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

Introduction 2
Diesel information 4
Warning lights 7
Starting 9
Driving tips 14
General maintenance information 19
Scheduled maintenance 32
Minor troubleshooting guide 33
Capacities and specifications 36
Service points 38
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system or translation in whole or part is not permitted without written
authorization from Ford Motor Company.
Copyright
r1998 Ford Motor Company
Table of contents
1

The following warning may be required by California law:
California Proposition 65 Warning: Diesel engine exhaust, some
of its constituents, and certain vehicle components contain or
may emit chemicals known to the State of California to cause cancer or
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 Power Stroke (7.3L DIT) 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.
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 the ªQualified Vehicle Modifiers
Guidelines.º Using a Ford vehicle without theFord Ambulance
Preparation Packageto produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
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. Warnings remind you to
be especially careful to avoid personal injury.
Introduction
2

ECONOLINE
F-SERIES
F±250/350
F±450/550
0 1020304050
60
70
80
90
10 0
20 km/h
406080
10 0
12 0
14 0
H
L
16 0
MPH
000000
0000
18
8
WAIT
TO
START
WATER
IN
FUEL
FH
C
E
0
000000000
MPH20km/h
406080
100
120
140
160
010 20304050
60
70
80
90
100
WATER
IN
FUEL
WAIT
TO
STARTFUEL
RESET
ABSLEF
H
RPM1000X0 123
5
6 4
PRN 218C 18
H
D
FUEL FILL
0
000000000
MPH20km/h
406080
100
120
140
160
010 20304050
60
70
80
90
100WAIT
TO
START
WATER
IN
FUEL
LEF
H
RPM1000X0 123
5
6 4
PRN 218C 18
H
D
FUEL FILL
Warning lights
7

WAIT TO START
With the key in the ON position, the
WAIT TO START 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 to the
Startingchapter in this guide. 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 fuel filter/water separator 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 filter bowl.
Refer to theGeneral maintenancechapter for 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.
WAIT
TO
START
WATER
IN
FUEL
Warning lights
8

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
General maintenance information
26