oil change FORD SUPER DUTY 2003 1.G 7.3L Diesel Engine Owners Manual

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
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•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
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4. When the engine starts, release the key. The glow plugs will continue
to be activated for up to two minutes. If the engine is not started before
the activation ceases, the glow plug system must be reset by turning the
ignition key to OFF.
5. After the engine starts, allow it to idle for about 15 seconds. (Do not
increase engine speed until the oil pressure gauge indicates normal
pressure.)
STOPPING THE ENGINE
Turn the ignition to OFF. To prolong engine life (after extended high
speed or maximum GVW operation), it is recommended that a hot engine
be allowed to operate at low idle for about 7–10 minutes which would
allow sufficient time for the turbocharged engine to cool down.
COLD WEATHER OPERATION
Changing to a lighter grade engine oil also makes starting easier under
these conditions. Refer toEngine Oil Specificationsin theGeneral
maintenance informationchapter.
At temperatures below–7°C (20°F), Number 2–D Diesel fuel may
thicken enough to clog the fuel filter. Your engine is equipped with a fuel
filter/heater/water/separator to keep the wax melted which will help
prevent fuel filter clogging. However, if the engine starts but stalls after a
short time and will not restart, the fuel filter may be clogged. For best
results in cold weather, use Number 1–D Diesel fuel or“winterized”
Number 2–D Diesel fuel which has an additive to minimize wax
formation.
Your vehicle is also equipped with a bypass relief valve, located on the
in-tank fuel sending unit, which provides fuel flow to the engine if the
fuel pickup should become plugged by ice or wax. To allow this bypass
valve to function and avoid engine fuel starvation, it is recommended
that, during cold weather operation 0°C (32°F) or below, the fuel level in
your tank should not be allowed to drop below 1/4 full. This will help
prevent air from entering the fuel system and stalling the engine.
In cold weather below 0°C (32°F) your Diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). The sound of the engine
may change also, as an exhaust device engages to improve heater
performance and reduce exhaust smoke.
Starting
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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.
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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.
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4. Protecting yourself from engine
heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
6. Maintain the oil level between ADD and OPERATING RANGE on the
dipstick by adding oil as required. The distance from ADD to
OPERATING RANGE on the dipstick represents 1.9L (2 quarts). Do not
overfill. If the oil level exceeds OPERATING RANGE, oil consumption
may result.
Engine oil specifications
To help achieve proper engine performance and durability, it is important
that only engine lubricating oils of the proper quality are used in your
Diesel engine and that the engine oil is changedno laterthan the
recommended interval. Diesel engines require specially formulated oil to
resist contamination. Proper quality oils also provide maximum efficiency
of the crankcase ventilating system which reduces air pollution.
For normal or severe service, use Motorcraft oil or an equivalent oil
conforming to Ford Specification WSS-M2C171–C or API Service
categories CH-4, CH-4/SJ, CH-4/SL or DHD-1. If CH-4 oil is not available,
CG-4 is acceptable.
Engine oils with improved fuel economy properties (energy conserving)
are currently available. If you use an energy conserving oil, be sure it
meets the recommended Ford Specification,APIservice categories and
SAE viscosity grades listed in the Lubricant and Maintenance Materials
Specifications chart. Some energy conserving oilsdo notmeet the
requirements necessary for your Diesel engine.
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* Heavy duty trailer towing with ambient temperatures above 10°C
(50°F) requires 15W-40 engine oil.
The use of correct oil viscosities for Diesel engines is important for
satisfactory operation. Determine which oil viscosity best suits the
temperature range you expect to encounter for the next service interval.
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 scheduled maintenance guide.
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
Engine Lubrication for Severe Service Operationfor 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“will fit”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.
APISERVICECH-4/SLSAE15W-40
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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.
Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
•towing a trailer over 1,600 km (1,000 miles)
•sustained, high speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation during hot
weather-above 32°C [90°F]).
•frequent or extended idling (over 10 minutes per hour of normal
driving).
•operating in severe dust conditions.
•frequent, 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:
•Change engine oil and filter every 5,000 km (3,000 miles).
•Use Motorcraft oil or an equivalent oil conforming to Ford
Specification WSS-M2C171–C or API categories CH-4, CH-4/SJ,
CH-4/SL or DHD-1. If CH-4 oil is not available, CG-4 is acceptable..
For more information refer theSevere Duty Maintenance Schedulein
the“Service Guide”.
REPLACING THE AIR FILTER ELEMENT
When replacing the air filter element, use the Motorcraft air filter
element listed. Refer toLubricant and Maintenance Materials
Specificationsin this supplement.
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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
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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 scheduled maintenance guide 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
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