FORD E SERIES 1999 4.G 7.3L Diesel Supplement Manual

Operation in standing water
Ingestion of water into the diesel engine can result in immediate and
severe damage to the engine. If driving through water, slow down to
avoid splashing water into the intake. If the engine stalls, and ingestion
of water into the engine is suspected, 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 theStartingchapter in your Owner Guide.
JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Do not push start your vehicle. You could damage the catalytic
converter.
Batteries contain sulfuric acid which burns skin, eyes, and
clothing.
Preparing your vehicle
Also see the label on the battery.
1. Use only a 12±volt supply to start your vehicle. If you connect your
battery to a 24±volt power supply you can damage your starter, ignition
system and other electrical components. Do not attach the jumper cables
to the glow plug relay as this could severely damage the glow plugs,
injector driver module and PCM.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle's electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure theydo nottouch. Set the parking brake on both vehicles
and stay clear of the engine cooling fan and other moving parts.
Starting
11

4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Connecting the jumper cables
1. Position the vehicles so that they
do not touch one another.
2. Switch off the engine. Switch off
any unnecessary electrical
equipment.
3. Connect the positive (+) terminal
of the discharged battery to the
positive (+) terminal of the booster
battery.Do notjump start the
driver's side or frame mounted
battery.
4. Connect one end of the second
lead to the negative (-) terminal of
the booster battery and the other
end to a metal part of the engine to be started, not to the negative (-)
terminal of the discharged battery.
5. Make sure that the jump leads are clear of moving parts of the engine.
Do not connect the end of the second cable to the negative (-)
terminal of the battery to be jumped. A spark may cause an
explosion of the gases that surround the battery.
Jump starting
1. Start the booster vehicle and run the engine at moderately increased
speed.
2. Start the engine of the vehicle with the discharged battery.
3. Once the engine has been started, run both vehicles for a further
three minutes before disconnecting the leads.
+–
+–
41
2
3
Starting
12

Removing the jumper cables
1. Remove the jumper cables in
reverse order. Take the cable off the
metallic surface first, followed by
the cable on the negative (-)
booster battery terminal.
2. Remove the cable from the
positive (+) terminal of the booster
battery and then the discharged
battery.
3. After the disabled vehicle has
been started, allow it to idle for a
while so the engine can ªrelearnº its
idle conditions.
+–
+–
14
3
2
Starting
13

TRANSMISSION SHIFT SPEEDS
Do not overspeed the engine when going downhill or steep grades. Do
not allow engine speed to exceed the redline area of the tachometer.
Operating the engine beyond the governed speed can cause severe
engine damage.
Upshift 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 mph) 13 km/h (8 mph)
3-4 48 km/h (30 mph) 19 km/h (12 mph)
4-
D(Overdrive) 64 km/h (40 mph) 24 km/h (15 mph)
Maximum downshift speeds1
6-speed transmission
Shift from: Transfer case position (if equipped)2
2H or 4H 4L
D(Overdrive) - 4 72 km/h (45 mph) 26 km/h (16 mph)
4-3 56 km/h (35 mph) 19 km/h (12 mph)
3-2 32 km/h (20 mph) 13 km/h (8 mph)
2-1 8 km/h (5 mph) 3 km/h (2 mph)
1-LO Only shift to LO when at a stop.
1Use 2H or 4H for 4WD equipped vehicles.2Downshift at lower speeds when driving on slippery surfaces.
TRAILER TOWING
Refer to your ªOwner Guideº for full details on towing a trailer.
Econoline trailer towing tables
Your vehicle may tow a class I, II or III trailer provided the maximum
trailer weight is less than or equal to the maximum trailer weight listed
for your engine and rear axle ratio on the following charts.
Driving tips
14

GCWR (Gross Combined Weight Rating)/Trailer Weights
Rear axle
ratioMaximum
GCWR-kg
(lbs.)Trailer weight
range-kg (lbs.)
(0-Maximum)Maximum Frontal
Area Of
Trailer-m
2(ft2)
Regular Van E-350
3.55 7 258 (16 000) 4 536 (10 000) 5.52 (60)
4.10 9 072 (20 000) 4 536 (10 000) 5.52 (60)
Super Van E-350
3.55 7 258 (16 000) 4 445 (9 800) 5.52 (60)
4.10 9 072 (20 000) 4 536 (10 000) 5.52 (60)
Club Wagon Regular E-350 (12 passenger)
3.55 7 258 (16 000) 4 309 (9 500) 5.52 (60)
4.10 9 072 (20 000) 4 536 (10 000) 5.52 (60)
Club Wagon Super E-350 (15 passenger)
3.55 7 258 (16 000) 4 173 (9 200) 5.52 (60)
4.10 9 072 (20 000) 4 536 (10 000) 5.52 (60)
E-350 RV Cutaway (single rear wheel)
4.10 9 072 (20 000) 4 717 (10 400)* 5.52 (60)
E-350 RV Cutaway (dual rear wheel)
4.10 9 072 (20 000) 4 309 (9 500) 5.52 (60)
E-350 Commercial Cutaway (single rear wheel)
4.10 9 072 (20 000) 4 717 (10 400)* 5.52 (60)
E-350 Commercial Cutaway (dual rear wheel)
4.10 9 072 (20 000) 4 400 (9 700) 5.52 (60)
E-Super Duty
4.63 9 072 (20 000) 4 536 (10 000) 5.52 (60)
Maximum loaded trailer weight of 4 717 kg (10 400 lbs.) on 7.3L E350 RV
and commercial cutaways (single rear wheel) applicable to fifth wheel trailer
usage only. Otherwise, maximum trailer weight is 4 717 kg (10 000 lbs.).
For high altitude operation reduce GCWR by 2% per 300 meters (1 000 ft)
elevation.
To determine the maximum trailer weight designed for you particular
vehicle as equipped, follow the sectionCalculating the load your vehicle
can tow/carryearlier in this chapter.
Driving tips
15

