Fueling FORD SUPER DUTY 2004 1.G Diesel Supplement Manual

Water in fuel
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 HFCM 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 HFCM. Refer
toDraining the HFCM and changing the fuel filtersin the
Maintenance and specificationssection of this supplement for the
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
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The condition should be verified by inspecting the underhood air filter
restriction gauge; the warning light is only a secondary indicator. Always
use the underhood air filter restriction gauge to determine when the air
filter element needs to be changed.
The vehicle may be driven with the engine air filter warning light
illuminated/or when the underhood air filter restriction gauge has moved
to the CHANGE FILTER mark for up to 400 km (250 miles) without
damaging the engine or related components. However, the air filter
element must be replaced at the earliest opportunity. Refer toAir filter
restriction gauge (if equipped)in this section of the supplement for
more information.
Instrumentation
7

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.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1 1/8 inch fuel dispensing nozzle.
Pumping fuel at greater flow rates may result in premature nozzle
shut-off or spitback.
HORIZONTAL FUEL CONDITIONING MODULE (HFCM)
(FUEL FILTER/WATER SEPARATOR)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission.
Maintenance and specifications
25

If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
Do not use starting fluid such as ether or gasoline in the Diesel
air intake system. Such fluids can cause immediate explosive
damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your Diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
MINOR TROUBLESHOOTING GUIDE
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or if
when the ignition is turned to START the lights become dim or go out,
the battery connections may be loose or corroded, or the battery may be
Maintenance and specifications
37