coolant reservoir FORD SUPER DUTY 2003 1.G 7.3L Diesel Engine Owners Manual

Rotunda Battery and Antifreeze Tester, 014–R1060). The level of coolant
should be maintained at the“cold full”of“cold fill range”level in the
coolant reservoir. If the level falls below, add coolant per the instructions
in theAdding Engine Coolantsection.
Your vehicle was factory-filled with a 50/50 engine coolant and water
concentration. If the concentration of coolant falls below 40% or above
60%, the engine parts could become damaged or not work properly.A
50–50 mixture of coolant and water provides the following:
•freeze protection down to -36°C (-34°F).
•boiling protection up to 129°C (265°F).
•protection against rust and other forms of corrosion.
•enables calibrated gauges to work properly.
When the engine is cold, check the level of the engine coolant in the
reservoir.
•The engine coolant should be at the“cold fill level”or within the“cold
fill range”as listed on the engine coolant reservoir (depending upon
application).
•Refer to the scheduled maintenance guide for service interval
schedules.
•Be sure to read and understandPrecautions when servicing your
vehiclein your owner guide.
If the engine coolant has not been checked at the recommended interval,
the engine coolant reservoir may become low or empty. If the reservoir is
low or empty, add engine coolant to the reservoir. Refer toAdding
engine coolantin this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant, antifreeze or windshield washer fluid outside of its specified
function and vehicle location.
Vehicles with Diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors cause the additives in the
coolant to“wear out”in a shorter time. For vehicles equipped with green
coolant, 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-16 to the
cooling system. For vehicles with extensive idling time, add 237–295 ml
(8–10 oz.) of coolant additive FW-16 after every 500 hours of operation.
(see scheduled maintenance guide). For vehicles equipped with yellow
coolant (Extended Life Coolant), the service interval is five years or
General maintenance information
37

100,000 miles and three years or 50,000 miles thereafter. Vehicles
equipped with the Extended Life Coolant do not require any additives.
Adding engine coolant
When adding coolant, make sure it is a 50/50 mixture of engine coolant
and distilled water. Add the mixture to the coolant reservoir,when the
engine is cool, until the appropriate fill level is obtained.
Do not add engine coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
Do not put engine coolant in the windshield washer fluid
container. If sprayed on the windshield, engine coolant could
make it difficult to see through the windshield.
The cooling system in your vehicle is filled with either green-colored
Motorcraft Premium Engine Coolant meeting Ford specification
ESE-M97B44–A or yellow-colored Motorcraft Premium Gold Engine
Coolant meeting Ford Specification WSS-M97B51–A1. To determine your
vehicle’s coolant type (color), check your coolant reservoir.
•Add Motorcraft Premium Engine Coolant (green-colored),
VC-4–A (U.S.) or CXC-10 (Canada) or Motorcraft Premium
Gold Engine Coolant (yellow-colored), VC-7–A, depending on
the type of coolant originally equipped in your vehicle.If you
are unsure which type of coolant your vehicle requires, check your
coolant reservoir or contact your local dealer.
•Do not add/mix an orange-colored, extended life coolant such
as Motorcraft Speciality Orange Engine Coolant, VC-2 (US) or
CXC-209 (Canada), meeting Ford specification WSS-M97B44–D
with the factory-filled coolant.Mixing Motorcraft Speciality Orange
Engine Coolant or any orange-colored extended life product with your
factory filled coolant can result in degraded corrosion protection.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
General maintenance information
38

•Do not use alcohol, methanol or brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
•Do not mix with recycled coolant unless from a Ford-approved
recycling process (seeUse of Recycled Engine Coolantsection).
For vehicles with overflow coolant systems with a non-pressurized cap
on the coolant recovery system, add coolant to the coolant recovery
reservoir when the engine is cool. Add the proper mixture of coolant and
water to the“cold full”level. For all other vehicles, which have a coolant
degas system with a pressurized cap, or if it is necessary to remove the
coolant pressure relief cap on the radiator of a vehicle with an overflow
system, follow these steps to add engine coolant.
To reduce the risk of personal injury, make sure the engine is
cool before unscrewing the coolant pressure relief cap. The
cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly.
1. Before you begin, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the coolant
pressure relief cap on the coolant reservoir (an semi-clear plastic bottle).
Slowly turn cap counterclockwise (left) until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
5. Fill the coolant reservoir slowly with the proper coolant mixture (see
above), to within the“cold fill range”or the“cold full”level on the
reservoir. If you removed the radiator cap in an overflow system, fill the
radiator until the coolant is visible and radiator is almost full.
6. Replace the cap. Turn until tightly installed. (Cap must be tightly
installed to prevent coolant loss.)
After any coolant has been added, check the coolant concentration see
Checking Engine Coolantsection). If the concentration is not 50/50
(protection to–34°F/–36°C), drain some coolant and adjust the
concentration. It may take several drains and additions to obtain a 50/50
coolant concentration.
General maintenance information
39

