FORD SUPER DUTY 2005 1.G Diesel Supplement Manual

Introduction
2
Instrumentation
6
Driving
12
Roadside emergencies
19
Cleaning
25
Maintenance and Specifications
27
General Owner’s Information
50
Normal Scheduled Maintenance and Log 54
Exceptions 64
Special Operating Conditions and Log 65
Motorcraft Premium Gold Coolant Change Record 69
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Copyright © 2004 Ford Motor Company
Table of Contents
1
Table of Contents

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
Your new diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the 6.0L Power Stroke diesel engine. It
provides recommendations on engine care and operating procedures. For
complete vehicle information, also refer to theOwner’s Guideincluded
with the vehicle. It also describes equipment and gives specifications for
equipment that was in effect when this guide was approved for printing,
and should be considered a permanent part of the vehicle.
Some aftermarket products may cause severe engine and/or
transmission damage. There are various manufacturers offering
devices to increase turbocharger boost, exhaust brakes to
increase stopping/hauling capacity or other such devices to
increase the power/torque of the Power Stroke engine. Many
owners’ past experience with these products has been very poor.
Severe powertrain damage may result from the use of these
aftermarket products which will not be covered by the Ford
warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if equipped
with the Ford ambulance preparation package. In addition, Ford urges
ambulance manufacturers to follow the recommendation of theFord
Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book
(and pertinent supplements) and theQualified Vehicle Modifiers
Guidelines. Using a Ford vehicle without the Ford ambulance
preparation package to produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
Introduction
Introduction
2

overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with the Ford 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 of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•On F-Super Duty and Excursion vehicles,a frame-mounted
Horizontal Fuel Conditioner Module (HFCM)
•On E-Series vehicles,a Fuel Conditioner Module (FCM) mounted on
the driver-side of the transmission case
•an engine-mounted secondary fuel filter
•a unit injector for each cylinder
The FCM/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 FCM/HFCM filter should be changed at the
recommended service interval. Refer to theGeneral Owner’s
Informationsection of this supplement for more information.
Introduction
3

The FCM/HFCM 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) and Fuel Injection Control Module (FICM).
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, fuel economy and
engine life. Refer to the engine oil specification chart located under
Engine oil specificationsin theMaintenance and Specifcations
section of this supplement.
Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM 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.
Introduction
4

Engine cooling system
The cooling system contains an engine oil cooler which is mounted in the
center valley of the engine. 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.
On F-Super Duty vehicles equipped with a manual transmission,
refer toManual transmission shift speedsin theDrivingsection of
yourOwner’s Guidefor maximum vehicle speed in various gears. Do not
exceed 3,600 rpm. Maximum engine governed speed is 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.
Introduction
5

E-SERIES
EXCURSION
F-SUPER DUTY (EXCEPT HARLEY-DAVIDSON)
C
H
LH
E
F
CHSELECT
RESET
RPMX1000
DIESEL FUEL ONLYP R N 3 2 1D
TOW
HAULMPHKM/H020406080
00
20
40
60
Instrumentation
Instrumentation
6

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.
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 FCM/HFCM has a significant
quantity of water in it.
Type A
Instrumentation
7

Type B
Type C
If the light illuminates when the engine is running, stop the vehicle as
soon as safely possible, shut off the engine, then drain the FCM/HFCM.
Refer toDraining the FCM/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 (if equipped)
The engine air filter warning light illuminates when the air filter
restriction gauge reaches the CHANGE FILTER mark.
Type A
Type B
Type C
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.
Instrumentation
8

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.
Transmission Tow/Haul Feature
(if equipped):Illuminates when
the Tow/Haul feature has been
selected. Refer to theDriving
chapter for transmission function and operation. If the light flashes
steadily or does not illuminate, have the transmission serviced soon, or
damage may occur.
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
section of this supplement.
•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 the
Engine 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 7,500 miles (12,000
km). If the vehicle is operated in extremely dusty conditions, check the
gauge at least every 500 miles (800 km), or two weeks, whichever comes
first.
AIRFILTERRESTAA
CHANGE FILTER
PUSH BUTTON RESET75%
50%65%
Instrumentation
9

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 miles
(kilometers) 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.
AIRFILTERRESTAA
CHANGE FILTER
PUSH BUTTON RESET75%
50%65%
Instrumentation
10