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Ford 2002 excursion, Owner'S Manual

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Ford 2002 excursion Owner'S Manual Download Page 1

Introduction

2

Diesel information

4

Warning lights

7

Starting

9

Driving tips

12

General maintenance information

16

Scheduled maintenance

32

Minor troubleshooting guide

33

Capacities and specifications

36

Service points

38

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.

Copyright © 2000 Ford Motor Company

Table of contents

1

Summary of Contents for 2002 excursion

Page 1: ...Service points 38 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 Copyright 2000 Ford Motor Company Table of cont...

Page 2: ...ssion damage There are various manufacturers offering devices to increase turbocharger boost exhaust brakes to increase stopping hauling capacity or other such devices to increase the power torque of the 7 3L engine Many owners past experience with these products has been very poor Severe powertrain damage may result from the use of these aftermarket products which will not be covered by the Ford ...

Page 3: ... or other reproductive harm WARNINGS Throughout this guide you will find warnings Warnings remind you to be especially careful to avoid personal injury NEW VEHICLE BREAK IN Your vehicle does not need an extensive break in Try not to drive continuously at the same speed for the first 1 600 km 1 000 miles of new vehicle operation Vary your speed to allow parts to adjust themselves to other parts Dri...

Page 4: ...n from the fuel tank by a frame mounted electric fuel pump The fuel pump provides pressurized fuel to the engine and is electronically controlled by the fuel pump PCM relay The fuel pump contains a pressure relief valve for overpressure protection in the event of restricted flow Lubrication system It is important to change the engine oil at the recommended service intervals because oil viscosity i...

Page 5: ...nted to the side of the cylinder block The cooler s function is to regulate engine oil temperature Engine governed speed The engine governor is controlled by the PCM The PCM controls fuel input to limit maximum engine speed It will not however prevent engine overspeeding resulting from downshifting at high vehicle speed or by descending steep grades at too high a vehicle speed for the selected tra...

Page 6: ...lter element should be replaced when the colored band on the gauge reaches the CHANGE FILTER mark Engine performance and fuel economy are adversely affected when maximum restriction is reached After servicing the air filter element reset the restriction gauge by pressing the button the end of the gauge AIR FILTER GAUGE CHANGE FILTER CHANGE FILTER AIR FILTER GAUGE CHANGE FILTER CHANGE FILTER Diesel...

Page 7: ...when the ignition key is in the ON position If the light does not illuminate there may be a problem Refer to the Starting chapter in this guide After the engine starts the light should remain off The light should always illuminate at least momentarily when the engine is cold and the ignition is turned to ON If it does not illuminate the glow plug system should be checked and repaired promptly to a...

Page 8: ...separator has a significant quantity of water in it If the light illuminates when the engine is running stop the vehicle as soon as safely possible shut off the engine then drain the filter bowl Refer to the General maintenance chapter for drain procedure Allowing water to stay in the system could result in extensive damage to or failure of the fuel injection system Do not drain the water separato...

Page 9: ...econds before trying again Do not use starting fluid such as ether in the air intake system see Air Cleaner Decal Such fluid could cause immediate explosive damage to the engine and possible personal injury Do not add gasoline gasohol or alcohol to diesel fuel This practice creates a serious fire hazard and causes engine performance problems 1 Make sure all vehicle occupants have buckled their saf...

Page 10: ...ay be clogged For best results in cold weather use Number 1 D diesel fuel or winterized Number 2 D diesel fuel which has an additive to minimize wax formation Your vehicle is also equipped with a bypass relief valve located on the in tank fuel sending unit which provides fuel flow to the engine if the fuel pickup should become plugged by ice or wax To allow this bypass valve to function and avoid ...

Page 11: ...er into the intake If the engine stalls and ingestion of water into the engine is suspected do not try to restart the engine Consult your dealer for service immediately Follow the cylinder compression test procedure outlined in the Workshop Manual then check the engine oil for contamination Engine block heater if equipped Refer to the Starting chapter in your Owner Guide Starting 11 ...

Page 12: ...nd restarting the engine MANUAL TRANSMISSION SHIFT SPEEDS Do not overspeed the engine when going downhill or steep grades If equipped use the tachometer and do not allow engine speed to exceed the redline area Operating the engine beyond the recommended speeds can cause severe engine damage If your vehicle is an F Series equipped with a manual transmission your vehicle has an electronic operating ...

Page 13: ...12 mph 4 D Overdrive 64 km h 40 mph 24 km h 15 mph Maximum downshift speeds 1 6 speed transmission Shift from Transfer case position if equipped 2 2H or 4H 4L D Overdrive 4 72 km h 45 mph 26 km h 16 mph 4 3 56 km h 35 mph 19 km h 12 mph 3 2 32 km h 20 mph 13 km h 8 mph 2 1 8 km h 5 mph 3 km h 2 mph 1 LO Only shift to LO when at a stop 1 Use 2H or 4H for 4WD equipped vehicles 2 Downshift at lower s...

