2002 Ford Focus Owners Manual

or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Ford Motor Company.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or Ford Motor Company.

To contact NHTSA, you may either call the Auto Safety Hotline tollĆfree at 1Ć800Ć424Ć9393 (202Ć366Ć0123 in the Washington D.C. area) or write to:

NHTSA U.S.Department of Transportation 400 Seventh Street Washington D.C. 20590

You can also obtain other information about motor vehicle safety from the Hotline.

251

Cleaning

CLEANING AND CARING FOR YOUR VEHICLE Refer to the Accessories chapter for a list of FordĆapproved cleaners, polishes and sealants.

Washing the exterior of your vehicle Never wash a vehicle that is "hot to the touch" or during exposure to strong, direct sunlight. It is recommended that you wash your vehicle regularly with cool or lukewarm water and a neutral Ph shampoo, such as Detail Wash (ZCĆ3ĆA), which is available from your authorized Ford, Lincoln or Mercury dealer. Always use a clean sponge or carwash mitt with plenty of water for best results. Dry the vehicle with a chamois or soft terry cloth towel in order to eliminate water spotting.

Never use strong household detergents or soap, such as dish washing or laundry liquid. These products can discolor and spot painted surfaces.

It is especially important to wash the vehicle regularly during winter months, as dirt and road salt are difficult to remove and do cause damage to the vehicle. Items such as gasoline, diesel fuel, bird droppings and insect deposits should be washed and sponged off as soon as possible. Deposits not removed promptly can cause damage to the vehicle's paintwork and trim over time.

252

Remove any exterior accessories, such as antennas, before entering a car wash.

Protecting your vehicles’ paint finish Applying a polymer paint sealant to your vehicle on a regular basis will assist in reducing minor scratches and paint damage. A typical paint sealant lasts approximately six months to a year, depending on local weather conditions and the cleaning soap that is used in washing the vehicle.

Do not use a wax that beads excessively.

Do not allow paint sealant to come in contact with any nonĆbody (lowĆgloss black) colored trim, such as grained door handles, roof racks, bumpers, side moldings, mirror housings or the windshield cowl area. The paint sealant will "gray" or stain the parts over time.

Cleaning

253

Cleaning

Repairing paint chips Remove particles such as bird droppings, tree sap, insect deposits, tar spots, road salt and industrial fallout before repairing paint chips.

Minor scratches or paint damage from road debris may be repaired using the Ultra Touch Prep and Finishing Kit (F7AZĆ19K507ĆBA), which is available at your authorized Ford, Lincoln or Mercury dealer. This kit contains: • Lacquer TouchĆUp Paint (ALBZĆ19500ĆXXXXA) • Exterior Acrylic Spray Lacquer (ALAZĆ19500ĆXXXXA)

Please note that the part numbers (shown as XXXX above) will vary with your vehicle's specific coloring.

Carefully observe the application instructions on the products.

Cleaning the wheel rims and covers Aluminum wheel rims or covers are coated with a clearcoat paint finish.

Some automatic car washes may cause damage to the finish on your wheel rims or covers. ChemicalĆstrength cleaners, or cleaning chemicals, in combination with brush agitation to remove brake dust and dirt, could wear away the clearcoat finish over time.

254

Do not use hydrofluoric acidĆbased or high causticĆbased wheel cleaners, steel wool, fuels or strong household detergents for soiled wheel rims and covers.

Never apply any cleaning chemical to hot or warm wheel rims or covers.

Clean wheel rims and covers with Detail Wash (ZCĆ3ĆA), which is available from your authorized Ford, Lincoln or Mercury dealer. Spray cleaner on cool wheel rims or covers and allow to set for 2Ć5
minutes. Agitate the area with a sponge and rinse off with plenty of water.

Use Extra Strength Tar and Road Oil Removal (B7AĆ19520ĆAA), available from your authorized Ford, Lincoln or Mercury dealer, in order to remove tar and grease from wheel rims and covers.

Cleaning

255

Cleaning

Cleaning the engine Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal. When washing: • The engine must be cool to the touch before spraying with water. • Never spray a hot engine with cold water, as damage to the engine block or engine components may occur. • Use caution when using a selfĆserve power washer (1000psi maximum pressure) to clean the engine, as the highĆpressure fluid could penetrate the sealed parts and cause damage. • Never apply anything to any exposed belts in the engine compartment, including the belt dressing.

For general cleaning of the engine and engine compartment, spray Engine Shampoo and Degreaser (FYAZĆ19A536ĆA) on all parts that require cleaning and pressure rinse the area with cool water.

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

256

2.0 L SPI Engine

Cleaning

Cover the highlighted areas to prevent water damage when cleaning

257

Cleaning

2.0 L Zetec-E Engine

Cover the highlighted areas to prevent water damage when cleaning

258

Washing non-painted plastic exterior parts Use Detail Wash (ZCĆ3ĆA) for routine cleaning.

If tar or grease spots are present, clean with Extra Strength Tar and Road Oil Removal (B7AĆ19520ĆAA).

Use only approved products to clean plastic parts.

These products are available from your authorized Ford, Lincoln or Mercury dealer.

Washing mirrors, mirror housings and reflective surfaces Do not clean mirrors, mirror housings or reflective surfaces with abrasive materials or a dry cloth.

Use a soft cloth and Detail Wash (ZCĆ3ĆA) mixed with water in order to clean the mirror housing. Use Glass Cleaner (E4AZĆ19C507ĆAA) in order to clean the reflective mirror surface.

