1997 Ford Expedition Owners Manual

Maintenance and care

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Working with the engine on 1. Set the parking brake fully and ensure the gearshift is securely latched in P (Park). 2. Block the wheels to prevent your vehicle from moving unexpectedly.

Do not start your engine with the air cleaner

removed and do not remove it while the engine is running.

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT

4.6 / 5.4 L engine

10

1. Battery 2. Automatic transmission dipstick

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3. Engine oil dipstick (For more information on the engine oil dipstick location and maintenance, refer to Checking and adding engine oil in this chapter.) 4. Brake fluid reservoir 5. Engine compartment fuse panel 6. Engine coolant reservoir 7. Air cleaner filter 8. Power steering fluid reservoir 9. Engine oil filler cap 10. Washer fluid reservoir

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CHECKING AND ADDING ENGINE OIL Use WSS-M2C153–F motor oil CERTIFIED FOR GASOLINE ENGINES by the American Petroleum Institute. Engine oils with an SAE 5W-30
viscosity and displaying the American Petroleum Institute certification mark are preferred for your vehicle. They provide the best engine performance, fuel economy and engine protection for all climates down to –25°C (-15°F). Do not use: • “non-detergent” oils • oils labeled API SA, SB, SC, SD, • additional engine oil additives,

SE, SF or SG

oil treatments or engine treatments

Additional engine oil additives, oil treatments or engine treatments

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are never needed and could, under certain conditions, lead to engine damage which is not covered by your Ford warranty. Synthetic engine oils which are CERTIFIED and of the preferred viscosity may be used in your engine. The engine oil and oil filter must still be changed according to the “Service Guide”.

Checking the engine oil Check the engine oil each time you fuel your vehicle. To check the oil: 1. Make sure the vehicle is on level ground. If the engine is running, turn the engine off and wait a few minutes for the oil to drain into the oil pan. 2. Set the parking brake and ensure the gearshift is securely latched in P. 3. Open the hood. Protect yourself from engine heat.

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4. Locate and carefully remove the engine oil dipstick. 5. Wipe the dipstick clean. Insert the dipstick fully, then remove it again. The oil level should be in the range shown on the dipstick. 6. If the oil level is below the minimum line, add engine oil as necessary. If the oil level is beyond the maximum line, engine damage or high oil consumption may occur and some oil must be removed from the engine by a service technician.

7. Put the dipstick back in and ensure it is fully seated.

Adding engine oil 1. Check the engine oil. For instructions, refer to Checking the engine oil in this chapter. 2. If the fluid level is not within the normal range, add only certified engine oil of the preferred viscosity. Add engine oil through the oil filler cap. Remove the filler cap and use a funnel to pour oil in the opening. 3. Recheck the oil level. Make sure the oil level is not above the full mark on the dipstick.

Continuous contact with used motor oil has caused

cancer in laboratory mice.

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ADD

FULL

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Changing the engine oil and filter Change your engine oil and filter according to the following kilometers (mileage) and time requirements, whichever occurs first: • Normal Schedule – 8,000 km (5,000 miles) or six months. • Severe Duty Schedule – 5,000
km (3,000 miles) or three months. Severe duty operation would include extensive idling, trailer towing, driving in severe dust and police, taxi or delivery service.

Ford production and aftermarket (Motorcraft) oil filters are designed for added engine protection and long life. If a replacement oil filter is used that does not meet Ford material and design specifications, startup engine noises or knock may be experienced. It is recommended you use the appropriate Motorcraft oil filter (or another brand meeting Ford specifications) for your engine application.

Checking and adding brake fluid Brake fluid should be checked and refilled as needed at least once each year:

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• Clean the reservoir cap before removal to prevent dirt or water from entering the reservoir. • Visually inspect the fluid level. • If necessary, add brake fluid

until the level reaches MAX. Do not fill above this line.

• Use only a DOT 3 brake fluid

certified to meet Ford specifications. Refer to Lubricant specifications in the Capacities and specifications chapter.

MAX

MIN

Brake fluid is toxic.

If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes.

Do not let the reservoir for the master cylinder run dry. This may cause the brakes to fail.

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CHECKING AND ADDING WASHER FLUID

Adding washer fluid 1. Lift the washer fluid reservoir cover. 2. Add washer fluid until the level reaches the FULL line. Use only fluid that meets Ford Specifications. Refer to Capacities and specifications. The addition of a bug shield to the front of the vehicle may adversely affect the washer system from delivering fluid to the windshield. Devices such as bug shields are not recommended.

Windshield washer fluid contains methanol and it is poisonous. Follow all instructions on the bottle of washer fluid.

What you should know about washer fluid In freezing weather [temperatures below 0°C (32°F)], use washer fluid containing a small amount of antifreeze, such as methanol. State or local regulations on volatile organic compounds (VOCs) may restrict the use of methanol, a common type of antifreeze. Use a non-methanol antifreeze in freezing weather only if the fluid does not damage the paint finish, wiper blades and washer system.

