2003 FORD SUPER DUTY fuel cap

Seating and Safety Restraints 63
Seating 63
Safetyrestraints 68
Air bags 79
Child restraints 87
Driving 98
Starting 98
Brakes 102
Transmission operation 106
Trailer towing 127
Roadside Emergencies 152
Getting roadside assistance 152
Hazard flasher switch 153
Fuel pump shut-off switch 153
Fuses and relays 154
Changing tires 159
Jump starting 168
Wrecker towing 173
Customer Assistance 175
Reporting safetydefects (U.S. only) 183
Cleaning 184
Maintenance and Specifications 191
Engine compartment 193
Engine oil 194
Battery197
Fuel information 205
Air filter(s) 221
Part numbers 228
Refill capacities 228
Lubricant specifications 232
Table of Contents
2

manufacturers to follow the recommendations of theFord Incomplete
Vehicle Manual, Ford Truck Body Builder’s Layout Bookand theQVM
guidelinesas well as pertinent supplements. For additional information,
please contact the Truck BodyBuilders AdvisoryService
1–877–840–4338.
Use of your Ford light truck as an ambulance, without the Ford
Ambulance Preparation Package voids the Ford New Vehicle Limited
Warrantyand mayvoid the Emissions Warranties. In addition, ambulance
usage without the preparation package could cause high underbody
temperatures, overpressurized fuel and a risk of spraying fuel which
could lead to fires.
If your vehicle is equipped with the
Ford Ambulance Preparation
Package, it will be indicated on the
Certification label. The label is
located on the driver’s side door
pillar or on the rear edge of the
driver’s door. You can determine
whether the ambulance
manufacturer followed Ford’s
recommendations bydirectly
contacting that manufacturer. Ford
Ambulance Preparation Package is
onlyavailable on certain 7.3L Diesel
engine equipped vehicles.
Notice to owners with vehicles equipped with Power Take Off
(PTO) capability
Refer to theDrivingchapter for more information and guidelines for
operating vehicles equipped with PTO.
Middle East/North Africa vehicle specific information
For your particular global region, your vehicle may be equipped with
features and options that are different from the ones that are described
in this Owner Guide; therefore, a supplement has been supplied that
complements this book. Byreferring to the pages in the provided
supplement, you can properlyidentifythose features, recommendations
and specifications that are unique to your vehicle.Refer to this Owner
Guide for all other required information and warnings.
Introduction
7

Vehicle Symbol Glossary
Power Windows
Front/Rear
Power Window Lockout
Child SafetyDoor
Lock/UnlockInterior Luggage
Compartment Release
Symbol
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBatteryAcid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
9

WARNING LIGHTS AND CHIMES
Warning lights and gauges can alert you to a vehicle condition that may
become serious enough to cause expensive repairs. A warning light may
illuminate when a problem exists with one of your vehicle’s functions.
Many lights will illuminate when you start your vehicle to make sure the
bulb works. If anylight remains on after starting the vehicle, have the
respective system inspected immediately.
Service engine soon:If this light
illuminates while driving, it is a
possible indication that one of the
engine’s emission control systems
has failed.
Check fuel cap (if equipped):
Illuminates when the fuel cap may
not be properlyinstalled. Continued
driving with this light on maycause
the Service engine soon warning
light to come on.
Check gage:Illuminates when any
of the following conditions has
occurred:
•The engine coolant temperature
is high.
•The engine oil pressure is low.
•The fuel gauge is at, or near empty.
CHECK
GAGE
Instrument Cluster
10

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 fullyseated.
5. Fullyinstall the engine oil filler cap byturning the filler cap clockwise
1/4 of a turn until three clicks are heard or until the cap is fullyseated.
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.
Onlyuse oils “Certified For Gasoline Engines” bythe 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. Theyare unnecessaryand could, under certain conditions,
lead to engine damage which is not covered byyour 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 maybe experienced.
It is recommended you use the appropriate Motorcraft oil filter (or
another brand meeting Ford specifications) for your engine application.
Maintenance and Specifications
196

When lifting a plastic-cased battery, excessive pressure on the
end walls could cause acid to flow through the vent caps,
resulting in personal injuryand/or damage to the vehicle or battery.
Lift the batterywith a batterycarrier 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 batteryto protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediatelywith water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Batteryposts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
For information on transmission operation after the batteryhas been
disconnected see “Shift strategy” in the driving section.
Because your vehicle’s engine is also electronicallycontrolled bya
computer, some control conditions are maintained bypower from the
battery. When the batteryis disconnected or a new batteryis installed,
the engine must relearn its idle and fuel trim strategyfor optimum
driveabilityand performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park) (automatic transmission) or the neutral
position (manual transmission), 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.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Drive the vehicle to complete the relearning process.
•The vehicle mayneed to be driven 16 km (10 miles) or more to
relearn the idle and fuel trim strategy.
•If you do not allow the engine to relearn its idle trim, the idle
quality of your vehicle may be adversely affected until the idle
trim is eventually relearned.
If the batteryhas been disconnected or a new batteryhas been installed,
the clock and the preset radio stations must be reset once the batteryis
reconnected.
Maintenance and Specifications
198

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 completelyshutting down automaticallyto prevent engine
damage, therefore:
1. Pull off the road as soon as safelypossible 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
maycause leakage and lead to fuel sprayand 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 completelyremoving the fuel filler cap. Otherwise, fuel may
sprayout and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank maydamage the fuel system or cause
the fuel cap to disengage in a collision, which mayresult in possible
personal injury.
Maintenance and Specifications
205

When refueling always shut the engine off and never allow
sparks or open flames near the filler neck. Never smoke while
refueling. Fuel vapor is extremelyhazardous under certain conditions.
Care should be taken to avoid inhaling excess fumes.
The flow of fuel through a fuel pump nozzle can produce static
electricity, which can cause a fire if fuel is pumped into an
ungrounded fuel container.
Use the following guidelines to avoid static build-up when filling an
ungrounded fuel container:
•Place approved fuel container on the ground.
•DO NOT fill a fuel container while it is in the vehicle (including the
cargo area).
•Keep the fuel pump nozzle in contact with the fuel container while
filling.
•DO NOT use a device that would hold the fuel pump handle in the fill
position.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/8 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefullyturn the filler cap counterclockwise 1/8 of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/8 of a turn until it stops.
If the “Service Engine Soon/Check Engine” indicator comes on and stays
on after you start the engine, the fuel filler cap may not be properly
installed. Turn off the engine, remove the fuel filler cap, align the cap
properlyand reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
Maintenance and Specifications
207