2003 FORD SUPER DUTY lights

Introduction
2
Diesel information
4
Warning lights
8
Starting
10
Driving tips
13
General maintenance information
23
Scheduled maintenance
38
Minor troubleshooting guide
39
Capacities and specifications
42
Service points
44
General Owner’s Information
45
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Copyright © 2002 Ford Motor Company
Table of contents
1

Air filter restriction gauge
The restriction gauge, located on
the upper housing of the air cleaner
assembly, monitors the condition of
the air filter element in two ways:
First, the colored indictor inside the gauge highlights the percentage that
the air filter element is clogged with dust or contaminants. Refer to
Engine CompartmentinService Pointschapter.
Second, the gauge contains an electrical switch which illuminates a
warning light on the instrument cluster when the air filter element is
100% clogged. Refer to theWarning lightschapter.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance. If the vehicle is operated in
extremely dusty conditions, check the gauge at least every 800 km (500
miles), or two weeks, whichever comes first.
The air filter element must be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when the maximum
restriction is reached.
Blowing-out the air filter element with compressed air is not
recommended as the compressed air may damage the filter paper.
Note:It is not possible to determine the level of filter clogging by visual
appearance alone. A filter which appears to be dirty may actually have
several thousand kilometers (miles) of life remaining.
Diesel information
6

Always use the underhood air filter restriction gauge or engine
air filter warning light on the instrument cluster to determine
when the air filter element needs to be changed.
After servicing the air filter element,
reset the restriction gauge by
pressing the button on the end of
the gauge.
Note:If the vehicle is operated in a heavy snow storm, in blowing snow
or the vehicle is equipped with a snowplow, the engine air filter element
may become partially clogged with snow and/or ice. If this occurs, the air
filter restriction gauge will move to the CHANGE FILTER mark and the
engine may experience a significant reduction in power output. The
vehicle may be driven under these conditions for up to 400 km (250
miles) without damage to the engine or related components.
At the earliest opportunity, clear all snow and ice from the air induction
system and replace the air filter element, or remove the element and dry
it out. Reset the restriction gauge by pressing the button on the end of
the gauge.
The air filter warning light on the instrument cluster may be used, in
addition to the underhood restriction gauge, to monitor the condition of
the air filter element. Refer to theWarning lightschapter.
Diesel information
7

WAIT TO START
With the key in the ON position, the
WAIT TO START light will illuminate
if glow plug heat is necessary as a starting aid. Wait until the light goes
off before starting. The light should always illuminate briefly, when the
ignition key is in the ON position. If the light does not illuminate, there
may be a problem. Refer to theStartingchapter in this guide. After the
engine starts, the light should remain off.
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 an
HFCM 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 HFCM 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 HFCM. Refer
to theGeneral maintenance informationchapter for drain procedure.
Allowing water to stay in the system could result in extensive damage to,
or failure of, the fuel injection system.
Warning lights
8

Do not drain the HFCM while the engine is running. Fuel may
ignite if the separator is drained while the engine is running or
the vehicle is moving.
ENGINE AIR FILTER
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The vehicle may be driven with the engine air filter warning light
illuminated for up to 400 km (250 miles) without damaging the engine or
related components. However, the air filter elementmustbe replaced at
the earliest opportunity. Refer toAir filter restriction gaugein the
Diesel informationchapter for more information.
Warning lights
9

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.
COLD WEATHER OPERATION
Changing to a lighter grade engine oil also makes starting easier under
these conditions. Refer toEngine oil specificationsin theGeneral
maintenance informationchapter.
At temperatures below–7°C (20°F), Number 2–D Diesel fuel may
thicken enough to clog the fuel filter. Your vehicle is equipped with an
HFCM which acts as a fuel filter/heater/water separator to keep the wax
melted which will help prevent fuel filter clogging. However, if the engine
starts but stalls after a short time and will not restart, the fuel filter(s)
may 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
fuel control module, 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 engine fuel starvation, it is recommended that,
during cold weather operation 0°C (32°F) or below, the fuel level in your
tank should not be allowed to drop below 1/4 full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 0°C (32°F) your Diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). As the engine warms-up,
the engine sound level will decrease due to the activation of
PCM-controlled sound reduction features.
Operation in snow
Vehicle operation in heavy snowfall or in dry loose snow that may swirl
around the front of the vehicle may feed excessive amounts of snow into
the air intake system. This could plug the air cleaner with snow and
cause the engine to stall.
Refer toAir filter restriction gaugein theDiesel informationchapter
and Engine air filter in theWarning lightschapter for more information.
Starting
11

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

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