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WASHER FLUID

ONLY

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Washer fluid in the liftgate reservoir Washer fluid for liftgate wiper and washer operation is supplied by the washer fluid reservoir located in the engine compartment. For information on adding fluid to this main reservoir, refer to Washer fluid in the windshield reservoir in this chapter.

CHECKING AND ADDING ENGINE COOLANT

Adding engine coolant

Do not put engine coolant in the container for the

windshield washer fluid.

If sprayed on the windshield, engine coolant could make it difficult to see through the windshield. When the engine is cool, add a 50/50 mixture of engine coolant and water to the engine coolant recovery reservoir — DO NOT ADD DIRECTLY TO THE RADIATOR. Add straight water only in an emergency, but you should replace it with a 50/50
mixture of coolant and distilled water as soon as possible.

COOLANT FILL

LEVEL

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Check the coolant level in the coolant recovery reservoir the next few times you drive the vehicle. If necessary, add enough of a 50/50
mixture of coolant and water to bring the liquid level to the fill line on the reservoir.

Never remove the coolant recovery cap while the

engine is running or hot.

If you must remove the coolant recovery cap, follow these steps to avoid personal injury: 1. Before you remove the cap, turn the engine off and let it cool. 2. When the engine is cool, wrap a thick cloth around the cap. Slowly turn cap counterclockwise to the first stop. 3. Step back while the pressure releases. 4. When you are sure that all the pressure has been released, use the cloth to press the cap down, turn it counterclockwise and remove it. Use Ford Premium Cooling System Fluid E2FZ-19549–AA (in Canada, Motorcraft CXC-8–B) or an equivalent premium engine coolant that meets Ford Specification ESE-M97B44–A. Ford Premium Engine Coolant is an optimized formula that will protect all metals and rubber elastomers used in Ford cooling systems for 4 years or 80,000 km(50,000 miles).

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Do not use alcohol or methanol antifreeze or any engine coolants mixed with alcohol or methanol antifreeze. Do not use supplemental coolant additives in your vehicle. These additives may harm your engine cooling system. The use of an improper coolant may void the warranty of your vehicle’s engine cooling system. Recycledenginecoolant Ford Motor Company recommends that Ford and Lincoln-Mercury dealers use recycled engine coolant produced by Ford-approved processes. Not all coolant recycling processes produce coolant which meets Ford specification ESE-M97B44–A, and use of such coolant may harm engine and cooling system components.

Always dispose of used

automotive fluids in a responsible manner. Follow your community’s regulations and standards for recycling and disposing of automotive fluids. Coolantrefillcapacity To find out how much fluid your vehicle’s cooling system can hold, refer to Refill capacities in the Capacities and specifications chapter. Have your dealer check the engine cooling system for leaks if you have to add more than a liter (quart) of engine coolant per month.

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Severewinterclimate If you drive in extremely cold climates [less than 36°C (34°F)], it may be necessary to increase the coolant concentration above 50%. Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle is such that the coolant will not freeze at the temperature level in which you drive during winter months. Never increase the engine coolant concentration above 60%. Leave a 50/50 mixture of engine coolant and water in your vehicle year-round in non-extreme climates.

Checking the cooling system hoses Inspect all engine and heater system hoses and hose connections for:

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• deterioration • leaks • loose hose clamps What you should know about fail-safe cooling Vehicles equipped with 4.6L, and 5.4L engines have a fail-safe cooling mode. If the engine coolant supply is depleted, this feature allows the vehicle to be driven temporarily before incremental component damage is incurred. The “fail safe” distance depends on ambient temperatures, vehicle load and terrain. Whenfail-safemodeis activated • Pull off the road as soon as • Immediately turn the engine off

possible.

to prevent severe engine damage.

• Wait for the engine to cool. • Check the coolant level.

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Howfail-safecoolingworks If the engine overheats, the engine will automatically switch from eight to alternating four cylinder operation. Each disabled cylinder acts as an air pump and cools the engine. When this occurs, the engine coolant temperature gauge will move into the red area and the

light illuminates.

The service engine soon light will illuminate, indicating that vehicle service is required. The vehicle will still operate, but will have limited engine power and no air conditioning capability. Continued operation will increase engine temperature and cause the engine to completely shut down. The vehicle will coast to a stop. As the engine temperature cools, the engine may be re-started. Take your vehicle to a service facility as soon as possible to minimize engine damage.

CHECKING AND ADDING POWER STEERING FLUID Check the power steering fluid level at least twice a year. 1. Start the engine.

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2. When the engine coolant temperature gauge reaches the normal zone, turn the engine off.

3. Visually inspect the fluid level in the power steering fluid reservoir. 4. Add power steering fluid until the fluid level reaches MAX.

MAX MIN

MAX MIN

Use only fluid that meets Ford specifications. Refer to Capacities and specifications.

