2003 FORD F SERIES MOTORHOME AND COMMERCIAL CHASSIS fuel cap

Customer assistance 53
Cleaning 54
Maintenance and specifications 55
Engine compartment 56
Engine oil 57
Battery 59
Fuel information 67
Air filter(s) 83
Part numbers 88
Refill capacities 89
Lubricant specifications 91
Reporting safety defects (U.S. only) 93
Reporting safety defects (U.S. only) 93
Index 94
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Copyright © 2002 Ford Motor Company
Table of contents
2

Child Safety Door
Lock/UnlockInterior Luggage
Compartment Release
Symbol
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
7

GAUGES
Speedometer:Indicates the
current vehicle speed.
Engine coolant temperature
gauge:Indicates engine coolant
temperature. At normal operating
temperature, the needle will be in
the normal range (between “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
and let the engine cool.
Never remove the coolant reservoir cap while the engine is
running or hot.
F
E
CH H
L
18
8
PRN 21LOW
FUEL
+ -+ -000000000
0
50
60
70
20
10
0 3040
80
90
100
20406080
100
120
140
180
MPH km/hBRAKE!
1
02
RPMx1000
3
4
5
6
SERVICE
ENGINE
SOONABSFUEL
RESETDOOR
AJARBRAKE
H
C
Instrumentation
11

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
6 20A* Parklamp feeds, Instrument panel
fuse #41, Warning chime module,
Trailer tow running lamp relay
coil, I/P dimmer module
7 15A* Starter relay coil, BB neutral
sense
8 10A* Stoplamp switch (logic): Brake
pressure switch, Power brake
assist module***, Speed control
module, PCM, Anti-lock Brake
System (ABS) module, Brake shift
interlock actuator
9 5A* Alternator
10 20A* Daytime Running Lamps (DRL)
11 30A* Ignition coils, Radio capacitors #1
and #2, PCM relay
12 20A* Trailer tow running lamps feed,
Trailer tow back-up lamps feed, IP
- backup lamp feed
13 30A** Trailer tow electric brake
controller feed
14 60A** IP battery feed (fuse #9, 15, 21)
15 -- Not used
16 60A** ABS module
17 -- Not used
18 20A** Horn feed
19 -- Not used
20 40A** PCM relay
21 20A** Fuel pump motor
22 20A** Diagnostic tool connector, Cigar
lighter feed
23 40A** Blower motor feed
Roadside emergencies
43

2. If the engine oil level is not within the MIN and MAX 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 engine oil level. Make sure the oil level is not above the
MAX mark on the engine oil level indicator (dipstick).
4. Install the indicator and ensure it is fully seated.
5. Fully install the engine oil filler cap by turning the filler cap clockwise
until three clicks can be heard.
To avoid possible oil loss, DO NOT operate the vehicle with the
engine oil level indicator and/or the engine oil filler cap removed.
Engine oil and filter recommendations
Look for this certification
trademark.
SAE 5W-20 engine oil is recommended.
Only use oils “Certified For Gasoline Engines” by the American
Petroleum Institute (API). Use Motorcraft or an equivalent oil meeting
Ford specification WSS-M2C153–H.SAE 5W-20 oil provides optimum
fuel economy and durability performance meeting all
requirements for your vehicle’s engine.
Do not use supplemental engine oil additives, oil treatments or engine
treatments. They are unnecessary and could, under certain conditions,
lead to engine damage which is not covered by your warranty.
Change your engine oil and filter 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, start-up
engine noises or knock may be experienced.
It is recommended you use the appropriate Motorcraft oil filter (or
another brand meeting Ford specifications) for your engine application.
Maintenance and specifications
58

When lifting a plastic-cased 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.
To account for customer driving habits and conditions, your automatic
transmission (4R100) electronically controls the shift quality by using an
adaptive learning strategy. The adaptive learning strategy is maintained
by power from the battery. When the battery is disconnected or a new
battery is installed, the transmission must relearn its adaptive strategy.
Optimal shifting will resume within a few hundred kilometers (miles) of
operation.
If the shift quality does not improve within a few hundred
kilometers (miles) of operation, or if the downshifts and other
throttle conditions do not function normally or after a long
deceleration period, see your dealer or a qualified service
technician as soon as possible.
Because your vehicle’s engine is also 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 and fuel trim strategy for optimum
driveability and performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
Maintenance and specifications
60

Once the engine temperature cools, the engine can be re-started. Take
your vehicle to a service facility as soon as possible to minimize engine
damage.
When fail-safe mode is activated
You have limited engine power when in the fail-safe mode, so drive the
vehicle with caution. The vehicle will not be able to maintain high-speed
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.
3. If this is not possible, wait a 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. Re-start 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.
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.
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.
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.
Maintenance and specifications
67

Fuel filter replacement
The fuel filter assembly is located inside the driver side frame rail, near
the transmission.
The fuel filter should be replaced every 24 000 km (15 000 miles).
Removal
If the fuel filter is being serviced with the rear of the vehicle
higher than the front, or if the fuel tank is pressurized, fuel
leakage or siphoning from the tank fuel tubes could occur. To prevent
this condition, maintain the vehicle front end at or above the level of
the rear of the vehicle.
Do not smoke or carry lighted tobacco or open flame of any type
when working on or near any fuel related component. Highly
flammable mixtures are always present and may be ignited, resulting in
possible personal injury.
Fuel in the fuel system remains under high pressure even when
the engine is not running. Before servicing or disconnecting any
of the fuel lines or fuel system components, the fuel system pressure
must be relieved in order to prevent accidental spraying of fuel,
causing personal injury or a fire hazard.
1. Shut the engine off and relieve the fuel system pressure.
•Remove the Schrader valve cap
(located at the right rear of
intake manifold) and install the
EFI/CFI Fuel Pressure Gauge.
The EFI/CFI Fuel Pressure Gauge
310–012 (T80L-9974–B) is
available at a certified Ford parts
dealer.
Maintenance and specifications
71