EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
²Use only unleaded fuel.
²Avoid running out of fuel.
²Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
²Have the items listed in your maintenance guide and or service guide
performed according to the specified schedule.
The scheduled maintenance items listed in the maintenance guide and or
service guide are essential to the life and performance of your vehicle
and to its emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the charging system warning light, ªService Engine Soonº
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of oil pressure, could indicate that the emission control system is
not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, items, 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
Maintenance and care
178
Do not remove lamp bulbs unless they will be replaced immediately. If a
bulb is removed for an extended period of time, contaminants may enter
the lamp housings and affect performance.
Replacing headlamp bulbs (aerodynamic)
Handle a halogen headlamp bulb carefully and keep out of
children's reach. Grasp the bulb only by its plastic base and do
not touch the glass. The oil from your hand could cause the bulb to
break the next time the headlamps are operated.
To remove the headlamp bulb:
1. Make sure headlamp switch is in OFF position.
2. Open the hood.
3. Push each clip tab toward the
engine compartment and lift upward
to the stop position.
4. Remove the headlamp assembly.
5. Release clip and disconnect the
electrical connector from the bulb.
6. Remove the bulb retaining ring by
rotating it counterclockwise (when
viewed from the rear) about
1/8 turn to free it from the bulb
socket, and slide the ring off the
plastic base. Keep the ring to retain
the new bulb.
7. Without turning, remove the old bulb from lamp assembly by gently
pulling it straight back out of the lamp assembly and replace.
Maintenance and care
180
Washing your vehicle
Wash your vehicle regularly with
cold or lukewarm water. Never use
strong detergents or soap. If your
vehicle is particularly dirty, use a
quality car wash detergent. Always
use a clean sponge, washing glove
or similar device and plenty of water
for best results. To avoid spots,
avoid washing when the hood is still
warm, immediately after or during
exposure to strong sunlight.
During winter months, it is especially important to wash the vehicle on a
regular basis. Large quantities of dirt and road salt are difficult to
remove and also cause damage to the vehicle.
Remove any exterior accessories, such as antennas, before entering a car
wash. If you have wax applied to the vehicle at a commercial car wash, it
is recommended that you clean the wiper blades and windshield as
described inCleaning the wiper blades and windshield.
After washing, apply the brakes several times to dry them.
Waxing your vehicle
Wax when water stops beading on the surface. This could be every three
or four months, depending on operating conditions.
Use only carnauba or synthetic-based waxes. Use cleaning fluid or
alcohol with a clean cloth to remove any bugs and tar before waxing
vehicle. Use tar remover to remove any tar spots.
Avoid getting wax on the windshield. If you have wax applied at a
commercial car wash, it is recommended that you clean the wiper blades
and windshield as described inCleaning the wiper blades and
windshield.
Repairing paint chips
Minor scratches or paint damage from road debris may be repaired with
touch-up paint, repair foil or aerosol paint spray from the Ford accessory
line. Observe the application instructions on the products.
Remove particles such as bird droppings, tree sap, insect remains, tar
spots, road salt and industrial fallout immediately.
Maintenance and care
184
MOTORCRAFT PART NUMBERS
Com-
ponent*4.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Air filter FA-1634 FA-1634 FA-1634 FA-1634
Battery
(standard)BXT-65-650 BXT-65-650 BXT-65-650 BXT-65-650
Battery
(optional)BXT-65-750 BXT-65-750 BXT-65-750 BXT-65-750
Battery
(auxiliary)BH-65DC BH-65DC BH-65DC BH-65DC
Fuel filter FG-872 FG-872 FG-872 FG-872
Oil filter FL-400-S FL-820-S FL-820-S FL-820-S
PCV valve EV-152 EV-233 EV-233 EV-233
Spark
plugs**AGSF-
34EE***AWSF-
32PP****AWSF-22E AWSF-22E
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor Motorcraft diesel engine service part
numbers.
**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.
**** If a spark plug is removed for inspection, it must be reinstalled in
the same cylinder. Cylinders No. 1, 2, 3 and 4 have a ªPGº suffix.
Cylinders No. 5, 6, 7 and 8 have a ªPº suffix. If a spark plug needs to be
replaced, use only spark plugs with the service part number suffix letter
as shown on the engine decal.
Capacities and specifications
188
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine
oil-gasoline
engine (includes
filter change)Motorcraft 5W30
Super Premium
Motor OilAll 5.7L
(6.0 quarts)
Engine oil-diesel
engine (includes
filter change)Refer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner's Supplement.
Engine
coolant-gasoline
engine
14.2L V6 engine 22.0L
(23.3 quarts)
4.2L V6 engine
with aux rear
heat24.0L
(25.4 quarts)
4.6L V8 engine 23.7L
(25.0 quarts)
4.6L V8 engine
with aux rear
heat25.7L
(27.2 quarts)
5.4L V8 engine 27.4L
(29.0 quarts)
5.4L V8 engine
with aux rear
heat29.4L
(31.0 quarts)
6.8L V10 engine 29.0L
(30.6 quarts)
6.8L V10 engine
with aux rear
heat31.0L
(32.8 quarts)
Engine
coolant-diesel
engineRefer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner's Supplement.
