engine FORD SUPER DUTY 2005 1.G Diesel Supplement Manual

2. When the glow plug pre-heat
indicator 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 indicator
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.
STOPPING THE ENGINE
Turn the ignition to 3 (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 Specificationssection of this supplement.
At temperatures below 20°F(–7°C), Number 2–D diesel fuel may thicken
enough to clog the fuel filter. Your vehicle is equipped with either an
FCM (E-Series) or an HFCM (F-Super Duty and Excursion) 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 32°F(0°C) or below, the fuel level in your
tank should not be allowed to drop below
1⁄4full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C) your diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). As the engine warms-up,
Driving
13

the engine sound level will decrease due to the activation of
PCM-controlled sound reduction features.
If your vehicle is operated in a heavy snow storm or blowing snow
conditions, the engine air induction may become partially clogged with
snow and/or ice. If this occurs, the engine may experience a significant
reduction in power output. At the earliest opportunity, clear all the snow
and/or ice away from the air induction inlet.
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 and/or lose power.
Refer toAir filter restriction gaugeandEngine air filterin the
Instrumentationsection of this supplement 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.
Engine block heater (if equipped)
Refer to theDrivingchapter in theOwner’s Guide.
DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED)
If your vehicle is equipped with dual
fuel tanks, you will have a selector
control, located to the right of the
steering wheel, which allows you to
draw fuel from either tank. Your fuel
gauge will display the amount of
fuel in the currently selected tank.
Fuel level indication is delayed for several minutes when the tank
selector switch is actuated. Fuel level indication can be obtained
immediately by turning off and restarting the engine.
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14

TRAILER TOWING
Refer to yourOwner’s Guidefor full details on towing a trailer.
Trailer towing tables - E-Series
Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
E-350 Regular Van (9500 GVWR)
6.0L 3.55 16000 (7257) 9700 (4400)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Van (Crew) (9500 GVWR)
6.0L 3.55 16000 (7257) 9400 (4264)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Van (9400 GVWR)
6.0L 3.55 16000 (7257) 9500 (4309)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Van (Crew) (9400 GVWR)
6.0L 3.55 16000 (7257) 9300 (4218)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (7–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (8–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (12–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Wagon (12–passenger) (9300 GVWR)
6.0L 3.55 16000 (7257) 9000 (4082)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Wagon (15–passenger) (9400 GVWR)
6.0L 3.55 16000 (7257) 9000 (4082)
6.0L 4.10 20000 (9072) 10000 (4536)
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Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
E-350 Cutaway 138”wheelbase, single rear wheel) (9600
GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 138”wheelbase, dual rear wheel) (10700 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 158”wheelbase, dual rear wheel) (11500 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176”wheelbase, dual rear wheel) (11500 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-450 Cutaway 158”wheelbase) (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176”wheelbase) (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
Trailer towing tables - Excursion & F-Super Duty
Excursion
Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
4x2
6.0L 3.73 20000 (9072) 11000 (4988)
4x4
6.0L 3.73 20000 (9072) 11000 (4988)
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F-Super Duty
Maximum GCWR - lbs (kg.)
Engine Rear axle
ratioManual
transmissionAutomatic
transmission
F–250/F–350 Single Rear Wheel (SRW)
6.0L 3.73 23000 (10433) 23000 (10433)
F–350 Dual Rear Wheel (DRW)
6.0L 3.73 23500 (10659) 23500 (10659)
4.10 23500 (10659) 23500 (10659)
F–450
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 30000 (13608)
F–550
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 33000 (14969)
*With high capacity trailer tow package, see rear axle label to identify
actual vehicle content.
Integrated hitch rating
The standard integrated hitch has two ratings depending on mode of
operation:
•Weight carrying- requires a draw bar and hitch ball. The draw bar
supports all the vertical tongue load of the trailer.
•Weight distributing- requires an aftermarket weight distributing
system which includes draw bar, hitch ball, spring bars and snap-up
brackets. The vertical tongue load of the trailer is distributed between
the truck and the trailer by this system.
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17

JUMP STARTING YOUR VEHICLE (E-SERIES ONLY)
F-Super Duty and Excursion vehicles equipped with the 6.0L
diesel engine can be jump started using the same procedure as a
gasoline engine; refer to yourOwner’s guidefor the jump starting
procedure.
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which can burn skin, eyes and
clothing, if contacted.
Do not attempt to push-start your vehicle. Automatic
transmissions do not have push-start capability; doing so may
damage the catalytic converter.
Preparing your vehicle
When the batteries are disconnected or new batteries are installed, the
transmission must relearn its shift strategy. As a result, the transmission
may have firm and/or soft shifts. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation
1.Use only a 12–volt supply to start your vehicle.
2. Do not disconnect the batteries of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the passenger side of the disabled
vehicle making sure the two vehiclesdo nottouch. Set the parking
brake on both vehicles.
Note:This vehicle has two frame-mounted batteries located on the
passenger side frame rail, behind the front passenger door. A battery
positive (+) jumper stud is located on the frame rail behind the rear
most battery box.
Roadside emergencies
Roadside emergencies
19

4. Make the final connection of the negative (-) cable to an exposed
metal part of the disabled vehicle’s frame or chassis, away from the
batteries.Do notuse fuel lines, brake lines, exhaust components or the
battery trays asgroundingpoints.
Do not connect the end of the second cable to the negative (-)
terminal of the battery to be jumped. A spark may cause an
explosion of the gases that surround the battery.
5. Ensure that the cables are clear of moving parts or any fuel delivery
system, brake system or exhaust system parts.
Jump starting
1. Start the engine of the booster vehicle and run the engine at
moderately increased speed.
2. Start the engine of the disabled vehicle.
3. Once the disabled vehicle has been started, run both engines for an
additional three minutes before disconnecting the jumper cables.
Roadside emergencies
22

3. Remove the jumper cable from the positive (+) terminal of the booster
vehicle’s battery.
4. Remove the jumper cable from the positive (+) jumper stud of the
disabled vehicle. Reinstall the cap onto the jumper stud.
After the disabled vehicle has been started and the jumper cables
removed, allow it to idle for several minutes so the engine computer can
relearnits idle conditions.
Roadside emergencies
24

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
Cleaning
Cleaning
25

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
E-Series
1. Windshield washer fluid reservoir
2. Automatic transmission dipstick
3. Engine oil filler cap
4. Secondary fuel filter assembly
5. Power steering fluid reservoir
6. Brake fluid reservoir
7. Engine coolant reservoir
8. Air filter assembly
The Fuel Conditioner Module (FCM) is located on the driver-side of the
vehicle next to the transmission case.
Maintenance and Specifications
Maintenance and Specifications
27