2005 FORD E SERIES maintenance

Maintenance and Specifications 197
Engine compartment 199
Engine oil 200
Battery 203
Fuel information 211
Air filter(s) 226
Part numbers 227
Refill capacities 228
Lubricant specifications 233
Accessories 240
Index 243
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Copyright © 2004 Ford Motor Company
Table of Contents
3
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Special instructions
For your added safety, your vehicle is fitted with sophisticated electronic
controls.
Please read the sectionSupplemental restraint system (SRS)
in theSeating and Safety Restraintschapter. Failure to follow
the specific warnings and instructions could result in personal injury.
Front seat mounted rear-facing child or infant seats should
NEVERbe placed in front of an active passenger air bag.
Notice to owners of diesel-powered vehicles
Read the6.0 Liter Power Stroke Direct Injection Turbo Diesel Owner’s
GuideSupplement for information regarding correct operation and
maintenance of your Diesel-powered light truck.
Notice to owners of pickup trucks and utility type vehicles
Utility vehicles have a significantly higher rollover rate than
other types of vehicles.
Before you drive your vehicle, please read thisOwner’s Guidecarefully.
Your vehicle is not a passenger car. As with other vehicles of this type,
failure to operate this vehicle correctly may result in loss of vehicle
control, vehicle rollover, personal injury or death.
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Introduction
7

WARNING LIGHTS AND CHIMES
Warning lights and gauges can alert you to a vehicle condition that may
become serious enough to cause expensive repairs. A warning light may
illuminate when a problem exists with one of your vehicle’s functions.
Many lights will illuminate when you start your vehicle to make sure the
bulb works. If any light remains on after starting the vehicle, have the
respective system inspected immediately.
If your vehicle is equipped with a Diesel engine, it has a unique cluster,
refer toStarting the engine in your 6.0 Liter Power Stroke Direct
Injection Turbo Diesel Owner’s Guide Supplement.
Service engine soon:TheService
engine soonindicator light
illuminates when the ignition is first
turned to the ON position to check
the bulb. Solid illumination after the engine is started indicates the On
Board Diagnostics System (OBD-II) has detected a malfunction. Refer to
On board diagnostics (OBD-II)in theMaintenance and Specifications
chapter. If the light is blinking, engine misfire is occurring which could
damage your catalytic converter. Drive in a moderate fashion (avoid
heavy acceleration and deceleration) and have your vehicle serviced
immediately.
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.
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Instrument Cluster
Instrument Cluster
12

