ignition FORD E-150 2002 Owner's Guide

For commercial stripped chassis
vehicles, the fuel pump shut-off
switch is located on a bracket above
the brake pedal.
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
Fuses
If electrical components in the
vehicle are not working, a fuse may
have blown. Blown fuses are
identified by a broken wire within
the fuse. Check the appropriate
fuses before replacing any electrical
components.
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Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
5 20A RKE module, Power lock
switches, Memory lock, Power
locks with RKE
6 10A Brake shift interlock, Speed
control, DRL module
7 10A Multi-function switch, Turn signals
8 30A Radio capacitor(s), Ignition coil,
PCM diode, PCM power relay,
Fuel heater (Diesel only), Glow
plug relay (Diesel only)
9 30A Wiper control module, Windshield
wiper motor
10 20A Main light switch, Park lamps,
License lamp (external lamps),
Multi-function switch
(flash-to-pass)
11 15A Brake pressure switch,
Multi-function switch (hazards),
Brake lamp switch, Brake lamps
12 15A Transmission Range (TR) sensor,
Backup lamps, Auxiliary battery
relay
13 15A Blend door actuator, A/C heater,
Function selector switch
14 5A Instrument cluster (air bag and
charge indicator)
15 5A Trailer battery charge relay
16 30A Power seats
17—Not used
18—Not used
19 10A Air bag diagnostic monitor
20 5A Overdrive cancel switch
21 30A Power windows*
22 15A Memory power radio, E-Traveler
radio, E-Traveler console
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
8 60A** I/P fuses 4, 5, 10, 11, 16, 22, 23,
28, 32, 38
9 30A** PCM power relay, Engine
compartment fuse 4
10 60A** Auxiliary battery relay, Engine
compartment fuses 14, 22
11 30A** IDM relay (Diesel only)
12 60A** Engine compartment fuses 25, 27
13 50A** Blower motor relay (blower
motor)
14 30A** Trailer running lamps relay,
Trailer backup lamps relay
15 40A** Main light switch, Daytime
Running Lights (DRL)
16 50A** Auxiliary blower motor relay
17 30A** Fuel pump relay
18 60A** I/P fuses 33, 37, 39, 40, 41
19 60A** 4WABS module
20 20A** Electric brake controller
21 50A** Modified vehicle power
22 40A** Trailer battery charge relay,
Modified vehicles
23 60A** Ignition switch, Fuse panel
24 30A* Natural gas tank valves (NGV
only)
25 20A* NGV module (NGV only)
26 10A* A/C clutch (4.2L only)
27 15A* DRL module, Horn relay
28—PCM diode
29—Not used
A—Marker lamps relay
B—Stop lamp relay
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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
For fuel filter replacement, see your dealer or a qualified service
technician. Refer to the scheduled maintenance guide for the appropriate
intervals for changing the fuel filter.
Replace the fuel filter with an authorized Motorcraft part. The
customer warranty may be void for any damage to the fuel system
if an authorized Motorcraft fuel filter is not used.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
possible. Fuel expense, frequency of fill-ups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1,600 km (1,000
miles) of driving (engine break-in period). You will get a more accurate
measurement after 3,000 km–5,000 km (2,000 miles-3,000 miles).
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
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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.
5. Follow one of the simple calculations in order to determine fuel
economy:
Calculation 1:Multiply liters used by 100, then divide by total
kilometers traveled.
Calculation 2:Divide total miles traveled by total gallons used.
Keep a record for at least one month and record the type of driving (city
or highway). This will provide an accurate estimate of the vehicle’s fuel
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•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.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your“Check Engine/Service Engine
Soon”light is on, refer to the description in theWarning lights and
chimessection of theInstrument clusterchapter. Your vehicle may not
pass the I/M test with the“Check Engine/Service Engine Soon”light on.
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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.
2Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of Visteon
Traction-Lok rear axles.
3Add 237 ml (8 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of Dana
Traction-Lok rear axles.
