The trademark POWER STROKE Is used

under Ilcense from C.M.R. Canada Ltd.

F7UJ-19A285-AA

FCS-12252-97
OWNER'S GUIDE SUPPLEMENT
SEPTEMBER 1997 POWER STROKE
SECOND PRINTING LITHO IN U.S.A.
eD
7.3 Liter
Stroke
Direct Injection
Turbo Diesel
OWNER'S GUIDE
SUPPLEMENT
..
INTRODUCTION
The following warning nillY be required by California law:
CALIFORNIA
Proposi,tion 65 Warning
WARNING: Diesel,engine exhaus4 some ofits constiments,
and certain interior and exterior vehicle components contain
or emit chemicals known to the state of California to cause
cancer, or birth defects or other reproductive hann.
Ford Motor Company welcomes you to the growing number of
people who have chosen the dependability and fuel economy of
a truck. Although the diesel engine.is more
technically complex than the gasoline engine, it is also' relatively
more trouble free. 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 Power Stroke (7.3L DIT)
diesel engine. It provides recommendations on engine and
operating procedures. For complete vehicle information, also
refer to the Owner Guide included with the vehicle.
This guide should be considered a permanent part of the
vehicle and remain with the vehicle, if sold, to provide the next
owner with engine operating and maintenance information.
This gUide describes equipment and gives specific<itions for
equipment that was in effect when this guide was approved
for printing. Ford may discontinue models or change
spcifications or design without any notice and without
incurroihg obligation.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if
equipped with The Ford Ambulance Preparation Package,
which includes a 215 AMP alternator. In addition, Ford urges
ambulance manufacturers to follow the recommendation of the
Ford Incomplete Vehicle Manual, Ford Truck Body
Builder's Layout Book (and pertinent supplements) and the
QHalified Vehicle Modifiers Guidelines.
The trademark POWER STROKE is msed
under license from C.M.R. Canada Ltd.
Copyright 1996, Ford Motor Company
I
IMPORTANT NOTICE
DIESEL ENGINE INFORMATION
Using a Ford vehicle without the Ford Ambulance
The diesel engine fuel system consists of a fuel supply
Preparation Package to produce an ambulance voids the
pump, an engine mounted fuel filter/water separator, fuel
Ford warranty and could result in elevated underbody
restriction sensor, and a u'nit injector for each cylinder.
temperatures, fue,l overpressurization and the risk of fuel
The combination fuel filter/water separator removes both
expulsion and fires. Whether the vehicle is equipped with
water and impurities from the fuel. The filter requires
the FordAmbulance Preparation Package may be
periodic replacement. The filter should be changed at the
determined by inspecting the information plate on the
recommended maintenance interval or when the dash
driver's side door pillar. Whether the ambulance
I
mounted fuel restriction warning light goes on during
manufacturers followed Ford's recommendations can be
normal operation.
L
determined by contacting the manufacturer of your vehicle.
The filter bowl should be drained at regular intervals or
Ford Vehicles Built With Turbochargers
J
whenever the WATER IN FUEL light comes on and stays
The Ford Power Stroke diesel powertrain is one of the first
on. See Maintenance Schedules in the Index for
hydraulically actuated electronically controlled fuel injected
recommended intervals.
diesel engines. This engine is designed to be more efficient,
1
A standard feature fuel heater is built into the filter header.
while providing greater power. The Direct Injection turbo
This device activates automatically when cold operating
diesel engine is built with stronger internal parts. These
temperatures are experienced.
internal parts are designed to withstand the increased
performance capabilities and provide the reliability and
The cylinder head is designed to incorporate electronically
durability expected of the Power Stroke diesel engine.
controlledlhydraulically actuated fuel injectors. The fuel
injectors are located in the center of the combustion
N,OTES AND WARNrNGS
chambers in the cylinder head between the rocker arm
assemblies.
Throughout this guide, you will find WARNINGS and
The glow plug system used on the Power Stroke diesel
NOTES. WARNINGS remind you to be especially careful
engine is controlled through the powertrain control module
to avoid personal injury. NOTES are given to prevent you
(peM).
from making an error which could damage the engine or
vehicle and possibly cause personal injury.
The fuel injection system used on the Power Stroke diesel
engine is controlled by the powertrain control module. Fuel
NEW VEHICLE BREAKIN
is drawn from the fuel tank by a tandem fuel pump. The
tandem fuel pump circulates fuel at low pressure through
Your new vehicle does not need an extensive break-in. Try
the fuel filter and then the fuel is directed back to the fuel
not to drive continuously at the same speed as par.ts tend to
I
pump where fuel is pumped at high pressure into the
better adjust themselves to other parts if various speeds are
cylinder head fuel galleries. Fuel is delivered into the
used during the first 1,000 miles (l,600 km). I'
combustion chamber through electronically controlledV
New vehicles should be driven 500 miles (800 Ian) before
hydraulically actuated injectors.
towing atrailer.
