maintenance FORD SUPER DUTY 2007 1.G Diesel Supplement Manual

Introduction
2
Instrument Cluster
6
Driving
11
Roadside emergencies
19
Cleaning
25
Maintenance and Specifications
27
Scheduled Maintenance Guide
49
Normal scheduled maintenance and log 54
Exceptions 62
Special operating conditions and log 63
Motorcraft Premium Gold Coolant change record 68
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Copyright © 2006 Ford Motor Company
Table of Contents
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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
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 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 thescheduled maintenance
informationin this supplement for more information.
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Introduction
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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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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.
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
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.
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.
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GAUGES
Air filter restriction (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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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/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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Driving
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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 (out of view)
5. Power steering fluid reservoir
6. Brake fluid reservoir
7. Engine coolant reservoir
8. Air filter assembly
9. Engine oil dipstick
10. Power distribution box
The Fuel Conditioner Module (FCM) is located on the driver-side of the
vehicle next to the transmission case.
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F-Super Duty
1. Automatic transmission dipstick (if equipped)
2. Engine oil fill
3. Engine oil filter
4. Engine-mounted fuel filter assembly
5. Engine coolant reservoir
6. Brake fluid reservoir
7. Clutch fluid reservoir (if equipped)
8. Power distribution box
9. Battery (dual batteries shown)
10. Power steering fluid reservoir
11. Air filter assembly
12. Engine oil dipstick
13. Windshield washer fluid reservoir
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The Horizontal Fuel Conditioner Module (HFCM) is located on the
frame-rail under the driver-side floorboard near the transmission.
SCHEDULED MAINTENANCE
The scheduled maintenance services in thescheduled maintenance
information of this supplement are required because they are
considered essential to the life and performance of your vehicle.
Use only recommended fuel, lubricants, fluids and service parts
conforming to Ford specifications. Motorcraft parts are designed and
built for best performance in your vehicle.
FUEL REQUIREMENTS
Choosing the right fuel
The engine is designed to use either low sulfur (less than 500 parts per
million) number 1–D or 2–D Diesel fuel or ultra low sulfur diesel (less
than 15 parts per million) fuel only. If your vehicle has a label which
states that ultra low sulfur diesel fuel is required, you must put
ultra low sulfur diesel fuel in your vehicle.
Number 1–D or winter blend number 2–D fuel is recommended at
temperatures below 20°F (-7°C) (see Cold weather operationin the
Driving chapter of this supplement). Diesel fuel containing no more
than 5% of biodiesel may be used. Biodiesel fuel is a product derived
from renewable fuel sources such as vegetable oil, animal fat and cooking
oil. Since it is normal for a small amount of unburned fuel to enter the
crankcase and mix with the engine oil, the use of biodiesel requires that
the engine oil and filter be changed more often. Refer to the Exceptions
section of the Scheduled Maintenance Guide chapter for more
information.
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Do not use home heating oil or any diesel fuel not intended for
highway use. Red dye is used to identify fuels intended for
agricultural and non-highway use. Damage to the fuel injection
system, engine and exhaust catalyst can occur if an improper fuel
is used. Do not add gasoline, gasohol or alcohol to diesel fuel.
This practice creates a serious fire hazard and engine
performance problems.
Fuel Filler Cap
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise until it stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise until a few clicks are heard.
If the “Check Fuel Cap” message comes on and stays on after you start
the engine, the fuel filler cap may not be properly installed. Turn off the
engine, remove the fuel filler cap, align the cap properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Fuel quality
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated diesel fuel that meets the ASTM D
975 industry specification. Aftermarket additives can damage the injector
system or engine. Repairs to correct the effects of using an aftermarket
product in your fuel may not be covered by your warranty.
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