Ford E-150 2002, E-250 2002, E-350 2002, E-450 2002 Owner Manual

Introduction 4

Congratulations 4 Safety and environment protection 5 Symbol glossary 10

Instrument cluster 12

Warning and control lights 12 Gauges 16

Entertainment systems 20

AM/FM stereo 20 AM/FM stereo cassette 20 AM/FM stereo cassette with CD 31 AM/FM stereo with CD 41

Climate controls 78

Heater only 78 Manual heating and air conditioning 79

Lights 85

Headlamps 85 Bulb replacement 88

Driver controls 94

Windshield wiper/washer control 94 Steering wheel adjustment 95 Power windows 96 Mirrors 97

Locks and security 108

Keys 108 Locks 108 Anti-theft system 109

Table of contents

Seating and safety restraints 113

Seating 113 Safety restraints 121 Air bags 132 Child restraints 137

Driving 148

Starting 148 Brakes 152 Transmission operation 156 Vehicle loading 160 Trailer towing 163 Recreational towing 172

Roadside emergencies 173

Hazard flasher switch 174 Fuses and relays 177 Changing tires 184 Jump starting 191 Wrecker towing 196

Customer assistance 197

The dispute settlement board 200 Utilizing the mediation/arbitration 203 Getting assistance outside the U.S. and Canada 203 Ordering additional owner’s literature 204 Reporting safety defects (U.S. only) 206

Cleaning 207

Cleaning your vehicle 207 Underbody preservation 212

Table of contents

Maintenance and specifications 214

Hood 215 Engine compartment 216 Engine oil 217 Battery 220 Fuel information 233 Air filter(s) 247 Part numbers 253 Refill capacities 254 Lubricant specifications 258 Engine data 260 Vehicle dimensions 261

Accessories 264 Index 267

All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

Introduction

The following warning may be required by California law:

CALIFORNIA Proposition 65 Warning

WARNING: Engine exhaust, some of its constituents, and

certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

CONGRATULATIONS

Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it.

For more information on Ford Motor Company and its products visit the following website:

In the United States: www.ford.com In Canada: www.ford.ca In Australia: www.ford.com.au In Mexico: www.ford.com.mx Additional owner information is given in separate publications.

This Owner’s Guide describes every option and model variant

available and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available.

Remember to pass on the Owner’s Guide when reselling the

vehicle. It is an integral part of the vehicle.

Introduction

Fuel pump shut-off switch In the event of an accident the

safety switch will automatically cut off the fuel supply to the engine. The switch can also be activated through sudden vibration (e.g. collision when parking). To reset the switch, refer to the Fuel pump shut-off switch in the Roadside emergencies chapter.

SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed.

Warning symbols on your vehicle

When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind.

Protecting the environment

We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.

BREAKING-IN YOUR VEHICLE

There are no particular guidelines for breaking-in your vehicle. During the first 1 600 km (1 000 miles) of driving, vary speeds frequently. This is recommended to give the moving parts a chance to break in.

Introduction

SPECIAL NOTICES Emission warranty

The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

Special instructions

For your safety, your vehicle is fitted with sophisticated electronic controls.

By operating other electronic equipment (e.g. mobile telephone

without exterior aerial) electromagnetic fields can occur which can cause malfunctions of the vehicle electronics. Therefore you should observe the instructions of the equipment manufacturers.

Please read the section Air bag in the Seating and safety

restraints chapter. Failure to follow the specific warnings and instructions could result in personal injury.

Rear facing child or baby seats should NEVER be used in front

of a passenger side air bag.

Notice to owners of diesel-powered vehicles

Read the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for information regarding correct operation and maintenance of your diesel-powered light truck.

Introduction

Notice to owners of pickup trucks and utility type vehicles

Utility vehicles have a significantly higher rollover rate than

other types of vehicles.

Before you drive your vehicle, please read this Owner’s Guide carefully. Your vehicle is not a passenger car. As with other vehicles of this type, failure to operate this vehicle correctly may result in loss of control or an accident.

Using your vehicle as an ambulance

If your light truck is equipped with the Ford Ambulance Preparation Package, it may be utilized as an ambulance. Ford urges ambulance manufacturers to follow the recommendations of the Ford Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book and the QVM guidelines as well as pertinent supplements. For additional information,

please contact the Truck Body Builders Advisory Service 1–877–840–4338.

Use of your Ford light truck as an ambulance, without the Ford Ambulance Preparation Package voids the Ford New Vehicle Limited Warranty and may void the Emissions Warranties. In addition, ambulance usage without the preparation package could cause high underbody temperatures, overpressurized fuel and a risk of spraying fuel which could lead to fires.