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CHECKING AND ADDING TRANSMISSION FLUID

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Checking and adding automatic transmission fluid (if equipped) Service the automatic transmission according to the scheduled intervals in the 9Service Guide.9
Before adding any fluid, make sure the correct type will be used. This information is indicated on the dipstick. • 4R7OW automatic transmissions

are used with 4.6 L engine applications.

• E4OD automatic transmissions

are used with 5.4 L engine applications.

Do not drive the vehicle if the fluid level is below the bottom hole on the blade type dipstick (4R70W transmission) or below the COLD area on the bullet type dipstick (E4OD transmission) and outside temperatures are above 10°C (50°F). Your vehicle does not use up transmission fluid. However, it is recommended that you check the transmission fluid at least twice a year. The fluid level should be checked if the transmission is not working properly, i.e., if the transmission slips or shifts slowly or if you notice some sign of fluid leakage. It is preferable to check the transmission fluid level at normal operating temperature, after

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approximately 32 km (20 miles) of driving. However, you can check the fluid level without driving to obtain a normal operating temperature if the outside temperature is above 10°C (50°F). If your vehicle has been operated for an extended period at high speeds, in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. 1. Park the vehicle on a level surface. 2. Start the engine and move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage. 3. Latch the gearshift lever in P(Park), set the parking brake and leave the engine running. 4. Remove the dipstick, wiping it clean with a clean, dry rag. 5. Install the dipstick. 6. Remove the dipstick and inspect the fluid level.

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For 4R70W transmissions, the fluid level should be within the crosshatched area, or if the vehicle has not been driven, between the holes near the bottom of the indicator.

DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT

IDLING IN PARK

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For E4OD transmissions, the fluid level should be within the HOT area, or if the vehicle has not been driven, within the COLD area.

7. If necessary, add fluid in .25L (.5 pint) increments through the filler tube until the level is at the correct area on the dipstick. If an overfill occurs, excess fluid should be removed by a qualified technician.

REAR AXLE MAINTENANCE The rear axle is filled with synthetic lubricant and will not require a lubricant change during the life of the vehicle unless the rear axle has been submerged in water. In addition, rear axle quantities are not to be checked or changed unless a leak is suspected or repair required.

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TRACTION-LOK REAR AXLE (IF EQUIPPED) This axle provides added drive away traction on slippery surfaces, particularly when one or more wheels are on a surface with poor traction. Extended use of other than matching size tires on a Traction-Lok rear axle could result in a permanent reduction in effectiveness. This loss of effectiveness does not effect normal driving and should not be noticeable to the driver.

To avoid injury, never run the engine with one wheel

off the ground, such as when changing a tire.

BATTERY If the original equipment maintenance-free battery needs replacing, it may be replaced with a low-maintenance battery. For information on replacement batteries, refer to Motorcraft part numbers in the Capacities and specifications chapter.

The gases around the battery can explode if

exposed to flames, sparks, or lit cigarettes. An explosion could result in injury or vehicle damage.

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Batteries contain sulfuric acid which burns skin,

eyes, and clothing.

Servicing your battery A low-maintenance replacement battery has removable vent caps for checking the electrolyte level and adding water. Check the electrolyte level every 24 months or 40,000 km (24,000 miles) in average temperatures below 32°C (90°F).

Keep the electrolyte level in each cell up to the level indicator. Do not overfill. If the level gets low, refill the battery with distilled water. If the battery needs water quite often, have the charging system checked for a possible malfunction. Your vehicle is equipped with a battery saver feature designed to prevent your battery from accidental wear down due to doors left ajar. For information on this system, refer to the Controls and features chapter.

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Relearningidleconditions Because your vehicle’s engine is electronically controlled by a computer, some control conditions are maintained by power from the battery. When the battery is disconnected or a new battery is installed, the computer must “relearn” its idle conditions before your vehicle will drive properly. To complete this process: 1. Put the gearshift in P(Park). 2. Turn off all accessories, and start the engine. 3. Let the engine idle for at least one minute. 4. The relearning process will automatically complete as you drive the vehicle. • If you do not allow the engine to relearn its idle, the idle quality of your vehicle may be adversely affected until the idle is eventually relearned. • If the battery has been

disconnected or a new battery has been installed, the clock and preset radio stations must be reset once the battery is reconnected.

Always dispose of used

automotive batteries in a responsible manner. Follow your community’s standards for disposal. Call your local recycling center to find out more about recycling automotive batteries.

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AIR CLEANER FILTER MAINTENANCE Refer to the “Service Guide” for the appropriate intervals for changing the air cleaner filter.

Do not start your engine with the air cleaner

removed and do not remove it while the engine is running.

CHANGING THE AIR FILTER 1. Loosen the clamp that secures the air cleaner in place. 2. Separate the two halves of the air cleaner. 3. Remove the air filter element from the open end of the engine air cleaner and replace it with a new element. Be careful not to crimp the filter edges between halves. This could cause filter damage if not properly seated. 4. Replace the two halves of the air cleaner and secure the clamp. For information on replacement air filter elements, refer to the Capacities and specifications chapter.