Your vehicle's load capacity is designated by weight, not by volume, so
you cannot necessarily use all available space when loading a vehicle.
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 carefully after any towing operation.
Do not exceed the GVWR or the GAWR specified on the
certification label.
Towing trailers beyond the maximum recommended gross trailer
weight could result in engine damage, transmission/axle damage,
structural damage, loss of control, and personal injury.
F-Series trailer towing tables
GCWR (Gross Combined Weight Rating)/Trailer Weights
ModelRear axle
ratioMaximum
GCWR-kg (lbs.)Maximum trailer
weight-
kg (lbs.)
1
F-250 3.73 9 072 (20 000) 4 536 (10 000)
F-350 3.73 9 072 (20 000) 4 536 (10 000)
F-350 (DRW) 4.10 9 072 (20 000) 4 536 (10 000)
F-450 4.88 11 794 (26 000) 4 536 (10 000)
F-550
(17 500 GVW)4.88 11 794 (26 000) 4 536 (10 000)
F-550
(19 000 GVW)4.88 11 794 (26 000) 4 536 (10 000)
1Conventional/Class IV trailer hitch only. Fifth wheel trailer maximum
weights can be calculated by subtracting the GVW from the GCWR.
Driving tips
16

AUXILIARY POWERTRAIN CONTROL MODULE (APCM)
(IF EQUIPPED)
Your vehicle may be equipped with an auxiliary PCM. It has the following
features:
RPM control
This feature is used for elevating the
engine's idle speed. Rpm control can
be activated from inside the vehicle
and can be programmed to activate
automatically upon engine start-up.
Programmable speed presets range
from 1300±2500 rpm. This is the
recommended method of elevating
idle speed for PTO applications.
Charge Protect
This feature is used for maintaining
battery charge. In ªCharge
Protectionº mode, the battery
voltage is monitors and the engine
idle speed is increased so the
battery charge is maintained as
required. Charge Protection can be
activated from inside the vehicle
and programmed to activate
automatically upon engine start-up.
LCD screen
Displays current engine speed and
battery voltage.
RPM
CONTROLCHARGE
PROTECTPOWER
RPM
CONTROLCHARGE
PROTECTPOWER
RPM
CONTROLCHARGE
PROTECTPOWER
Driving tips
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Arrow keys
Each arrow key contains a preset
speed allowing four programmable
rpm settings. The arrow keys can
also be used to manually increase or
decrease engine idle speed at a
faster of slower rate.
RPM
CONTROLCHARGE
PROTECTPOWER
Driving tips
18

SCHEDULED MAINTENANCE
The Scheduled Maintenance Services in the Service 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.
WASHING THE DIESEL ENGINE
Never wash the engine when it is warm, hot or running. Spraying water
or other cleaning fluids on a warm engine can seriously damage the
engine's fuel system. When washing the engine, the air cleaner must be
in place to prevent water from splashing into the engine.
FUEL REQUIREMENTS
The engine is designed to use low sulfur number 1±D or 2±D diesel fuel
only. At temperatures below -7ÉC (20ÉF), number 1±D or winter blend
number 2±D fuel is recommended. (See ªCold Weather Operationº in the
Startingchapter.)
Do not use fuel intended for agricultural use (agricultural fuel is
dyed red), home heating oil or any diesel fuel not intended for
highway use. Damage to the fuel injection system or engine can
occur if an improper fuel is used.
Do not add gasoline, gasohol or alcohol to diesel fuel. This practice
creates a serious fire hazard and engine performance problems.
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated diesel fuel that meets the ASTM D
975 industry specification. Aftermarket additives can damage the injector
system or engine.
Do not blend used engine oil with diesel fuel under any circumstances.
Blending used oil with the fuel will significantly increase your vehicle's
exhaust emissions and reduce engine life due to increased internal wear.
Do not crank the engine for more than 30 seconds at a time as
damage to the starter motor may result.
If the engine fails to start in 30 seconds, turn the key to the OFF
position and wait 30 seconds before trying again.
General maintenance information
19

Truck stops have pumps and nozzles designed for larger, heavy-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 will purge the trapped air as it runs. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low octane
rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of diesel fuel.
Care should be taken whenever diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
solution until it is run through the engine where it will be deposited in
the fuel injectors causing expensive-to-repair damage.
General maintenance information
20