ENGINE DATA
Engine*4.2L V6
engine4.6L V8
engine5.4L V8
engine6.8L V10
engine
Cubic inches 256 281 330 415
Required
fuel87 octane 87 octane 87 octane 87 octane
Firing order1-4-2-5-3-6 1-3-7-2-6-5
-4-81-3-7-2-6-5
-4-81-6-5-10-2-7
-3-8-4-9
Spark plug
gap1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)1.3-1.4 mm
(0.052-0.056
inch)
Ignition
systemEDIS Coil on plug Coil on plug Coil on plug
Compression
ratio9.3:1 9.4:1 9.0:1 9.0:1
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor diesel engine information.
Maintenance and Specifications
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refill capacities ........................236
specifications ..................240, 243
Exhaust fumes ..........................140
F
Fail safe cooling ........................214
Fluid capacities .........................236
Four-Wheel Drive vehicles
preparing to drive your
vehicle .....................................144
Fuel ............................................216
calculating fuel economy .......220
cap ...........................................218
capacity ...................................236
choosing the right fuel ...........218
comparisons with EPA fuel
economy estimates .................223
detergent in fuel .....................220
filling your vehicle with
fuel ...........................216, 218, 220
filter, specifications ........220, 235
fuel pump shut-off switch .....160
gauge .........................................16
improving fuel economy ........220
low fuel warning light ..............12
octane rating ...........219, 243–244
quality ......................................219
running out of fuel .................220
safety information relating to
automotive fuels .....................216
Fuses ..................................161–162
G
Garage door opener ....................93
Gas cap (see Fuel cap) ............218
Gas mileage (see Fuel
economy) ...................................220
Gauges .........................................14battery voltage gauge ...............15
engine coolant temperature
gauge .........................................14
engine oil pressure gauge ........15
fuel gauge ..................................16
odometer ...................................16
speedometer .............................16
trip odometer ............................16
GAWR (Gross Axle Weight
Rating) .......................................149
calculating ...............................151
definition .................................149
driving with a heavy load ......149
location ....................................149
GVWR (Gross Vehicle Weight
Rating) .......................................149
calculating .......................149, 151
definition .................................149
driving with a heavy load ......149
location ....................................149
H
Hazard flashers .........................159
Headlamps ...................................76
aiming ........................................77
bulb specifications ....................79
daytime running lights .............76
flash to pass ..............................77
high beam ...........................13, 76
replacing bulbs ...................80–81
turning on and off ....................76
warning chime ..........................14
Heating
auxiliary heater and air
conditioner ................................75
heater only system ...................70
heating and air conditioning
system .......................................71
Hood ..........................................199
I
Ignition .......................136, 243–244
Index
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Infant seats
(see Safety seats) .....................127
Inspection/maintenance (I/M)
testing ........................................224
Instrument panel
cleaning ...................................194
cluster ........................................10
lighting up panel and
interior .......................................77
J
Jack ............................................168
positioning ...............................168
storage .....................................168
Jump-starting your vehicle ......175
K
Keys
key in ignition chime ...............14
positions of the ignition .........136
L
Lamps
bulb replacement
specifications chart ..................79
cargo lamps ...............................77
daytime running light ...............76
headlamps .................................76
headlamps, flash to pass ..........77
instrument panel, dimming .....77
interior lamps ...........................78
replacing bulbs ...................79–83
Lane change indicator
(see Turn signal) ........................77
Lights, warning and indicator ....10
air bag ........................................12
anti-lock brakes (ABS) ....12, 142
brake ..........................................11charging system ........................12
check coolant ............................13
cruise indicator .........................13
engine oil pressure ...................13
high beam .................................13
low fuel ......................................12
safety belt .................................12
service engine soon ..................10
speed control ............................92
turn signal indicator .................13
Limited slip axle (see Traction
Loc) ............................................143
Load limits .................................149
GAWR ......................................149
GVWR ......................................149
trailer towing ..........................149
Loading instructions .................150
Lubricant specifications ...240, 243
Lumbar support, seats .............102
M
Mirrors
fold away ...................................88
side view mirrors (power) .......87
Motorcraft parts ................220, 235
O
Octane rating ............................219
Odometer .....................................16
Oil (see Engine oil) ..................201
Overdrive .....................................92
P
Panic alarm feature, remote
entry system ................................99
Parking brake ............................142
Index
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