brake LINCOLN AVIATOR 2003 Service Manual

Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
The high-current fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
1 60A** PJB
2 30A** Door locks (BSM)
3 — Not used
4 40A** Heated backlight/mirrors
5 40A** Anti-lock Brake System (ABS)
module (pump)
6 60A** Delayed accessory
7 20A** DRL
8 20A** Electric cooling fan
9 20A** Headlampswitch, Foglampswitch
10 30A** ABS module (valves)
11 40A** PTEC relay contacts
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
12 50A** Ignition/Starter relay
13 40A** Trailer tow relays
14 15A* Brake lampfeed
15 10A* Keepalive power
(PTEC/cluster/DEATC)
16 20A* Power point #3
17 20A* Rear wiper module
18 20A* 4x4 module
19 30A** Driver window motor
20 30A** Electric trailer brakes
21 30A** Memory seat module
22 20A** High beam relays fuse
23 30A** Ignition switch
24 20A* Horn relay
25 20A* Power point #1
26 20A* Fuel pump relay contacts
27 20A* Trailer tow lamps
28 20A* Power point #2
29 60A** PJB
30 30A** Front wiper module
31 30A** Climate-controlled seats
32 30A** Passenger seat switch
33 30A** Auxiliary blower motor
34 20A** Right HID relay
35 20A** Left HID relay
36 40A** Blower motor
37 15A* A/C clutch relay, TXV,
Transmission, Speed control
38 15A* HEGO, VMV, Canister vent,
IMCC-LSRC, Heated PCV, EGR
module
39 15A* Injectors
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
40 15A* PTEC, Mass Air Flow (MAF)
Sensor, Fuel pump relay
41 25A* Coil on plug, PTEC relay
42 10A* Right low beam (halogen)
43 10A* Left low beam (halogen)
44 15A* Fog lamprelay
45 2A* Brake Pressure Switch
46 20A* High beam
47 — Horn relay
48 — Fuel pump relay
49 — High beam relay
50 — Fog lamprelay
51 — DRL relay
52 — A/C clutch relay
53 — Trailer tow right turn relay
54 — Trailer tow left turn relay
55 — Blower motor relay
56 — Starter motor relay
57 — PTEC relay
58 — Ignition relay
59 — Driver brake applied relay
60 — PCM diode
61 — A/C clutch diode
62 30A*** Power windows
* Mini Fuses ** Maxi Cartridge Fuses *** Circuit breaker
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The relays are coded as follows:
Fuse/Relay Location Description
Relay 1 Liftgate release solenoid
Relay 2 Open
Relay 3 Open
Relay 4 Trailer tow back-uplamps
Relay 5 Open
Relay 6 Open
Relay 7 Trailer tow battery charge
Relay 8 Trailer tow park lamps
Relay 9 Open
Relay 10 Puddle lamps
Diode 11 Open
Diode 12 Open
CHANGING THE TIRES
If you get a flat tire while driving:
•do not brake heavily.
•gradually decrease the vehicle’s speed.
•hold the steering wheel firmly.
•slowly move to a safe place on the side of the road.
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The use of tire sealants is not recommended and may
compromise the integrity of your tires. The use of tire sealants
may also affect your tire pressure monitoring system (if equipped).
If your vehicle is equipped with a tire pressure monitoring
system, refer toTire Pressure Monitoring System (if
equipped)in theMaintenance and specificationssection for
important information. If the tire pressure monitor sensor becomes
damaged, it will no longer function.
Spare tire information
The spare tire can be used as a spare or a regular tire and is identical to
the other tires on your vehicle.
If your vehicle is equipped with AWD, a spare tire of a different
size than the road tires should not be used. Such a tire could
make the vehicle difficult to control as well as result in damage to
driveline components.
Stopping and securing the vehicle
1. 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.
2. Park on a level surface, activate
the hazard flashers and set the
parking brake.
3. Place gearshift lever in P (Park)
and turn engine OFF.
When one of the rear wheels is off the ground, the transmission
alone will not prevent the vehicle from moving or slipping off the
jack, even if the transmission is in P (Park).
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2. Insert the lug wrench on the
winch drive nut.
The wrench will stopmoving and
forward resistance to turning will be
felt when properly engaged.
3. Turn the wrench
counterclockwise until the tire is
lowered to the ground and the cable
has slack. When turning the wrench,
make sure that it does not scuff the
kick plate.
4. Slide the tire rearward, lift one
side and remove the retainer from
the spare tire.
Changing the spare tire
To prevent the vehicle from moving when you change a tire, be
sure the parking brake is set, then block the wheel that is
diagonally opposite (other end of the vehicle) to the tire being
changed.
If the vehicle slips off the jack, you or someone else could be
seriously injured.
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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 converter may become damaged.
Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its shift strategy. As a result, the transmission
may have firm and/or soft shifts. 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.
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.
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PAINTCHIPS
Your dealer has touch-up paint and sprays to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jam) to
your dealer to ensure you get the correct color.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND WHEEL COVERS
Aluminum wheels and wheel covers are coated with a clearcoat paint
finish. In order to maintain their shine:
•Clean weekly with Motorcraft Wheel and Tire Cleaner (ZC-37–A),
which is available from your dealer. Heavy dirt and brake dust
accumulation may require agitation with a sponge. Rinse thoroughly
with a strong stream of water.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•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 detergent.
•To remove tar and grease, use Ford Extra Strength Tar and Road Oil
Removal (B7A-19520–AA), available from your dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildupkeepthe engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
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SERVICE RECOMMENDATIONS
To helpyou service your vehicle:
•We highlight do-it-yourself items in the engine compartment for easy
location.
•We 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 Guide/Owner
Information 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
•Do not work on a hot engine.
•Make sure that nothing gets caught in moving parts.
•Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
•Keepall open flames and other lit material away from the battery and
all fuel related parts.
Working with the engine off
1. Set the parking brake and shift to P (Park).
2. Turn off the engine and remove the key.
3. Block the wheels.
Working with the engine on
1. Set the parking brake and shift to P (Park).
2. Block the wheels.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
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IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
4.6L V8 engines
1. Engine oil dipstick
2. Brake fluid reservoir
3. Power distribution box
4. Battery
5. Power steering fluid reservoir
6. Engine oil filler cap
7. Engine coolant reservoir
8. Windshield washer fluid reservoir
9. Air filter assembly
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