2004 FORD F SERIES MOTORHOME AND COMMERCIAL CHASSIS ignition

Use the following procedure to reset the fuel pump shut-off switch.
1. Turn the ignition to the OFF position.
2. Check the fuel system for leaks.
3. If no fuel leak is apparent, reset the fuel pump shut-off switch by
pushing in on the reset button.
4. Turn the ignition to the ON position. Pause for a few seconds and
return the key to the OFF position.
5. Make a further check for leaks in the fuel system.
FUSES AND RELAYS
Standard fuse amperage rating and color
COLOR
Fuse
ratingMini
fusesStandard
fusesMaxi
fusesCartridge
maxi
fusesFuse link
cartridge
2A Grey Grey———
3A Violet Violet———
4A Pink Pink———
5A Tan Tan———
7.5A Brown Brown———
10A Red Red———
15A Blue Blue———
20A Yellow Yellow Yellow Blue Blue
25A Natural Natural———
30A Green Green Green Pink Pink
40A——Orange Green Green
50A——Red Red Red
60A——Blue—Yellow
70A——Ta n—Brown
80A——Natural—Black
2004 Motorhome(mot)
Supplement
USA English(fus)
Roadside emergencies
41

The high-current fuses are coded as follows.
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
1 5A* Power brake assist module***
2 10A* A/C system
3 20A* Transmission, Vapor Management
Valve (VMV) solenoid, Heated
exhaust gas oxygen (HEGO)
sensors
4 5A* Powertrain Control Module (PCM)
memory
5 15A* PCM power, Fuel pump relay coil,
Fuel injectors, Mass Air Flow
(MAF) sensor with IAT, A/C
system relay coil
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): Power
brake assist module***, Speed
control module, PCM, Anti-lock
Brake System (ABS) module,
Brake shift interlock actuator
9 5A* Alternator, Charge indicator
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
2004 Motorhome(mot)
Supplement
USA English(fus)
Roadside emergencies
46

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
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
24 40A** IP battery feed (fuses #4, 10, 16)
25 50A** Ignition switch feed (IP fuses #1,
5, 7, 11, 13, 14, 17, 19, PDB fuses
#7, 9, 11)
26 60A** Ignition switch feed (IP fuses #5,
11, 17, 26, 32, 38)
27 30A** Multifunction switch (headlamps)
28—Not used
29 60A** Power brake assist motor***
Relay 1—DRL on/off relay
Relay 2—Fuel pump relay
Relay 3—Horn relay
Relay 4—A/C system relay
Relay 5—Blower motor relay
Relay 6—PCM relay
Diode 1—PCM diode
Diode 2—Park brake diode
* Mini Fuses ** Maxi Fuses ***Vehicles with Hydromax brake assist
only
2004 Motorhome(mot)
Supplement
USA English(fus)
Roadside emergencies
47

Cleaner air
Ford endorses the use of reformulated“cleaner-burning”gasolines to
improve air quality.
Running out of fuel
Avoid running out of fuel because this situation may have an adverse
affect on powertrain components.
If you have run out of fuel:
•You may need to cycle the ignition from OFF to ON several times after
refueling, to allow the fuel system to pump the fuel from the tank to
the engine.
•Your“Service Engine Soon”indicator may come on. For more
information on the“Service Engine Soon”indicator, refer to the
Instrument clusterchapter.
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.
2004 Motorhome(mot)
Supplement
USA English(fus)
Maintenance and specifications
82