Use care when removing ice from outside mirrors as you may damage the reflective surface.

Cleaning

259

Cleaning

Washing the exterior lamps In order to avoid scratching the plastic lamps, do not use dry paper towels, nonĆapproved chemical solvents or abrasive cleaners.

Use a soft cloth and a solution of Triple Clean (EOAZĆ19526ĆAA), mixed properly with water, in order to remove bug residue. If tar or grease spots are present, clean with Extra Strength Tar and Road Oil Removal (B7AĆ19520ĆAA).

Cleaning the windshield, wiper blades and rear window If the wiper does not wipe properly, substances on the windshield, rear window or the wiper blades may be the cause. These may include hot wax treatments used by commercial car washes, tree sap, or other organic contamination.

Do not clean the windshield or rear window glass with abrasives, as they may cause scratches.

Do not use fuel, kerosene, or paint thinner to clean the windshield, rear window or the wiper blades as damage may occur.

260

Clean the outside of the windshield or rear window with a nonĆabrasive cleaner such as Ultra Clear Spray Glass Cleaner (E4AZĆ19C507ĆAA), available from your authorized Ford, Lincoln or Mercury dealer. If after cleaning the glass surface, the water sheets from the glass (e.g., does not bead), then the window is clean.

The windshield, rear window and wiper blades should be cleaned regularly. Wiper blades can be cleaned with isopropyl (rubbing) alcohol or windshield washer solution. Be sure to replace wiper blades when they appear worn or do not function properly.

Cleaning the instrument panel Clean the instrument panel with a damp cloth, then dry with a dry cloth.

Avoid cleaners or polish that increase the gloss of the upper portion of the instrument panel. The dull finish in this area helps protect the driver from undesirable windshield reflection.

Do not use chemical solvents or strong

detergents when cleaning the steering wheel or instrument panel to avoid contamination of the air bag system.

Cleaning

261

Cleaning

Cleaning the instrument cluster lens Wipe the cluster area with a soft, damp cotton towel. Dry the area with a clean, dry towel.

Cleaning seats equipped with side air bags Remove dust and loose dirt with a vacuum cleaner. In order to remove stains and soil, clean with Extra Strength Upholstery Cleaner (E8AZĆ19523ĆAA).

Never saturate the seat covers with any cleaning solution.

Do not use chemical solvents or strong

detergents when cleaning the seat where the side air bag is mounted. Such products could contaminate the side air bag system and affect performance of the side air bag in a collision. The air bag may not function correctly and not provide injury reduction benefits.

Cleaning the interior fabric, carpets and cloth seats Remove dust and loose dirt with a vacuum cleaner. Remove light stains and soil with Extra Strength Upholstery Cleaner (E8AZĆ19523ĆAA).

262

Never saturate the seat covers with cleaning solution.

Do not use household cleaning products or glass cleaners, which can stain and discolor the fabric and affect the flame retardent abilities of the seat materials.

If grease or tar is present on the material, spotĆclean the area first with Spot and Stain Remover (F3AZĆ19521ĆWA). Follow up by recleaning the area with Extra Strength Upholstery Cleaner (E8AZĆ19523ĆAA).

Do not use chemical solvents or strong

detergents when cleaning the steering wheel or instrument panel to avoid contamination of the air bag system.

Cleaning leather seats (if equipped) All Ford, Lincoln and Mercury vehicles with leather seating surfaces have a clear, protective coating over the leather.

To clean the leather seats, simply use a soft cloth with Deluxe Leather and Vinyl Cleaner (F2AZĆ19521ĆWA). Dry the area with a soft cloth.

Cleaning

263

Cleaning

It is recommended that you use the Deluxe Leather Care Kit (F8AZĆ19G253ĆAA), available from your authorized Ford, Lincoln or Mercury dealer. The mild cleaner and special pad available in the kit cleans the leather and maintains its natural beauty. For best results, follow the instructions printed on the cleaner label. Regular cleaning of your leather upholstery helps maintain its resiliency and color.

Do not use household cleaning products, alcohol solutions, solvents or cleaners intended for rubber, vinyl and plastics, or oil/petroleumĆbased leather conditioners. These products may cause premature wearing of the clear, protective coating.

Cleaning the inside windows Use Ultra Clear Spray Glass Cleaner (E4AZĆ19C507ĆAA) for the inside windows if they become fogged.

To clean, use two lintĆfree, soft towels, folded into a padĆshape. Mist the glass completely with cleaner, and use one of the towels to evenly agitate the surface. Use the other towel to remove the residue.

264

Cleaning and maintaining the safety belts Clean the safety belts with Extra Strength Upholstery Cleaner (E8AZĆ19523ĆAA), available from your authorized Ford, Lincoln or Mercury dealer.

Do not use bleach, dye or any other solvent to clean the belts, as these actions may weaken the belt webbing.

Underbody Flush the complete underside of your vehicle frequently. Keep body and door drain holes free from packed dirt.

