engine FORD WINDSTAR 2003 2.G Owner's Guide

engine/transmission combination, any required option weight for trailer
towing and the weight of the driver from the GCWR for the towing
vehicle.
•Maximum Trailer Weight:Maximum weight of a trailer the loaded
vehicle, including occupants and cargo, is permitted to tow. It is
determined by subtracting the weight of the loaded trailer towing
vehicle from the GCWR for the towing vehicle.
•Trailer Weight Range:Specified range of trailer weight from zero to
the maximum trailer weight rating.
Remember to figure in the tongue load of your loaded trailer when
figuring the total weight.
The Safety Certification Label, located on the driver’s door pillar, lists
vehicle weight rating limitations. Before adding any additional equipment,
refer to these limitations.
Always ensure that the weight of occupants, cargo and equipment is
within the weight limitations, including both gross vehicle weight and
front and rear gross axle weight rating limits.
Note:Do not exceed the GVWR or the GAWR specified on the
certification label.
Exceeding any vehicle weight rating limitation could result in
serious damage to the vehicle, loss of vehicle control, vehicle
rollover, and/or personal injury.
Do not use replacement tires with lower load carrying capacities than the
originals because they may lower the vehicle’s GVWR and GAWR
limitations. Replacement tires with a higher limit than the originals do
not increase the GVWR and GAWR limitations.
Calculating the load your vehicle can carry/tow
1. Use the appropriate maximum gross combined weight rating (GCWR)
chart to find the maximum GCWR for your vehicle type and whether it’s
equipped with a trailer tow option.
2. Weigh your vehicle as you customarily operate the vehicle without
cargo. To obtain correct weights, try taking your vehicle to a shipping
company or an inspection station for trucks.
3. Subtract your loaded vehicle weight from the maximum GCWR on the
following charts. This is the maximum trailer weight your vehicle can tow
and must fall below the maximum shown under maximum trailer weight
on the chart.
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145

TRAILER TOWING
Trailer towing with your vehicle requires the optional trailer tow
electrical package and may require the use of an additional medium duty
trailer tow option package.
Trailer towing puts additional loads on your vehicle’s engine,
transmission, axle, brakes, tires, and suspension. For your safety and to
maximize vehicle performance, be sure to use the proper equipment
while towing.
Follow these guidelines to ensure safe towing procedure:
•Stay within your vehicle’s load limits. If exceeded, cargo should be
removed from the trailer and/or the vehicle until all weights are within
specified limits.
•Thoroughly prepare your vehicle for towing. Refer toPreparing to
towin this chapter.
•Use extra caution when driving while trailer towing. Refer toDriving
while you towin this chapter.
•Service your vehicle more frequently if you tow a trailer. Refer to
Special Operating Conditions in the scheduled maintenance guide.
•Do not tow a trailer until your vehicle has been driven at least 800 km
(500 miles).
•Refer to the instructions included with towing accessories for the
proper installation and adjustment specifications.
If your vehicle is equipped with the optional heavy duty trailer tow
wiring, it is pre-wired for trailer towing. An electrical connector is
provided under the instrument panel for installing a customer-supplied
electric brake controller. Another electrical connector is provided at the
hitch. This connector provides power to the trailer for taillamps, stop
and turn lamps, back up lamps, battery charge, electric brakes (when a
customer provided controller is installed) and ground. The kit included
with your vehicle provides you with adaptors to attach the brake
controller and convert the hitch connector for Class I trailer usage.
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146

EngineMaximum
GCWR - kg (lbs.)Trailer weight range
(0 - maximum) - kg (lbs.)
Van/Wagon
3.8L without
Trailer Tow
package3175 (7000) 0-907 (0-2000)
Wagon
3.8L with
Trailer Tow
Package3856 (8500) 0-1588 (0-3500)
Do not exceed the maximum loads listed on the Safety Compliance
Certification label. For load specification terms found on the label, refer
toVehicle loadingin this chapter. Remember to figure in the tongue
load of your loaded trailer when figuring the total weight.
Towing trailers beyond the maximum recommended gross trailer
weight exceeds the limit of the vehicle and could result in
engine damage, transmission damage, structural damage, loss of control
and personal injury.
Preparing to tow
Use the proper equipment for towing a trailer and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use hitches that clamp onto the vehicle bumper. Use a load
carrying hitch. You must distribute the load in your trailer so that
10–15% of the total weight of the trailer is on the tongue.
Safety chains
Always connect the trailer’s safety chains to the hook retainers on the
hitch. To connect the trailer’s safety chains, cross the chains under the
trailer tongue and allow slack for turning corners.
If you use a rental trailer, follow the instructions that the rental agency
gives to you.
Do not attach safety chains to the bumper.
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147

Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
•Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
•Allow more distance for stopping with a trailer attached.
•If you are driving down a long or steep hill, shift to a lower gear. Do
not apply the brakes continuously, as they may overheat and become
less effective.
•
The trailer tongue weight should be 10–15% of the loaded trailer weight.
•After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•To aid in engine/transmission cooling and A/C efficiency during hot
weather while stopped in traffic, place the gearshift lever in P (Park).
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
RECREATIONAL TOWING
Follow these guidelines for your specific powertrain combination to tow
your vehicle with all four wheels on the ground (such as behind a
recreational vehicle).
These guidelines are designed to ensure that your transmission is not
damaged due to insufficient lubrication.
All Front Wheel Drive (FWD) vehicles:
It is not recommended to tow front wheel drive vehicles with the front
drive wheels on the ground. It is recommended to tow your vehicle with
the drive wheels on a dolly or two wheel car hauling trailer.
In case of a roadside emergency with a disabled vehicle (without access
to wheel dollies, car hauling trailer or flatbed transport vehicle) your
vehicle can be flat towed (all wheels on the ground) under the following
conditions:
•Place the transmission in N (Neutral).
•Maximum speed is 56 km/h (35 mph).
•Maximum distance is 80 km (50 miles).
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149

Canadian customers who require roadside assistance, call
1–800–665–2006.
If you need to arrange roadside assistance for yourself, Ford Motor
Company will reimburse a reasonable amount. To obtain reimbursement
information, U.S. Ford or Mercury vehicles customers call
1-800-241-3673; Lincoln vehicle customers call 1–800–521–4140.
Canadian customers who need to obtain reimbursement information, call
1–800–665–2006.
ROADSIDE COVERAGE BEYOND BASIC WARRANTY
In the United States, you may purchase additional roadside assistance
coverage beyond this period through the Ford Auto Club by contacting
your Ford or Lincoln Mercury dealer.
Similarly in Canada, for uninterrupted Roadside Assistance coverage, you
may purchase extended coverage prior to your Basic Warranty’s Roadside
Assistance expiring. For more information and enrollment, contact
1–877–294–2582 or visit our website at www.ford.ca.
HAZARD FLASHER
The hazard flasher is located on the
steering column, just behind the
steering wheel. The hazard flashers
will operate when the ignition is in
any position.
Push in the flasher control and all
front and rear direction signals will
flash. Press the flasher control again
to turn them off. Use it when your
vehicle is disabled and is creating a
safety hazard for other motorists.
Note:With extended use, the flasher may run down your battery.
FUEL PUMP SHUT-OFF SWITCH
FUEL
RESET
This device stops the electric fuel pump from sending fuel to the engine
when your vehicle has had a substantial jolt.
After an accident, if the engine cranks but does not start, this switch
may have been activated.
Roadside Emergencies
151

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse Panel
Description
Relay 2—Accessory delay relay
Relay 3—Front blower motor relay
Relay 4—Switched system power relay #3
Relay 5—Rear defrost relay
Relay 6—Auxiliary blower motor relay
Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle’s main electrical systems from overloads.
Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
The cover for the power distribution box can be removed by releasing
the tab on the back left corner of the cover, then pulling the cover up.
503
304
303
302301
502
501
207201
202
203
204122118114110106102
121117113109105101
120116112108104
119115111107103
24
209206
208
18161412108642
1715131197531
205
23
22
21
401
20
19
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157