CHECKING AND REPLACING WIPER BLADES

Checking wiper blades Check the windshield wiper blades at least twice a year or whenever they seem to work less effectively than usual. Substances such as tree sap and some hot wax

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treatments used by commercial car washes can reduce the effectiveness of wiper blades. To make reaching the wiper blades easier, simply: 1. Turn the ignition to the 3(On) position.

2. Turn the wipers on. 3. Wait for the wipers to reach a vertical position and turn the ignition to 2(Lock). • Do not move the wipers

manually across the windshield, this may cause damage to both wipers and windshield.

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Replacing front wiper blades If the wiper blades do not function properly after cleaning, replacement of the blade assembly or the blade element may be necessary. The blade lengths for your vehicle are as follows: • Front wiper blades — • Rear wiper blades —

approximately 56 cm (22 in)

approximately 41 cm (16 in)

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To replace the wiper blades: 1. Pull the wiper arm away from the windshield and lock into service position (front wiper only). 2. Turn the blade at an angle from the wiper arm. Push the lock pin with a screwdriver to release the blade and pull the wiper blade down toward the windshield to remove it from the wiper arm. 3. Attach the new wiper blade to the wiper arm and press it in place until a click is heard.

Replacing rear wiper blades Unlike the front wiper, the rear wiper arm does not have a service position. Instead, follow these steps to change the rear wiper blade: 1. Lift the rear wiper arm out of the ramp position. 2. Pull out the arm and release the blade latch. 3. Manipulate the blade to remove it. • To rotate the liftgate wiper for removal, lift the wiper arm out of stop and pull the wiper arm away from liftgate at a 45° angle.

4. Attach the new wiper blade to the wiper arm and press into place until a click is heard.

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IMPORTANT TIRE MAINTENANCE INFORMATION

Information about tire quality grades New vehicles are fitted with tires that have their Tire Quality Grade (described below) molded into the tire’s sidewall. These Tire Quality Grades are determined by standards that the United States Department of Transportation has set. Tire Quality Grades apply to new pneumatic tires for use on passenger cars. They do not apply to deep tread, winter-type snow tires, space-saver or temporary use spare tires, tires with nominal rim diameters of 10 to 12 inches or limited production tires as defined in Title 49 Code of Federal Regulations Part 575.104(c)(2). U.S. Department of Transportation-Tire quality grades: The U.S. Department of Transportation requires Ford to give you the following information about tire grades exactly as the government has written it. Treadwear The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire grade 150
would wear one and one-half (1
1/2) times as well on the government course as a tire grade

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100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices, and differences in road characteristics and climate. TractionABC The traction grades, from highest to lowest are A, B, and C, and they represent the tire’s ability to stop on wet pavement as measured under test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Warning: The traction grade assigned to this tire is based on braking (straightahead) traction tests and does not include cornering (turning) traction. TemperatureABC The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of

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performance on the laboratory test wheel than the minimum required by law.

The temperature grade for this tire is established for a

tire that is properly inflated and not overloaded. Excessive speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure.

Checking the tire pressure Check the tire pressure periodically and inflate tires as necessary. To check the tire pressure, insert the tire pressure gauge into the valve system.

The cold pressure amount is listed on the Safety Compliance Certification label.

Improperly inflated tires can affect vehicle handling

and can fail suddenly, possibly resulting in loss of vehicle control.

Rotating the tires Rotate your tires at regular intervals for even wear. Rotation intervals are listed in the “Service Guide”.

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• Four tire rotation

• Five tire rotation

Replacing the tires Replace the tires when the wear band is visible through the tire treads.

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When replacing full size tires, never mix radial, bias-belted, or bias-type tires. Use only the tire sizes that are listed on the tire pressure decal. Make sure that all tires are the same size, speed rating, and load-carrying capacity. Use only the tire combinations recommended on the decal. If you do not follow these precautions, your vehicle may not drive properly and safely.

Make sure that all replacement tires are of

the same size, type, load-carrying capacity and tread design (e.g., “All Terrain”, etc.), as originally offered by Ford.

Do not replace your tires with “high performance“

tires or larger size tires.

Failure to follow these precautions may adversely affect the handling of the vehicle and make it easier to lose control and roll over.

Your vehicle requires the use of the following tire types: • A/S BSW P255/70R 16
• A/T OWL P255/70R 16
• A/T OWL P265/70R 17

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Ford recommends only tires of this type and size for your vehicle. When purchasing replacement tires for your vehicle, consult your dealer or qualified service technician to ensure that the correct tire types are used.

Using snow tires and traction devices

Snow tires must be the same size and grade as the tires you currently have on your vehicle.