Page 14: ...on 3 55 7 258 16 000 4 309 9 500 5 52 60 4 10 9 072 20 000 4 536 10 000 5 52 60 Super E 350 15 passenger Wagon 3 55 7 258 16 000 4 173 9 200 5 52 60 4 10 9 072 20 000 4 536 10 000 5 52 60 E 350 RV Cutaway single rear wheel 4 10 9 072 20 000 4 717 10 400 5 52 60 E 350 RV Cutaway dual rear wheel 4 10 9 072 20 000 4 309 9 500 5 52 60 E 350 Commercial Cutaway single rear wheel 4 10 9 072 20 000 4 717 ...

Page 15: ...trailer weight could result in engine damage transmission axle damage structural damage loss of control and personal injury F Series and Excursion trailer towing tables GCWR Gross Combined Weight Rating Trailer Weights Model Rear axle ratio Maximum GCWR kg lbs Maximum trailer weight kg lbs 1 F 250 and Excursion 3 73 9 072 20 000 4 536 10 000 F 250 4 10 9 072 20 000 4 536 10 000 F 350 3 73 9 072 20...

Page 16: ...pter Do not use fuel intended for agricultural use agricultural fuel is dyed red home heating oil or any diesel fuel not intended for highway use Damage to the fuel injection system or engine can occur if an improper fuel is used Do not add gasoline gasohol or alcohol to diesel fuel This practice creates a serious fire hazard and engine performance problems It should not be necessary to add any af...

Page 17: ...time An engine that suddenly becomes noisy or operates poorly after a fuel fill could be using substandard fuel i e high water content low cetane rating or gasoline in the fuel Diesel fuel should be purchased from a reputable station which sells a large amount of diesel fuel Care should be taken whenever diesel fuel is stored Use only clean approved containers which will prevent the entry of dirt ...

Page 18: ... cover 2 Disconnect the battery ground cable then all electrical connectors vacuum tubes and fasteners as necessary for removal 3 Release the four retaining clamps on the air cleaner assembly then lift the air cleaner cover and remove the air cleaner s 4 Loosen the clamp on the air inlet tube then disconnect the air inlet tube from the resonator 5 Remove the three bolts on the turbocharger heat sh...

Page 19: ...to fuel filter element 3 Install new fuel filter and o ring into the fuel filter housing 4 Tighten cap onto fuel filter housing slowly allowing fuel to soak into the fuel filter element Tighten cap until it contacts the housing 5 Install engine appearance cover After replacing the fuel filter the engine will purge the trapped air as it runs The engine may run roughly and smoke until the air is com...

Page 20: ...on the turbocharger heat shield 7 Connect the air inlet tube to the resonator then tighten the clamp on the air inlet tube 8 Install the air cleaner s close the air cleaner cover then close the four retaining clamps on the air cleaner assembly 9 Connect the battery ground cable then all electrical connectors vacuum tubes and fasteners as necessary for installation 10 Install the engine appearance ...

Page 21: ...d 3 Allow at least 20 minutes after engine shutdown to assure that the oil contained in the upper parts of the engine has returned to the oil pan 4 Protecting yourself from engine heat pull out the dipstick wipe it clean and reinsert fully 5 Read oil level on both sides of dipstick and use highest level reading for the actual engine oil level 6 Maintain the oil level between ADD and OPERATING RANG...

Page 22: ... API Service categories CG 4 SH Do not use oil labeled with only one of the following category designations SG SH CE CF 4 or CG 4 as they could cause engine damage Engine oils with improved fuel economy properties energy conserving are currently available If you use an energy conserving oil be sure it meets the recommended Ford Specification API service categories and SAE viscosity grades listed i...

Page 23: ...long time in cold temperatures or driving short distances See the following section Engine Lubrication for Severe Service Operation for all severe duty restrictions Use Ford Engine Oil Filter Part No F4TZ 6731 A FL 1995 or equivalent These filters protect your engine by filtering harmful abrasive or sludge particles The FL 1995 filters particles significantly smaller than most available will fit f...

Page 24: ...171 C or API categories CG 4 SH Do not use oils labeled with only one of the following category designations SG SH CE CF 4 or CG 4 as they could cause engine damage For more information refer the Severe Duty Maintenance Schedule in the Service Guide REPLACING THE AIR FILTER ELEMENT When replacing the air filter element use the Motorcraft air filter element listed Refer to Lubricant and Maintenance...

Page 25: ... combination fuel filter water separator located in the V of the engine Water should be drained from the filter bowl whenever the warning light comes on or every 8 000 km 5 000 miles The WATER IN FUEL light will come on when approximately 100 cc 0 2 pints of water accumulates in the separator Replace the fuel filter with Motorcraft Part No FD 4596 Ford Part No F81Z 9N184 AA Fuel filter water separ...