If your vehicle is equipped with the Ford Ambulance Preparation Package, it will be indicated on the Certification label. The label is located on the driver’s side door pillar or on the rear edge of the driver’s door. You can determine whether the ambulance manufacturer followed Ford’s recommendations by directly contacting that manufacturer. Ford Ambulance Preparation Package is only available on certain 7.3L Diesel engine equipped vehicles.

Introduction

Notice to owners of natural gas fueled vehicles

Before you drive your vehicle, be sure to read the “Natural Gas Vehicle Owner’s Guide Supplement.” This book contains important operation and maintenance information.

Introduction

Middle East/North Africa vehicle specific information

For your particular global region, your vehicle may be equipped with features and options that are different from the ones that are described in this Owner Guide; therefore, a supplement has been supplied that complements this book. By referring to the pages in the provided supplement, you can properly identify those features, recommendations and specifications that are unique to your vehicle. Refer to this Owner

Guide for all other required information and warnings.

Introduction

These are some of the symbols you may see on your vehicle.

Vehicle Symbol Glossary

Safety Alert

Fasten Safety Belt Air Bag-Front

Air Bag-Side Child Seat

Child Seat Installation Warning

Brake System Anti-Lock Brake System

Brake Fluid Non-Petroleum Based

Master Lighting Switch Hazard Warning Flasher

Fog Lamps-Front Fuse Compartment

Fuel Pump Reset Windshield Wash/Wipe

See Owner’s Guide

Child Seat Tether Anchorage

Traction Control

Windshield Defrost/Demist

Power Windows Front/Rear

Rear Window Defrost/Demist

Power Window Lockout

Vehicle Symbol Glossary

MAX

MIN

Introduction

Child Safety Door Lock/Unlock

Interior Luggage Compartment Release Symbol

Panic Alarm Engine Oil

Engine Coolant

Engine Coolant Temperature

Do Not Open When Hot Battery

Avoid Smoking, Flames, or Sparks

Battery Acid

Explosive Gas Fan Warning

Power Steering Fluid

Maintain Correct Fluid Level

Emission System Engine Air Filter

Passenger Compartment Air Filter

Jack

Check fuel cap Low tire warning

Instrument cluster

WARNING LIGHTS AND CHIMES

Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works. If any light remains on after starting the vehicle, have

the respective system inspected immediately.

Service engine soon

Illuminates briefly to ensure the system is functional. If it comes on after the engine is started, one of the engine’s emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will usually be drivable and will not require towing.

Light turns on solid:

Temporary malfunctions may cause the light to illuminate. Examples are:

1. The vehicle has run out of fuel.

2. Poor fuel quality or water in the fuel.

3. The fuel cap may not have been properly installed and securely tightened.

These temporary malfunctions can be corrected by filling the fuel tank with high quality fuel of the recommended octane and/or properly installing and securely tightening the fuel cap. After three driving cycles without these or any other temporary malfunctions present, the light should turn off. (A driving cycle consists of a cold engine startup

SERVICE

ENGINE

SOON

Instrument cluster

followed by mixed city/highway driving.) No additional vehicle service is required.

If the light remains on, have your vehicle serviced at the first available opportunity.

Light is blinking:

Engine misfire is occurring which could damage your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity.

Under engine misfire conditions, excessive exhaust temperatures

could damage the catalytic converter, the fuel system, interior floor coverings or other vehicle components, possibly causing a fire.

Brake system warning

Illuminates if the parking brake is engaged. Also momentarily illuminates at start up to ensure the circuit is functional. If the brake warning lamp does not illuminate at these times, or illuminates after releasing the parking brake, seek service immediately. Refer to Brakes in the Driving chapter for more information.

BRAKE

Anti-lock brake system (ABS)

Momentarily illuminates at start up to ensure the circuit is functional. If the light does not illuminate, remains on or continues to flash, the ABS needs to be serviced (refer to Brakes in the Driving chapter for more information). With the ABS light on, the ABS is disabled and normal braking is still functional.

Safety belt

Illuminates to remind you to fasten your safety belts. For more information, refer to the Seating and safety restraints chapter.

ABS

Instrument cluster

Air bag readiness

Illuminates to confirm that the air bags (front or side) are operational. If the light fails to illuminate, continues to flash or remains on, have the system serviced immediately.

Charging system

Illuminates when the battery is not charging properly.

Low fuel

Illuminates when the fuel level in the fuel tank is at, or near, empty (refer to Fuel gauge in this chapter for more information).

Speed control (if equipped)

Illuminates when the speed control is activated.

LOW

FUEL

Oil pressure/Engine coolant

Illuminates when the engine coolant temperature is above the normal range or the engine oil pressure is below normal range. Check the engine oil and coolant level refer to

Adding engine oil and Adding coolant in the Maintenance and specifications chapter.