The tires on your vehicle have all—weather treads to provide traction in rain and snow. However, in some climates, using snow tires and traction devices may be necessary. Ford offers tire cables as a Ford approved accessory and recommends use of these or their equivalents. See your dealer or qualified service technician for more information on tire cables for your vehicle. Follow these guidelines when using snow tires and traction devices:

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Maintenance and care • Install cables securely, verifying that the cables do not touch any wiring, brake lines or fuel lines. • Drive cautiously. If you hear the cables rub or bang against the vehicle, stop and retighten them. If this does not work, remove the cables to prevent vehicle damage. • Avoid overloading your vehicle. • Remove the tire cables when they are no longer needed. • Do not use cables on dry roads. • The suspension insulation and bumpers will help prevent vehicle damage. Do not remove these components from the vehicle when using snow tires and traction devices.

• Do not exceed 48 km/h (30

mph) with tire cables on your vehicle.

Consult your dealer for information on other Ford approved methods of traction control.

FUEL INFORMATION The ignition key must be turned to 3 (Off) or 1 (Acc) during refueling to obtain accurate fuel gauge ratings.

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Important safety precautions

Do not overfill the fuel tank. The pressure in an

overfilled tank may cause leakage and lead to fuel spray and fire.

If you do not use the proper fuel cap, the

pressure in the fuel tank can damage the fuel system or cause it to work improperly in a collision.

The fuel system may be under pressure. If the fuel

cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the cap.

Automotive fuels can cause serious injury or

death if misused or mishandled.

Observe the following guidelines when handling automotive fuel: • Extinguish all smoking materials

and any open flames before fueling your vehicle. • Always turn off the vehicle • Automotive fuels can be harmful

before fueling.

or fatal if swallowed. If fuel is swallowed, call a physician immediately, even if no symptoms are immediately

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apparent. The toxic affects of fuel may not be visible for hours. • Fuels can also be harmful if absorbed through the skin. If fuel is splashed on the skin, promptly remove contaminated clothing and wash skin thoroughly with soap and water.

• If fuel is splashed in the eyes, remove contact lenses, flush with water for 15 minutes and seek medical attention. • Be particularly careful if you are

taking “Antabuse” or other forms of disulfiram for the treatment of alcoholism. Breathing gasoline vapors or skin contact could cause an adverse reaction. Consult a physician immediately.

Choosing the right fuel Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law and could damage your vehicle. The damage may not be covered by your warranty. Your vehicle was not designed to use fuel containing manganese-based additives such as MMT. Additionally, vehicles certified to California emission standards (indicated on the underhood Vehicle Emissions Control Information label) are designed to operate on California reformulated gasolines. If California reformulated gasoline is not available when you refuel, your

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vehicle can be operated on non-California fuels. However, even though your engine will perform adequately on other gasolines, the performance of the emission control devices and systems may be adversely affected. Repair of damage caused by using a fuel that your vehicle was not designed for may not be covered by your warranty.

Octane recommendations Your vehicle is designed to use regular gasoline with an (R+M)/2
octane rating of 87. We do not recommend gasolines labeled as “regular” in high altitude areas that are sold with octane ratings of 86
or even less.

Do not be concerned if your vehicle sometimes knocks lightly. However, if it knocks heavily under most driving conditions on the recommended octane fuel, see your dealer or a qualified service technician to prevent any engine damage.

Fuel quality If you are experiencing starting, rough idle or hesitation problems try a different brand of fuel. If the condition persists, see your dealer or a qualified service technician. The American Automobile Manufacturers Association (AAMA)

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87

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issued a gasoline specification to provide information on high quality fuels that optimize the performance of your vehicle. We recommend the use of gasolines that meet the AAMA specification if they are available. It should not be necessary to add any aftermarket products to your fuel tank if you continue to use a high-quality fuel.

Cleaner air Ford approves the use of gasolines to improve air quality, including reformulated gasolines, that contain oxygenates such as a maximum of 10% ethanol or 15% MTBE. There should be no more than 5% methanol with cosolvents and additives to protect the fuel system.

Filling the fuel tank 1. Turn the engine off. After opening the fuel door, remove the cap carefully and slowly by turning it counterclockwise 1⁄4 turn until it stops. Pull to remove the cap. A tether attaches the cap to the fuel filler pipe. 2. Make sure that you pump unleaded fuel and put the nozzle inside the fuel filler pipe. • To optimize fill, it may be necessary to reposition the nozzle in the filler pipe.

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SNA P PULL T O REMOVE EN

PO

• The help reduce early nozzle shut offs and fuel spillage, park your vehicle so that the fuel filler door is level. • Avoid excessively fast fuel

dispensing rates (over 38 L [10
gallons] per minute). • If you spill any fuel on the body of your vehicle, clean it off immediately. The fuel may dull or soften the paint if it is not washed off promptly.

