2003 Ford F250 7.3L Diesel Supplement 3rd Printing
2003 Ford F250 Manual
2003 Ford F250 manual content summary:
- 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 1
Table of contents Introduction Diesel information Warning lights Starting Driving tips General maintenance information Scheduled maintenance Minor troubleshooting guide Capacities and specifications Service points 2 4 8 10 13 25 44 45 48 50 All rights reserved. Reproduction by any means, electronic - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 2
products may cause severe engine and/or transmission damage. There are various manufacturers offering devices to increase turbocharger boost, exhaust brakes to increase stopping/hauling capacity or other such devices to increase the power/torque of the 7.3L engine. Many owners' past experience with - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 3
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. See Engine oil in the - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 4
the fuel. The filter should be changed at the recommended service interval. Refer to the scheduled maintenance guide for more information. The filter bowl should be drained at regular intervals or when the WATER IN FUEL light illuminates in the instrument cluster. The fuel injectors are located in - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 5
can cause severe engine damage. Air filter restriction gauge, E-Series The restriction gauge, located on the clean-air side of the air cleaner upper housing, shows if the air filter is clogged. Refer to Engine Compartment in Service points chapter. AIR FILTER GAUGE FILTER CHANGE FILTER CHANGE 5 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 6
an electrical switch which illuminates a warning light on the instrument cluster when the air filter element is 100% clogged. Refer to F-250/350/450/550, Excursion in Warning Lights chapter. Check the air filter restriction gauge whenever the hood is raised to perform general engine maintenance. If - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 7
(miles) of life remaining. Always use the underhood air filter restriction gauge or engine air filter warning light on the instrument cluster to determine when the air filter element needs to be changed. After servicing the air filter element, reset the restriction gauge by pressing the button on - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 8
should always illuminate briefly, when the ignition key is in the ON position. If the light does not illuminate, there may be a problem. Refer to the Starting chapter in this guide. After the engine starts, the light should remain off. The light should always illuminate at least momentarily when the - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 9
is turned to START (as part of the light function check) and when the fuel filter/water separator has a significant quantity of water in it. If the light illuminates when the engine is running, stop the vehicle as soon as safely possible, shut off the engine, then drain the filter bowl. Refer to - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 10
before you start your vehicle. For temperatures below 0°C (32°F), the use of the correct grade engine oil is essential for proper operation. If your vehicle is equipped with a manual transmission, make sure the parking brake is set fully before you turn the key. Depress the clutch pedal and place - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 11
OPERATION Changing to a lighter grade engine oil also makes starting easier under these conditions. Refer to Engine Oil Specifications in the General maintenance information chapter. At temperatures below -7°C (20°F), Number 2-D Diesel fuel may thicken enough to clog the fuel filter. Your engine is - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 12
, do not try to restart the engine. Consult your dealer for service immediately. Follow the cylinder compression test procedure outlined in the Workshop Manual, then check the engine oil for contamination. Engine block heater (if equipped) Refer to the Starting chapter in your Owner Guide. 12 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 13
is delayed for several minutes when the tank selector switch is actuated. Fuel level indication can be obtained immediately by turning off and restarting the engine. MANUAL TRANSMISSION SHIFT SPEEDS Do not overspeed the engine when going downhill or steep grades. If equipped, use the tachometer - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 14