Ford, Lincoln and Mercury car care products Your Ford, Lincoln or Mercury dealer has many quality products available to clean your vehicle and protect its finishes. These quality products have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and appearance of your vehicle. Each product is made from high quality materials that meet or exceed rigid specifications. For best results, use the following or products of equivalent quality:

Cleaning

265

Cleaning

Ford Custom Clearcoat Polish*

Ford Custom Silicone Gloss Polish

Ford Custom Vinyl Protectant* (not available in Canada)

Motorcraft Vinyl Conditioner (Canada only)

Ford Deluxe Leather and Vinyl Cleaner (not available in Canada)

Motorcraft Vinyl Cleaner (Canada only)

Ford Extra Strength Tar and Road Oil Remover* (not available in Canada)

Ford Extra Strength Upholstery Cleaner (not available in Canada)

Ford Custom Bright Metal Cleaner

Motorcraft Premium Car Wash Concentrate

Motorcraft Carlite Glass Cleaner (Canada only)

Ford Spot and Stain Remover*

Ford Super Premium Tire and Trim Dressing

Ford Triple Clean

Ford UltraĆClear Spray Glass Cleaner (not available in Canada)

Ford Engine Shampoo and Degreaser

* May be sold with the Motorcraft name

266

Maintenance and Specifications

SERVICE RECOMMENDATIONS To help you service your vehicle: • We highlight doĆitĆyourself 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 necessary parts and service. Check your Warranty Guide" to 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 Be especially careful when inspecting or servicing your vehicle. • Do not work on a hot engine. • When the engine is running, keep loose clothing, jewelry or long hair away from moving parts.

267

Maintenance and Specifications

• Do not work on a vehicle with the engine running in an enclosed space, unless you are sure you have enough ventilation. • Keep all lit cigarettes, open flames and other lit material away from the battery and all fuel related parts.

If you disconnect the battery, the engine must relearn" its idle conditions before your vehicle will drive properly, as explained under the Battery section in this chapter.

Inside the vehicle, pull the hood

OPENING THE HOOD 1. release handle located at the bottom of the instrument panel below the steering wheel.

2. Go to the front of the vehicle and release the auxiliary latch that is located under the front of the hood.

3. Lift the hood and support it with the yellow end of its strut in the holes in the hood ensuring it is secure.

4. To close, replace the support strut in its retaining clip, lower the hood and allow it to drop into the catch for at least 20 - 30 cm (8 - 12 inches).

268

Maintenance and Specifications

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT 2.0 L SPI Engine

Power

steering fluid

reservoir

Engine oil filler cap

Brake/clutch

fluid

reservoir

Fuse box

Air filter assembly

Engine coolant

Engine oil

Transaxle

Battery

reservoir

(marked red and black)

dipstick

fluid

dipstick

Windshield washer fluid

reservoir

For ease of identification, most filler caps and the engine oil dipstick are marked yellow and black.

269

Maintenance and Specifications

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT 2.0 L Zetec-E Engine

Power

steering fluid

reservoir

Engine oil filler cap

Brake/clutch

fluid

reservoir

Fuse box

Air filter assembly

Engine coolant

Engine oil

reservoir

dipstick

(marked red and

black)

Transaxle

fluid

dipstick

Battery

Windshield washer fluid

reservoir

For ease of identification, most filler caps and the engine oil dipstick are marked yellow and black.

270

Maintenance and Specifications

WINDSHIELD WASHER FLUID Checking and adding washer fluid Check the washer fluid whenever you stop for fuel.

If the level is low, add enough fluid to fill the reservoir. In very cold weather, do not fill the reservoir all the way.

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.

ENGINE OIL Checking the engine oil Refer to the Scheduled Maintenance Guide" for the appropriate intervals for checking the engine oil. 1. Make sure the vehicle is on level ground. 2. Turn the engine off and wait a few minutes for the oil to drain into the oil pan. 3. Set the parking brake and ensure the gearshift is securely latched in P (Park) (automatic transaxle) or 1
(First) (manual transaxle). 4. Open the hood. Protect yourself from engine heat. 5. Locate and carefully remove the engine oil level indicator (dipstick). 6. Wipe the indicator clean. Insert the indicator fully, then remove it again.

271

Maintenance and Specifications

2.0 SPI engine

2.0 ZetecĆengine

• If the oil level is between the MIN and MAX marks (2.0 SPI engine) or between ADD and FULL (2.0 ZetecĆengine), the oil level is acceptable. DO NOT ADD OIL. • If the oil level is below the MIN/ADD mark, add enough oil to raise the level within the MIN-MAX/ADD-FULL range. • Oil levels above the MAX/FULL mark may cause engine damage. Some oil must be removed from the engine by a service technician.

7. Put the indicator 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 engine oil level is not within the MIN and MAX/ADD and FULL ranges, add only certified engine oil of the recommended viscosity. Remove the engine oil filler cap and use a funnel to pour the engine oil into the opening.

3. Recheck the oil level. Make sure the oil level is not above the MAX mark (2.0 SPI engine) or the FULL mark (2.0 ZetecĆ engine) on the dipstick.

4. Replace oil filler cap and ensure it is fully tightened.

272

Maintenance and Specifications

Engine oil and filter recommendations Look for this certification trademark.

SAE 5W-20 engine oil is recommended. Use oils Certified For Gasoline Engines" by the American Petroleum Institute (API).

Use Motorcraft or an equivalent oil meeting Ford specification WSSĆM2C153ĆH. Use oils Certified For Gasoline Engines" by the American Petroleum Institute (API). SAE 5WĆ20 oil provides optimum fuel economy and durability performance meeting all requirements for your vehicle's engine.Do not use supplemental engine oil additives or other engine treatments. They are unnecessary and could lead to engine damage that is not covered by Ford warranty. Change your engine oil according to the appropriate schedule listed in the Scheduled Maintenance Guide.

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, startĆup engine noises or knock may be experienced.