Electronic throttle control (if
equipped):Illuminates when the
engine has defaulted to a
’limp-home’ operation. Report the
fault to a dealer at the earliest opportunity.
Check fuel cap:Illuminates when
the fuel cap may not be properly
installed. Continued driving with
this light on may cause the Service
Engine Soon warning light to come
on, refer toFuel filler capin the
Maintenance and Specificationchapter.
Brake system warning light:To
confirm the brake system warning
light is functional, it will
momentarily illuminate when the
ignition is turned to the ON position
when the engine is not running, or in a position between ON and START,
or by applying the parking brake when the ignition is turned to the ON
position. If the brake system warning light does not illuminate at this
time, seek service immediately from your dealership. Illumination after
releasing the parking brake indicates low brake fluid level and the brake
system should be inspected immediately by your servicing dealership.
Driving a vehicle with the brake system warning light on is
dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle
checked by your dealer immediately.
Anti-lock brake system:
If the
ABS light stays illuminated or
continues to flash, a malfunction has
been detected, have the system
serviced immediately. Normal braking
is still functional unless the brake warning light also is illuminated.
Air bag readiness:If this light fails
to illuminate when ignition is turned
to ON, continues to flash or remains
on, have the system serviced
immediately. A chime will also sound when a malfunction in the
supplemental restraint system has been detected.
P!
BRAKE
ABS
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Instrument Cluster
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Battery voltage gauge:Indicates
the battery voltage when the
ignition is in the ON position. If the
pointer moves and stays outside the
normal operating range, have the
vehicle’s electrical system checked
as soon as possible.
Engine oil pressure gauge:
Indicates engine oil pressure. The
needle should stay in the normal
operating range (between “L” and
“H”). If the needle falls below the
normal range, stop the vehicle, turn
off the engine and check the engine
oil level. Add oil if needed. If the oil level is correct, have your vehicle
checked at your dealership or by a qualified technician.
Fuel gauge:Indicates
approximately how much fuel is left
in the fuel tank (when the ignition
is in the ON position). The fuel
gauge may vary slightly when the
vehicle is in motion or on a grade.
The FUEL icon and arrow indicates
which side of the vehicle the fuel filler door is located.
Refer toFilling the tankin theMaintenance and Specifications
chapter for more information.
H
L
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Instrument Cluster
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How to disengage the automatic locking mode
Disconnect the combination lap/shoulder belt and allow it to retract
completely to disengage the automatic locking mode and activate the
vehicle sensitive (emergency) locking mode.
After any vehicle collision, the safety belt systems at all outboard
seating positions (except the driver position, which does not
have this feature) must be checked by a qualified technician to verify
that the automatic locking retractor feature for child seats is still
functioning properly. In addition, all seat belts should be checked for
proper function.
BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED if
the seat belt assembly “automatic locking retractor” feature or
any other seat belt function is not operating properly when checked
according to the procedures in Workshop Manual. Failure to replace
the Belt and Retractor assembly could increase the risk of injury in
collisions.
Safety belt pretensioner
Your vehicle is equipped with safety belt pretensioners at the driver and
front outboard passenger seating positions.
The safety belt pretensioner is a device which removes excess webbing
from the safety belt system. The safety belt pretensioner uses the same
crash sensor system as the front air bag supplemental restraint system
(SRS). When the safety belt pretensioner deploys, webbing from the lap
and shoulder belt is tightened. Refer to theSafety belt maintenance
section in this chapter.
The driver and front passenger seat belt system (including
retractors, buckles and height adjusters) must be replaced if the
vehicle is involved in a collision that results in deployment of front air
bags and safety belt pretensioners.
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Seating and Safety Restraints
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•This will enable the BeltMinder feature for that seating position if it is
currently disabled. As confirmation, the restraint system warning light
will flash 4 times per second for 3 seconds, followed by 3 seconds with
the light off, then followed by the airbag warning light flashing 4 times
per second for 3 seconds again.
5. After receiving confirmation, the deactivation/activation procedure is
complete.
Safety belt extension assembly
If the safety belt is too short when fully extended, there is a 8 inch (20
cm) 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. Replace 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), shoulder belt guide on seatback (if
equipped), child safety seat LATCH and tether anchors, and attaching
hardware, should be inspected after a collision. Ford Motor Company
recommends that all safety belt assemblies in use 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. 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 toInteriorin theCleaningchapter.
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Seating and Safety Restraints
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Determining if the system is operational
The SRS uses a readiness light in the instrument cluster or a tone to
indicate the condition of the system. Refer toAir bag readinesssection
in theInstrument Clusterchapter. Routine maintenance of the air bag is
not required.
A difficulty with the system is indicated by one or more of the following:
•The readiness light will either
flash or stay lit.
•The readiness light will not
illuminate immediately after ignition is turned on.
•A 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 SRS serviced
at your dealership or by a qualified technician immediately. Unless
serviced, the system may not function properly in the event of a
collision.
Disposal of air bags and air bag equipped vehicles (including
pretensioners)
See your local dealership or qualified technician. Air bags MUST BE
disposed of by qualified personnel.
SAFETY RESTRAINTS FOR CHILDREN
See the following sections for directions on how to properly use safety
restraints for children. Also seeAir bag supplemental restraint system
(SRS)in this chapter for special instructions about using air bags.
Important child restraint precautions
You are required by law to use safety restraints for children in the U.S.
and Canada. If small children (generally children who are four years old
or younger and who weigh 18 kg [40 lb.] or less) ride in your vehicle, you
must put them in safety seats made especially for children. Many states
require that children use approved booster seats until they are eight
years old. Check your local and state or provincial laws for specific
requirements regarding the safety of children in your vehicle. When
possible, always place children under age 12 in the rear seat of your
vehicle. Accident statistics suggest that children are safer when properly
restrained in the rear seating positions than in the front seating position.
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Seating and Safety Restraints
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