Page 26: ...appearance cover Refer to Engine Compartment in the Service points chapter 4 On F Series and Excursion models open fuel filter drain valve by turning clockwise Allow to drain for approximately 25 seconds or until clean fuel is observed Close filter drain valve by turning counterclockwise until firmly seated D R A IN CLOSE General maintenance information 26 ...

Page 27: ...y resetting handle to original position 5 Verify that the fuel filter drain valve is closed If removed install the engine appearance cover 6 Close the hood and remove the container from under the vehicle 7 Restart the engine and check WATER IN FUEL indicator light The light should not glow If it continues to glow have fuel system checked and repaired General maintenance information 27 ...

Page 28: ...vel stabilizes at the top hose fitting Replace and tighten cap Fill the radiator when cold Level the coolant in the coolant bottle 4 Reinstall the coolant bottle cap 5 Start and idle engine until the radiator upper hose is warm approximately 10 15 minutes If the hose does not get warm then repeat at a higher engine speed 6 Immediately shut off engine Cautiously remove coolant bottle cap and add co...

Page 29: ...e sure all the pressure has been released still with a cloth turn and remove it Stand clear of the opening Hot coolant may splash out Whenever coolant level checks are made check condition of coolant bottle cap rubber seal Make sure it is clean and free of any dirt particles Rinse off with water if necessary When replacing cap on coolant bottle also make sure coolant bottle neck seal is clean Chec...

Page 30: ...inoperative Further modifications of the emission control system s could create liability on the part of the individual owners under the laws of some states In Canada modifications of the emission control system s could create liability under applicable Federal or Provincial laws Do not remove or alter the original equipment floor covering or insulation between it and the metal floor of the vehicl...

Page 31: ...son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts which the U S En...

Page 32: ...urmeters it may be necessary for you to approximate your time and plan engine oil and filter changes accordingly Any modification of the emissions control system could create liability under federal law U S if made prior to sale and registration under the laws of some states if made thereafter Further federal law prohibits vehicle manufacturers dealers and other persons engaged in the business of ...

Page 33: ...her or gasoline in the diesel air intake system Such fluids can cause immediate explosive damage to the engine and possible personal injury If you fuel your vehicle at a truck stop you may notice that the fuel nozzle may shut off every 5 10 seconds This is due to the flow rates being designed for larger heavy duty trucks You may have to fuel at a slower rate don t depress the nozzle trigger fully ...

Page 34: ...r to operate For vehicles with automatic transmissions the gearshift lever must be in Park or Neutral in order for the starter to operate Try operating the starter switch several times Should the switch be corroded this operation may clean the contacts or make the switch temporarily operable until you can reach the dealer If all electrical connections are tight and you need assistance to start see...

Page 35: ...though a fuse may occasionally burn out from vibration Insert a second fuse If this fuse immediately burns out and you cannot locate the cause return your vehicle to your dealer for a circuit check Replacement fuses and circuit breakers must always be the same rating as the original equipment shown Never replace a fuse or circuit breaker with one of a higher rating Higher rated fuses or circuit br...

Page 36: ...s Automatic transmission Refer to Owner Guide 1 Includes heater and 4 7L 5 quarts in coolant recovery 2 Add 2 5L 2 6 quarts if equipped with auxiliary heater option 3 Includes 1 9L 2 quarts in engine oil filter 4 Optional DRW cutaway and all standard E 450 models are 208 2L 55 0 gallons 5 Use Motorcraft MERCONt ATF Ford part number XT 2 QDX meeting Ford specification MERCONt BULB SPECIFICATIONS La...

Page 37: ...is filter Only F4TZ 6731 A FL 1995 Air Filter F Series and Excursion 1 FA 1680 ES E95AE 9601 AA Air Filter Econoline 2 Required FA 1618 ES E95AE 9601 AA Battery 2 Required BXT 65 750 Engine Coolant Premium Cooling System Fluid E2FZ 19549 AA ESE M97B44 A Engine Coolant Additive FW 16 _ 1 Always use the authorized Motorcraft air filter listed Failure to use the correct air filter may result in sever...

Page 38: ...el filter water separator drain valve release handle 5 Automatic transmission fluid dipstick 6 Air filter assembly 7 Engine oil filler 8 Air filter restriction gauge 9 Power steering fluid reservoir 10 Brake fluid reservoir 11 Engine coolant recovery reservoir 1 2 3 4 5 6 7 8 9 10 11 Service points 38 ...

Page 39: ...ngine oil filler 4 Engine oil dipstick 5 Automatic transmission dipstick if equipped 6 Fuel filter drain valve 7 Clutch fluid reservoir if equipped 8 Brake fluid reservoir 9 Air filter restriction gauge 10 Air filter assembly 11 Power steering fluid reservoir 12 Windshield washer fluid reservoir Service points 39 ...

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