273

Maintenance and Specifications

It is recommended you use the appropriate Motorcraft oil filter (or another brand meeting Ford specifications) for your engine application.

BATTERY Your vehicle is equipped with a Motorcraft maintenanceĆfree battery which normally does not require additional water during its life of service.

However, for severe usage or in high temperature climates, check the battery electrolyte level. Refer to the Scheduled Maintenance Guide" for the service interval schedules.

If the electrolyte level in the battery is low, you can add plain tap water to the battery, as long as you do not use hard water (water with a high mineral or alkali content). If possible, however, try to only fill the battery cells with distilled water. If the battery needs water often, have the charging system checked.

Keep the electrolyte level in each cell up the the level indicator". Do not overfill the battery cells.

For longer, troubleĆfree operation, keep the top of the battery clean and dry. Also, make certain the battery cables are always tightly fastened to the battery terminals.

274

Maintenance and Specifications

If you see any corrosion on the battery cables or terminals, remove the cables from the terminals and clean with a wire brush. You can neutralize the acid with a solution of baking soda and water. Reinstall the cables when you are done cleaning them.

If your battery has a cover/shield, make sure it is reinstalled after the battery has been cleaned or replaced.

Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide proper ventilation.

275

Maintenance and Specifications

When lifting a plasticĆcased battery, excessive pressure on the end walls could cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery. Lift the battery with a battery carrier or with your hands on opposite corners.

Keep batteries out of reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Shield your eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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 engine must relearn its idle conditions before your vehicle will drive properly. To begin this process:

276

Maintenance and Specifications

1. Set your parking brake.

2. Put the gearshift in P (Park) (automatic transaxle) or the neutral position (manual transaxle). 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 if a new battery has been installed, the clock and preset radio stations must be reset once the battery is reconnected.

Always dispose of automotive batteries in a responsible

manner. Follow your local authorized standards for disposal. Call your local authorized recycling center to find out more about recycling automotive batteries.

277

Maintenance and Specifications

ENGINE COOLANT

Checking engine coolant The concentration and level of engine coolant should be checked at the mileage intervals listed in the Scheduled Maintenance Guide". The coolant concentration should be maintained at 50/50 coolant and water, which equates to a freeze point of -36° C (-34° F). Coolant concentration testing is possible with a hydrometer or antifreeze tester (such as the Rotunda Battery and Antifreeze Tester, 014ćR1060). The level of coolant should be maintained at the "cold full" or "cold fill range" level in the coolant reservoir. If the level falls below, add coolant per the instructions in the Adding Engine Coolant section.

Your vehicle was factoryĆfilled with a 50/50 engine coolant and water concentration. If the concentration of coolant falls below 40% or above 60%, the engine parts could become damaged or not work properly.

278

Maintenance and Specifications

A 50Ć50 mixture of coolant and water provides the following: • Freeze protection down to -36º C (-34º F). • Boiling protection up to 129º C (265º F). • Protection against rust and other forms of corrosion. • Enables calibrated gauges to work properly.

When the engine is cold, check the level of the engine coolant in the reservoir. • The engine coolant should be at the "cold fill level" or within the "cold fill range" as listed on the engine coolant reservoir (depending upon application). • Refer to the Scheduled Maintenance Guide for service interval schedules. • Be sure to read and understand Precautions when servicing your vehicle in this chapter.

279

Maintenance and Specifications

If the engine coolant has not been checked at the recommended interval, the engine coolant reservoir may become low or empty. If the reservoir is low or empty, add engine coolant to the reservoir. Refer to Adding engine coolant in this chapter.

Note: Automotive fluids are not interchangeable; do not use engine coolant, antifreeze or windshield washer fluid outside of its specified function and vehicle location.

Adding engine coolant When adding coolant, make sure it is a 50/50 mixture of engine coolant and distilled water. Add the mixture to the coolant reservoir, when the engine is cool, until the appropriate fill level is obtained.

Do not add engine coolant when the engine is hot.

Steam and scalding liquids released from a hot cooling system can burn you badly. Also, you can be burned if you spill coolant on hot engine parts.

Do not put engine coolant in the windshield washer

fluid container. If sprayed on the windshield, engine coolant could make it difficult to see through the windshield.

280

Maintenance and Specifications

The cooling system in your vehicle is filled with either greenĆcolored Motorcraft Premium Engine Coolant meeting Ford specification ESEĆM97B44ĆA or yellowĆcolored Motorcraft Premium Gold Engine Coolant meeting Ford Specification WSSĆM97B51ĆA1. To determine your vehicle's coolant type (color), check your coolant reservoir. • Add Motorcraft Premium Engine Coolant (greenĆcolored), VCĆ4ĆA (U.S.) or CXCĆ10 (Canada) or Motorcraft Premium Gold Engine Coolant (yellowĆcolored), VCĆ7ĆA, depending on the type of coolant originally equipped in your vehicle. If you are unsure which type of coolant your vehicle requires, check your coolant reservoir or contact your local dealer.

Note: Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens the color of Motorcraft Premium Engine Coolant from yellow to golden tan.

