Ford 2002 Excursion Owner's Manual
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Ford 2002 Excursion Owner's Manual

Ford motor company 2002 ford excursion owner's guide
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See also: Owner's Manual
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

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Summary of Contents for Ford 2002 Excursion

  • Page 1: Table Of Contents

    Ford Motor Company. Ford may change the contents without notice and without incurring obligation. Copyright © 2000 Ford Motor Company...

  • Page 2: Introduction

    Severe powertrain damage may result from the use of these aftermarket products which will not be covered by the Ford warranty. Ford may discontinue models or change specifications without any notice and without incurring obligations.

  • Page 3: New Vehicle Break-In

    Package, inspect the information plate on the driver’s side door pillar. Contact the manufacturer of your vehicle to determine whether the ambulance manufacturer’s followed Ford’s recommendations. 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.

  • Page 4: Diesel Engine Information

    Diesel information DIESEL ENGINE INFORMATION The diesel engine fuel system consists of: a frame-mounted electric fuel supply pump an engine mounted fuel filter/water separator a fuel restriction sensor a unit injector for each cylinder The combination fuel filter/water separator removes both water and impurities from the fuel.
  • Page 5 Fast start glow plug system The glow plug system consists of: eight glow plugs the glow plug relay engine oil temperature (EOT) sensor barometric pressure (BARO) sensor The glow plug system is electronically controlled by the PCM. The PCM energizes the glow plugs immediately after the ignition is placed in the ON position, then determines how long the glow plugs will be on according to the EOT and BARO sensors.
  • Page 6 Diesel information Air filter restriction gauge The restriction gauge, located on the clean-air side of the air cleaner upper housing, shows if the air filter is clogged. Refer to “Engine Compartment” in Service Points chapter. The air filter element should be replaced when the colored band on the gauge reaches the CHANGE FILTER mark.

  • Page 7: Warning Lights

    Warning lights ECONOLINE F–250/350/450/550, EXCURSION WAIT TO START With the key in the ON position, the WAIT WAIT TO START light will illuminate if glow plug heat is necessary as a starting aid. Wait until the light goes START off before starting. The light should always illuminate briefly, when the ignition key is in the ON position.
  • Page 8 Warning lights WATER IN FUEL During refueling, it is possible for water-contaminated diesel fuel to be pumped into your tank. Your vehicle fuel system is equipped with a fuel filter/water separator to remove water from the fuel. The WATER IN FUEL light will illuminate when the ignition is turned to START (as part of the light function check) and when the fuel filter/water separator has a significant quantity of water in If the light illuminates when the engine is running, stop the vehicle as...

  • Page 9: Starting The Engine

    Starting STARTING THE ENGINE Read all starting instructions carefully before you start your vehicle. For temperatures below 0°C (32°F), the use of the correct grade engine oil is essential for proper operation. If your vehicle is equipped with a manual transmission, make sure the parking brake is set fully before you turn the key.

  • Page 10: Stopping The Engine

    Starting 5. After the engine starts, allow it to idle for about 15 seconds. (Do not increase engine speed until the oil pressure gauge indicates normal pressure.) STOPPING THE ENGINE Turn the ignition to OFF. To prolong engine life (after extended high speed or maximum GVW operation), it is recommended that a hot engine be allowed to operate at low idle for about 7–10 minutes which would allow sufficient time for the turbocharged engine to cool down.
  • Page 11 Starting Operation in standing water Ingestion of water into the diesel engine can result in immediate and severe damage to the engine. If driving through water, slow down to avoid splashing water into the intake. If the engine stalls, and ingestion of water into the engine is suspected, do not try to restart the engine.

  • Page 12: Driving Tips

    Driving tips DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED) If your vehicle is equipped dual fuel tanks, you will have a selector control, located to the right of the steering wheel, which allows you to draw fuel from either tank. Your fuel gauge will display the amount of fuel in the currently selected tank.

