fuel cap FORD F SERIES MOTORHOME AND COMMERCIAL CHASSIS 2002 10.G Owners Manual

Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
6

What you should do if the Service Engine Soon light illuminates
Light turns on solid:
This means that the OBD system has detected a malfunction.
Temporary malfunctions may cause yourService Engine Soonlight to
illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been properly installed and securely
tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with high quality fuel of the recommended octane and/or properly
installing and securely tightening the fuel cap. After three driving cycles
without these or any other temporary malfunctions present, theService
Engine Soonlight should turn off. (A driving cycle consists of a cold
engine startup followed by mixed city/highway driving.) No additional
vehicle service is required.
If theService Engine Soonlight remains on, have your vehicle serviced
at the first available opportunity.
Light is blinking:
Engine misfire is occurring which could damage your catalytic converter.
You should drive in a moderate fashion (avoid heavy acceleration and
deceleration) and have your vehicle serviced at the first available
opportunity.
Under engine misfire conditions, excessive exhaust temperatures
could damage the catalytic converter, the fuel system, interior
floor coverings or other vehicle components, possibly causing a fire.
The Transmission Control Indicator
Light (TCIL), which is located on
the gearshift lever (the word OFF),
may flash steadily if a transmission
malfunction has been detected. If
the TCIL is flashing, contact your Ford dealer as soon as possible. If this
condition persists, damage to the transmission may occur.
OVERDRIVE
Instrumentation
8

Battery voltage gauge
Indicates battery voltage. If the
pointer moves and stays outside the
normal operating range (as
indicated by the arrows), have the
vehicle’s electrical system checked
as soon as possible.
Fuel gauge
Displays approximately how much
fuel is in the fuel tank. The fuel
gauge may vary slightly when the
vehicle is in motion or on a grade.
When refueling the vehicle from
empty indication, the amount of fuel
that can be added will be less than
the advertised capacity due to the
reserve fuel.
Speedometer
Indicates the current vehicle speed.
818
Instrumentation
13

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
5 15A* Powertrain Control Module Power,
Fuel Pump Relay Coil, Fuel
Injectors, Mass Air Flow 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): Brake
Pressure Switch, Power Brake
Assist Module***, Speed Control
Module, Powertrain Control
Module, ABS module, Brake Shift
Interlock Actuator
9 5A* Alternator
10 20A* Daytime Running (DRL) Lamps
11 30A* Ignition Coils, Radio Capacitors #1
and #2, Powertrain Control
Module Relay
12 20A* Trailer Tow Running Lamps Feed,
Trailer Tow Backup Lamps Feed,
IP-Backup Lamp Feed
13 30A** Trailer Tow Electric Brake
Controller Feed
14 60A** Instrument Panel Battery Feed
(Fuse #9, 15, 21)
15 -- Not Used
16 60A** ABS Module
17 -- Not Used
18 20A** Horn Feed
19 -- Not Used
Roadside emergencies
46

Adding engine oil
1. Check the engine oil. For instructions, refer toChecking the engine
oilin this chapter.
2. If the engine oil level is not within the MIN and MAX ranges, add only
certified engine oil of the recommended viscosity. Remove the engine oil
filler cap and use a funnel to pour the engine oil into the opening.
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 fully seated.
5. Fully install the engine oil filler cap by turning the filler cap clockwise
until three clicks can be heard.
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.
Only use oils “Certified For Gasoline Engines” by the 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. They are unnecessary and could, under certain conditions,
lead to engine damage which is not covered by your warranty.
Change your engine oil and filter according to the appropriate schedule
listed in the scheduled maintenance guide.
Maintenance and specifications
62

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
may cause leakage and lead to fuel spray and 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 completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Gasoline may contain benzene, which is a cancer-causing agent.
Maintenance and specifications
72

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.
1. Shut the engine off and relieve the fuel system pressure.
•Remove the Schrader valve cap
(located at the right rear of
intake manifld) and install the
EFI/CFI Fuel Pressure Gauge.
The EFI/CFI Fuel Pressure Gauge
310–012 (T80L-9974–B) is
available at a certified Ford parts
dealer.
Maintenance and specifications
76

Installation
1. Install the fuel filter.
2. Lubricate the tube end with clean
engine oil meeting Ford
specification WSS-M2C153–H to
ease assembly.
•Pull on the fitting to make sure it
is fully engaged, then install
safety clip.
•Align and push the tube into the
fitting until you hear a click.
3. Remove the EFI/CFI Fuel
Pressure Gauge.
4. Install the Schrader valve cap securely.
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 fillups 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.
Maintenance and specifications
78

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.
Maintenance and specifications
79

MOTORCRAFT PART NUMBERS
Component 6.8L V10 engine
Air filter element FA-1634
Battery BXT-65-750
Fuel filter FG-986B
Oil filter FL-820-S
PCV valve EV-233
Spark plugs* AWSF-22E
*Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine oil
(includes filter
change)Motorcraft SAE
5W-20 Super
Premium Motor
OilAll 5.7L
(6.0 quarts)
Engine coolant
1Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)All 29.0L
(30.6 quarts)
Maintenance and specifications
95