3. To replace the fuel cap, align the tabs on the cap with the notches on the filler pipe. Turn it clockwise until it stops. 4. Push the fuel door closed. If the check engine warning light illuminates and remains illuminated while the engine is started, the fuel cap may not be properly seated. Turn off the engine, remove the fuel cap and replace it. being sure to align the cap properly. If the fuel cap is lost, replace it with an authorized Motorcraft or equivalent part.

Calculating fuel economy To accurately calculate your vehicle’s fuel economy: 1. Fill the tank completely and record the initial odometer reading. 2. Each time you fill the tank, record the amount of fuel added (in liters or gallons).

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3. After at least three to five fuel tank fill-ups, fill the fuel tank and record the current mileage reading. 4. Use one of the following equations to calculate fuel economy. Liters used x 100 4 Total kilometers traveled Total miles traveled 4 Total gallons used Keep a record for at least one month. This will provide an accurate estimate of the vehicle’s fuel economy.

WHAT YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM For more information on your vehicle’s emission control system, refer to the Vehicle Emission Control Information Decal located on the inside, left of the engine compartment. The catalytic converter enables the vehicle’s emission control system to operate properly. Follow these guidelines to ensure proper emission system operation: • Use only unleaded fuel. • Avoid running out of fuel.

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• Do not turn off the ignition while your vehicle is in motion. • Have maintenance performed according to intervals in the “Service Guide”.

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If you notice one or more of the following, the emission system may not be functioning properly; have the vehicle serviced as soon as possible: • Fluid leaks •

lights illuminate in

the instrument cluster and remain lit

• Strange odors • Engine runs for more than five seconds after shut off or engine misfires, surges, stalls or backfires

• Loss of oil pressure

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Important emission control information By law, anyone who manufacturers, repairs, services, leases, trades vehicles or supervises a fleet of vehicles is not permitted to intentionally remove an emission control device or prevent it from working. Do not make any unauthorized changes to the vehicle or engine. Changes that cause more unburned fuel to reach the exhaust system can increase the temperature of the engine or exhaust system. When your vehicle is serviced, never use a metal exhaust collector. The use of a metal collector may melt or deform plastic parts.

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.

Preparing your vehicle for inspection/maintenance (I/M) testing In some localities it may be a legal requirement to pass an I/M test of the on-board diagnostic (OBD II) system. If your vehicle’s powertrain system or battery has just been serviced, the OBD II system is reset to a condition unready for I/M testing. To ready the OBD II system for I/M testing, the law

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specifies that additional city and highway driving is necessary to complete the check of the OBD II system. The driving modes required to reach the ready condition consist of a minimum of 30 minutes of city and highway driving: • At least 20 minutes driving in

stop and go city-type traffic with at least four idle periods.

• At least ten minutes of driving on an expressway or highway.

Before completing the above driving modes, the engine must be warmed up and at operating temperature. Once started, the vehicle must not be turned off during these modes.

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REPLACING THE EXTERIOR BULBS

Check the operation of the following exterior lamps frequently: • headlamps • foglamps • high-mount brakelamp • license plate lamp • tail lamps • back-up lamps Do not remove lamp bulbs unless they may be replaced immediately with new ones. If a bulb is removed for an extended period of time, contaminants may enter the lamp housings and affect lamp performance.

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exd_headlamps_turnsignals

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.

Replacement bulbs For specifications for exterior and interior replacement bulbs for your vehicle, refer to Bulb specifications in this chapter. Replacingheadlampbulbs

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.

1. Make sure that the headlamp control is in the OFF position. 2. Open the hood.

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3. At the back of the headlamp, pull clips rearward and up (about ¾”) to release the headlamp assembly. 4. Slide headlamp assembly forward and off of guide ribs to expose the back of the bulb and wiring connector.

5. Remove the electrical connector from the bulb by grasping the wire and pulling it rearward. 6. Remove bulb retainer ring by turning it counterclockwise about 1⁄4 turn, then slide the ring off the plastic base.

7. Without turning, carefully pull bulb assembly out of headlamp assembly. 8. Insert the glass end of the new bulb into the headlamp assembly socket. When the grooves in the plastic base are aligned, push the bulb into the socket until the plastic base contacts the rear of the socket. 9. Slip bulb retaining ring over the plastic base and lock the ring into the socket by turning it clockwise until you feel a “stop.” 10. Push the electrical connector into the rear of the plastic base until it “snaps.”

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11. Straighten alignment pins, making them parallel with the outer edges of the attachment standoff. 12. Carefully insert the headlamp assembly into the vehicle making sure the alignment pins are inserted into the proper holes and into the guide ribs. 13. Hold the headlamp assembly snugly against the vehicle and push down on the clips to lock the lamp into position.

Replacingparkinglamp/turn signalbulbs 1. Remove screw from the top of lamp assembly. 2. Disengage lamp assembly (it has a snap fit).

