check engine FORD SUPER DUTY 2007 1.G Diesel Supplement Manual

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
chapter 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.
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 FCM/HFCM has a significant
quantity of water in it.
Type A
Type B
Type C
If the light illuminates when the engine is running, stop the vehicle as
soon as safely possible, shut off the engine, then drain the FCM/HFCM.
Refer toDraining the FCM/HFCM and changing the fuel filtersin the
Maintenance and Specificationschapter 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.
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Instrument Cluster
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GAUGES
Air filter restriction (if
equipped):
The restriction gauge, located on
the upper housing of the air cleaner
assembly, measures the vacuum
inside the air cleaner. The more the
air cleaner is restricted (dirty,
clogged), the higher the vacuum
reading
Check the air filter restriction gauge
whenever the hood is raised to perform general engine maintenance at
least every 7,500 miles (12,000 km). If the vehicle is operated in
extremely dusty conditions, check the gauge at least every 500 miles
(800 km), or two weeks, whichever comes first.
Change the air filter when the gauge reads 25 inches (635 mm). 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 miles (kilometers) 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.
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Your vehicle is also equipped with a bypass relief valve, located on the
fuel control module, which provides fuel flow to the engine if the fuel
pickup should become plugged by ice or wax. To allow this bypass valve
to function and avoid engine fuel starvation, it is recommended that,
during cold weather operation 32°F (0°C) or below, the fuel level in your
tank should not be allowed to drop below
14full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C) your diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). As the engine warms-up,
the engine sound level will decrease due to the activation of
PCM-controlled sound reduction features.
If your vehicle is operated in a heavy snow storm or blowing snow
conditions, the engine air induction may become partially clogged with
snow and/or ice. If this occurs, the engine may experience a significant
reduction in power output. At the earliest opportunity, clear all the snow
and/or ice away from the air induction inlet.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they are in
optimum condition.
•Use Motorcraft Premium Gold Engine Coolant solution at the
concentration recommended to protect the engine against damage
from freezing.
•Try to keep the fuel tank full as much as possible at the end operation
to prevent condensation in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level.
•At temperatures of -4°F (-20°C) or below, it is recommended that you
use an engine block heater to improve cold engine starting.
•If operating in arctic temperatures of -20°F (-29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling in cold weather can cause
a buildup of heavy deposits of carbon and rust on valve stems causing
them to stick, which in turn, can cause valve train damage.
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Driving
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Do not use home heating oil or any diesel fuel not intended for
highway use. Red dye is used to identify fuels intended for
agricultural and non-highway use. Damage to the fuel injection
system, engine and exhaust catalyst 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.
Fuel Filler Cap
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise until it stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise until a few clicks are heard.
If the “Check Fuel Cap” message comes on and stays on after you start
the engine, the fuel filler cap may not be properly installed. Turn off the
engine, remove the fuel filler cap, align the cap properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Fuel quality
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. Repairs to correct the effects of using an aftermarket
product in your fuel may not be covered by your warranty.
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3. Remove the drain plug, using a 6mm hex drive, by turning it
counterclockwise. Allow the HFCM to drain for approximately 25 seconds
or until clean fuel is observed. Install the drain plug by turning it
clockwise until it is firmly seated.
4. Verify that the drain plug is closed and sealed, then remove the
container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light; it
should not be illuminated. If it continues to illuminate, have the fuel
system checked and repaired.
Removal - HFCM filter (F-Super Duty)
1. Remove the fuel filter cap by
turning counterclockwise.
2. Remove and discard the old fuel
filter element.
3. Carefully clean the mating
surfaces.
Removal - FCM filter (E-Series)
1. Remove the fuel filter cap by
turning counterclockwise.
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2. Remove and discard the old fuel filter element.
3. Carefully clean the mating surfaces.
Installation - both
The engine will not run properly if the fuel filter is not installed
in housing.
1. Install the new fuel filter and cap seal (Motorcraft Part No. FD-4604,
F-Series and FD-4606, E-Series) into the fuel filter housing.
2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
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 the 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 ensure that the
oil contained in the upper parts of the engine has returned to the oil
pan.
