2003 FORD SUPER DUTY light

SCHEDULED MAINTENANCE
The scheduled maintenance services in theScheduled maintenance
guidesection are required because they are considered essential to the
life and performance of your vehicle.
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.
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 self-serve power washer (1,000 psi
maximum pressure) to clean the engine, as the high-pressure 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 (ZC-20) on all parts that require cleaning and pressure
rinse the area with cool water.
Cover the highlighted areas to prevent water damage when cleaning the
engine(never wash or rinse the engine while it is running; water
in the running engine may cause internal damage):
General maintenance information
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Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
solution until it is run through the engine where it will be deposited in
the fuel injectors causing expensive-to-repair damage.
Diesel fuel dispensing nozzle fill rate
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).
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1 1/8 inch fuel dispensing nozzle.
Pumping fuel at greater flow rates may result in premature nozzle
shut-off or spitback.
HORIZONTAL FUEL CONDITIONING MODULE (HFCM) (FUEL
FILTER/WATER SEPARATOR)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission.
Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 100 cc (0.2 pints) of water accumulates in the module.
Replace the fuel filters with Ford Part No. 3C3Z-9N184–CA. This part
number includes filters and seals for both the engine-mounted and
frame-mounted filters.
DRIAINING THE HFCM AND CHANGING THE FUEL FILTERS
Your vehicle is equipped with two fuel filters; one mounted on top of the
engine and the other, the HFCM, mounted inside the frame rail under
the driver-side floorboard near the transmission. Both filters should be
replaced at the same time.
HFCM drain procedure
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the HFCM. Fuel may ignite if separator is drained while the
engine is running or vehicle is moving.
General maintenance information
25

2. Locate the HFCM and place an
appropriate container under the
drain plug (see illustration).
3. Remove the drain plug, using a 6mm hex drive, by turning it
counterclockwise. Allow the HFCM to drain for approximately 25 seconds
or until clean fuel is observed. Install the drain plug by turning it
clockwise until it is firmly seated.
4. Verify that the drain plug is closed and sealed, then remove the
container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light; it
should not be illuminated. If it continues to illuminate, have the fuel
system checked and repaired.
Removal - HFCM filter
1. Remove the fuel filter cap by
turning counterclockwise.
2. Remove and discard the old fuel
filter element.
3. Carefully clean the mating
surfaces.
General maintenance information
26

To reduce the risk of 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 semi-clear 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.
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 coolantsection). If the concentration is not 50/50
(protection to–34°F/–36°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.
General maintenance information
34

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. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to START, this may also
indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
•For vehicles with manual transmissions, the clutch pedalmustbe fully
depressed in order for the starter 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,
seeJump Startingin theRoadside emergencieschapter of your
owner guide.
IF ENGINE CRANKS BUT WON’T START
Prolonged starter cranking (in excess of 30 seconds) could cause
damage to the starter motor.
•Check the fuel gauge. You may be out of fuel. If the gauge shows that
there is fuel in the tank, the trouble may be in the electrical system or
the fuel system. If equipped with an auxiliary tank, be sure that the
tank control switch is set for the tank with fuel and not on an empty
tank.
•Leaving the ignition key ON for over two minutes without starting may
make starting difficult because the glow plugs will cease activation.
Reset the system by turning the ignition key to OFF and then back to
ON again.
Minor troubleshooting guide
40

REFILL CAPACITIES
Component Capacity
Cooling system126.0L (27.5 quarts)
Engine oil214.2L (15.0 quarts)
Fuel tank (F-250/350/450/550) Refer to Owner Guide
Fuel tank (Excursion) 166.6L (44.0 gallons)
Radiator cap 110 kPa (16 psi)
Manual transmission
35.5L (5.8 quarts)
Automatic transmission Refer to Owner Guide
1Includes heater and 4.7L (5 quarts) in coolant recovery.
2Includes 1.0L (1 quart) in engine oil filter.
3Use Motorcraft MERCON
ATF, Motorcraft part number XT-2–QDX,
meeting Ford specification MERCON
.
BULB SPECIFICATIONS
Lamp descriptionNumber of bulbs
requiredTrade number
Wait to Start Light 1 194
Water-in-Fuel Light 1 194
Engine Temp. Light 1 194
Capacities and specifications
42

Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To assure the proper
performance of your vehicle and its emission control systems, it is
imperative that scheduled maintenance be completed at the designated
intervals.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraft or Ford authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult your Warranty Guide for complete warranty information.
Quality Care - one stop for all your maintenance needs
When you need maintenance for your Ford, Lincoln or Mercury vehicle,
there’s only one name to remember: Quality Care, available at your Ford
and Lincoln Mercury dealership. From scheduled maintenance to more
complicated repair work, nobody knows your car or truck better. Protect
your investment by choosing Quality Care service.
The right people
The difference is factory training and equipment, which means nobody is
more qualified to work on your Ford, Lincoln or Mercury than our
Quality Care service technicians. They’ll fix it right the first time.
The right parts
From headlights to taillights and everything in between, nothing fits like
an original. With Quality Care service, you’ll get the parts made
especially for your car or truck–genuine Ford and Motorcraft
parts.
The right prices
Our commitment to quality extends to pricing as well as service. Your
Ford and Lincoln Mercury Dealership offers competitive prices on
Genuine Ford and Motorcraft
parts and services, making Quality Care a
great value.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed by
the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in the Owner’s Guide.
General Owner’s Information
48

Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
Maximum Oil Change Interval:
Normal Schedule: 7,500 miles or 6 months, whichever occurs first.
Special Operating Conditions: 5,000 miles or 6 months, see appropriate
schedule.
Check every month:
•Check function of all interior and exterior lights
•Check tires for wear and proper air pressure
•Check engine oil fluid level
•Check windshield washer solvent fluid level
•Check and drain fuel filter/water separator
Check every six months:
•Check lap/shoulder belts and seat latches for wear and function
•Check air pressure in spare tire
•Check that externally-mounted spare tire is tight (see Owner’s Guide)
•Check power steering fluid level
•Check washer spray, wiper operation and clean all wiper blades
•Check parking brake for proper operation
•Check and lubricate all hinges, latches and outside locks
•Check and lubricate door rubber weatherstrips
•Check and clean body and door drain holes
•Check safety warning lamps (brake, ABS, air bag, safety belt) for
operation
•Check cooling system fluid level and coolant strength
•Check battery connections and clean if necessary
•Check clutch fluid level, if equipped
General Owner’s Information
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