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

A symbol has been developed by the
American Petroleum Institute (API)
to help you select the proper engine
oil. It will be included on the oil
container you purchase. The top
section of the symbol shows the oil
performance by the API designation.
This should match the owner guide recommendation. The center section
will show the SAE viscosity grade. The lower section will state energy
conserving if the oil has proven fuel saving capabilities.
Changing engine oil and filter
Change your oil and filter according to the ªService Guideº. Change more
frequently if your vehicle operation includes extended periods of idling
or low-speed operation, driving for a long time in cold temperatures or
driving short distances. See the following section ªEngine Lubrication for
Severe Service Operationº for all severe duty restrictions.
Use Ford Engine Oil Filter Part No. F4TZ-6731±A (FL±1995) or
equivalent. These filters protect your engine by filtering harmful,
abrasive or sludge particles. The FL±1995 filters particles significantly
smaller than most available ªwill fitº filters.
To replace, use an oil filter wrench to unscrew the filter from the oil
cooler fitting. Turn it horizontally to let excess oil drain off, and remove.
Do not handle a hot oil filter with bare hands.
Clean the filter mounting area on the oil cooler, lightly coat the gasket
surface of the new filter with clean engine oil and hand tighten until the
gasket contacts the base.Then tighten another 1±1/4 to 2 turns.Fill
the crankcase and run the engine to check for leaks.
Continuous contact with USED motor oil has caused cancer in
laboratory mice. Protect your skin by washing with soap and
water.
APISERVICECG-4/SHSAE15W-40
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24

Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
²towing a trailer over 1 600 km (1 000 miles)
²sustained, high speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation during hot
weather-above 32ÉC [90ÉF]).
²frequent or extended idling (over 10 minutes per hour of normal
driving).
²operating in severe dust conditions.
²frequent, short trips of 16 km (10 miles) or less during freezing
weather
If you are operating your vehicle under any of these conditions, observe
the following service procedures:
²Change engine oil and filter every 5 000 km (3 000 miles).
²Use Motorcraft oil or an equivalent oil conforming to Ford
Specification ESR-M2C171±C or API categories CG-4/SH. Do not use
oils labeled withonlyone of the following category designations, SG,
SH, CE, CF-4 or CG-4, as they could cause engine damage.
For more information refer theSevere Duty Maintenance Schedulein
the ªService Guideº.
REPLACING AIR CLEANER
When replacing the air cleaner, use a Motorcraft filter or its equivalent.
Refer toLubricant and Maintenance Materials Specificationsin this
supplement.
Failure to use the correct filter may result in severe engine
damage when driving through deep water and/or encountering
unusually heavy precipitation conditions.
1. Remove air cleaner, taking care to prevent dirt from falling into the
engine air intake.
2. Clean the air cleaner tray and cover to ensure good sealing.
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25

3. After replacing the air cleaner, be sure that the rubber water drain
hose is not kinked under the tray. If so, adjust the hose so that it hangs
free. Failure to do so may result in severe engine damage when driving
through deep water and/or encountering unusually heavy precipitation
conditions.
FUEL FILTER/WATER SEPARATOR
The engine is equipped with a combination fuel filter/water separator
located in the ªVº of the engine.
Water should be drained from the
filter bowl whenever the warning
light comes on or every 8 000 km (5
000 miles). The WATER IN FUEL
light will come on when
approximately 100 cc (0.2 pints) of water accumulates in the separator.
Replace the fuel filter with Motorcraft Part No. FD-4595±A (Ford Part
No. F4TZ-9N184±B).
Fuel filter/water separator drain procedure
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the filter bowl. Fuel may ignite if separator is drained while the
engine is running or vehicle is moving.
2. Open the hood. Place an
appropriate container under the
filter drain under the vehicle.
WATER
IN
FUEL
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26