Whenever coolant has been added, the coolant level in the coolant
reservoir should be checked the next few times you drive the vehicle. If
necessary, add enough 50/50 concentration of engine coolant and
distilled water to bring the liquid level to the proper level.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant per
month, have your dealer check the engine cooling system. Your cooling
system may have a leak. Operating an engine with a low level of coolant
can result in engine overheating and possible engine damage.
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 (refer to the scheduled maintenance guide), or due to
service performed, adhere to the following instructions:
1. Drain and flush the cooling system to remove dirt deposits, oil, rust
particles.
Note:When filling the system with Motorcraft Premium Engine Coolant
(green-colored) or equivalent meeting Ford specification
ESE-M97B44–A, a supplemental coolant additive is required. Refer to
Adding Coolantsection to determine the coolant type in your vehicle.
Add 1.89L (4 pints) of Motorcraft Heavy Duty Cooling System Additive
FW-16 or equivalent meeting Ford specification ESN-M99B169–A,
directly to the cooling system. An additional 237–295 ml (8–10 oz.) of
supplemental coolant additive FW-16 should be added at 24,000 km
(15,000 mile) intervals to maintain proper concentration.Do not use
this additive with yellow-colored coolant meeting Ford
specification WSS-M97B51–A1.
2. 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 coolant bottle to the cold fill mark.
3. Reinstall the coolant bottle cap.
4. 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.
5. Immediately shut off engine. Allow engine to cool before removing
coolant bottle cap. Cautiously remove coolant bottle cap and add coolant
to Cold Fill mark.
General maintenance information
40

Recycled engine coolant
Ford Motor Company recommends the use of a recycled engine coolant
produced by Ford-approved processes in vehicles originally equipped
with Motorcraft Premium Engine Coolant (green-colored). However, not
all coolant recycling processes produce coolant that meets Ford
specification ESE-M97B44–A. Use of such coolant may harm the engine
and cooling system components.
Ford Motor Company does NOT recommend the use of recycled engine
coolant in vehicles originally equipped with Motorcraft Premium Gold
Engine Coolant since a Ford-approved recycling process is not yet
available.
Used engine coolant should be disposed of in an appropriate
manner. Follow your community’s regulations and standards for recycling
and disposing of automotive fluids.
Coolant refill capacity
To find out how much fluid your vehicle’s cooling system can hold, refer
toRefill capacitiesin this chapter.
Fill your engine coolant reservoir as outlined inAdding engine coolant.
Severe climates
If you drive in extremely cold climates (less than–36°C[–34°F]):
•it may be necessary to increase the coolant concentration
above 50%.
•NEVER increase the coolant concentration above 60%.
•increased engine coolant concentrations above 60% will
decrease the overheat protection characteristics of the engine
coolant and may cause engine damage.
•refer to the chart on the coolant container to ensure the
coolant concentration in your vehicle will provide adequate
freeze protection at the temperatures in which you drive in the
winter months.
If you drive in extremely hot climates:
•it is still necessary to maintain the coolant concentration
above 40%.
•NEVER decrease the coolant concentration below 40%.
•decreased engine coolant concentrations below 40% will
decrease the corrosion protection characteristics of the engine
coolant and may cause engine damage.
General maintenance information
41

E-SERIES ENGINE COMPARTMENT
1. Battery
2. Windshield washer fluid reservoir
3. Engine oil dipstick
4. Fuel filter/water separator drain valve release handle
5. Automatic transmission fluid dipstick
6. Air filter assembly
7. Engine oil filler
8. Air filter restriction gauge
9. Power steering fluid reservoir
10. Brake fluid reservoir
11. Engine coolant recovery reservoir
1
2345678910
11
Service points
50

F-SERIES AND EXCURSION ENGINE COMPARTMENT
1. Battery (dual batteries shown)
2. Engine coolant recovery reservoir
3. Engine oil filler
4. Engine oil dipstick
5. Automatic transmission dipstick (if equipped)
6. Fuel filter drain valve
7. Clutch fluid reservoir (if equipped)
8. Brake fluid reservoir
9. Air filter restriction gauge
10. Air filter assembly
11. Power steering fluid reservoir
12. Windshield washer fluid reservoir
Service points
51