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

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

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
17

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

CHANGING FUEL FILTER
Removal
1. Remove fuel filter cap by turning
counterclockwise. Fuel filter
element will come out with cap.
2. Remove and discard bevel gasket. Carefully clean mating surfaces.
3. Press in on fuel filter element locking tabs, to separate element from
cap.
Installation
The engine will not run properly if the fuel filter is not installed
in housing.
1. Apply a coating of clean diesel fuel to new bevel gasket and install
onto fuel filter housing gland.
2. Install new fuel filter element onto cap. Place new fuel filter element
and cap into fuel filter housing. Allow fuel to soak into fuel filter
element. Tighten cap onto fuel filter housing until cap contacts the
aluminum housing.
Fuel with more than average impurities may require more frequent filter
changing intervals.
General maintenance information
21

After changing the fuel filter, the engine will purge the trapped air as it
runs. Engine may run roughly and smoke until the air is completely
eliminated.
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.
4. 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.
5. Protecting yourself from engine
heat, pull out the dipstick, wipe it
clean and reinsert fully.
6. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
7. Maintain the oil level between ADD and OPERATING RANGE on the
dipstick by adding oil as required. The distance from ADD to
OPERATING RANGE on the dipstick represents 1.9L (2 quarts). Do not
overfill. If the oil level exceeds OPERATING RANGE, oil consumption
may result.
General maintenance information
22

Engine oil specifications
To help achieve proper engine performance and durability, it is important
that only engine lubricating oils of the proper quality are used in your
diesel engine and that the engine oil is changedno laterthan the
recommended interval. Diesel engines require specially formulated oil to
resist contamination. Proper quality oils also provide maximum efficiency
of the crankcase ventilating system which reduces air pollution.
For normal or severe service, use Motorcraft oil or an equivalent oil
conforming to Ford Specification WSS-M2C171±C or API Service
categories CG-4/SH. Do not use oil labeled with only one of the following
category designations; SG, SH, CE, CF-4, or CG-4, as they could cause
engine damage.
Engine oils with improved fuel economy properties (energy conserving)
are currently available. If you use an energy conserving oil, be sure it
meets the recommended Ford Specification,APIservice categories and
SAE viscosity grades listed in the Lubricant and Maintenance Materials
Specifications chart. Some energy conserving oilsdo notmeet the
requirements necessary for your diesel engine.
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.
SAE VISCOSITY GRADES
EXPECTED TEMPERATURE RANGE
F˚ -20 -10 0 10 20 30 40
40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 C˚50 60 70 80 90 100
*15W-40 Preferred
10W-30
5W-30
0W-30Preferred
General maintenance information
23