air condition FORD SUPER DUTY 2004 1.G Diesel Supplement Manual

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

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

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.
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 cetane
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.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1 1/8 inch fuel dispensing nozzle.
Pumping fuel at greater flow rates may result in premature nozzle
shut-off or spitback.
HORIZONTAL FUEL CONDITIONING MODULE (HFCM)
(FUEL FILTER/WATER SEPARATOR)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission.
Maintenance and specifications
25

If you are operating your vehicle under any of these conditions, observe
the following service procedures:
•Change engine oil and filter every 8,000 km (5,000 miles).
•Use Motorcraft oil or an equivalent oil conforming to Ford
Specification WSS-M2C171–D or API categories CI-4, CI–4/SL or
DHD-1. If CI-4 oil is not available, CH-4 is acceptable.
For more information refer theGeneral owner’s informationsection of
this supplement.
REPLACING THE AIR FILTER ELEMENT
When replacing the air filter element, use the Motorcraft air filter
element listed. Refer to theMotorcraft part numberschart in this
section.
Note: Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
Failure to use the correct air filter element may result in severe
engine damage.
1. Remove the air filter element from the housing, taking care to prevent
dirt from falling into the engine air intake.
2. Clean the air filter housing and cover to ensure good sealing.
3. Install a new air filter element. Be careful not to crimp the filter edges
between the air filter housing and cover. This could cause damage to the
air filter element and possible severe damage to the engine.
When servicing the air filter, always be sure that the auxiliary
hose is not kinked or obstructed. Failure to do so may result in
severe engine damage when driving through deep water and/or
encountering unusually heavy precipitation conditions.
ENGINE COOLANT
Checking engine coolant
The concentration and level of engine coolant should be checked at the
mileage intervals listed in the scheduled maintenance guide. The coolant
concentration should be maintained at 50/50 coolant and distilled water,
which equates to a freeze point of -36°C (-34°F). Coolant concentration
testing is possible with a hydrometer or antifreeze tester (such as the
Rotunda Battery and Antifreeze Tester, 014–R1060). The level of coolant
should be maintained at the“cold full”of“cold fill range”level in the
coolant reservoir. If the level falls below, add coolant per the instructions
in theAdding engine coolantsection.
Maintenance and specifications
31

If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
Do not use starting fluid such as ether or gasoline in the Diesel
air intake system. Such fluids can cause immediate explosive
damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your Diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
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
Maintenance and specifications
37

FIND YOUR WAY
Symbol Key
Diesel
Towing a trailer or using a camper or car-top
carrier
Extensive idling and/or low-speed driving for long
distances as in heavy commercial use such as
delivery, taxi, patrol car or livery
Operating in dusty conditions such as unpaved or
dusty roads
Off-road operation
Short trip cold operating conditions
GENERAL MAINTENANCE INFORMATION
Why maintain your vehicle?
This guide describes the scheduled maintenance required for your
vehicle. Carefully following this schedule helps protect against major
repair expenses resulting from neglect or inadequate maintenance and
may also help to increase the value of your vehicle when you sell or
trade it.
It is your responsibility to see that all scheduled maintenance is
performed and that the materials used meet Ford engineering
specifications. Failure to perform scheduled maintenance specific in this
guide will invalidate warranty coverage on parts affected by the lack of
maintenance. Be sure receipts for completed maintenance are kept with
the vehicle and confirmation of the work performed is always recorded in
this guide.
Your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Quality
Care Center has factory trained technicians who can perform the
required maintenance using genuine Ford parts. They are committed to
meeting your service needs and to assuring your continuing satisfaction.
Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To assure the proper
General Owner’s Information
43

The right prices
Our commitment to quality extends to pricing as well as service. Your
Ford and Lincoln Mercury Dealership offers competitive prices on
Genuine Ford and Motorcraft
parts and services, making Quality Care a
great value.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed
by the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in the Owner’s
Guide.
Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
Maximum Oil Change Interval:
Normal Schedule: 7,500 miles or 6 months, whichever occurs first.
Special Operating Conditions: 5,000 miles or 6 months, see appropriate
schedule.
Check every month:
•Check function of all interior and exterior lights
•Check tires for wear and proper air pressure
•Check engine oil fluid level
•Check windshield washer solvent fluid level
•Check and drain fuel filter/water separator
Check every six months:
•Check lap/shoulder belts and seat latches for wear and function
•Check air pressure in spare tire
•Check that externally-mounted spare tire is tight (see Owner’s Guide)
•Check power steering fluid level
•Check washer spray, wiper operation and clean all wiper blades
(replace as necessary)
General Owner’s Information
45

Every 60,000 miles:Change transfer case fluid
As required:Replace cabin air filter, if equipped
Operating in dusty conditions such as unpaved or dusty roads
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 5,000 miles:Check air filter minder (replace air filter as required
or when air filter minder indicates)
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
General Owner’s Information
55

Every 60,000 miles:Change transfer case fluid
As required:Replace cabin air filter, if equipped
Off-road operation
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Lubricate 4x4 hub needle bearings
Every 60,000 miles:Change transfer case fluid
As required:Inspect and lubricate 4x2 ball joints and steering idler
arms. Replace cabin air filter, if equipped
Short trip in cold operating conditions
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 40,000 miles:Change transfer case fluid
MAINTENANCE AND SERVICE RECORD
See an authorized dealer
This section of the guide is designed to allow your Ford or Lincoln
Mercury dealer, or Ford or Lincoln Mercury Auto Care service center or
other qualified service technician to record that the recommended
service was completed at the appropriate mileage intervals. Be sure to
ask your service provider to record the type of service rendered (Normal
or Special Operating Conditions—SOC) each time service is performed.
Date:
Mileage:
Normal


SOC

Dealer’s Stamp:
See corresponding mileage in maintenance schedule for services performed.
General Owner’s Information
56