281

Maintenance and Specifications

• Do not add/mix an orangeĆcolored, extended life coolant such as Motorcraft Speciality Orange Engine Coolant, VCĆ2 (US) or CXCĆ209
(Canada), meeting Ford specification WSSĆM97B44ĆD with the factoryĆfilled coolant. Mixing Motorcraft Speciality Orange Engine Coolant or any orangeĆcolored extended life product with your factory filled coolant can result in degraded corrosion protection. • A large amount of water without engine coolant may be added, in case of emergency, to reach a vehicle service location. In this instance, the cooling system must be drained and refilled with a 50/50 mixture of engine coolant and distilled water as soon as possible. Water alone (without engine coolant) can cause engine damage from corrosion, overheating or freezing. • Do not use alcohol, methanol or brine or any engine coolants mixed with alcohol or methanol antifreeze (coolant). Alcohol and other liquids can cause engine damage from overheating or freezing. • Do not add extra inhibitors or additives to the coolant. These can be harmful and compromise the corrosion protection of the engine coolant. • Do not mix with recycled coolant unless from a FordĆapproved recycling process (see Recycled Engine Coolant section).

282

Maintenance and Specifications

To avoid personal injury, make sure the engine is cool

before unscrewing the coolant pressure relief cap. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.

1. Before you begin, turn the engine off and let it cool.

2. When the engine is cool, wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir (an opaque plastic bottle). Slowly turn cap counterclockwise (left) until pressure begins to release.

3. Step back while the pressure releases.

4. When you are sure that all the pressure has been released, use the cloth to turn it counterclockwise and remove the cap.

283

Maintenance and Specifications

5. Fill the coolant reservoir slowly with the proper coolant mixture (see above), to within the "cold fill range" or the "cold full" level on the reservoir. If you removed the radiator cap in an overflow system, fill the radiator until the coolant is visible and radiator is almost full.

6. Replace the cap. Turn until tightly installed. (Cap must be tightly installed to prevent coolant loss.) After any coolant has been added, check the coolant concentration (see Checking Engine Coolant section). If the concentration is not 50/50
(protection to Ć34° F/Ć36° C), drain some coolant and adjust the concentration. It may take several drains and additions to obtain a 50/50 coolant concentration.

Whenever coolant has been added, the coolant level in the coolant reservoir should be checked the next few times you drive the vehicle. If necessary, add enough 50/50 concentration of engine coolant and distilled water to bring the liquid level to the proper level.

If you have to add more than 1.0
liter (1.0 quart) of engine coolant per month, have your dealer check the engine cooling system. Your cooling system may have a leak. Operating an engine with a low level of coolant can result in engine overheating and possible engine damage.

284

Maintenance and Specifications

Recycled engine coolant Ford Motor Company recommends the use of a recycled engine coolant produced by FordĆapproved processes in vehicles originally equipped with Motorcraft Premium Engine Coolant (greenĆcolored). However, not all coolant recycling processes produce coolant that meets Ford specification ESEĆM97B44ĆA. Use of such coolant may harm the engine and cooling system components.

Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a FordĆapproved recycling process is not yet available.

Used engine coolant should be disposed of in an appropriate manner. Follow your community's regulations and standards for recycling and disposing of automotive fluids.

Coolant refill capacity To find out how much fluid your vehicle's cooling system can hold, refer to Refill capacities in this chapter.

Fill your engine coolant reservoir as outlined in Adding engine coolant in this chapter.

285

Maintenance and Specifications

Severe climates If you drive in extremely cold climates (less than Ć36° C [Ć34° F]): • It may be necessary to increase the coolant concentration above 50%. • NEVER increase the coolant concentration above 60%. • Increased engine coolant concentrations above 60% will decrease the overheat protection characteristics of the engine coolant and may cause engine damage. • Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate freeze protection at the temperatures in which you drive in the winter months.

If you drive in extremely hot climates: • It is still necessary to maintain the coolant concentration above 40%. • NEVER decrease the coolant concentration below 40%. Decreased engine coolant concentrations below 40% will decrease the corrosion and the freeze protection characteristics of the engine coolant and may cause engine damage.

286

Maintenance and Specifications

• Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate protection at the temperatures in which you drive.

Vehicles driven yearĆround in nonĆextreme climates should use a 50/50 mixture of engine coolant and distilled water for optimum cooling system and engine protection.

What you should know about fail-safe cooling (2.0 L Zetec engines only) If the engine coolant supply is depleted, this feature allows the vehicle to be driven temporarily before incremental component damage is incurred. The "failĆsafe" distance depends on ambient temperatures, vehicle load and terrain.

287

Maintenance and Specifications

How fail-safe cooling works If the engine begins to overheat: • The engine coolant temperature gauge will move to the red area. • The MultiĆfunction warning light:automatic tranaxle/cooling system will illuminate. • The Check Engine indicator will illuminate.

If the engine reaches a preset overĆtemperature condition, the engine will automatically switch to alternating cylinder operation. Each disabled cylinder acts as an air pump and cools the engine.

When this occurs the vehicle will still operate. However: • The engine power will be limited. • The air conditioning system will be disabled. • The Check Engine warning light also illuminates.

Extended operation will increase the engine temperature and the engine will completely shut down, causing steering and braking effort to increase.

Once the engine temperature cools, the engine can be reĆstarted. Take your vehicle to a service facility as soon as possible to minimize engine damage.

288

Maintenance and Specifications

When fail–safe mode is activated You have limited engine power when in the failĆsafe mode, so drive the vehicle with caution. The vehicle will not be able to maintain highĆspeed operation and the engine will run rough. Remember that the engine is capable of completely shutting down automatically to prevent engine damage, therefore:

1. Pull off the road as soon as safely possible and turn off the engine.

2. Arrange for the vehicle to be taken to a service facility.

If this is not possible, wait a

3. short period for the engine to cool.

4. Check the coolant level and replenish if low.

Never remove the coolant reservoir cap while the

engine is running or hot.

