service interval FORD SUPER DUTY 2007 1.G Diesel Supplement Manual

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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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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2. Remove and discard the old fuel filter element.
3. Carefully clean the mating surfaces.
Installation - both
The engine will not run properly if the fuel filter is not installed
in housing.
1. Install the new fuel filter and cap seal (Motorcraft Part No. FD-4604,
F-Series and FD-4606, E-Series) into the fuel filter housing.
2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run roughly and smoke until the air
is completely eliminated.
Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
ENGINE OIL
Checking the engine oil level
Because it is normal to add some oil between oil changes, check your
engine oil level each time you stop for fuel. To check the engine oil level
consistently and accurately, the following procedure is recommended:
1. Have engine at normal operating temperature (at least into the
NORMAL range on the engine coolant temperature gauge).
2. Park the vehicle on a level surface, then turn off the engine and open
the hood.
3. Allow at least20 minutesafter engine shutdown to ensure that the
oil contained in the upper parts of the engine has returned to the oil
pan.
4. Protecting yourself from engine heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
6. Maintain the oil level between MIN and MAX or the ADD and
OPERATING RANGE on the dipstick by adding oil as required. The
distance from MIN to MAX or ADD to OPERATING RANGE on the
dipstick represents 2.0 quarts (1.9L). Do not overfill. If the oil level
exceeds MAX or OPERATING RANGE, oil consumption may result.
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Engine oil specifications
To help achieve proper engine performance and durability, it is important
that only engine lubricating oils of the proper quality are used in your
diesel engine and that the engine oil is changedno laterthan the
recommended interval. Diesel engines require specially formulated oil to
resist contamination. Proper quality oils also provide maximum efficiency
of the crankcase ventilating system which reduces air pollution.
For normal or severe service, use Motorcraft oil or an equivalent oil
conforming to Ford Specification WSS-M2C171–D or API Service
categories CI-4 PLUS, CI-4/SL or DHD-1. If CI-4 PLUS oil is not available
CI-4 or CH-4 is acceptable.
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Engine oils with improved fuel economy properties (energy conserving)
are currently available. If you use an energy conserving oil, be sure it
meets the recommended Ford Specification,APIservice categories and
SAE viscosity grades listed in theLubricant Specificationschart later
in this chapter. Some energy conserving oilsdo notmeet the
requirements necessary for your diesel engine.
The use of correct oil viscosities for diesel engines is important for
satisfactory operation. From the following SAE viscosity grade chart,
determine which oil viscosity best suits the temperature range you
expect to encounter for the next service interval.
*15W-40 recommended for trailer towing.
A symbol has been developed by the
American Petroleum Institute (API)
to help you select the proper engine
oil. It will be included on the oil
container you purchase. The top
section of the symbol shows the oil
performance by the API designation.
This should match the owner guide recommendation. The center section
will show the SAE viscosity grade. The lower section will state energy
conserving if the oil has proven fuel saving capabilities.
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SCHEDULED MAINTENANCE GUIDE
VEHICLE IDENTIFICATION NUMBER (VIN):
OWNER NAME:
ADDRESS:
GENERAL MAINTENANCE INFORMATION
Why maintain your vehicle?
This guide describes the scheduled maintenance required for your
vehicle. Carefully following this schedule helps protect against major
repair expenses resulting from neglect or inadequate maintenance and
may also help to increase the value of your vehicle when you sell or
trade it.
It is your responsibility to see that all scheduled maintenance is
performed and that the materials used meet Ford engineering
specifications. Failure to perform scheduled maintenance in this guide
will invalidate warranty coverage on parts affected by the lack of
maintenance. Be sure receipts for completed maintenance are kept with
the vehicle and confirmation of the work performed is always recorded in
this guide.
Your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Quality
Care Center has factory trained technicians who can perform the
required maintenance using genuine Ford parts. They are committed to
meeting your service needs and to assuring your continuing satisfaction.
Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To ensure the proper
performance of your vehicle and its emission control systems, it is
imperative that scheduled maintenance be completed at the designated
intervals.
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Your vehicle is very sophisticated and built with multiple complex
performance systems. Every manufacturer develops these systems using
different specifications and performance features. That’s why it’s
important to rely upon your Ford or Lincoln Mercury dealership to
properly diagnose and repair your vehicle.
Ford Motor Company has recommended maintenance intervals for
various parts and component systems based upon engineering testing.
Ford Motor Company relies upon this testing to determine the most
appropriate mileage for replacement of oils and fluids to protect your
vehicle at the lowest overall cost to you and recommends against
maintenance schedules that deviate from the scheduled maintenance
information.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraft or Ford authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult yourWarranty Guidefor complete warranty information.
Non-Ford approved chemicals or additives are not required for factory
recommended maintenance. In fact, Ford Motor Company recommends
against the use of such additive products unless specifically
recommended by Ford for a particular application.
Oils, Fluids and Flushing
In many cases, fluid discoloration is a normal operating characteristic of
the chemical compound and may not necessarily demonstrate that a fluid
needs to be changed. Oils and fluids identified in this guide should be
changed at the specified interval or in conjunction with a repair. Flushing
is a viable way to change fluid for many vehicle sub-systems during
scheduled maintenance and should only be done using the same fluid
required to finish the maintenance procedure, or a Ford approved
flushing chemical.