3.On F-Series models,open filter
drain valve by turning clockwise.
Allow to drain for approximately 25
seconds or until clean fuel is
observed. Close drain valve by
turning counterclockwise until firmly
seated.
3.On Econoline models,open filter drain valve release handle. Allow
to drain for approximately 25 seconds or until clean fuel is observed.
Close drain valve by resetting handle to original position.
4.On all models,verify that the fuel drain is closed. Close the hood and
remove the container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light. The
light should not glow. If it continues to glow, have fuel system checked
and repaired.
DRAIN
CLOSE
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ENGINE COOLANT
Replacing coolant
A coolant mixture of 50% coolant concentrate and 50% water is
recommended to maintain best overall performance. To avoid damaging
the engine and radiator, the coolant concentrate should not exceed 60%.
When refilling the coolant system either as part of the regular
maintenance (48 months, or 80 000 km [50 000 miles], whichever comes
first and then every 36 months or 48 000 km [30 000 miles], whichever
comes first), or due to service performed, adhere to the following
instructions:
1. Drain and flush the cooling system to remove dirt deposits, oil, rust
particles.
2. Add 1.89L (4 pints) of supplemental coolant additive FW-15, directly
to the cooling system. An additional 237±295 ml (8±10 oz.) of
supplemental coolant additive FW-15 should be added at 24 000 km (15
000 mile) intervals to maintain proper concentration.
3. Fill the coolant reservoir with the specified coolant/water mixture until
the level stabilizes at the top hose fitting. Replace and tighten cap. Fill
the radiator when cold. Level the coolant in the coolant bottle.
4. Reinstall the coolant bottle cap.
5. Start and idle engine until the radiator upper hose is warm
(approximately 10±15 minutes). If the hose does not get warm then
repeat at a higher engine speed.
6. Immediately shut off engine. Cautiously remove coolant bottle cap and
add coolant to Cold Fill mark.
Checking coolant level
Check coolant level in coolant reservoir bottle at least once a month,
only when the engine is cool. Fill to within the ªCold Fill Levelº range
noted on the reservoir as required with a 50/50 mixture of coolant
concentrate and water.
A coolant mixture of 50% coolant concentrate and 50% water is
recommended to maintain best overall performance. A 60/40 antifreeze
to water ratio is acceptable for extremely cold climates, but must be
returned to a 50/50 ratio at the end of the winter season.
Vehicles with diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors cause the additives in the
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coolant to ªwear outº in a shorter time. Ford recommends an interim
service interval performed at 12 months or 24 000 km (15 000 miles),
whichever occurs first. Add 237±295 ml (8±10 oz.) of supplemental
coolant additive FW-15 to the cooling system. For vehicles with extensive
idling time, add 237±295 ml (8±10 oz.) of coolant additive FW-15 after
every 500 hours of operation.
Operating engine with insufficient coolant and/or coolant additive can
cause severe engine damage.
Failure to follow these instructions could result in serious
personal injury from hot coolant or steam blow out and/or
damage to the cooling system or engine. Never remove the coolant
bottle cap under any circumstances while the engine is operating.
Switch off the engine and wait until it has cooled. Wrap a thick cloth
around the cap and turn it slowly while the pressure is relieved. Step
back while the pressure is released from the cooling system. When you
are sure all the pressure has been released, still with a cloth Ð turn
and remove it. Stand clear of the opening. Hot coolant may splash out.
Whenever coolant level checks are made, check condition of coolant
bottle cap rubber seal. Make sure it is clean and free of any dirt
particles. Rinse off with water, if necessary. When replacing cap on
coolant bottle, also make sure coolant bottle neck seal is clean. Check
that overflow hose is not kinked.
Coolant specification
Use only a permanent-type coolant that meets Ford Specification
ESE-M97B44±A such as Ford Premium Cooling System Fluid
E2FZ-19549±AA. Do not use alcohol or methanol antifreeze or mix them
with the specified coolant.
Use of the wrong coolant may cause radiator and/or engine damage.
Plain water may be used in an emergency, but replace it with the
specified coolant as soon as possible to avoid damage to the system. With
only water in the system, do not let the engine run hot or remain parked
in temperatures below 0ÉC (32ÉF).
Coolant conditioner (liquid)
A supplemental coolant additive FW-15 has been added to the coolant in
this engine.
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This additive aids in the prevention of rust and scale buildup on the
internal parts of the cooling system. Prevention of rust and scale buildup
allows for proper dissipation of heat generated by combustion.
See the ªService Guideº for recommended intervals.
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 4 536 kg (10 000 lbs.) GVWR (Gross
Vehicle Weight Rating). The following statements concerning prohibited
tampering acts and maintenance, and the noise warranty found in the
Warranty Facts Booklet, are applicable to complete chassis cabs over
4 536 (10 000 lbs.) GVWR.
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.
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Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
²Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
²Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer's specifications.
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VEHICLE EMISSIONS CONTROL INFORMATION (VECI)
Emissions information appears on
the VECI decal on the engine valve
cover. This decal identifies engine
displacement and provides certain
engine specifications.
SCHEDULED MAINTENANCE SERVICES
Refer to your ªService Guideº for details of maintenance on your vehicle.
If you are using your vehicle in a manner in which it will remain
stationary (door to door service, taxi, etc.), then it is recommended that
you change the engine oil every 200 engine hours as opposed to a
mileage limit. Since most vehicles are not equipped with hourmeters, it
may be necessary for you to approximate your time and plan engine oil
and filter changes accordingly.
Any modification of the emissions control system could create liability
under federal law (U.S.) if made prior to sale and registration, under the
laws of some states if made thereafter. Further, 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 knowingly removing or rendering an
emissions control system inoperative after sale and delivery to an
ultimate purchaser. In Canada, modifications of the emissions control
system could create liability under applicable federal or provincial laws.
Scheduled maintenance
32

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:
²a plugged air inlet system.
²water in the fuel filter/water separator.
²a clogged fuel filter.
²contaminated fuel.
²air in the fuel system, due to loose connections.
²an open or pinched sensor hose.
²low engine oil level.
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
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