1
Capacities and specifications
189
LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid High Perfor-
mance DOT 3
Motor Vehicle
Brake FluidC6AZ-19542-AB ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantC0AZ-19553-AA
and
F5AZ-19553-AAESR-M13P4-A
Engine coolant Ford Premium
Engine Coolant
(green in color)E2FZ-19549-AA ESE-M97B44-A
Ford Extended
Life Engine
Coolant (orange
in color)F6AZ-19544-AA WSS-M97B44-D
or DEX-COOLt
equivalent
Engine
oil-gasoline
engineMotorcraft 5W30
Super Premium
Motor OilXO-5W30-QSP WSS-M2C153-G
with API Certi-
fication Mark
Engine oil-diesel
engineRefer to the7.3 Liter Power Stroke Direct
Injection Turbo Diesel Owner's Guide Supplement.
Hinges, latches,
Striker plates, fuel
filler door hinge,
and seat tracksMulti-Purpose
GreaseD0AZ-19584-AA
or
F5AZ-19G209-AAESB-M1C93-B or
ESR-M1C159-A
Lock cylinders Penetrating
LubricantE8AZ-19501-B none
Power steering
fluidMotorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic trans-
mission (4R100)1Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic trans-
mission (4R70W)Motorcraft MER-
CONtVATFXT-5-QM MERCONtV
Disc brake
caliper railsSilicone Brake
Caliper and
Dielectric
compoundD7AZ-19A331-A
WA-10ESE-M1C171-A
Capacities and specifications
193
ENGINE DATA
Engine*4.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Cubic inches 256 281 330 415
Horsepower200 @
4800 rpm215 @
4500 rpm235 @
4450 rpm265 @
4250 rpm
Torque250 lb.-ft. @
2800 rpm290 lb.-ft. @
3250 rpm335 lb.-ft. @
3000 rpm405 lb.-ft. @
2750 rpm
Recom-
mended fuel87 octane 87 octane 87 octane 87 octane
Firing order1-4-2-5-3-6 1-3-7-2-
6-5-4-81-3-7-2-
6-5-4-81-6-5-10-2-
7-3-8-4-9
Spark plug
gap1.3-1.4 mm
(0.052-
0.056 inch)1.3-1.4 mm
(0.052-
0.056 inch)1.3-1.4 mm
(0.052-
0.056 inch)1.3-1.4 mm
(0.052-
0.056 inch)
Ignition
systemEDIS EDIS Coil on plug Coil on plug
Compression
ratio9.3:1 9.0:1 9.0:1 9.0:1
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor diesel engine information.
VEHICLE DIMENSIONS
Van/wagon models
E-150 E-250 E-350
(1) Overall height 2 054.8 mm
(80.9 in)2 118.4 mm
(83.4)2 136.1
(84.1 in)
(2) Track front/rear 1 762.8 mm (69.4 in)/ 1 701.8 mm (67.0 in)
(3) Overall width
(excluding mirrors)2 014.2 mm (79.3 in)
(4) Wheelbase 3 505 mm (138 in)
(5) Overall length Regular van, 5 379.7 mm (211.8 in)
Supervan, 5 892.8 mm (232.0 in)
Capacities and specifications
195
Air bag supplemental restraint
system ..........................................83
and child safety seats ..............84
description ................................83
disposal ......................................87
indicator light ...........................86
passenger air bag .....................85
Automatic transmission
driving an automatic
overdrive ...................109,110,111
Axle
refill capacities ........................189
Battery
disconnecting ............161,162,163
voltage gauge ............................14
Brakes ........................................103
anti-lock .....................103,104,105
anti-lock brake system (ABS)
warning light ...........................104
fluid, checking and adding ....150
shift interlock ..........................108
Break-in period ..........................2,3
CD player ....................................53
Child safety seats
attaching with tether straps ....93
in rear seat ................................90
tether anchorage
hardware ..............................93,97
Cleaning your vehicle ...............183
engine compartment ..............185
exterior .............................184,187
exterior lamps .........................186
interior .....................................186
plastic parts ............................186
washing ....................................184
waxing .....................................184
wheels ......................................185
windows ..................................187
wiper blades ............................186
Controls
power seat .................................72
Coolant ...............................153,154checking and adding ..............152
refill capacities ........................154
Driveline universal joint and
slip yoke ....................................159
Emission control system ..........178
Engine
coolant .....................................151
idle speed control ...................159
service points ..........................147
starting after a collision .........123
Engine block heater .................101
Engine oil
checking and adding ..............149
dipstick ....................................147
specifications ...................147,149
Exhaust fumes ..........................101
Fail safe cooling .................154,155
Fuel
choosing the right fuel ...........171
comparisons with EPA fuel
economy estimates .................177
detergent in fuel .....................172
filling your vehicle
with fuel ...........................170,173
gauge .........................................12
quality ......................................172
running out of fuel .................172
safety information relating to
automotive fuels .....................170
Fuses ...................................125,126
Gas mileage (see Fuel
economy) ..............174,175,176,177
Gauges .........................................12
engine coolant temperature
gauge .........................................13
engine oil pressure gauge ........13
GVWR
(Gross Vehicle Weight Rating)
calculating ...............................113
Hazard flashers .........................123
Headlamps
aiming ......................................183
Index
200