and downshift according to the following shift speed charts: Upshifts when accelerating (recommended for best fuel economy) 6-speed transmission Shift from: Transfer case position1 (if equipped) 2H or 4H 4L LO-1 8 km/h (5 mph) 3 km/h (2 mph) 1-2 16 km/h (10 mph) 6 km/h (4 mph) 2-3 32 km/h (20 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 15
Van (9400 GVWR) 3.55 7258 (16000) 4354 (9600) 5.52 (60) 4.10 9072 (20000) 4536 (10000) 5.52 (60) E-350 Extended Van (Crew) (9400 GVWR) 3.55 7258 (16000) 4264 (9400) 5.52 (60) 4.10 9072 (20000) 4536 (10000) 5.52 (60) E-350 Regular Wagon (8 passenger) (8700 GVWR) 3.55 7258 (16000) 4264 (9400) 5.52 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 16
. Distribute the load so that only 10 to 15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch. Towing a trailer places an additional load on your vehicle's engine, transmission, axle, brakes, tires and suspension. Inspect these components - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 17
) 5897 (13000) Crew Cab Pickup 4x2 with manual transmission and fifth wheel 7.3L All 9072 (20000) 5942 (13100) Crew Cab Pickup 4x2 with automatic transmission and fifth wheel 7.3L All 9072 (20000) 5987 (13200) Crew Cab Pickup 4x4 with fifth wheel 7.3L All 9072 (20000) 5806 (12800) Engine Rear axle - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 18
and fifth wheel 7.3L All 9072 (20000) 6260 (13800) 4x4 with manual transmission and fifth wheel 7.3L All 9072 (20000) 6033 (13300) 4x4 with automatic transmission and fifth wheel 7.3L All 9072 (20000) 6078 (13400) F-350 Regular Cab Dual Rear Wheel Pickup Fifth Rear axle Maximum GCWR Maximum Wheel - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 19
13400) 4x4 with fifth wheel All 9072 (20000) 5897 (13000) F-350 SuperCab Dual Rear Wheel Pickup Fifth Rear axle Maximum GCWR Maximum Wheel ratio ) 5942 (13100) 4x4 with manual transmission and fifth wheel 7.3L All 9072 (20000) 5761 (12700) 4x4 with automatic transmission and fifth wheel 7.3L All - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 20
) 5670 (12500) 4x2 with manual transmission and fifth wheel 7.3L All 9072 (20000) 5942 (13100) 4x2 with automatic transmission and fifth wheel 7.3L All 9072 (20000) 5987 (13200) 4x4 with fifth wheel 7.3L All 9072 (20000) 5806 (12800) Fifth Wheel Option F-350 Crew Cab Dual Rear Wheel Pickup Rear - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 21
kg (lbs.) trailer weight Option kg (lbs.) 4x2 with manual transmission 7.3L All 9072 (20000) 5942 (13100) 4x2 with automatic transmission 7.3L All 9072 (20000) 5987 (13200) 4x4 7.3L All 9072 (20000) 5761 (12700) F-350 Regular Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Fifth Rear axle Maximum - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 22
weight Option kg (lbs.) 4x2 7.3L All 9072 (20000) 5715 (12600) 4x4 with manual transmission 7.3L All 9072 (20000) 5488 (12100) 4x4 with automatic transmission 7.3L All 9072 (20000) 5534 (12200) F-350 Crew Cab Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Fifth Rear axle Maximum GCWR Maximum Wheel - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 23
) 8074 (17800) SuperCab Chassis Cab 4x4 with manual transmission 7.3L All 11793 (26000) 7847 (17300) SuperCab Chassis Cab 4x4 with automatic transmission 7.3L All 11793 (26000) 7893 (17400) Crew Cab Chassis Cab 4x2 7.3L All 11793 (26000) 7938 (17500) Crew Cab Chassis Cab 4x4 7.3L All 11793 (26000 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 24
All 11793 (26000) 7802 (17200) SuperCab Chassis Cab 4x4 with automatic transmission 7.3L All 11793 (26000) 7847 (17300) Crew Cab Chassis Cab 4x2 with manual transmission 7.3L All 11793 (26000) 7893 (17400) Crew Cab Chassis Cab 4x2 with automatic transmission 7.3L 4.88 11793 (26000) 7939 (17500) 7.3L - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 25
guide are required because they are considered essential to the life and performance of your vehicle. Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. CLEANING THE ENGINE - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 26
• E-Series • F-250/350/450/550 & Excursion FUEL REQUIREMENTS The engine is designed to use low sulfur number 1-D or 2-D Diesel fuel only. At temperatures below -7°C (20°F), number 1-D or winter blend number 2-D fuel is recommended. (See Cold Weather Operation in the Starting chapter.) 26 - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 27