The high-current fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
1 30A* Powertrain Control Module (PCM) relay
2 10A* PCM, Front electronic module (FEM)
3 10A* A/C compressor clutch
4 25A* Horns, Horn relay (coil)
5 15A* Fuel pump motor, PCM
6 30A* Front wiper motor, Front wiper relay, Front
washer pump, FEM
7 25A* Rear wiper motor, Rear washer pump, Rear
wiper relay (coil)
8—Not used
9 15A* Right headlamp
10 15A* Right front park lamp, Right front turn lamp,
Right front cornering lamp, Right front
auxiliary driving lamp
11 15A* Left front park lamp, Left front turn lamp,
Left front cornering lamp, Left front auxiliary
driving lamp
12 15A* Left headlamp (low and high beam)
13 10A* Alternator field sense
14 10A* FEM (left door lock motor)
15 20A* Trailer tow park lamps
16 20A* Trailer tow turn lamps
17—Not used
18—Not used
19 15A* AX4S transaxle, Vapor Management Valve
(VMV), A/C clutch relay coil, EGR control
solenoid, Engine fuel control HO2S #11
sensor, Engine fuel control HO2S #21 sensor,
Catalyst monitor HO2S #12 sensor, Catalyst
monitor HO2S #22 Sensor, Canister vent
solenoid, Intake manifold runner control
Roadside Emergencies
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
20 15A* Ignition coil, Intake Air Control (IAC) valve,
Fuel injectors, Mass Air Flow (MAF) sensor,
Fuel pump relay coil, Intake manifold runner
control, High-speed cooling fan relay coil,
Low-speed cooling fan relay coil, PCM,
Passive anti-theft receiver
21—Not used
22—Not used
23—Not used
24—Not used
101 40A** Anti-lock Brake System (ABS) module or IVD
Module
102 40A** ABS module or IVD module
103 40A** SSP4 Relay, SSP4 Relay (coil)
104 30A** Left-hand power seat motors, Left-hand
power lumbar motor, Driver seat memory
module
105 30A** Starter motor solenoid, Ignition switch
106 30A** Delayed accessory relay, Delayed accessory
relay coil, FEM- right-hand front window
motor
107 50A** Engine cooling fan motors, Cooling fan
dropping resistor
108—Not used
109 30A** Heated seat modules
110 50A** Right-hand Power Sliding Door (PSD) module
111 40A** Fuse junction box
112 30A** Trailer tow, Electric brake controller
113 30A** FEM - left-hand window motor
114 40A** SSP3 relay, SSP3 relay coil
115 50A** Fuse junction box bus #2
116 30A** Heated backlight relay
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
117 40A** Auxiliary blower relay coil, Auxiliary blower
motor
118 50A** Left-hand PSD module
119 30A** Fuse junction box bus #1
120 40A** Front blower relay coil, Front blower motor
121 20A** Ignition switch, Rear defrost relay coil
122 40A** Right-hand power seat motors, Right-hand
power lumbar motor
201—Not used
202—Front wiper ON/OFF relay
203—Rear wiper relay
204—A/C clutch relay
205—Horn relay
206—Not used
207—Fuel pump relay
208—Not used
209—Front wiper HI/LO relay
301—Starter interrupt relay
302—High-speed engine cooling fan relay
303—Low-speed engine cooling fan relay
304—PCM Relay
401—Not used
501—PCM diode
502—Not used
503—Not used
* Mini Fuses ** Maxi Fuses
CHANGING A FLAT TIRE
If you get a flat tire while driving:
•do not brake heavily.
•gradually decrease the vehicle’s speed.
•hold the steering wheel firmly.
•slowly move to a safe place on the side of the road.
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1. Park on a level surface, activate
hazard flashers and set parking
brake.
2. Place gearshift lever in P (Park),
turn engine off, and block the
diagonally opposite wheel.
3. Remove the spare tire, jack and
lug wrench.
4. If equipped with a bolted-on
wheel cover, remove the wheel
cover with the tapered end of the
wheel nut wrench.
5. Loosen the plastic nuts on the
center ornament with the wheel nut
wrench, then remove the plastic
nuts.
6. Remove the center ornament or wheel cover from the wheel with the
tapered end of the wheel nut wrench. Insert and twist the handle, then
pry against the wheel.
7. Loosen each wheel lug nut
one-half turn counterclockwise but
do not remove them until the wheel
is raised off the ground.
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164