4. Protecting yourself from engine heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
6. Maintain the oil level between MIN and MAX or the ADD and
OPERATING RANGE on the dipstick by adding oil as required. The
distance from MIN to MAX or ADD to OPERATING RANGE on the
dipstick represents 2.0 quarts (1.9L). Do not overfill. If the oil level
exceeds MAX or OPERATING RANGE, oil consumption may result.
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5. Pull up on the filter element to
remove it.
6. Installation is reverse of removal.
When servicing the air filter, always be sure that the auxiliary
hose is not kinked or obstructed and that it is placed back into
the hole in the front cowl near the back of the headlamp. Check
all hose and wiring positions. Failure to do so may result in
severe engine damage when driving through deep water and/or
encountering unusually heavy precipitation conditions.
EMISSION CONTROL SYSTEM(S) LAWS
Federal law prohibits vehicle manufacturers, dealers and other persons
engaged in the business of repairing, servicing, selling, leasing or trading
motor vehicles as well as fleet operations from unknowingly removing or
rendering emission control system(s) inoperative. Further, modifications
of the emission control system(s) could create liability on the part of the
individual owners under the laws of some states. In Canada,
modifications of the emission control system(s) could create liability
under applicable Federal or Provincial laws.
Do not remove or alter the original equipment floor covering or
insulation between it and the metal floor of the vehicle. The floor
covering and insulation protect occupants of the vehicle from the engine
and exhaust system heat and noise. On vehicles with no original
equipment floor covering insulation, do not carry passengers in a manner
that permits prolonged skin contact with the metal floor. Provide
adequate insulation.
NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS
AND MAINTENANCE
On January 1, 1978, Federal regulation became effective governing the
noise emission on trucks over 10,000 lbs. (4,536 kg) GVWR (Gross
Vehicle Weight Rating). The following statements concerning prohibited
tampering acts and maintenance, and the noise warranty found in the
Warranty Guide, are applicable to complete chassis cabs over 10,000
lbs. (4,536 kg) GVWR.
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Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use, or
(2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
•Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
•Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer’s specifications.
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 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.
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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 when
the ignition is turned to 5 (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 clicking or stuttering sound coming from the
engine compartment when you turn the key to 5 (START), this may also
indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
Battery posts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
•For vehicles with manual transmissions,the clutch pedalmustbe
fully depressed in order for the starter to operate.
•For vehicles with automatic transmissions,the gearshift lever
must be in P (Park) or N (Neutral) in order for the starter to operate.
•Try operating the starter switch several times. Should the switch be
corroded, this operation may clean the contacts or make the switch
temporarily operable until you can reach the dealer.
•If all electrical connections are tight and you need assistance to start,
refer toJump startingin theRoadside Emergencieschapter of your
Owner’s Guide(F-Super Duty ) or refer to theJump starting
section in theRoadside Emergencieschapter of this supplement
(E-Series).
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If engine cranks but won’t start
Prolonged starter cranking (in excess of 30 seconds) could cause
damage to the starter motor.
•
Check the fuel gauge. You may be out of fuel. If the gauge shows that
there is fuel in the tank, the trouble may be in the electrical system or
the fuel system. If equipped with an auxiliary tank, be sure that the tank
control switch is set for the tank with fuel and not on an empty tank.
•Leaving the ignition key turned to 4 (ON) for over two minutes
without starting may make starting difficult because the glow plugs
will cease activation. Reset the system by turning the ignition key to 3
(OFF) and then back to 4 (ON) again.
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 heavy trailers during hot weather.
•Grill or radiator air blockage.
•Slipping or missing drive belt.
•Plugged or very dirty air cleaner element.
If fuses burn out
Burned-out or blown fuses usually indicate an electrical short-circuit,
although a fuse may occasionally burn out from vibration. Insert a second
fuse. If this fuse immediately burns out and you cannot locate the cause,
return your vehicle to your dealer for a circuit check.
Replacement fuses and circuit breakers must always be the same
rating as the original equipment shown. Never replace a fuse or
circuit breaker with one of a higher rating. Higher rated fuses or circuit
breakers could allow circuit overloading in the event of a circuit
malfunction, resulting in severe vehicle damage or personal injury due
to fire.
Refer to theOwner’s Guidefor replacement of fuses.
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