2003 FORD WINDSTAR maintenance

Seating and Safety Restraints 87
Seating 87
Safety restraints 98
Air bags 111
Child restraints 117
Driving 131
Starting 131
Brakes 134
Traction control 135
Transmission operation 139
Trailer towing 146
Roadside Emergencies 150
Getting roadside assistance 150
Hazard flasher switch 151
Fuel pump shut-off switch 151
Fuses and relays 152
Changing tires 160
Jump starting 167
Wrecker towing 172
Customer Assistance 173
Reporting safety defects (U.S. only) 181
Cleaning 182
Maintenance and Specifications 188
Engine compartment 190
Engine oil 191
Battery 194
Fuel information 201
Low tire warning system 215
Part numbers 220
Refill capacities 220
Lubricant specifications 222
Table of Contents
2

SAFETY AND ENVIRONMENT PROTECTION
Warning symbols in this guide
How can you reduce the risk of personal injury and prevent possible
damage to others, your vehicle and its equipment? In this guide, answers
to such questions are contained in comments highlighted by the warning
triangle symbol. These comments should be read and observed.
Warning symbols on your vehicle
When you see this symbol, it is
imperative that you consult the
relevant section of this guide before
touching or attempting adjustment
of any kind.
Protecting the environment
We must all play our part in
protecting the environment. Correct
vehicle usage and the authorized
disposal of waste cleaning and
lubrication materials are significant
steps towards this aim. Information in this respect is highlighted in this
guide with the tree symbol.
BREAKING-IN YOUR VEHICLE
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,600 km (1,000 miles) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 800 km (500 miles) before towing a
trailer.
Do not add friction modifier compounds or special break-in oils during
the first few thousand kilometers (miles) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and carechapter for more information on oil usage.
Introduction
5

Driving a vehicle with the brake system warning light on is
dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle
checked by your dealer immediately.
Anti-lock brake system:If the
ABS light stays illuminated or
continues to flash, a malfunction has
been detected, have the system
serviced immediately. Normal
braking is still functional unless the brake warning light also is
illuminated.
Air bag readiness:If this light fails
to illuminate when ignition is turned
to ON, continues to flash or remains
on, have the system serviced
immediately. A chime will also sound when a malfunction in the
supplemental restraint system has been detected.
Safety belt:Reminds you to fasten
your safety belt. A chime will also
sound to remind you to fasten your
safety belt.
Charging system:Illuminates when
the battery is not charging properly.
Engine oil pressure:Illuminates
when the oil pressure falls below the
normal range, refer toEngine oilin
theMaintenance and
specificationschapter.
Traction Control
or
AdvanceTrac
active
(if equipped):Illuminates when
the Traction Control
is active,
refer to theDrivingchapter for more information.
ABS
TRAC
ACTIVE
Instrument Cluster
11

Traction Control
or
AdvanceTrac
off light
(if equipped):Illuminates when
the Traction Control
has been
disabled (by the driver or as a result of a system failure). Refer to the
Drivingchapter for more information.
Low tire warning:Illuminates
when the low tire warning system is
enabled. If the light remains on
while driving, the tire pressure
should be checked, refer toLow
tire warningin theMaintenance and Specificationschapter.
Low fuel:Illuminates when the fuel
level in the fuel tank is at or near
empty (refer toFuel gaugein this
chapter).
Speed control:Illuminates when
the speed control is engaged. Turns
off when the speed control system
is disengaged.
O/D off:Illuminates when the
overdrive function of the
transmission has been turned off.
Low washer fluid:Illuminates
when the windshield washer fluid is
low.
Door ajar:Illuminates when the
ignition is in the ON position and
any door is open.
Anti-theft system:Flashes when
the Securilock
Passive Anti-theft
System has been activated.TRAC
OFF
O/D
OFF
Instrument Cluster
12

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.
Odometer:Registers the total
kilometers (miles) of the vehicle.
Trip odometer:Registers the
kilometers (miles) of individual
journeys. To reset, depress the
control.
Low tire warning reset:May be
used to reset the Low Tire Warning
System, refer toLow Tire Warningin theMaintenance and
Specificationschapter.
Tachometer:Indicates the engine
speed in revolutions per minute.
Driving with your tachometer
pointer continuously at the top of
the scale may damage the engine.
TEMP
H
12345
6
7RPMX1000
Instrument Cluster
14

