fuel cap FORD E SERIES 2004 4.G 7.3L Diesel Supplement Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 2004, Model line: E SERIES, Model: FORD E SERIES 2004 4.GPages: 56, PDF Size: 0.43 MB
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California Proposition 65 Warning: Diesel engine exhaust, some
of its constituents, and certain vehicle components contain or
may emit chemicals known to the State of California to cause cancer or
birth defects or other reproductive harm.
Your new Diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the Power Stroke (7.3L DIT) Diesel
engine. It provides recommendations on engine care and operating
procedures. For complete vehicle information, also refer to the Owner
Guide included with the vehicle. It also describes equipment and gives
specifications for equipment that was in effect when this guide was
approved for printing, and should be considered a permanent part of the
vehicle.
Some aftermarket 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 these products has been very poor. Severe
powertrain damage may result from the use of these aftermarket
products which will not be covered by the Ford warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if equipped
with theFord Ambulance Preparation Package.In addition, Ford
urges ambulance manufacturers to follow the recommendation of the
Ford Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout
Book(and pertinent supplements) and theQualified Vehicle Modifiers
Guidelines. Using a Ford vehicle without theFord Ambulance
Preparation Packageto produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with theFord Ambulance Preparation
Package,inspect the information plate on the driver’s side door pillar.
Contact the manufacturer of your vehicle to determine whether the
ambulance manufacturer’s followed Ford’s recommendations.
Introduction
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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
surfaces.
Removal — E-Series
1. Remove the engine appearance cover.
2. Disconnect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for removal.
3. Release the four retaining clamps on the air cleaner assembly, then lift
the air cleaner cover and remove the air cleaner(s).
4. Loosen the clamp on the air inlet tube, then disconnect the air inlet
tube from the resonator.
5. Remove the three bolts on the turbocharger heat shield, then the
turbocharger heat shield.
6. Remove the bolt and resonator from the vehicle.
General maintenance information
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7. Remove the fuel filter cap by
turning counterclockwise.
8. Remove and discard old fuel filter
element and fuel filter o-ring.
9. Carefully clean the mating
surfaces.
Installation—F-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 housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install engine appearance cover.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run 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.
Installation—E-Series
The engine will not run properly if the fuel filter is not installed
in housing.
General maintenance information
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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 housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install the resonator and resonator bolt.
6. Install the turbocharger heat shield, then the three bolts on the
turbocharger heat shield.
7. Connect the air inlet tube to the resonator, then tighten the clamp on
the air inlet tube.
8. Install the air cleaner(s), close the air cleaner cover, then close the
four retaining clamps on the air cleaner assembly.
9. Connect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for installation.
10. Install the engine appearance cover.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run 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, check your
engine oil level each time you stop for fuel. To check the engine oil level
consistently and accurately, the following procedure is recommended:
1. Have engine at normal operating temperature (at least into the
NORMAL range on the engine coolant temperature gauge).
2. Park the vehicle on a level surface, then turn off the engine and open
the hood.
3. Allow at least20 minutesafter engine shutdown to assure that the oil
contained in the upper parts of the engine has returned to the oil pan.
General maintenance information
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* Heavy duty trailer towing with ambient temperatures above 10°C
(50°F) requires 15W-40 engine oil.
The use of correct oil viscosities for Diesel engines is important for
satisfactory operation. Determine which oil viscosity best suits the
temperature range you expect to encounter for the next service interval.
A symbol has been developed by the
American Petroleum Institute (API)
to help you select the proper engine
oil. It will be included on the oil
container you purchase. The top
section of the symbol shows the oil
performance by the API designation.
This should match the owner guide
recommendation. The center section will show the SAE viscosity grade.
The lower section will state energy conserving if the oil has proven fuel
saving capabilities.
Changing engine oil and filter
Change your oil and filter according to the scheduled maintenance guide.
Change more frequently if your vehicle operation includes extended
periods of idling or low-speed operation, driving for a long time in cold
temperatures or driving short distances. See the following section
Engine Lubrication for Severe Service Operationfor 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–1995 filters particles significantly
smaller than most available“will fit”filters.
To replace, use an oil filter wrench to unscrew the filter from the oil
cooler fitting. Turn it horizontally to let excess oil drain off, and remove.
APISERVICECH-4/SLSAE15W-40
General maintenance information
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REFILL CAPACITIES
Component Capacity
Cooling system (E-Series)1, 2, 328.5L (30.0 quarts)
Cooling system (F-Series and Excursion)1, 331.0L (32.75 quarts)
Engine oil414.2 L (15.0 quarts)
Fuel tank (F-Series) Refer to Owner Guide
Fuel tank (Excursion) 166.6L (44.0 gallons)
Fuel tank (E-Series)
5132.5L (35.0 gallons)
Radiator cap 90 kPa (13 psi)
Manual transmission
65.5L (5.8 quarts)
Automatic transmission Refer to Owner Guide
1Includes heater and 4.7L (5 quarts) in coolant recovery.
2Add 2.5L (2.6 quarts) if equipped with auxiliary heater option.
3Add the coolant type originally equipped in your vehicle. For vehicles
filled with Motorcraft Premium Engine Coolant (green-colored) add
1.89L (4 pints) of supplemental coolant additive, FW-16 or equivalent,
meeting Ford Specification ESN-M99B169–A.
4Includes 1.9L (2 quarts) in engine oil filter.
5Optional DRW cutaway and all standard E-450 models are 208.2L (55.0
gallons).
6Use Motorcraft MERCONATF, Motorcraft part number XT-2–QDX,
meeting Ford specification MERCON.
BULB SPECIFICATIONS
Lamp descriptionNumber of bulbs
requiredTrade number
Wait to Start Light 1 194
Water-in-Fuel Light 1 194
Engine Temp. Light 1 194
Capacities and specifications
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