5. ReĆstart the engine and take your vehicle to a service facility.

Driving the vehicle without repairing the engine problem increases the chance of engine damage. Take your vehicle to a service facility as soon as possible.

289

Maintenance and Specifications

WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS

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.

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Maintenance and Specifications

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 before fueling. • Automotive fuels can be harmful or fatal if swallowed. Fuel such as gasoline is highly toxic and if swallowed can cause death or permanent injury. If fuel is swallowed, call a physician immediately, even if no symptoms are immediately apparent. The toxic effects of fuel may not be visible for hours. • Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind can lead to eye and respiratory tract irritation. In severe cases, excessive or prolonged breathing of fuel vapor can cause serious illness and permanent injury. • Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes, remove contact lenses (if worn), flush with water for 15 minutes and seek medical attention. Failure to seek proper medical attention could lead to permanent injury.

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Maintenance and Specifications

• Fuels can also be harmful if absorbed through the skin. If fuel is splashed on the skin and/or clothing, promptly remove contaminated clothing and wash skin thoroughly with soap and water. Repeated or prolonged skin contact with fuel liquid or vapor causes skin irritation. • 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. In sensitive individuals, serious personal injury or sickness may result. If fuel is splashed on the skin, promptly wash skin thoroughly with soap and water. Consult a physician immediately if you experience an adverse reaction.

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Maintenance and Specifications

If you do not use the proper fuel filler cap, excessive pressure or vacuum in the fuel tank may damage the fuel system or cause the fuel cap to disengage in a collision, which may result in possible personal injury.

Fuel filler cap lock (if equipped) Your vehicle may be equipped with a locking fuel filler cap.

When fueling your vehicle:

1. Turn the engine off.

2. Open the fuel filler flap.

3. Unlock the fuel filler cap, using the key and turn cap counterclockwise to remove.

4. To close, turn the cap clockwise until it clicks.

Refer to the previous section Fuel filler cap for additional information.

Fuel filler cap After refueling, if the Check fuel cap indicator comes on and stays on when you start the engine, the fuel filler cap may not be properly installed. Turn off the engine, remove the fuel filler cap, align the cap properly and reinstall it securely. The Check fuel cap indicator should turn off after three driving cycles with the fuel filler cap properly installed. A driving cycle consists of a cold engine startĆup followed by mixed city/highway driving.

If you must replace the fuel filler cap, replace it with a fuel filler cap that is designed for your vehicle. The customer warranty may be void for any damage to the fuel tank or fuel system if the correct genuine Ford or Motorcraft fuel filler cap is not used.

The fuel system may be under pressure. If the fuel

filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out and injure you or others.

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Maintenance and Specifications

Choosing the right fuel Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law and could damage your vehicle.

Your vehicle was not designed to use fuel or fuel additives with metallic compounds, including manganeseĆbased compounds containing (MMT).

Vehicles certified to meet California emission standards (indicated on the underhood Vehicle Emission Control Information label) are designed to operate on California reformulated gasolines. If California reformulated gasoline is not available when you refuel, your vehicle can be operated on nonĆCalifornia 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 for which your vehicle was not designed may not be covered by your warranty.

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Maintenance and Specifications

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

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

Fuel quality If you are experiencing starting, rough idle or hesitation driveability problems during a cold start, try a different brand of Regular" unleaded gasoline. Premium" unleaded gasoline is not recommended (particularly in the United States) because it may cause these problems to become more pronounced. If the problems persist, see your dealer or qualified service technician.

87(R+M)/2 METHOD

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Maintenance and Specifications

It should not be necessary to add any aftermarket products to your fuel tank if you continue to use high quality fuel of the recommended octane rating. Aftermarket products could cause damage to the fuel system. Repairs to correct the effects of using an aftermarket product in your fuel may not be covered by your warranty.

Many of the world's automakers issued the WorldĆwide Fuel Charter that recommends gasoline specifications to provide improved performance and emission control system protection for your vehicle. Gasolines that meet the WorldĆwide Fuel Charter should be used when available. Ask your fuel supplier about gasolines that meet the WorldĆwide Fuel Charter. In Canada, look for fuels that display the Auto Makers' ChoiceT logo.

Cleaner air Ford endorses the use of reformulated cleanerĆburning" gasolines to improve air quality.

Do not use gasolines containing methanol, which can damage critical fuel system components. Damage resulting from the use of methanol may not be covered by your warranty.

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Maintenance and Specifications

Running out of fuel Avoid running out of fuel because this situation may have an adverse affect on modern powertrain components.

If you have run out of fuel: • You may need to crank the engine several times before the system starts to pump fuel from the tank to the engine. • Your Check engine light may come on. For more information on the Check engine light, refer to the Instrument Cluster chapter.

Fuel filter Your vehicle is equipped with a fuel filter that is mounted on the underbody.

For fuel filter replacement, see your dealer or a qualified service technician. Refer to the Scheduled Maintenance Guide" for the appropriate intervals for changing the fuel filter.

If you replace the fuel filter, replace it with an authorized Motorcraft part. The customer warranty may be void for any damage to the fuel system if an authorized Motorcraft fuel filter is not used.

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Maintenance and Specifications

ESSENTIALS OF GOOD FUEL ECONOMY

Measuring techniques Your best source of information about actual fuel economy is you, the driver. You must gather information as accurately and consistently as possible. Fuel expense, frequency of fillups or fuel gauge readings are NOT accurate as a measure of fuel economy. We do not recommend taking fuel economy measurements during the first 1,600 km (1,000 miles) of driving (engine breakĆin period). You will get a more accurate measurement after 3,000 km - 5,000 km (2,000 miles - 3,000 miles).