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3. Remove the electrical connector from the bulb by grasping the wire and pulling it rearward. 4. Remove bulb retainer ring by turning it counterclockwise about 1/4 turn, then slide the ring off the plastic base. 5. Without turning, carefully pull bulb assembly out of parking lamp assembly. 6. Insert the glass end of the new bulb into the parking lamp assembly socket. When the grooves in the plastic base are aligned, push the bulb into the socket until the plastic base contacts the rear of the socket. 7. Slip bulb retaining ring over the plastic base and lock the ring into the socket by turning it clockwise until you feel a “stop.” 8. Push the electrical connector into the rear of the plastic base until it “snaps.” 9. Align top and bottom ribs of parking lamp assembly with corresponding slots on front of vehicle. 10. Push gently until parking lamp assembly seats (you will hear a snap). 11. Replace screw removed in step 1.

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Replacingfoglampbulbs 1. Disconnect the electrical connector from the back of the foglamp assembly. 2. Twist, then pull the bulb from the foglamp assembly. 3. Install the new bulb. 4. Connect the electrical connector to the back of the foglamp assembly.

High-mountbrakelamp To change the high-mount brakelamp bulbs:

1. Remove the four screws that secure the high-mount brakelamp lens. 2. Carefully remove the lens. 3. Each of the three bulbs may be removed with a 1⁄4 turn counterclockwise and a careful pull. 4. Replace the bulbs as needed and replace the high-mount brakelamp lens.

Maintenance and care

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Replacingtaillamp/backup lampbulbs The tail lamp/backup lamp assemblies are located in the same portion of the vehicle rear, one just below the other. Follow the same steps to replace either bulb: 1. Open the liftgate to expose the lamp assemblies. 2. Remove the two screws at the top of the lens. 3. Carefully pop the lens off and to the right (it may be necessary to use a screwdriver to remove the lens). 4. Twist the connector 1⁄4 turn couterclockwise and pull it out for replacement. 5. Pull the bulb straight out of the recess and replace it. 6. Replace the lens and secure the two screws. Replacinglicenseplatelamp bulbs The license plate bulbs are located under and behind the rear bumper. To change the license plate lamp bulbs: 1. Reach under and behind the rear bumper to locate the bulb connector. 2. Twist the connector counterclockwise 1⁄4 turn and carefully pull to remove it. 3. Pull out the old bulb and press in the replacement bulb.

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4. Replace the connector by placing it back into the assembly and turning it 1⁄4 turn clockwise.

REPLACING THE INTERIOR BULBS Check the operation of the following interior bulbs frequently: • interior overhead lamp • map lamp • courtesy and cargo lamps • hazard flasher Map lamps To change the map lamp bulbs: 1. Use a small screwdriver to remove the map lamp lens. 2. To remove the old bulb, twist 1⁄4
turn and pull it out. 3. Twist in a new bulb. 4. Press the map lamp lens back on and test the lamp operation.

BULB SPECIFICATIONS

Number of bulbs

Function Front park/turn lamps Foglamps Headlamps Rear/turn/sidemarker To replace all instrument panel lights - see your dealer.

Trade number

3157NAK

9006
9007
3157K

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Maintenance and care

AIMING THE HEADLAMPS The alignment of your headlamps should be checked by a qualified service technician if: • Oncoming motorists frequently signal you to deactivate your high beams, and your high beams are not activated.

• The headlamps do not seem to provide enough light for clear night vision.

• The headlamp beams are

pointed substantially away from a slightly down and to the right position.

CLEANING AND CARING FOR YOUR VEHICLE

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 they also cause damage to the vehicle. Remove any exterior accessories,

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such as antennas, before entering a car wash. • After washing, apply the brakes

several times to dry them.

Waxing your vehicle The best way to determine when the paintwork needs waxing is by noting 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. Remove any bugs and tar before waxing vehicle. Use cleaning fluid or alcohol with a clean cloth to remove. Use tar remover to remove any tar spots.

Repairing paint chips Minor scratches or paint damage from road debris may be repaired with touch-up paint, 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

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Maintenance and care

Cleaning the wheels Wash the wheels with the same detergent you use to clean the body of your vehicle. Do not use acid-based wheel cleaners, steel wool, fuel or strong detergents. Never use abrasives that will damage the finish of special wheel surfaces. Use a tar remover to remove grease and tar.

Cleaning the engine Engines are more efficient when they are clean because grease and dirt buildup act as insulators and keep the engine warmer than normal. Follow these guidelines to clean your engine: • 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 with cold water to avoid cracking the engine block.

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• Cover the highlighted areas to prevent water damage when cleaning the engine.

• Never wash or rinse the engine while it is running; water in the running engine may cause internal damage.

Cleaning plastic exterior parts Use a vinyl cleaner for routine cleaning of plastic. Clean with a tar remover if necessary. Do not clean plastic parts with thinners, solvents or petroleum-based cleaners.

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Maintenance and care

Cleaning the exterior lamps Wash the exterior lamps with the same detergent you used to wash the exterior of your vehicle. Use glass cleaner or tar remover if necessary. To avoid scratching the lamps, do not use a dry paper towel, chemical solvents or abrasive cleaners to clean the lamps.