-duty trucks. When refueling at truck stops: if the nozzle shuts off repeatedly when refueling, wait 5-10 seconds; then use a slower rate of flow (don't depress the nozzle trigger as far). If air is allowed to enter the fuel system (during fuel filter change or if you run out of fuel) the engine - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 28
General maintenance information CHANGING FUEL FILTER Removal - F-250/350/450/550 and Excursion 1. Remove the engine appearance cover. 2. Remove the fuel filter cap by turning counterclockwise. 3. Remove and discard old fuel filter element and fuel filter o-ring. 4. Carefully clean the mating - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 29
250/350/450/550 and Excursion The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring. 2. Install new fuel filter o-ring onto fuel filter element. 3. Install new fuel filter and o-ring into the fuel filter - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 30
roughly and smoke until the air is completely eliminated. Using a fuel which has more than average impurities may require the fuel filter to be replaced more frequently than the service interval specifies. ENGINE OIL Checking engine oil level Because it is normal to add some oil between oil changes - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 31
If the oil level exceeds OPERATING RANGE, oil consumption may result. Engine oil specifications To help achieve proper engine performance and durability, it is important that only engine lubricating oils of the proper quality are used in your Diesel engine and that the engine oil is changed no later - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 32
driving short distances. See the following section Engine Lubrication for Severe Service Operation for all severe duty restrictions. Use Ford Engine Oil Filter Part No. F4TZ-6731-A (FL-1995) or equivalent. These filters protect your engine by filtering harmful, abrasive or sludge particles. The FL - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 33
of 16 km (10 miles) or less during freezing weather If you are operating your vehicle under any of these conditions, observe the following service procedures: • Change engine oil and filter every 5,000 km (3,000 miles). • Use Motorcraft oil or an equivalent oil conforming to Ford Specification WSS - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 34
. Replace the fuel filter with Motorcraft Part No. FD-4596 (Ford Part No. F81Z-9N184-AA). Fuel filter/water separator drain procedure 1. Stop the vehicle and shut off the engine. The vehicle must be stopped with the engine off when draining the fuel filter/water separator. Fuel may ignite if - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 35
General maintenance information 2. Open the hood. Place an appropriate container under the filter drain under the vehicle. 3. Locate the fuel filter drain valve. If necessary, remove the engine appearance cover. Refer to Engine Compartment in the Service points chapter. 4. On F-Series and Excursion - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 36
for approximately 25 seconds or until clean fuel is observed. Close filter drain valve by resetting handle to original position. 5. Verify that the fuel filter drain valve is closed. If removed, install the engine appearance cover. 6. Close the hood and remove the container from under the vehicle - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 37
and vehicle location. Vehicles with Diesel engines typically are used to carry heavy loads and accumulate mileage rapidly. These two factors cause the additives in the coolant to "wear out" in a shorter time. For vehicles equipped with green coolant, Ford recommends an interim service interval - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 38
product with your factory filled coolant can result in degraded corrosion protection. • A large amount of water without engine coolant may be added, in case of emergency, to reach a vehicle service location. In this instance, the cooling system must be drained and refilled with a 50/50 mixture of - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 39
and compromise the corrosion protection of the engine coolant. • Do not mix with recycled coolant unless from a Ford-approved recycling process (see Use of Recycled Engine Coolant section). For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 40
maintenance guide), or due to service performed, adhere to the following instructions: 1. Drain and flush the cooling system to remove dirt deposits, oil, rust particles. Note: When filling the system with Motorcraft Premium Engine Coolant (green-colored) or equivalent meeting Ford specification - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 41
Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. Used engine coolant should be disposed of in an appropriate manner. Follow your community's regulations and standards for recycling and disposing of automotive fluids. Coolant refill capacity To find - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 42
with green-colored Motorcraft Premium Engine Coolant, a supplemental coolant additive FW-16 meeting Ford specification ESN-M99B169-A has been added to the coolant in this engine. This additive aids in the prevention of rust and scale buildup on the internal parts of the cooling system. Prevention - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 43
trucks over 4,536 kg (10,000 lbs.) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Facts Booklet, are applicable to complete chassis cabs over 4,536 (10 prior to its sale or delivery to hood - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 44
stationary (door to door service, taxi, etc.), then it is recommended that you change the engine oil every 200 engine hours as opposed to a mileage limit. Since most vehicles are not equipped with hourmeters, it may be necessary for you to approximate your time and plan engine oil and filter changes - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 45
Minor troubleshooting guide The complexity of the Diesel engine makes it so the owner is discouraged from attempting to perform maintenance other than the services described in this supplement. If you experience difficult starting, rough idling, excessive exhaust smoke, a decrease in engine - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 46
Minor troubleshooting guide IF THE ENGINE WON'T CRANK Turn on the headlights. If the lights are dim, do not go on at all or if when the ignition is turned to START the lights become dim or go out, the battery connections may be loose or corroded, or the battery may be discharged. If there is a - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 47
Minor troubleshooting guide IF THE ENGINE RUNS HOT The following could cause the engine to overheat: • Lack of coolant. • Dirty cooling system. • Plugged radiator fins, charge air cooler, A/C condenser and/or oil cooler. • Driving with frozen coolant. • Sticking thermostat. • Overloading or pulling - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 48
system (F-Series and Excursion) Engine oil 4 Fuel tank (F-Series) Fuel tank (Excursion) Fuel tank (E-Series) 5 Radiator cap Manual transmission 6 Automatic transmission 1 2 3 1, 3 Capacity 28.5L (30.0 quarts) 31.0L (32.75 quarts) 14.2 L (15.0 quarts) Refer to Owner Guide 166.6L (44.0 gallons - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 49
Ford Part Ford Specification Name Number Motorcraft Motor Oil XO-15W40-QSD, WSS-M2C171-C, 15W40 Super XO-10W30-QSD CH-4/SJ/SL, DHD-1 Duty, 10W30 Super Duty F4TZ-6731-A (FL-1995) FA-1750 FA-1618 BXT-65-750 VC-4-A (US) or CXC-10 (Canada) VC-7-A ES-E95AE-9601-AA ES-E95AE-9601-AA ESE-M97B44-A Engine - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 50
Service points E-SERIES ENGINE COMPARTMENT 2 3 4 5 6 7 8 9 10 1 11 1. Battery 2. Windshield washer fluid reservoir 3. Engine oil dipstick 4. Fuel filter/water separator drain valve release handle 5. Automatic transmission fluid dipstick 6. Air filter assembly 7. Engine oil filler 8. Air - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 51
Engine coolant recovery reservoir 3. Engine oil filler 4. Engine oil dipstick 5. Automatic transmission dipstick (if equipped) 6. Fuel filter drain valve 7. Clutch fluid reservoir (if equipped) 8. Brake fluid reservoir 9. Air filter restriction gauge 10. Air filter assembly 11. Power steering fluid - 2003 Ford F250 | 7.3L Diesel Supplement 3rd Printing - Page 52
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Introduction
2
Diesel information
4
Warning lights
8
Starting
10
Driving tips
13
General maintenance information
25
Scheduled maintenance
44
Minor troubleshooting guide
45
Capacities and specifications
48
Service points
50
All rights reserved. Reproduction by any means, electronic or mechanical
including photocopying, recording or by any information storage and retrieval
system or translation in whole or part is not permitted without written
authorization from Ford Motor Company. Ford may change the contents without
notice and without incurring obligation.
Copyright © 2002 Ford Motor Company
Table of contents
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