FORD E SERIES 2004 4.G 7.3L Diesel Supplement Manual

Introduction
2
Diesel information
4
Warning lights
8
Starting
10
Driving tips
13
General maintenance information
25
Scheduled maintenance
44
Minor troubleshooting guide
45
Capacities and specifications
48
Service points
50
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Copyright © 2002 Ford Motor Company
Table of contents
1

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.
Some aftermarket products may cause severe engine and/or
transmission damage. There are various manufacturers offering
devices to increase turbocharger boost, exhaust brakes to
increase stopping/hauling capacity or other such devices to
increase the power/torque of the 7.3L engine. Many owners’ past
experience with these products has been very poor. Severe
powertrain damage may result from the use of these aftermarket
products which will not be covered by the Ford warranty.
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 theQualified Vehicle Modifiers
Guidelines. 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.
Introduction
2

WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
WARNINGS
Throughout this guide, you will find warnings. Warnings remind you to
be especially careful to avoid personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,600 km (1,000 miles) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 800 km (500 miles) before towing a
trailer.
Do not add friction modifier compounds or special break-in oils during
the first few thousand kilometers (miles) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin theGeneral
Maintenance Informationchapter for more information on oil usage.
Introduction
3

DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•a frame-mounted electric fuel supply pump
•an engine mounted fuel filter/water separator
•a fuel restriction sensor
•a unit injector for each cylinder
The combination fuel filter/water separator removes both water and
impurities from the fuel. The filter should be changed at the
recommended service interval. Refer to the scheduled maintenance guide
for more information. The filter bowl should be drained at regular
intervals or when the WATER IN FUEL light illuminates in the
instrument cluster.
The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. The fuel pump
contains a pressure relief valve for overpressure protection in the event
of restricted flow.
Lubrication system
It is important to change the engine oil at the recommended service
intervals, because oil viscosity is important in maintaining the oil
pressure required to actuate the fuel injectors. Extended oil change
intervals can negatively affect engine performance and fuel economy.
Pressurized oil from the turbocharger is also used to actuate an exhaust
backpressure warm-up system (if equipped). Pressurized oil from the
turbocharger is routed to the exhaust backpressure actuator. During
exhaust backpressure operation, the engine’s sound will be altered and
you may notice a change in engine performance while it’s engaged. This
function occurs only during cold weather warm-up cycle.
Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug relay
Diesel information
4

•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is electronically controlled by the PCM. The PCM
energizes the glow plugs immediately after the ignition is placed in the
ON position, then determines how long the glow plugs will be on
according to the EOT and BARO sensors. The required time for the glow
plugs to be energized decreases as the engine oil temperature and
barometric pressure increase.
Engine cooling system
The cooling system contains an engine oil cooler which is mounted to
the side of the cylinder block. The cooler’s function is to regulate engine
oil temperature.
Engine governed speed
The engine governor is controlled by the PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
For maximum vehicle speed in various gears, refer toManual
transmission shift speedsin theDriving tipschapter. Do not exceed
3,600 rpm. Maximum engine governed speed is 3,000–4,000 rpm
depending on engine load. Excessive rpm can only be achieved by
manually downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause severe
engine damage.
Air filter restriction gauge, E-Series
The restriction gauge, located on
the clean-air side of the air cleaner
upper housing, shows if the air filter
is clogged. Refer toEngine
CompartmentinService points
chapter.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
5

The air filter element should be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when maximum restriction
is reached. After servicing the air
filter element, reset the restriction
gauge by pressing the button on the
end of the gauge.
Air filter restriction gauge, F-250/350/450/550 & Excursion
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
Engine CompartmentinService
Pointschapter.
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 toF-250/350/450/550, ExcursioninWarning
Lightschapter.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance. 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.
The air filter element must be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when the maximum
restriction is reached.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
6

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 kilometers (miles) of life remaining.
Always use the underhood air filter restriction gauge or engine
air filter warning light on the instrument cluster to determine
when the air filter element needs to be changed.
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 replace the air filter element, or remove the element and dry
it out. Reset the restriction gauge by pressing the button on the end of
the gauge.
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 theWarning Lightschapter.
Diesel information
7

E-SERIES
F–250/350/450/550, EXCURSION
WAIT TO START
•E-Series
•F-250/350/450/550, Excursion
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 theStartingchapter 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.
Warning lights
8

WATER IN FUEL
•E-Series
•F-250/350/450/550, Excursion
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.
ENGINE AIR FILTER (F-250/350/450/550 & EXCURSION)
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The vehicle may be driven with the engine air filter warning light
illuminated for up to 400 km (250 miles) without damaging the engine or
related components. However, the air filter elementmustbe replaced at
the earliest opportunity. Refer toAir filter restriction gaugein the
Diesel informationchapter for more information.
Warning lights
9

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 0°C (32°F), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission, make sure the
parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission, ensure the
gearshift lever is in P (Park) and the parking brake is set before you turn
the key. Do not press the accelerator during starting.
COLD WEATHER STARTING
Do not crank the engine for more than 30 seconds at a time as starter
damage may occur. If the engine fails to start, turn the key to OFF and
wait 30 seconds before trying again.
Do not use starting fluid such as ether in the air intake system (see Air
Cleaner Decal). Such fluid could cause immediate explosive damage to
the engine and possible personal injury.
Do not add gasoline, gasohol or alcohol to Diesel fuel. This practice
creates a serious fire hazard and causes engine performance problems.
1. Make sure all vehicle occupants have buckled their safety belts. For
more information on safety belts and their proper usage, refer toSeating
and safety restraintschapter in the owner guide.
2. Make sure the headlamps and vehicle accessories are off.
3. Turn the key to the ON position. When the WAIT TO START light
goes off, turn the key to START. (For Canadian vehicles, the daytime
running lamps will be on if the parking brake is not applied and the key
is turned to ON.)
•E-Series
•F-250/350/450/550, Excursion
Starting
10