warning light FORD SUPER DUTY 2003 1.G 7.3L Diesel Engine Owners 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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Table of contents
1

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

Operation in snow
Vehicle operation in heavy snowfall or in dry loose snow that may swirl
around the front of the vehicle may feed excessive amounts of snow into
the air intake system. This could plug the air cleaner with snow and
cause the engine to stall.
Refer toAir filter restriction gaugein theDiesel informationchapter
and Engine air filter in theWarning lightschapter for more information.
Operation in standing water
Ingestion of water into the Diesel engine can result in immediate and
severe damage to the engine. If driving through water, slow down to
avoid splashing water into the intake. If the engine stalls, and ingestion
of water into the engine is suspected, do not try to restart the engine.
Consult your dealer for service immediately. Follow the cylinder
compression test procedure outlined in the Workshop Manual, then
check the engine oil for contamination.
Engine block heater (if equipped)
Refer to theStartingchapter in your Owner Guide.
Starting
12

Failure to use the correct air filter element may result in severe
engine damage.
1. Remove air filter element from the housing, taking care to prevent dirt
from falling into the engine air intake.
2. Clean the air filter housing and cover to ensure good sealing.
3. Install a new air filter element. Be careful not to crimp the filter edges
between the air filter housing and cover. This could cause damage to the
air filter element and possible severe damage to the engine.
When servicing the air filter, always be sure that the rubber
water drain hose is not kinked or obstructed. 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“V”of the engine.
•E-Series
•F-250/350/450/550, Excursion
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-4596 (Ford Part No.
F81Z-9N184–AA).
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 fuel filter/water separator. Fuel may ignite if separator is
drained while the engine is running or vehicle is moving.
General maintenance information
34