NOTE: For vehicles equipped with dual fuel tanks, do
Do not add anti-friction compounds or special b r e ~ k - i n oils
not allow one tank to run dry before switching tanks.
during the first few thousand miles of operation, since these
additives may prevent piston ring seating. See Engine Oil in
the Index for information on oil usage.
2
3
DIESEL ENGINE INFORMATION
The Power Stroke diesel engine is equipped with a fully
closed-crankcase v.entilation system. Crankcase vapors are
directed into the combustion chamber from the crankcase
breather assembly located on the left valve cover.
Lubrication System
The Power Stroke diesel engine has a two stage oil system.
The first stage is a gerotor pNmp driven by the crankshaft
that provides oil lubrication to the eRgine's rotating and
reciprocating components to reduce friction and Wear. It
also supplies oil to the reservoir which feeds the second
stage of the system. The second stage is a high pressure,
swash-plate oil pump which draws from the reservoir and
provides the hydraulic pressure required to actuate the fuel
injectors.
It is important to change the engine oil at recommended
maintenance intervals, because oil viscosity is important in
maintaining the oil pressure required to actuate the fuel
injectors. extended oil drain intervals can negatively impact
engine performance and fuel economy.
The turbocharger is supplied pressurized oil from the main
oil gallery through a passage in the turbocharger mounting
pedestal. Oil drains from the turbocharger through another
passage in the pedestal back to the oil sump. This design
eliminates any need for external lube lines to the
turbocharger.
The turbocharger pressurized lube oil is also used to actuate
an exhaust back pressure warm-up system. Pressurized oil
going to the turbochargr is routed to the exhaust back
pressure actuator which is used to control a butterfly valve
on the outlet side of the turbine housing. This function
occurs only during the cold weather warm-up cycle. During
exhaust back pressure operation the engine's sound will be
altered and you may notice a change in engine performance
while it's engaged.
The Power Stroke diesel engine also consists of a special
designed turbocharger, exhaust pipes, exhaust outlet to
muffler inlet pipe, low restriction muffler assembly, and a
special designed air cleaner assembly with element
restriction indicator.
4
~
I
. ~
, ~
DIESEL ENGINE INFORMATION
Fast Start Glow Plug System
The Power Stroke diesel engine uses a glow plug system
which preheats air in the combustion chamber to improve
cold engine starting.
The system con'sists of eight glow plugs, the glow plug
relay, peM, engine oil temperature (EOT) sensor and
barometric pressure (BARO) sensor.
The glow pl1,lg system is electronically controlled by the
powertrain control module (PCM). The PCM energizes the
glow plugs immediately after the igniti0TI is placed in the
ON position and then determines bow long the glow plugs
will be on according to the engine oil temperature and the
barometric pressure. The required time for the glow plugs to
be energized decreases as the engine oil temperature and
barometric pressure ,increase.
The glow plugs are self-regulating and the PCM controls
relay ON time.
,.
The PCM protects the glow plugs by energizing them for
short durations if the battery voltage is abnormally high.
Engine Oil Cooling System
The Power Stroke diesel engine cooling system contains
an engine oil cooler which is mounted to the side of the
cylinder block. The cooler's function is to regulate engine
oil temperature.
Engine Governed Speed
The engine governor is controlled by the powertrain control
module (PCM). The PCM controls fuel input to limit
maximum engine speed. It will not, however, prevent engine
overspeeding resulting from downshifting at high vehicle
speeds or by descending steep grades at too high a vehicle
speed for the selected transmission gear.
5
DIESEL ENGINE INFORMATION
NOTE: Operating the engine beyond the governed speed
can cause severe engine c!I'arnage.
Between idle and maximum speeds, fuel input is controlled
directly by the driver through the aecelerator pedal.
For maximum vehicle speed in various gears, see
Recommended Shift Speed chart on page 16. DO NOT
EXCEED 3,600 RPM. Maximum engine governed speed is
3,000-3,400 RPM depending on engine load. Excessive
RPM can only be achieved by manually downshifting at too
high of a.vehicle speed. Refer to shift chart to avoid
accidental over-revving of engine.