  • Page 13: Trailer Towing

    Upshift and downshift according to the following shift speed charts: Upshifts when accelerating (recommended for best fuel economy) 6-speed transmission Shift from: Transfer case position LO-1 8 km/h (5 mph) 16 km/h (10 mph) 32 km/h (20 mph) 48 km/h (30 mph) 64 km/h (40 mph) (Overdrive) Maximum downshift speeds...
  • Page 14 Driving tips Econoline trailer towing tables Your vehicle may tow a class I, II or III trailer provided the maximum trailer weight is less than or equal to the maximum trailer weight listed for your engine and rear axle ratio on the following charts. GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum Rear axle...
  • Page 15 Your vehicle’s load capacity is designated by weight, not by volume, so you cannot necessarily use all available space when loading a vehicle. Distribute the load so that only 10 to 15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch.

  • Page 16: General Maintenance Information

    Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. WASHING THE DIESEL ENGINE Never wash the engine when it is warm, hot or running.
  • Page 17 General maintenance information Truck stops have pumps and nozzles designed for larger, heavy-duty trucks. When refueling at truck stops: if the nozzle shuts off repeatedly when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t depress the nozzle trigger as far). If air is allowed to enter the fuel system (during fuel filter change or if you run out of fuel) the engine will purge the trapped air as it runs.

  • Page 18: Changing Fuel Filter

    General maintenance information CHANGING FUEL FILTER Removal — F-Series Super Duty and Excursion only 1. Remove the engine appearance cover. 2. Remove the fuel filter cap by turning counterclockwise. 3. Remove and discard old fuel filter element and fuel filter o-ring. 4.
  • Page 19 General maintenance information 7. Remove the fuel filter cap by turning counterclockwise. 8. Remove and discard old fuel filter element and fuel filter o-ring. 9. Carefully clean the mating surfaces. Installation — F-Series Super Duty and Excursion only The engine will not run properly if the fuel filter is not installed in housing.
  • Page 20 General maintenance information Installation — Econoline only The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean diesel fuel to the new fuel filter o-ring. 2. Install new fuel filter o-ring onto fuel filter element. 3.

  • Page 21: Engine Oil

    General maintenance information ENGINE OIL Checking engine oil level Because it is normal to add some oil between oil changes, check your engine oil level each time you stop for fuel. To check the engine oil level consistently and accurately, the following procedure is recommended: 1.
  • Page 22 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 in the Lubricant and Maintenance Materials Specifications chart.
  • Page 23 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”...

  • Page 24: Replacing The Air Filter Element

    Change engine oil and filter every 5 000 km (3 000 miles). Use Motorcraft oil or an equivalent oil conforming to Ford Specification ESR-M2C171–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.

  • Page 25: Fuel Filter/Water Separator

    (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 separator drain procedure 1.
  • Page 26 General maintenance information 2. Open the hood. Place an appropriate container under the filter drain under the vehicle. 3. Locate the fuel filter drain valve. If necessary, remove the engine appearance cover. Refer to “Engine Compartment” in the Service points chapter.
  • Page 27 General maintenance information 4. On Econoline models, open fuel filter drain valve by pulling on the release handle. Allow to drain for approximately 25 seconds or until clean fuel is observed. Close filter drain valve by resetting handle to original position. 5.

  • Page 28: Engine Coolant

    General maintenance information ENGINE COOLANT Replacing coolant A coolant mixture of 50% coolant concentrate and 50% water is recommended to maintain best overall performance. To avoid damaging the engine and radiator, the coolant concentrate should not exceed 60%. When refilling the coolant system either as part of the regular maintenance (48 months, or 80 000 km [50 000 miles], whichever comes first and then every 36 months or 48 000 km [30 000 miles], whichever comes first), or due to service performed, adhere to the following...
  • Page 29 General maintenance information coolant to “wear out” in a shorter time. Ford recommends an interim service interval performed at 12 months or 24 000 km (15 000 miles), whichever occurs first. Add 237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 to the cooling system. For vehicles with extensive idling time, add 237–295 ml (8–10 oz.) of coolant additive FW-15 after...

