FORD SUPER DUTY 2004 1.G Diesel Supplement Manual

Introduction
2
Instrumentation
6
Driving
11
Cleaning
22
Maintenance and specifications
23
General Owner’s Information
41
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Copyright © 2003 Ford Motor Company
Table of contents
1

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and 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 6.0L Power Stroke 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 Power Stroke 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
Introduction
2

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.
WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,600 km (1,000 miles) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves 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. SeeEngine oilin the
Maintenance and specificationssection for more information on oil
usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•an engine-mounted secondary fuel filter
•frame-mounted Horizontal Fuel Conditioner Module (HFCM)
•a unit injector for each cylinder
The HFCM acts as a primary fuel filter/water separator which removes
both water and impurities from the fuel. The engine-mounted fuel filter
and the HFCM filter should be changed at the recommended service
interval. Refer to theGeneral Owner’s Informationsection of this
supplement for more information.
The HFCM should be drained at
regular intervals or when the
WATER IN FUEL light illuminates in
the instrument cluster.
Introduction
3

The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM) and Fuel Injection Control Module (FICM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. The fuel pump
contains a pressure relief valve for overpressure protection in the event
of restricted flow.
Lubrication system
It is important to change the engine oil at the recommended service
intervals, because oil viscosity is important in maintaining the oil
pressure required to actuate the fuel injectors. Extended oil change
intervals can negatively affect engine performance, fuel economy and
engine life. Refer to the engine oil specification chart located under
Engine oil specificationsin theMaintenance and specifcations
chapter.
Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM energizes the glow
plugs immediately after the ignition
is placed in the ON position, then determines how long the glow plugs
will be on according to the EOT and BARO sensors. The required time
for the glow plugs to be energized decreases as the engine oil
temperature and barometric pressure increase.
Engine cooling system
The cooling system contains an engine oil cooler which is mounted in the
center valley of the engine. The cooler’s function is to regulate engine oil
temperature.
Introduction
4

Engine governed speed
The engine governor is controlled by the PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
For maximum vehicle speed in various gears, refer toManual
transmission shift speedsin theDrivingsection of your owner’s guide.
Do not exceed 3,600 rpm. Maximum engine governed speed is 4,000 rpm
depending on engine load. Excessive rpm can only be achieved by
manually downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause
severe engine damage.
Introduction
5

EXCURSION & F-SUPER DUTY (EXCEPT HARLEY-DAVIDSON)
F-SUPER DUTY HARLEY-DAVIDSON
Glow plug pre-heat indicator
With the key in the ON position,
the
light will illuminate if glow
plug heat is necessary as a starting
aid. Wait until the light goes off
before starting. The light 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 toCold weather startingin theDriving
section of this supplement. After the engine starts, the light should
remain off. The light should always illuminate at least momentarily when
the engine is cold and the ignition is turned to ON. If it does not
illuminate, the glow plug system should be checked and repaired
promptly to avoid difficulty in cold starting.
Instrumentation
6

Water in fuel
During refueling, it is possible for
water-contaminated diesel fuel to be
pumped into your tank. Your vehicle
fuel system is equipped with a fuel
filter/water separator to remove water from the fuel. The WATER IN
FUEL light will illuminate when the ignition is turned to START (as part
of the light function check) and when the HFCM 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 HFCM. Refer
toDraining the HFCM and changing the fuel filtersin the
Maintenance and specificationssection of this supplement for the
drain procedure. Allowing water to stay in the system could result in
extensive damage to, or failure of, the fuel injection system.
Do not drain the water separator while the engine is running.
Fuel may ignite if the separator is drained while the engine is
running or the vehicle is moving.
Engine air filter
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The condition should be verified by inspecting the underhood air filter
restriction gauge; the warning light is only a secondary indicator. Always
use the underhood air filter restriction gauge to determine when the air
filter element needs to be changed.
The vehicle may be driven with the engine air filter warning light
illuminated/or when the underhood air filter restriction gauge has moved
to the CHANGE FILTER mark for up to 400 km (250 miles) without
damaging the engine or related components. However, the air filter
element must be replaced at the earliest opportunity. Refer toAir filter
restriction gauge (if equipped)in this section of the supplement for
more information.
Instrumentation
7

Air filter restriction gauge (if equipped)
The restriction gauge, located on
the upper housing of the air cleaner
assembly, monitors the condition of
the air filter element in two ways:
•First, the colored indictor inside
the gauge highlights the
percentage that the air filter
element is clogged with dust or
contaminants. Refer to
Maintenance and specifications
chapter.
•Second, the gauge contains an electrical switch which illuminates a
warning light on the instrument cluster when the air filter element is
100% clogged. Refer to theEngine air filterwarning light in this
section of the supplement.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance at least every 12,000 km (7,500
miles). If the vehicle is operated in extremely dusty conditions, check
the gauge at least every 800 km (500 miles), or two weeks, whichever
comes first.
Instrumentation
8

The air filter element must be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when the maximum
restriction is reached.
Blowing-out the air filter
element with compressed air is
not recommended as the
compressed air may damage the
filter paper.
Note:It is not possible to determine the level of filter clogging by visual
appearance alone. A filter which appears to be dirty may actually have
several thousand kilometers (miles) of life remaining.
Always use the underhood air filter restriction gauge to
determine when the air filter element needs to be changed. The
warning light on the instrument cluster should not be used
exclusively for determining when the air filter element needs
changing.
Instrumentation
9

After servicing the air filter element,
reset the restriction gauge by
pressing the button on the end of
the gauge.
Note:If the vehicle is operated in a
heavy snow storm, in blowing snow
or the vehicle is equipped with a
snowplow, the engine air filter
element may become partially
clogged with snow and/or ice. If this
occurs, the air filter restriction
gauge will move to the CHANGE FILTER mark and the engine may
experience a significant reduction in power output. The vehicle may be
driven under these conditions for up to 160 km (100 miles) without
damage to the engine or related components.
At the earliest opportunity, clear all snow and ice from the air induction
system and reset the restriction gauge by pressing the button on the end
of the gauge. If the air filter restriction gauge moves the CHANGE
FILTER mark after clearing snow and/or ice, then replace the filter.
Reset filter restriction gauge after changing the air filter element.
The air filter warning light on the instrument cluster may be used, in
addition to the underhood restriction gauge, to monitor the condition of
the air filter element. Refer to theEngine air filterwarning light in this
section of the supplement.
Instrumentation
10