Air Cleaner Restriction Gauge
The Power Stroke diesel engine also has an air restriction
gauge. The restriction gauge shows if the air cleaner is
restricted. The air filter element should be replaced when
the yellow band in the restriction gauge reaches the
CHANGE FILTER mark. Engine performance and fuel
economy are adversely affected when maximum restriction
is reached. After servicing the air filter element, the
restriction gauge can be reset by pushing the button on the
end of the gauge. The restriction gauge is located on the
clean-air side of the air cleaner upper housing.
YELLOW
DIAPHRAGM
EXTENDED
REPLACE FILTER FILTER OK
DIESEL ENGINE INFORMATION
Power Brakes
Power for the hydraulic brake booster system is obtained
from a belt driven vacuum pump which operates when the
engine is running. This acts to multiply the force applied
to the brake pedal so that very little effort is required to
operate the brakes while the engine is running. Brakes will
operate with the engine off, but more effort is required.
WARNING - Do not drive the vehicle if the BRAKE
warning light glows while the engine is running. The
light indicates a loss of power assist (requiring greatly
increased pedal effort to stop the vehicle), low brake
fluid level or the parking brake is not fully released.
Make sure the parking brake is fully released. If the
BRAKE waruing light stays on, have the brake system
checked immediately.
WARNING LIGHTS AND GAUGES
Wait to Start Light
With the key in the ON position, the WAlT TO START
indicator will light if glow plug heat is necessary as a
starting aid. Wait until the light goes off before starting.
Light should always go c i ~ briefly, when ignition switch is in
the ON position. If light does not go on there is a problem.
Refer to "Starting and Operating the Diesel Engine" for
further explanation. After the engine starts, the indicator
light should remain off.
The light.should, alway,s come on at least momentarily when
the engine is cold and the ignition is first switched ON. If it
does not, the glow plug system should be checked and
repaired promptly to avoid difficult cold starting.
6
7
WARNING LIGHTS AND GAUGES
Water in Fuel Warningl Light
During refueling it is possible for water-col'ltaminated diesel
fuel to be pumped into your fuel tan1e Your vehicle fuel
system is equipped\ willi a fuel filteF/water separator to
remove water from the fuel. The WATER IN FUEL light
will glow when the fuel filter/water separator has a
significant quantity of water, OF when the ignition key is
switched to the START position (light function check). If
the light comes on while the engine is running, stop the
vehicle as soon as safely possible, shut off the engine and
drain the filter bowl. (Refer to Fuel Filter/Water Separator
Drain Procedure in the Index.) Allowing water to stay in the
system could res-ult in extensive dam<\ge to, or fa,ilure of, the
fuel injection system.
WARNING - Do not drain water separator while
engine is running. Fuel may ignite if separator is drained
while engine is running or vehicle is moving.
F-SERIES
WArT
TO START
FUEL
ALTER
TACHOMETER
CHECK ENGINE
LIGHT
WARNING LIGHTS AND GAUGES
ECONOLINE
WATER
IN FUEL
WAIT TO
START
FUEL
FILTER
SERVICE ENGINE
SOON LIGHT
STARTING PROCEDURES
Climate conditions and other factors playa large part in
deciding how you should g o a ~ o u t starting your vehicle.
Read all the starting instr:uction"s carefully, so you'1\ be
aware of these factors when you start your vehicle. Starting
Procedures are also shown on the vehide visor. For low
ambient temperatures (below 32F [aOCD the use of the
correct SAE viscosity (thickness) grade oil is essential for
proper operation.
The START position on the ignition lock cylinder is used to
crank the engine.
NOTE: If you have a manual transmission, before
turning the key, make sure tlie parking brake has been set
fully. Depress the clutchpedal and place the gearshift
lever in the NEUTRAL position. The clutch pedal
MUST be fully depressed in order to operate the starter.
DO NOT PRESS DOWNON TIIE ACCELERATOR
DURING STARTING.
8 9
STARTING PROCEDURES
NOTE: If you "have an automatic transmission, make
sure that the gearshift lever is in Park and the parking
brake is set before Y0U tYM th"e key. DO NOT PRESS
DOWN ON THE ACCELERATOR DURING
STARTING.
Cold Engine
I, Be sure your headIamps are off while you crank the
engine. This will reduce the electrical Yoad on your
batteries and allow aU the power to go to the starter
motor.
2. Tum key to the ON position. When the WAlT TO
START light goes off, tum key to START. (For
Canadian vehicles, the daytime running lights will be on
when the key is in the ON position, if the parking brake
is not applied.)
3. When engine starts release the key.
4. The glow plugs will continue to be activated for up to
two minutes. If the engine is not started before the
activation c e a s e ~ , the glow plug system must be reset by
turning the ignition key to OFF. (Under continuous
extreme cold overnight conditions, use of an engine
block heater and/or garage storage is recommended).