  • Page 30: Emission Control System(S) Laws

    General maintenance information This additive aids in the prevention of rust and scale buildup on the internal parts of the cooling system. Prevention of rust and scale buildup allows for proper dissipation of heat generated by combustion. See the “Service Guide” for recommended intervals. EMISSION CONTROL SYSTEM(S) LAWS Federal law prohibits vehicle manufacturers, dealers and other persons engaged in the business of repairing, servicing, selling, leasing or trading...

  • Page 31: Noise Emissions Warranty, Prohibited Tampering Acts And Maintenance

    General maintenance information NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS AND MAINTENANCE On January 1, 1978, Federal regulation became effective governing the noise emission on trucks over 4 536 kg (10 000 lbs.) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Facts Booklet, are applicable to complete chassis cabs over 4 536 (10 000 lbs.) GVWR.

  • Page 32: Scheduled Maintenance

    Scheduled maintenance VEHICLE EMISSIONS CONTROL INFORMATION (VECI) Emissions information appears on the VECI decal on the engine valve cover. This decal identifies engine displacement and provides certain engine specifications. SCHEDULED MAINTENANCE SERVICES Refer to your “Service Guide” for details of maintenance on your vehicle. If you are using your vehicle in a manner in which it will remain stationary (door to door service, taxi, etc.), then it is recommended that you change the engine oil every 200 engine hours as opposed to a...

  • Page 33: Minor Troubleshooting Guide

    The complexity of the diesel engine makes it so the owner is discouraged from attempting to perform maintenance other than the services described in this supplement. If you experience difficult starting, rough idling, excessive exhaust smoke, a decrease in engine performance or excess fuel consumption, perform the following checks: a plugged air inlet system.

  • Page 34: If The Engine Won't Crank

    Minor troubleshooting guide IF THE ENGINE WON’T CRANK Turn on the headlights. If the lights are dim, do not go on at all or if when the ignition is turned to START the lights become dim or go out, the battery connections may be loose or corroded, or the battery may be discharged.

  • Page 35: If The Engine Runs Hot

    IF THE ENGINE RUNS HOT The following could cause the engine to overheat: Lack of coolant. Dirty cooling system. Driving with frozen coolant. Sticking thermostat. Overloading or pulling heavy trailers during hot weather. Grill or radiator air blockage. Slipping or missing drive belt. Plugged or very dirty air cleaner element.

  • Page 36: Capacities And Specifications

    Add 2.5L (2.6 quarts) if equipped with auxiliary heater option. Includes 1.9L (2 quarts) in engine oil filter. Optional DRW cutaway and all standard E-450 models are 208.2L (55.0 gallons). Use Motorcraft MERCON ATF, Ford part number XT-2–QDX, meeting Ford specification MERCON . BULB SPECIFICATIONS Number of bulbs...
  • Page 37 Capacities and specifications LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS Ford Part Item Name Motorcraft Motor Oil 15W40 Engine Oil Super Duty, 10W30 Super Duty Engine Oil Filter (Use this filter Only) Air Filter (F-Series and Excursion) Air Filter (Econoline) (2 Required)

  • Page 38: Service Points

    Service points ECONOLINE ENGINE COMPARTMENT 1. Battery 2. Windshield washer fluid reservoir 3. Engine oil dipstick 4. Fuel 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.
  • Page 39 Service points F-SERIES AND EXCURSION ENGINE COMPARTMENT 1. Battery (dual batteries shown) 2. Engine coolant recovery reservoir 3. Engine oil filler 4. Engine oil dipstick 5. Automatic transmission dipstick (if equipped) 6. Fuel filter drain valve 7. Clutch fluid reservoir (if equipped) 8.

This manual is also suitable for:

2002 f-2502002 f-3502002 f-450

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