The advertised fuel capacity of the fuel tank on your vehicle is equal to the rated refill capacity of the fuel tank as listed in the Refill Capacities chart in this Owner Guide". The advertised capacity is the amount of the Indicated Capacity and the Empty Reserve combined. Indicated Capacity is the difference in the amount of fuel in a full tank and a tank when the fuel gauge indicates empty. Empty Reserve is the small amount of usable fuel remaining in the fuel tank after the fuel gauge indicates empty.

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Maintenance and Specifications

The amount of Empty Reserve varies and should not be relied upon to increase driving range. When refueling your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank.

Filling the tank Use the same filling rate setting (low - medium - high) each time the tank is filled. Allow three automatic clickĆoffs when filling. Always use fuel with the recommended octane rating of a known quality gasoline, preferably a national brand.

It may seem insignificant, but you should use the same side of the same pump and have the vehicle facing the same direction each time you fill up. The driver should also have the vehicle loading and distribution the same every time. Your results will be most accurate if your filling method is consistent. This is also true when calculating fuel economy.

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Maintenance and Specifications

Calculating fuel economy 1. Fill the fuel 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).

3. After at least three to five tank fillĆups, fill the fuel tank and record the current kilometer (mileage) reading.

4. Follow one of the simple calculations in order to determine fuel economy:

Multiply liters used by 100, then divide by total kilometers traveled.

Divide total miles traveled by total gallons used.

Keep a record for at least one month and record the type of driving (city or highway). This will provide an accurate estimate of the vehicle's fuel economy under current driving conditions. Additionally, keeping records during summer and winter will show how temperature impacts fuel economy. In general, lower temperatures give a deterioration in fuel economy.

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Maintenance and Specifications

Driving style – good driving and fuel economy habits Give consideration to the lists that follow and you may be able to change a number of variables and improve your fuel economy.

Habits • Smooth, moderate operation can yield up to 10% savings in fuel. • Steady speeds without stopping will always give the best fuel economy. • Idling for long periods of time (greater than one minute) will waste fuel. • Anticipate stopping; slowing down may eliminate the need to stop. • Sudden or hard accelerations will deteriorate fuel economy. • Slow down gradually. • Driving at reasonable speeds (traveling at 105 km/h [65 mph] uses 15% more fuel than traveling at 88 km/h [55 mph]). • Revving the engine before turning it off will deteriorate fuel economy. • Use of the air conditioner or defroster may deteriorate fuel economy.

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Maintenance and Specifications

• Use of speed control (if equipped) can improve fuel economy. Speed control can help maintain a constant speed and reduce speed changes. You may want to turn off the speed control in hilly terrain as unnecessary shifting between third and fourth gears may occur causing deterioration in fuel economy. • Warming up a vehicle on cold mornings is not required and deteriorates fuel economy. • Resting your foot on the brake pedal while driving will deteriorate fuel economy. • Combine errands and minimize stopĆandĆgo driving.

Maintenance • Keep tires properly inflated and use only recommended size. • Operating a vehicle with the wheels out of alignment will deteriorate fuel economy. • Use recommended engine oil. Refer to Lubricant Specifications. • Perform all regularly scheduled maintenance items. Follow the recommended maintenance schedule and owner maintenance checks found in your vehicle Scheduled Maintenance Guide".

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Maintenance and Specifications

Conditions • Heavily loading a vehicle or towing a trailer will sharply deteriorate fuel economy at any speed. • Carrying unnecessary weight will deteriorate fuel economy (approximately 0.4 l/100 km [1 mpg] is lost for every 180 kg [400 lb] of weight carried). • Adding certain accessories to your vehicle (for example bug deflectors, rollover/light bars, running boards, ski/luggage racks) will deteriorate fuel economy. • Use of fuel blended with alcohol will deteriorate fuel economy. • Fuel economy will deteriorate with lower temperatures during the first 12 - 16 km (8 - 10 miles) of driving. • Flat terrain driving improves fuel economy over hilly roads. • Transaxles give their best fuel economy when operated in the top cruise gear and with steady pressure on the gas pedal. • Close windows for high speed driving.

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Maintenance and Specifications

EPA window sticker Every new vehicle should have the EPA window sticker. Contact your dealer if the window sticker is not supplied with your vehicle. The EPA window sticker should be your guide for the fuel economy comparisons with other vehicles.

It is important to note the box in the lower left corner of the window sticker. These numbers represent the Range of L/100 km (MPG) expected on the vehicle depending upon the driver's method of operation and conditions.

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:

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Maintenance and Specifications

• Use only unleaded fuel. • Avoid running out of fuel. • Do not turn off the ignition while your vehicle is moving, especially at high speeds. • Have the items listed in your Scheduled Maintenance Guide" performed according to the specified schedule.

The scheduled maintenance items listed in the Scheduled Maintenance Guide" are essential to the life and performance of your vehicle and to its emissions system.

If other than Ford, Motorcraft or FordĆauthorized parts are used for maintenance replacements or for service of components affecting emission control, such nonĆFord 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.

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Maintenance and Specifications

Illumination of the Charging system warning light, Check engine light or a high engine temperature, 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 engine. This decal identifies engine displacement and gives some tune up specifications.