NOTE: Do not crank engine for more than 30 seconds
at a time as damage to starter motor may result. If the
engine fails to start, tum key to OFF position and wait
30 seconds before trying again.
WARNING - Do not use starting fluid such as ether in
the air intake system. (See Air Cleaner Decal.) Such fluid
can causecimmediate explosive damage to the engine and
possible personal injury;
NOTE: Do not add gasoline, gasohol or alcohol to diesel
fuel. Damage to the fuel injection system may result.
NOTE: 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.
10
STARTING PROCEDURES
5. After engine starts, allow engine to idle for about 15
seconds. (Do not increase engine speed until oil pressure
gauge indicates normal pressure. Depress brake pedal,
engage the transmission and release the parking brake.
Gradually release the brake and drive away in a normal
manner.
Warm Engine
Start engine with accelerator pedal at the idle position.
STOPPING THE ENGINE
Tum the ignition switch to the OFF position. 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 7 to 10 minu tes which would allow
sufficient time for the turbocharged engine to cool down.
COLD WEATHER OPERATION
When parking your vehicle overnight, leaving it inside a
garage, even if not heated, will make morning starting much
easier. ChaIilging to a lighter grade engine oil also makes
starting easier under these conditions (consistent with
recommended qua,Jity level and viscosity).
An auxiliary powertrain control module (APCM) can be
purchased through your Ford dealer which, in conjunction
with your vehicle's control software allows the engine to
run at an increased idle speed, improving cab heat.
At temperatures below 20F [-7C], Number 2-D diesel
fuel may thicken enough to clog the fuel filter. This is
usually caused by the naturally-occurring paraffin in diesel
fuel turning to wax as it gets colder. Your engine is equipped
with a fue]. filterlheater/water separator to keep the wax
melted which will help prevent fuel filter clogging.
However, if the engine starts but stalls out after a short time
and will not restart, the fuel filter may be clogged. For best
results in cold weather use number I-D diesel fuel or
"winterized" number 2-D diesel fuel which has an additive
to minimize wax fornation.
11
COLD WEATHER OPERATIQN
Due to diesel fuel'i; affinity for water and waxing
characteristics, your ehicle is equipped with a bypass relief
valve on the in-tank fuel sending unit. This valve provides
fuel flow to the engine if the fuel pickup should become
plugged by ice or wax.
NOTE: To allow this bypass valve to function and avoid
engine fuel starvation - it is recommended that, during l
cold weather operaHon (32F [DoC] or below), the fuel
level in your tank(s) not be aUo1>Ved to drop below 1/4
full, to prevent air from entering the fuel system and
stal'1ing the engine.
WARNING - Do not use starting fluids such as ether in
the air intake system (see Air Cleaner Decal). Such fluids
can cause immediate explosive damage to the engine and
possible personal injury.
NOTE: Do not add gasoline, gasohol or alcohol to diesel
fuel. Damage to the tiuel injection system may result.
NOTE: It should not be necessary to add any aftermarKet
additives to your fuel tank if you use a proJ)erly
formuJated diesel fuel that meets the D 975
industry specification. Aftermarket additives can damage
the injector system or engine.
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.
Operation in Standing Water
NOTE: Ingestiol1of wafer 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 air intake. If the engine stalls, and ingestion
of water into engine is suspected; do not try to restart the
engine. Consult your dealer for service immediately.
Follow the cylinder compression test procedure outlined
in the shop manual, and check the engine oil for
contamination.
COLD WEATHER OPERATION
Engine Black Heater (if equipped)
The engine block heater is used to warm the engine coolant which
improves starting, provides for engine wann-up, and results in
quicker response from the heater-defroster system. It is
recommended for use whenever the outside temperature is OaF [
18C] or below. The heater is plugged into a grounded l2D-volt
OI,ltlet (household system) and the heater unit"consumes 1(XX) watts
ofJXlwer. fuI; rest results the heater should re plugged in at least
three hours prior to starting. The use of the heater for longer periods
of time will not cause the engine to exceed the thermostat setting.
WARNING - Do not use with ungrounded electrical
systems or with two pronged (cheater) adaptors. An
electrical shock resulting in personal injury could occur
if an ungrounded connection is used.
NOTE: The block heater power cord should be
disconnected and safely stowed before vehicle is started.
JUMP STARTING
WARNIN.G - KEEP BATTERIES OUT
OF CHILDREN. THEY CONTAIN; SULFURIC ACID.