Cleaning the wiper blades If the wiper blades do not wipe properly, clean both the windshield and wiper blades using undiluted windshield wiper solution or a mild detergent. Rinse thoroughly with clean water. To avoid damaging the blades, do not use fuel, kerosene, paint thinner or other solvents.

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Cleaning the instrument panel

Maintenance and care

Clean instrument panel with a damp cloth, then dry with a dry cloth. Any cleaner or polish that increases the gloss of the upper portion of the instrument panel should be avoided. The dull finish in this area is to help protect the driver from undesirable windshield reflection.

Cleaning the interior fabric Remove dust and loose dirt with a whisk broom or a vacuum cleaner. Remove fresh spots immediately. Follow the directions that come with the cleaner.

Cleaning leather seats (if equipped) For routine cleaning, wipe the surface with a soft, damp cloth. For more thorough cleaning, wipe the surface with a leather and vinyl cleaner or a mild soap.

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Maintenance and care

Cleaning and maintaining the safety belts Clean the safety belts with a mild soap solution recommended for cleaning upholstery or carpets. Do not bleach or dye the belts, because these actions may weaken the belt webbing. Check your safety belt system periodically to ensure that it works properly and isn’t damaged. If the webbing shows any signs of wear, nicks or cuts, have it inspected by a qualified technician to determine if replacement is necessary. Always have your safety belt system checked after a collision by a qualified technician. All safety belt assemblies, including retractors, buckles, front seat belt buckle support assemblies (slide bar if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected after any 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. Safety belt assemblies not in use during a collision should be inspected and replaced if either damage or improper operation is noted.

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Capacities and specifications

MOTORCRAFT PART NUMBERS

Component

4.6 L engine

5.4 L engine

exd_motorcraft_parts_numbers

BXT-59

BXT-59

FA-1632

FA-1632

BXT-65-750

Air filter Battery - standard - optional Fuel filter Oil filter PCV valve Spark plug* - platinum AWSF-22F * Replacement double platinum spark plug 9EE9 will replace 9E9 and 9EG9 and 9P9 will replace 9P9 and 9PG9 suffixed plugs. Refer to the Engine data chart for spark plug gap specifications.

FG-872
FL-820-S EV-233

FG-872
FL-820-S

AWSF-32PP

BXT-65-750

EV-98

CAPACITIES

Your vehicle’s fuel capacity The fuel capacity of your vehicle is:

Vehicle 4x2 (standard suspension) 4x2 (with air suspension) 4x4 (if equipped) • Always use high quality fuel containing detergent and other additives. Using inferior fuel could result in engine damage. • To avoid overspill from the filler neck, stop fueling at the second automatic shut off. • For more information, refer to Choosing the right fuel in the Maintenance and care chapter.

Fuel capacity 98 L (26 gallons) 114 L (30 gallon) 114 L (30 gallons)

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Capacities and specifications

4.6 L engine

5.7 L (6.0

5.4 L engine

5.7 L (6.0

quarts) with filter

quarts) with filter

change

change

1.9L (2.0 quarts) 4R70W-13.1L (13.9 quarts)

E4OD (4 x 2) - 15.04L (15.9

quarts)

E4OD (4 x 4) - 15.51L (16.4

quarts)

4.1 L ( 4.5 quarts)

17.9 L (19.9 quarts)

17.0 L (18.0 quarts)

19.7 L (20.8 quarts) 5.7 L (6.0 quarts) 2.3 L (2.4 quarts)

5.5 pints

3.5 pints

Refill capacities

Capacities - liters (quarts)

Engine crankcase

Transfer case Automatic transmission

Washer fluid reservoir 4.6 L Engine coolant - 2 Row radiator -1 Row radiator 5.4 L Engine coolant Engine oil Power steering fluid Capacites - pints Axle (rear) Ford 8.89 / 9.759 Ring Gear Conventional and Traction-Lok1
Axle (front) Ford 8.8 9 Ring Gear 1 Add 4 oz. of additive friction modifier C8AZ-19B546–A, Ford specification EST-M2C118–A, for complete fill of 8.8 inch and 9.75
inch ring gear Traction-Lok axles. Service refill capacities are determined by filling the rear axle 1/4 inch to 9/16 below the bottom of the filler hole.

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SPECIFICATIONS

Lubricant specifications

Item

Ford part name

Ford part number

Ford Ultra-Clear

C9AZ-19550-AA

Ford

specification ESR-M17P5-A

Windshield washer fluid reservoir

Body hinges, latches, door striker plates and rotors, seat tracks, fuel filler door hinge and spring, hood latch, auxiliary latch Lock cylinders, swing-away spare tire carrier padlock Parking brake linkage pivots and clevises Brake master cylinder

Brake pedal pivot points and clevises

Windshield Washer Fluid