TRANSMISSION OVERHEATED.Indicates the transmission is
overheating. This warning may appear when towing heavy loads or when
driving in a low gear at a high speed for an extended period of time.
Stop the vehicle as soon as safely possible, turn off the engine and let it
cool. Check the transmission fluid and level. Refer toTransmission
fluidin theMaintenance and specificationschapter. If the warning
stays on or continues to come on, contact your dealer for transmission
service as soon as possible.
CHECK BRAKE LAMPS. Displayed when the brake lamps are
activated and at least one is burned out. Check the lamps as soon as
possible and have the burned out lamp replaced. The center high-mount
brakelamp is not monitored.
CHECK HEADLAMPS. Displayed when the headlamps are activated
and at least one is burned out. Check the lamps as soon as possible and
have the burned out lamp replaced. Refer toReplacing headlamp bulbs
in theLightschapter.
CHECK TAIL LAMPS.Displayed when the tail lamps are activated and
at least one is burned out. Check the lamps as soon as possible and have
the burned out lamp replaced.
CHECK FRONT TURN LAMPS.Displayed when the turn signals are
activated and at least one is burned out. Check the lamps as soon as
safely possible and have the burned out lamp replaced.
CHECK REAR TURN LAMPS.Displayed when the turn signals are
activated and at least one is burned out. Check the lamps as soon as
possible and have the burned out lamp replaced.
CHECK SIDE REPEATER LAMPS (if equipped).Displayed when
the turn signals are activated and at least one is burned out. Check the
lamps as soon as possible and have the burned out lamp replaced.
TURN SIGNAL ON REMINDER.Displayed when the turn signal is
activated and the vehicle is driven more that 0.8 km (1/2 mile).
LOW WASHER FLUID.Indicates the washer fluid reservoir is less than
one quarter full. Check the washer fluid level. Refer toWindshield
washer fluidin theMaintenance and specificationschapter.
CHECK TRACTION CONTROL (if equipped).Displayed when the
Traction Control
system is not operating properly. If this warning stays
on, contact your dealer for service as soon as possible. For further
information, refer toTraction control
in theDrivingchapter.
CHECK ADVANCETRAC (if equipped).Displayed when the
AdvanceTrac
system is not operating properly. If this message is
Driver Controls
67

Always transport children 12 years old and under in the back
seat and always properly use appropriate child restraints.
The passenger occupant classification sensor can automatically turn off
the passenger front air bag and side air bag (if equipped). The system is
designed to help protect small (child size) occupants from air bag
deployments when they are improperly seated or restrained in the front
passenger seat contrary to proper child-seating or restraint usage
recommendations. Even with this technology, parents areSTRONGLY
encouraged to always properly restrain children in the rear seat. The
sensor also turns off the air bag(s) when the passenger seat is empty to
prevent unnecessary replacement of the air bag(s) after a collision.
Front safety belt usage sensors
The front safety belt usage sensors detect whether or not the driver and
front outboard passenger safety belts are fastened. This information
allows your Personal safety system to tailor the air bag deployment and
safety belt pretensioner activation depending upon safety belt usage.
Refer toSafety beltsection in this chapter.
Front safety belt pretensioners
The safety belt pretensioners at the front outboard safety positions are
designed to tighten the safety belts firmly against the occupant’s body
during a frontal or near-frontal collision. This maximizes the effectiveness
of the safety belts and helps properly position the occupant relative to
the air bag to improve protection. The safety belt pretensioners can be
either activated alone or, if the collision is of sufficient severity, together
with the air bags.
Front safety belt energy management retractors
The front safety belt energy management retractors allow webbing to be
pulled out of the retractor in a gradual and controlled manner in
response to the occupant’s forward momentum. This helps reduce the
risk of force-related injuries to the occupant’s chest by limiting the load
on the occupant. Refer toEnergy management featuresection in this
chapter.
Determining if the Personal safety system is operational
The Personal safety system uses a warning light in the instrument cluster
or a back-up tone to indicate the condition of the system. Refer to the
Warning lightsection in theInstrument clusterchapter. Routine
maintenance of the Personal safety system is not required.
Seating and Safety Restraints
100

Use only extensions manufactured by the same supplier as the safety
belt. Manufacturer identification is located at the end of the webbing on
the label. Also, use the safety belt extension only if the safety belt is too
short for you when fully extended.
Do not use extensions to change the fit of the shoulder belt
across the torso.
Safety belt maintenance
Inspect the safety belt systems periodically to make sure they work
properly and are not damaged. Inspect the safety belts to make sure
there are no nicks, tears or cuts, replacing if necessary. All safety belt
assemblies, including retractors, buckles, front seat belt buckle
assemblies, buckle support assemblies (slide bar-if equipped), shoulder
belt height adjusters (if equipped), child safety seat tether bracket
assemblies (if equipped), LATCH child seat tether anchors and lower
anchors (if equipped), and attaching hardware, should be inspected after
a collision. Ford recommends that all safety belt assemblies used in
vehicles involved in a collision be replaced. However, if the collision was
minor and a qualified technician finds that the belts do not show damage
and continue to operate properly, they do not need to be replaced,
except as described in theReplacing the front passenger and second
row bench seat belt assemblies after a collisionsection of this chapter.
Safety belt assemblies not in use during a collision should also be
inspected and replaced if either damage or improper operation is noted.
Failure to inspect and if necessary replace the safety belt
assembly under the above conditions could result in severe
personal injuries in the event of a collision.
Refer toInteriorin theCleaningchapter.
Replacing the front passenger and second row bench seat belt
assemblies after a collision
All front passenger and second row bench seat belt assemblies adjacent
to a sliding door have special energy management retractors designed to
further reduce the risk of injury in the event of a head-on collision.
These retractors should be replaced if they were used in any accident in
which the front airbags deploy. If the safety belt assemblies are not
replaced, there may be increased risk of injury in the event of a
subsequent collision.
Seating and Safety Restraints
110