Instrument cluster

Transmission control indicator light (TCIL)

Illuminates when the overdrive function of the transmission has been turned OFF using the Transmission Control Switch (TCS). Refer to the Driving chapter for transmission function and operation.

If the light does not come on or if the light flashes steadily, have your vehicle serviced as soon as possible, damage to the transmission could occur.

Turn signal

Illuminates when the turn signals or the hazard lights are turned on. If the lights stay on continuously or flash faster, check for a burned-out bulb.

High beams

Illuminates when the high beam headlamps are turned on.

OVERDRIVE

Door ajar

Illuminates when any door is open (or not fully closed).

DOOR

AJAR

Safety belt warning chime/buzzer

For information on the safety belt warning chime, refer to the Seating and safety restraints chapter.

BeltMinder chime

Sounds intermittently to remind you to fasten your safety belts.

Instrument cluster

Supplemental restraint system (SRS) warning chime

Sounds when a malfunction in the supplemental restraint system (front or side airbags) has been detected. Have the supplemental restraint system inspected immediately.

Headlamps on warning chime (if equipped)

Sounds when the headlamps or parking lamps are on, the key is removed from the ignition and the driver’s door is opened.

Key-in-ignition warning chime/buzzer

Sounds when the key is left in the ignition and the driver’s door is opened.

GAUGES

Instrument cluster

Engine coolant temperature gauge

Indicates the temperature of the engine coolant. At normal operating temperature, the needle remains within the normal area (the area between the “H” and “C”). If it enters the red section, the engine is overheating. Stop the vehicle as soon as safely possible, switch off the engine immediately and let the engine cool. Refer to Engine coolant in the Maintenance and specifications chapter.

Never remove the coolant reservoir cap while the engine is

running or hot. Steam and scalding liquid from a hot cooling system can burn you badly.

This gauge indicates the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level the gauge indication will not be accurate. If the gauge enters the red section, the oil pressure/engine coolant and Check Engine/Service Engine Soon indicators illuminate, refer to What you should know about fail-safe cooling in the Maintenance and specifications chapter.

Engine oil pressure gauge

Indicates engine oil pressure. At normal operating temperature, the needle will be in the normal range (the area between the “L” and “H”); if the needle goes below the normal range, stop the vehicle as soon as safely possible and switch off the engine immediately. Check the oil level. Add oil if needed (refer to Engine oil in the Maintenance and specifications chapter). If the oil level is correct, have your vehicle checked at your dealership or by a qualified technician.

Instrument cluster

Battery voltage gauge

Indicates battery voltage. If the pointer moves and stays outside the normal operating range (as indicated by the arrows), have the vehicle’s electrical system checked as soon as possible.

Fuel gauge

Displays approximately how much fuel is in the fuel tank. The fuel gauge may vary slightly when the vehicle is in motion or on a grade.

When refueling the vehicle from empty indication, the amount of fuel that can be added will be less than the advertised capacity due to the reserve fuel.

Speedometer

Indicates the current vehicle speed.

000000

20 km/h

MPH

0000

100

120

140

160

10 0

Odometer

Registers the total kilometers (miles) of the vehicle.

Trip odometer

Registers the kilometers (miles) of individual journeys. To reset, depress the control.

Instrument cluster

100

120

000000

20 km/h

MPH

000000

0000

100

120

20 km/h

MPH

0000

140

160

10 0

140

160

10 0

Entertainment systems

USING YOUR AUDIO SYSTEM AM/FM Stereo (with 2 speakers)

VOL

PUSH

TONE

CLK

1 2 3 4 AM/FM

AM/FM Stereo (with 4 speakers and fade capability)

VOL

PUSH

TONE

CLK

TONE VOL

ST DX

SEEK TUNE

AM / FM STEREO

1 2 3 4 AM/FM

Entertainment systems

Volume/power control

Press the control to turn the audio system on or off.

Turn the control to raise or lower volume.

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

TONE

Press the TONE control once, then use the volume knob to adjust the

CLK

desired level.

VOL

PUSH

VOL

PUSH

VOL

PUSH

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

Press the TONE control twice, then use the volume knob to adjust the desired level.

TONE

CLK

VOL

PUSH

Entertainment systems

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

Press the TONE control three times, then use the volume knob to adjust the desired level.

Speaker fade adjust (if equipped)

Speaker sound can be adjusted between the front and rear speakers.

Press the TONE control four times, then use the volume knob to adjust the desired level.

Seek function

The seek function control works in radio mode.

Seek function in radio mode

• Press to find the next listenable station down the frequency band.

• Press

to find the next listenable station up the frequency band.

TONE

CLK

TONE

CLK

SEEK

TUNE

VOL

PUSH

VOL

PUSH

AM/FM select

The AM/FM select control works in radio mode.

AM/FM

AM/FM select in radio mode

This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations.