Please consult your Warranty Guide" for complete emission warranty information.

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Maintenance and Specifications

Readiness for inspection/ maintenance (I/M) testing In some localities, it may be a legal requirement to pass an I/M test of the onĆboard diagnostics system (OBDĆII). If your Check engine light is on, refer to the description in the Warning Lights and Chimes section of the Instrument Cluster chapter. Your vehicle may not pass the I/M test with the Check engine light on.

If the vehicle's powertrain system or its battery has just been serviced, the OBDĆII system is reset to a not ready for I/M test" condition. To ready the OBDĆII system for I/M testing, a minimum of 30 minutes of city and highway driving is necessary as described below: • First, at least 10 minutes of driving on an expressway or highway. • Next, at least 20 minutes driving in stopĆandĆgo, cityĆtype traffic with at least four idle periods.

Allow the vehicle to sit for at least eight hours without starting the engine. Then, start the engine and complete the above driving cycle. The engine must warm up to its normal operating temperature. Once started, do not turn off the engine until the above driving cycle is complete.

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Maintenance and Specifications

CHECKING AND ADDING POWER STEERING FLUID Check the power steering fluid. Refer to the Scheduled Maintenance Guide" for the service interval schedules. If adding fluid is necessary, use only Motorcraft MERCON ATF. 1. The power steering fluid level should be checked before starting the engine.

2. Check the fluid level in the reservoir. It should be between the MIN and MAX lines. Do not add fluid if the level is in this range.

If the fluid is low, add fluid in

3. small amounts, continuously checking the level until it reaches the range between the MIN and MAX lines. Be sure to put the cap back on the reservoir.

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Maintenance and Specifications

BRAKE FLUID Checking and adding brake fluid Brake fluid should be checked and refilled as needed. Refer to the Scheduled Maintenance Guide" for the service interval schedules:

1. Clean the reservoir cap before removal to prevent dirt or water from entering the reservoir.

2. Visually inspect the fluid level.

If necessary, add brake fluid

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

4. Use only brake fluids certified to meet Ford specifications. Refer to Lubricant specifications in this chapter. Use only DOT 3 brake fluid from a sealed container.

Brake fluid is toxic.

If you use DOT 5 or any other brake fluid that is not

DOT 3 or DOT 4, 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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Maintenance and Specifications

TRANSAXLE FLUID

Checking automatic transaxle fluid Refer to your Scheduled Maintenance Guide" for scheduled intervals for fluid checks and changes. Your transaxle does not consume fluid. However, the fluid level should be checked if the transaxle is not working properly, i. e., if the transaxle slips or shifts slowly or if you notice some sign of fluid leakage.

Automatic transaxle fluid expands when warmed. To obtain an accurate fluid check, drive the vehicle until it is warmed up (approximately 30 km [20 miles]). 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 fluid to cool before checking.

1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating temperature.

2. Park the vehicle on a level surface and engage the parking brake.

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Maintenance and Specifications

3. With the parking brake engaged and your foot on the brake pedal, start the engine and move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage.

4. Latch the gearshift lever in P (Park) and leave the engine running.

5. Remove the dipstick, wiping it clean with a clean, dry lint free rag.

Install the dipstick making sure

6. it is fully seated in the filler tube.

7. Remove the dipstick and inspect the fluid level. The fluid should be in the designated areas indicated by the figure to the right.

Low fluid level Do not drive the vehicle if the fluid level is at the bottom of the dipstick and the outside temperatures are above 10ºC (50ºF).

Correct fluid level The transaxle fluid should be checked at normal operating temperatures of 50ºCĆ60ºC (120ºFĆ140ºF) on a level surface. The transaxle fluid should be within the MIN and MAX marks shown on the indicator.

Automatic transaxle dipstick

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Maintenance and Specifications

High fluid level Fluid levels above the safe range may result in transaxle failure. An overfill condition of transaxle fluid may cause shift and/or engagement concerns and/or possible damage.

High fluid levels can be caused by overheated or aerated fluid. This can be caused by operating for an extended period at high speeds, in city traffic during hot weather, pulling a trailer, aggressive braking or aggressive steering maneuvers. If this occurs turn the vehicle off for about 30 minutes. This will allow the transaxle to return to normal operating conditions. Recheck the fluid level before correction of the overfill condition.

Adjusting automatic transaxle fluid levels Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the dipstick and/or dipstick handle and also in the Lubricant specifications section in this chapter.

Use of a nonĆapproved automatic transaxle fluid may cause internal transaxle component damage.

If necessary, add fluid in 250 ml (1/2 pint) increments through the filler tube until the level is correct.

If an overfill occurs, excess fluid should be removed by a qualified technician.

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Maintenance and Specifications

An overfill condition of transaxle fluid may cause shift and/or engagement concerns and/or possible damage.

Checking and adding manual transmission fluid (if equipped) 1. Clean the filler plug.

2. Remove the filler plug and inspect the fluid level.

3. The fluid level should be at the bottom of the opening.

4. Add enough fluid through the filler hole so that the fluid level is at the bottom of the opening.

Install and tighten the filler plug

5. securely.

Use only fluid which has been released by Ford under WSD M2C 200C.

CLUTCH FLUID (if equipped) Check the clutch fluid level. Refer to the Scheduled Maintenance Guide" for the service interval schedules.

The clutch master cylinder and brake master cylinder are part of the same system; both are refillable through the brake master cylinder with brake fluid. During normal operation, the fluid level in the brake fluid reservoir should remain constant. For more information on