Engine Emissions label
Emissions information appears on the Engine Emissions label on the
engine valve cover. This decal identifies engine displacement and
provides certain engine specifications.
Any modification of the emissions control system could create liability
under federal law (U.S.) if made prior to sale and registration, under the
laws of some states if made thereafter. Further, federal law prohibits
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•All Wheel Drive and4X4
•Automatic Transmission
•Engine Cooling and Cabin Heating
•Steering and Suspension
•Charge/Start/Battery
•Wheel Alignment
•Anti-Lock Brake System
Genuine Ford and Motorcraft Replacement Parts
Ford and Lincoln Mercury dealerships stock Ford and Motorcraft
branded replacement parts. These parts meet or exceed Ford Motor
Company’s specifications, and we stand behind them. Maintenance parts
installed at your Ford or Lincoln Mercury dealership carry a nationwide,
12 months, 12,000 mile (20,000 km) parts and labor limited warranty.
Your dealer can give you details.
Value Shopping for Your Vehicle’s Maintenance Needs
Your dealership recognizes the competitive landscape of maintenance and
light repair automotive services. With factory-trained technicians, and
one-stop service from routine maintenance like oil changes and tire
rotations to repairs like brake service, check out the value your Ford and
Lincoln Mercury dealers can offer.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed
by the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in theOwner’s
Guide.
Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
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Multi-point Inspection
In order to keep your vehicle running right, it is important that you have
the systems on your vehicle checked regularly. This can help identify any
potential issue before there are any problems. Ford Motor Company
suggests the following multi-point inspection to be performed at every
scheduled maintenance interval as the way to ensure your vehicle keeps
running right.
NORMAL SCHEDULED MAINTENANCE AND LOG
The following section contains the “Normal Schedule.” This schedule is
presented at specific mileage intervals with exceptions noted.
Additional information available on the Web
To learn more about the importance of routine and dealer-performed
maintenance on your vehicle, please visit the Ford Customer Service
website. You’ll also find important warranty information, customer
assistance, technical expertise, frequently asked questions and much
more. The website location is at: www.ford.com/
Then go to the vehicles and service pick at the web site.
Multi-point inspection - recommended at every visit
❑Check and top up fluid levels:❑brake
❑coolant recovery reservoir
❑manual and automatic transmission
❑power steering
❑window washer
❑Inspect tires for wear and check air pressure, including spare.
❑Check exhaust system for leaks, damage, loose parts and foreign materials.
❑Check battery performance.
❑Check operation of horn, exterior lamps, turn signals and hazard warning lights.
❑Check radiator, coolers and heater and air conditioning hoses.
❑Inspect windshield washer spray and wiper operation.
❑Check windshield for cracks, chips and pitting.
❑Inspect for oil and fluid leaks.
❑Inspect air cleaner filter.
❑Check shocks and struts and other suspension components for leaks and damage.
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Exceptions
In addition, there are several exceptions to the Normal Schedule. They
are listed below:
150,000 miles (240,000 km)
❑Change engine oil and replace oil filter❑Replace engine- and frame-mounted fuel filters❑Replace accessory drive belt(s)❑Change Premium Gold coolant (see Motorcraft Premium Gold
Coolant Change Record)
❑Change automatic transmission fluid and external filter ele-
ment
❑Change rear wheel drive (RWD) axle fluid - DANA axlesnot
using synthetic fluid only
❑Change front axle lubricant (4x4 only)❑Change transfer case fluid (see Special Operating Conditions)❑Replace 4x2 front wheel bearings, adjust wheel bearings and
replace grease seals (if non-sealed bearings)
❑Perform multi-point inspection (recommended)❑Inspect tires for wear and rotate❑Inspect air filter restriction gauge, replace filter as required❑Inspect and lubricate steering linkage, ball joints, suspension,
driveshaft and u-joints
❑Inspect engine cooling system and hoses❑Inspect brake pads, shoes, rotors, drums, brake lines and
hoses and parking brake system.
❑Inspect exhaust system and heat shields❑Check wheels for end play and noise❑Inspect and lubricate 4x4 front axle u-joints
DEALERVALIDATION:
RO#: P&A C
ODE:
D
ATE:MILEAGE:
Normal Vehicle Axle Maintenance
❑Rear axles and power take-off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design axles
are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or
the axle assembly has been submerged in water. The axle and PTO lubricant should be changed anytime the axle and PTO
have been submerged in water. Non-synthetic rear axle lubricants should be replaced every 3,000 miles (5,000 km) or 3
months, whichever occurs first, during extended trailer tow operation above 70°F (21°C) ambient and wide open throttle for
extended periods above 45 mph (72 km/h). The 3,000 mile (5,000 km) lube change interval may be waived if the axle
was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL-M2C192-A, part number F1TZ-19580-B or
equivalent. Add four ounces (118 mL) of additive friction modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent for com-
plete refill of Traction-Lok rear axles. The axle lubricant should be changed anytime an axle has been submerged in water.
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