Filling the tank
The advertised fuel capacity of the fuel tank on your vehicle is equal to
the rated refill capacity of the fuel tank as listed in theRefill capacities
section of this chapter.
The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.
The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.
For consistent results when filling the fuel tank:
•Turn the engine/ignition switch to the off position prior to refueling,
an error in the reading will result if the engine is left running.
•Use the same filling rate setting (low—medium—high) each time
the tank is filled.
•Allow no more than 2 automatic click-offs when filling.
•Always use fuel with the recommended octane rating.
•Use a known quality gasoline, preferably a national brand.
•Use the same side of the same pump and have the vehicle facing the
same direction each time you fill up.
•Have the vehicle loading and distribution the same every time.
Your results will be most accurate if your filling method is consistent.
Calculating fuel economy
1. Fill the fuel tank completely and record the initial odometer reading
(in kilometers or miles).
2. Each time you fill the tank, record the amount of fuel added (in liters
or gallons).
3. After at least three to five tank fill-ups, fill the fuel tank and record
the current odometer reading.
4. Subtract your initial odometer reading from the current odometer
reading.
2004 Motorhome(mot)
Supplement
USA English(fus)
Maintenance and specifications
85

EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with applicable
exhaust emission standards. To make sure that the catalytic converter and
other emission control components continue to work properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
•Have the items listed in your scheduled maintenance guide performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
guide are essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the“Service Engine Soon”light, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By law,
vehicle owners and anyone who manufactures, repairs, services, sells,
leases, trades vehicles, or supervises a fleet of vehicles are not permitted to
intentionally remove an emission control device or prevent it from working.
Information about your vehicle’s emission system is on the Vehicle
Emission Control Information Decal located on or near the engine. This
decal identifies engine displacement and gives some tune up specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
2004 Motorhome(mot)
Supplement
USA English(fus)
Maintenance and specifications
88

Item Ford part
nameFord part
numberFord
specification
Transmission
/steering/parking
brake linkages
and pivots,
brake and
clutch pedal
shaft (if
equipped)Premium
Long-Life
GreaseXG-1-C or XG-1-K ESA-M1C75-B
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCONand MERCONV type fluids are not interchangeable.
DO NOT mix MERCONand MERCONV. Use of a transmission
fluid that indicates dual usage (MERCONand MERCONV) in
an automatic transmission application requiring MERCONmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
ENGINE DATA
Engine 6.8L V10 engine
Cubic inches 415
Required fuel 87 octane
Firing order 1-6-5-10-2-7-3-8-4-9
Spark plug gap 1.3-1.4 mm (0.052-0.056 inch)
Ignition system Coil on plug
Compression ratio 9.0:1
2004 Motorhome(mot)
Supplement
USA English(fus)
Maintenance and specifications
113

E
Emergencies, roadside
jump-starting ............................52
Emission control system ............88
Engine ................................113–114
cleaning .....................................66
coolant .......................................73
fail-safe coolant ........................77
idle speed control .....................71
lubrication specifications 112–113
refill capacities ........................110
service points ............................68
starting after a collision ...........40
Engine block heater ...................23
Engine oil ....................................69
checking and adding ................69
dipstick ......................................69
filter, specifications ..........70, 109
recommendations .....................70
refill capacities ........................110
specifications ..................112–113
Exhaust fumes ............................23
F
Fail safe cooling ..........................77
Fluid capacities .........................110
Fuel ..............................................79
calculating fuel economy .........84
capacity ...................................110
choosing the right fuel .............81
comparisons with EPA fuel
economy estimates ...................87
detergent in fuel .......................82
filling your vehicle with
fuel .......................................79, 85
filter, specifications ..........82, 109
fuel pump shut-off switch .......40
improving fuel economy ..........84octane rating .............81, 113–114
quality ........................................81
running out of fuel ...................82
safety information relating to
automotive fuels .......................79
Fuses ......................................41–42
G
Gas mileage
(see Fuel economy) ...................84
Gauges .........................................11
GAWR
(Gross Axle Weight Rating) .......31
calculating .................................33
definition ...................................31
driving with a heavy load ........31
location ......................................31
GVWR
(Gross Vehicle Weight Rating) ..31
calculating ...........................31, 33
definition ...................................31
driving with a heavy load ........31
location ......................................31
H
Hazard flashers ...........................40
Headlamps ...................................14
daytime running lights .............14
flash to pass ..............................15
high beam .................................14
turning on and off ....................14
I
Ignition .........................20, 113–114
Inspection/maintenance (I/M)
testing ..........................................89
2004 Motorhome(mot)
Supplement
USA English(fus)
Index
117