fuel FORD SUPER DUTY 2006 1.G Diesel Supplement Manual

preparation package to produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
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 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 500 miles (800 km) before towing a
trailer.
Do not add friction modifier compounds or special break-in oils during
the first few thousand miles (kilometers) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•On F-Super Duty,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 thescheduled maintenance
informationin this supplement for more information.
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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 Specifications
chapter 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.
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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 theDrivingchapter 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.
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E-SERIES
F-SUPER DUTY STANDARD CLUSTER
F-SUPER DUTY OPTIONAL CLUSTER
MPHRPMX1000
km/h0 20406080
120 100140160
180L
H
E
F
DIESEL FUEL ONLY
TURBO
PSI
DPRND23
L
H
CH
SELECT/RESET
km/h11010090 80 70 50
40
30
20
10
060
2
1
0
020
40
3
4
5
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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
chapter 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.
Waterinfuel
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
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 Specificationschapter 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.
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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
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 250 miles (400 km) 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 chapter for more information.
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AIR FILTER RESTRICTION GAUGE (IF EQUIPPED)
The restriction gauge, located on
the upper housing of the air cleaner
assembly, measures the vacuum
inside the air cleaner. The more the
air cleaner is restricted (dirty,
clogged), the higher the vacuum
reading
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.
Change the air filter when the gauge reads 25 inches (635 mm). 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.
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STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F (0°C), 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
The engine block heater must be used for starting when the temperature
is -20°F (-29°C) or colder. Refer toUsing the engine block heater (if
equipped)in theDrivingchapter of theOwner’s Guide.
When operating in cold weather, use a minimum of 45 Cetane Diesel fuel
or use Cetane Index improvers from a reputable manufacturer.
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.
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1. Turn the key to 4 (ON) without
turning the key to 5 (START).Do
not start the engineuntil the
glow-plug pre-heat indicator
turns off.
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 Specificationschapter 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) 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.
3
2
1
5
4
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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
14full. 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,
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
Instrument Clusterchapter 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.
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