Entertainment systems

Radio station memory preset

The radio is equipped with four station memory preset controls. These controls can be used to select up to four preset AM stations and eight FM stations (four in FM1 and four in FM2).

Setting memory preset stations

1. Select the frequency band with the AM/FM select control.

2. Select a station. Refer to Tune adjust or Seek function for more information on selecting a station.

3. Press and hold a memory preset control until the sound returns, indicating the station is held in memory on the control you selected.

1 2 3 4

Setting the clock

Press CLK to toggle between listening frequencies and clock mode.

To set the hour, press and hold the CLK control until CLOCK SET appears in the display and press the SEEK control:

TONE

CLK

•

to decrease hours and to increase hours.

SEEK SEEK

TUNE TUNE

Entertainment systems

To set the minute, press and hold the CLK control until CLOCK SET appears in the display and press the TUNE control:

TONE

CLK

•

The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for ten seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for ten seconds before reverting back to the clock. In media mode, the media information will always be displayed.

Tune adjust

The tune control works in radio mode.

to decrease minutes and to increase minutes.

SEEK

TUNE

SEEK

TUNE

Tune adjust in radio mode

• Press to move to the next frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly.

• Press a listenable station is located there). Hold for quick movement.

to move to the next frequency up the band (whether or not

SEEK TUNE

AM/FM STEREO CASSETTE

VOL - PUSH ON

BASS TREB BAL FADE

Entertainment systems

FM1

CLK

TAPE

AMS

SEEK TUNE

SCAN

123456

Volume/power control

Press the control to turn the audio system on or off.

Turn the control to raise or lower volume.

SIDE REW FF

VOL - PUSH ON

1 - 2

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Entertainment systems

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

BASS

TREB

BAL

Entertainment systems

Speaker fade adjust

Speaker sound can be adjusted between the front and rear speakers.

Seek function

The seek function control works in radio mode.

Seek function in radio mode

• Press to find the next listenable station down the frequency band.

• Press listenable station up the frequency band.

Scan function

The scan function works in radio mode.

to find the next

FADE

SEEK

TUNE

SCAN

Scan function in radio mode

Press the SCAN control to hear a brief sampling of all listenable stations on the frequency band. Press the SCAN control again to stop the scan mode.

AM/FM select

The AM/FM select control works in radio and tape modes.

Entertainment systems

AM/FM select in radio mode

This control allows you to select AM or FM frequency bands. Press the AM control to select from AM selections, and press the FM control to select from FM1 or FM2 memory preset stations.

AM/FM select in tape mode

Press this control to stop tape play and begin radio play.

Radio station memory preset

The radio is equipped with six station memory preset controls. These controls can be used to select up to six preset AM stations and twelve FM stations (six in FM1 and six in FM2).

Setting memory preset stations

1. Select the frequency band with the AM or the FM select control.

2. Select a station. Refer to Tune adjust or Seek function for more

information on selecting a station.

3. Press and hold a memory preset control until the sound returns,

indicating the station is held in memory on the control you selected.

123456

Setting the clock

Press CLK to toggle between listening frequencies and clock mode while in radio mode.

To set the hour, press and hold the CLK control and press the SEEK control:

•

to decrease hours and to increase hours.

CLK

TAPE

AMS

SEEK

TUNE

DISCS

To set the minute, press and hold the CLK control and press the TUNE control:

Entertainment systems

CLK

TAPE

AMS

•

The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for 10 seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for 10 seconds before reverting back to the clock. In media mode, the media information will always be displayed.

Tune adjust

The tune control works in radio mode.

to decrease minutes and to increase minutes.

SEEK

TUNE

DISCS

Tune adjust in radio mode

• Press to move to the next frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly.

• Press a listenable station is located there). Hold for quick movement.

to move to the next frequency up the band (whether or not

SEEK TUNE

Entertainment systems

Tape select

• To enter tape mode while in radio mode, press the TAPE AMS control.

Automatic Music Search

The Automatic Music Search feature allows you to quickly locate the beginning of the tape selection being played or to skip to the next selection.

To activate the feature, momentarily depress the TAPE AMS button. Then, press either REW (for the beginning of the current selection) or FF (to advance to the next selection). The tape deck stops and returns to play mode when the AMS circuit senses a blank section on the tape.

In order to ensure proper operation of the AMS feature, the tape MUST have a blank section of at least four seconds duration between programs.

CLK

TAPE

AMS

CLK

TAPE

AMS

Rewind

The rewind control works in tape mode.

To rewind in tape mode, press the REW control.

Fast forward

The fast forward control works in tape mode.

To fast forward in tape mode, press the FF control.

In the tape mode, tape direction will automatically reverse when the end of the tape is reached.

SIDE

1 - 2

REW FF

SIDE

1 - 2

REW FF

+ 242 hidden pages