light FORD SUPER DUTY 2004 1.G Diesel Supplement Manual

overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with theFord Ambulance Preparation
Package,inspect the information plate on the driver’s side door pillar.
Contact the manufacturer of your vehicle to determine whether the
ambulance manufacturer’s followed Ford’s recommendations.
WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,600 km (1,000 miles) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 800 km (500 miles) before towing a
trailer.
Do not add friction modifier compounds or special break-in oils during
the first few thousand kilometers (miles) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and specificationssection for more information on oil
usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•an engine-mounted secondary fuel filter
•frame-mounted Horizontal Fuel Conditioner Module (HFCM)
•a unit injector for each cylinder
The HFCM acts as a primary fuel filter/water separator which removes
both water and impurities from the fuel. The engine-mounted fuel filter
and the HFCM filter should be changed at the recommended service
interval. Refer to theGeneral Owner’s Informationsection of this
supplement for more information.
The HFCM should be drained at
regular intervals or when the
WATER IN FUEL light illuminates in
the instrument cluster.
Introduction
3

EXCURSION & F-SUPER DUTY (EXCEPT HARLEY-DAVIDSON)
F-SUPER DUTY HARLEY-DAVIDSON
Glow plug pre-heat indicator
With the key in the ON position,
the
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 toCold weather startingin theDriving
section of this supplement. 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.
Instrumentation
6

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

Air filter restriction gauge (if equipped)
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
Maintenance and specifications
chapter.
•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 to theEngine air filterwarning light in this
section of the supplement.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance at least every 12,000 km (7,500
miles). 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.
Instrumentation
8

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.
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 to
determine when the air filter element needs to be changed. The
warning light on the instrument cluster should not be used
exclusively for determining when the air filter element needs
changing.
Instrumentation
9

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 reset the restriction gauge by pressing the button on the end
of the gauge. If the air filter restriction gauge moves the CHANGE
FILTER mark after clearing snow and/or ice, then replace the filter.
Reset filter restriction gauge after changing the air filter element.
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 theEngine air filterwarning light in this
section of the supplement.
Instrumentation
10

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 0°C (32°F), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission, make sure the
parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission, ensure the
gearshift lever is in P (Park) and the parking brake is set before you turn
the key. Do not press the accelerator during starting.
COLD WEATHER STARTING
Do not crank the engine for more than 30 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (OFF) and wait
30 seconds before trying again.
Do not use starting fluid, such as ether, in the air intake system
(see air cleaner decal). Such fluid could cause immediate
explosive damage to the engine and possible personal injury.
Note:Do not add gasoline, gasohol or alcohol to Diesel fuel. This
practice creates a serious fire hazard and causes engine performance
problems.
1. Turn the key to 4 (ON) without
turning the key to 5 (START).Do
not start the engineuntil the
glow-plug pre-heat light
turns
off.3
2
1
5
4
Driving
Driving
11

2. When the glow plug pre-heat light
turns off, turn the key to 5
(START), then release the key as
soon as the engine starts. The glow
plugs will continue to be activated for two minutes after the glow plug
pre-heat light
has turned off. If the engine is not started before the
glow plug activation time ends, the glow plugs will need to be reset by
turning the key to 3 (OFF).
3. 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.
Note:If the engine does not start within five seconds on the first try,
turn the key to 3 (OFF), wait 10 seconds and try again. If the engine still
fails to start, press the accelerator to the floor and try again; this will
allow the engine to crank with the fuel shut off in case the engine is
flooded with fuel.
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 theMaintenance
and specificationschapter.
At temperatures below–7°C (20°F), Number 2–D Diesel fuel may
thicken enough to clog the fuel filter. Your vehicle is equipped with an
HFCM which acts as 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(s)
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
fuel control module, 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
Driving
12

ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
•Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
•Cover the highlighted areas to prevent water damage when cleaning
the engine.
•F–Super Duty/Excursion 6.0L Diesel engine
Cleaning
Cleaning
22

Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 100 cc (0.2 pints) of water accumulates in the module.
Replace the fuel filters with Ford Part No. 3C3Z-9N184–CA. This part
number includes filters and seals for both the engine-mounted and
frame-mounted filters.
DRAINING THE HFCM AND CHANGING THE FUEL FILTERS
Your vehicle is equipped with two fuel filters; one mounted on top of the
engine and the other, the HFCM, mounted inside the frame rail under
the driver-side floorboard near the transmission. Both filters should be
replaced at the same time. The Motorcraft part number for the
replacement filters is FD-4604.
HFCM drain procedure
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the HFCM. Fuel may ignite if separator is drained while the
engine is running or vehicle is moving.
2. Locate the HFCM and place an
appropriate container under the
drain plug (see illustration).
3. Remove the drain plug, using a 6mm hex drive, by turning it
counterclockwise. Allow the HFCM to drain for approximately 25 seconds
or until clean fuel is observed. Install the drain plug by turning it
clockwise until it is firmly seated.
4. Verify that the drain plug is closed and sealed, then remove the
container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light; it
should not be illuminated. If it continues to illuminate, have the fuel
system checked and repaired.
Maintenance and specifications
26