FORD SUPER DUTY 2003 1.G 7.3L Diesel Engine Owner's Manual

F-350 Regular Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
7.3L All 9072 (20000) 5942 (13100)
4x2 with automatic transmission
7.3L All 9072 (20000) 5987 (13200)
4x4
7.3L All 9072 (20000) 5761 (12700)
F-350 Regular Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5806 (12800)
4x4
7.3L All 9072 (20000) 5579 (12300)
F-350 SuperCab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5806 (12800)
4x4 with manual transmission
7.3L All 9072 (20000) 5579 (12300)
4x4 with automatic transmission
7.3L All 9072 (20000) 5625 (12400)
Driving tips
21

F-350 SuperCab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5625 (12400)
4x4
7.3L All 9072 (20000) 5443 (12000)
F-350 Crew Cab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5715 (12600)
4x4 with manual transmission
7.3L All 9072 (20000) 5488 (12100)
4x4 with automatic transmission
7.3L All 9072 (20000) 5534 (12200)
F-350 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
7.3L All 9072 (20000) 5534 (12200)
4x2 with automatic transmission
7.3L All 9072 (20000) 5579 (12300)
4x4
7.3L All 9072 (20000) 5352 (11800)
Driving tips
22

F-450
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Regular Chassis Cab 4x2
7.3L All 11793 (26000) 8210 (18100)
Regular Chassis Cab 4x4
7.3L All 11793 (26000) 8074 (17800)
SuperCab Chassis Cab 4x2 with manual transmission
7.3L All 11793 (26000) 8029 (17700)
SuperCab Chassis Cab 4x2 with automatic transmission
7.3L All 11793 (26000) 8074 (17800)
SuperCab Chassis Cab 4x4 with manual transmission
7.3L All 11793 (26000) 7847 (17300)
SuperCab Chassis Cab 4x4 with automatic transmission
7.3L All 11793 (26000) 7893 (17400)
Crew Cab Chassis Cab 4x2
7.3L All 11793 (26000) 7938 (17500)
Crew Cab Chassis Cab 4x4
7.3L All 11793 (26000) 7802 (17200)
Driving tips
23

F-550
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Regular Chassis Cab 4x2
7.3L All 11793 (26000) 8165 (18000)
Regular Chassis Cab 4x4
7.3L All 11793 (26000) 8029 (17700)
SuperCab Chassis Cab 4x2
7.3L All 11793 (26000) 8029 (17700)
SuperCab Chassis Cab 4x4 with manual transmission
7.3L All 11793 (26000) 7802 (17200)
SuperCab Chassis Cab 4x4 with automatic transmission
7.3L All 11793 (26000) 7847 (17300)
Crew Cab Chassis Cab 4x2 with manual transmission
7.3L All 11793 (26000) 7893 (17400)
Crew Cab Chassis Cab 4x2 with automatic transmission
7.3L 4.88 11793 (26000) 7939 (17500)
7.3L 5.38 13608 (30000) 9752 (21500)
Crew Cab Chassis Cab 4x4
7.3L All 11793 (26000) 7756 (17100)
Driving tips
24

SCHEDULED MAINTENANCE
The Scheduled Maintenance Services in the scheduled maintenance
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.
CLEANING THE ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•The engine must be cool to the touch before spraying with water.
•Never spray a hot engine with cold water, as damage to the
engine block or engine components may occur.
•Use caution when using a self-serve power washer (1,000 psi
maximum pressure) to clean the engine, as the high-pressure fluid
could penetrate the sealed parts and cause damage.
•Never apply anything to any exposed belts in the engine
compartment, including the belt dressing.
For general cleaning of the engine and engine compartment, spray
Engine Shampoo (ZC-20) on all parts that require cleaning and pressure
rinse the area with cool water.
Cover the highlighted areas to prevent water damage when cleaning the
engine(never wash or rinse the engine while it is running; water
in the running engine may cause internal damage):
General maintenance information
25

•E-Series
•F-250/350/450/550 & Excursion
FUEL REQUIREMENTS
The engine is designed to use low sulfur number 1–Dor2–D Diesel fuel
only. At temperatures below -7°C (20°F), number 1–D or winter blend
number 2–D fuel is recommended. (SeeCold Weather Operationin the
Startingchapter.)
General maintenance information
26

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.
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 cetane
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
27

CHANGING FUEL FILTER
Removal—F-250/350/450/550 and Excursion
1. Remove the engine appearance
cover.
2. Remove the fuel filter cap by
turning counterclockwise.
3. Remove and discard old fuel filter
element and fuel filter o-ring.
4. Carefully clean the mating
surfaces.
Removal — E-Series
1. Remove the engine appearance cover.
2. Disconnect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for removal.
3. Release the four retaining clamps on the air cleaner assembly, then lift
the air cleaner cover and remove the air cleaner(s).
4. Loosen the clamp on the air inlet tube, then disconnect the air inlet
tube from the resonator.
5. Remove the three bolts on the turbocharger heat shield, then the
turbocharger heat shield.
6. Remove the bolt and resonator from the vehicle.
General maintenance information
28

7. Remove the fuel filter cap by
turning counterclockwise.
8. Remove and discard old fuel filter
element and fuel filter o-ring.
9. Carefully clean the mating
surfaces.
Installation—F-250/350/450/550 and Excursion
The engine will not run properly if the fuel filter is not installed
in housing.
1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring.
2. Install new fuel filter o-ring onto fuel filter element.
3. Install new fuel filter and o-ring into the fuel filter housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install engine appearance cover.
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.
Installation—E-Series
The engine will not run properly if the fuel filter is not installed
in housing.
General maintenance information
29

1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring.
2. Install new fuel filter o-ring onto fuel filter element.
3. Install new fuel filter and o-ring into the fuel filter housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install the resonator and resonator bolt.
6. Install the turbocharger heat shield, then the three bolts on the
turbocharger heat shield.
7. Connect the air inlet tube to the resonator, then tighten the clamp on
the air inlet tube.
8. Install the air cleaner(s), close the air cleaner cover, then close the
four retaining clamps on the air cleaner assembly.
9. Connect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for installation.
10. Install the engine appearance cover.
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 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 assure that the oil
contained in the upper parts of the engine has returned to the oil pan.
General maintenance information
30