as soon as possible and
have the burned out lamp replaced. Refer toReplacing headlamp bulbs
in theLightschapter.
CHECK TAIL LAMPS.Displayed when the tail lamps are activated and
at least one is burned out. Check the lamps as soon as possible and have
the burned out lamp replaced.
CHECK FRONT TURN LAMPS.Displayed when the turn signals are
activated and at least one is burned out. Check the lamps as soon as
safely possible and have the burned out lamp replaced.
CHECK REAR TURN LAMPS.Displayed when the turn signals are
activated and at least one is burned out. Check the lamps as soon as
possible and have the burned out lamp replaced.
Driver Controls
104

CHECK SIDE REPEATER LAMPS (if equipped).Displayed when
the turn signals are activated and at least one is burned out. Check the
lamps as soon as possible and have the burned out lamp replaced.
TURN SIGNAL ON REMINDER.Displayed when the turn signal is
activated and the vehicle is driven more that 0.8 km (1/2 mile).
LOW WASHER FLUID.Indicates the washer fluid reservoir is less than
one quarter full. Check the washer fluid level. Refer toWindshield
washer fluidin theMaintenance and specificationschapter.
CHECK TRACTION CONTROL (if equipped).Displayed when the
Traction Controlysystem is not operating properly. If this warning stays
on, contact your dealer for service as soon as possible. For further
information, refer toTraction controlyin theDrivingchapter.
CHECK ADVANCETRAC (if equipped).Displayed when the
AdvanceTracysystem is not operating properly. If this message is
displayed on the message center the AdvanceTracysystem might be
partially operable. If this warning stays on while the engine is running,
contact your dealer for service as soon as possible. For further
information, refer toAdvanceTracystability enhancement systemin
theDrivingchapter.
CHANGE OIL SOON/OIL CHANGE REQUIRED.Displayed when the
engine oil life remaining is 5 percent or less. When oil life left is between
5% and 0%, the CHANGE OIL SOON message will be displayed. When oil
life left reaches 0%, the OIL CHANGE REQUIRED message will be
displayed.
An oil change is required whenever indicated by the message center.
USE ONLY RECOMMENDED ENGINE OILS.
To reset the oil monitoring system to 100% after each oil change
[approximately 8 000 km (5 000 miles) or 180 days] perform the
following:
1. Press the SETUP control to
access the System Check function.
2. Press and release the RESET
control to display ªOIL LIFE XX%
HOLD RESET NEWº.
%
Driver Controls
105

Front safety belt energy management retractors
The front 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 toSafety beltsection 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 the
Warning lightsection in theInstrument clusterchapter. Routine
maintenance of the Personal safety system is not required.
The Restraints control module (RCM) monitors its own internal circuits
and the circuits for the air bag supplemental restraints, crash sensor(s),
safety belt pretensioners, front safety belt buckle sensors, driver seat
position sensor, and passenger occupant classification sensor (if
equipped). In addition, the RCM also monitors the restraints warning
light in the instrument cluster. A difficulty with the system is indicated
by one or more of the following.
²The warning light will either flash or stay lit.
²The warning light will not illuminate immediately after ignition is
turned on.
²A series of five beeps will be heard. The tone pattern will repeat
periodically until the problem and warning light are repaired.
If any of these things happen, even intermittently, have the Personal
safety 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.
Safety belt precautions
Always drive and ride with your seatback upright and the lap
belt snug and low across the hips.
To reduce the risk of injury, make sure children sit where they
can be properly restrained.
Seating and Safety Restraints
144

Safety belt extension assembly
If the safety belt is too short when fully extended, there is a 20 cm (8
inch) safety belt extension assembly that can be added (part number
611C22). This assembly can be obtained from your dealer at no cost.
Use only extensions manufactured by the same supplier as the safety
belt. Manufacturer identification is located at the end of the webbing on
the label. Also, use the safety belt extension only if the safety belt is too
short for you when fully extended. Do not use extensions to change the
fit of the shoulder belt across the torso.
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 used 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 passenger and second
row bench 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 toCleaning and maintaining the safety beltsin theCleaning
chapter.
Replacing the front passenger and second row bench seat belt
assemblies after a collision
All front passenger and second row bench seat belt assemblies adjacent
to a sliding door have special energy management retractors designed to
further reduce the risk of injury in the event of a head-on collision.
Seating and Safety Restraints
154

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:
²The readiness light (same light
for front and side air bag system)
will either flash or stay lit.
²The readiness light will not
illuminate immediately after ignition is turned on.
²A 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.
How does the air bag supplemental restraint system work?
The air bag SRS is designed to
activate when the vehicle sustains
longitudinal deceleration sufficient
to cause the sensors to close an
electrical circuit that initiates air
bag inflation.
The fact that the air bags did not
inflate in a collision does not mean
that something is wrong with the
system. Rather, it means the forces
were not of the type sufficient to
cause activation. Front air bags are designed to inflate in frontal and
near-frontal collisions, not rollover, side-impact, or rear-impacts unless
the collision causes sufficient longitudinal deceleration.
Seating and Safety Restraints
158

If you ever smell exhaust fumes of any kind inside your vehicle,
have your dealer inspect and fix your vehicle immediately. Do
not drive if you smell exhaust fumes. These fumes are harmful and
could kill you.
Have the exhaust and body ventilation systems checked whenever:
²the vehicle is raised for service
²the sound of the exhaust system changes
²the vehicle has been damaged in a collision
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. In addition, certain fluids contained in vehicles and
certain products of component wear contain or emit chemicals known
to the State of California to cause cancer and birth defects or other
reproductive harm.
Important ventilating information
If the engine is idling while the vehicle is stopped in an open area for
long periods of time, open the windows at least 2.5 cm (one inch).
Adjust the heating or air conditioning (if equipped) to bring in fresh air.
Improve vehicle ventilation by keeping all air inlet vents clear of snow,
leaves and other debris.
BRAKES
Your service brakes are self-adjusting. Refer to the scheduled
maintenance guide for scheduled maintenance.
Occasional brake noise is normal and often does not indicate a performance
concern with the vehicle's brake system. In normal operation, automotive
brake systems may emit occasional or intermittent squeal or groan noises
when the brakes are applied. Such noises are usually heard during the first
few brake applications in the morning; however, they may be heard at any
time while braking and can be aggravated by environmental conditions such
as cold, heat, moisture, road dust, salt or mud. If a ªmetal-to-metal,º
ªcontinuous grindingº or ªcontinuous squealº sound is present while braking,
the brake linings may be worn-out and should be inspected by a qualified
service technician.
Driving
179