AVOID CONTACT WITH SKIN, EYES OR
"I
S!IIELD YOUR EYES WHEN
WORJ(lNG NEAR THE'BATTERY TO PROTECT
AGAINST POSSIBLE OF THE
ACID SOLUTl!ON. IN CASE OF'ACID CONTACT
WITIi SKIN, EYES, OR CLOTHING, FLUSH
IMMEDIATELY WITH WATER FOR A MINIMUM
OF 15 MINUTES. IF ACID IS SWALLOWED, DRINK
LARGE QUANTITIES OF MILK OR WATER,
FOLLOWED BY MILK OF MAGNESIA, A BEATEN
EGG OR VEGETABLE OIL. CALL A PHYSICIAN
IMMEDIATELY.
WARNING -HYDROGEN AND OXYGEN GASES ARE
PRODUCED DURINGNORMAL BATTERYOPERATION.
UIIS GAS MIXTURE CAN EXPLODE IF FLAMES,
spARKs OR UGHTED TOBACCO AREBROUGlIT
NE,AR TIIE BATTERY. WHEN CHARGING OR USING A
BATTERY INAN ENCLOSE;I) SPACE, ALWAYS PROVIDE
VENTILATION AND SHIELD YOUR EYES.
12
13
JUMP STARTING
NOTE: Use only a 12-volt jumper system. A 12-volt
starting motor and electrical sys:t6m can be damaged
beyond repair by connecting it to a 24-volt power supply
(two 12-volt batteries in series, or a 24-volt motor
generator set).
NOTE: Follow procedure ill exact sequence.
NOTE: Filament failures of headlamps CaR occur when
vehicle with a dead battery is jump started. Place the
main light switch in OFF position.
NOTE: Do not allow vehicles to touch.
NOTE: Vehicles with manual transmissions can be
started by pushing, hut this is not recommended.
Use of Jumper Cables
WARNING - To avoid harm to yourself or damage to
your vehicle or hattery, follow these directions in order.
If in doubt, call for road service.
Use only a I 2-volt jumper system with negative ground.
You can damage a 12-volt starting motor and glow plug
system beyond repair by connecting it to a 24-volt power
supply (two 12-volt batteries in series or a 24-volt motor
generator set).
NOTE: The glow plug relay is located on the right
rocker arm cover of the engine. DO NOT attach jumper
cables to this relay. The glow plugs, injector driver
module, and powertrain control module could be
severely damaged.
Do not disconnect the battery of the vehicle to IDe jump
started. Disconnecting the battery could damage the
vehicle's electrical system.
Make sure the vehicles do not touch one another. Set the
parking brake fully on each.
WARNING - Stay clear of the engine cooling fan.
Turn on the climate control system fan of the vehicle to be
jump-started. Turn off all other switches and lights on
both vehicles. Turning on the fan helps protect the
electrical system from voltage surges when jumper cables
are connected and disconnected.
JUMP STARTING
Make jumper cable connections according to the
follO\ying Instructions. (See illustrations.) For optimum
power, connect booster battery cables to battery on
passenger side of vehicle to be jump-started. The battery
cable on the passenger side has been designed with larger
size wire to conduct the high starting currents during
jump-starting without damaging the cable. DO NOT
JUMP-START THE DRIVER'S SIDE OR FRAME
MOUNTED BATTERY.
ENGINE
ECONOLINE
ENGINE
D
FRONT OF VEHICLE
BOOSTER BATIERY
FRONT OF VEHICLE
BOOSTER BATIERY
F-SERIES
To Connect the Jumper Cables:
- Connect one end of the first jumper cable to positive (+)
terminal of the dead battery and then the other end to the
positive (+) t e r m i n a ~ of the booster battery.
- Connect one end of the second jumper cable to negative
(-) terminal of the booster hattery, and then the other end
to an engine boltbead or good metallic contact spot on
the engine of the vehicle to be started.
WARNING - Do not attach the other end to the
negative (-) battery tenninal, because a spark could
occur and cause explosion of gases nonnally present
around the battery.
14 15
--
JUMP STARTING
After the Jumper Cables Are Connected:
Make sure the jumper cables are not in the way of moving
engine parts.
Start the engine of the vehicle that has the booster battery.
Run the engine at a moderate speed.
Let the dead battery charge for a few minutes and then
start the engine of the vehicle that has the dead battery.
Reduce engine speed to idle on both vehicles to prevent
possible damage to the vehicle's electrical system.
WARNING - Use extreme care to avoid contact with
the fan and other moving engine parts. Loose clothing
can become entangled in moving parts, resulting in
severe personal injury.
To Remove the Jumper Cables:
- Remove the negative (-) end of the jumper cable from
the engine of the vehicle with the dead battery.
- Remove the end of the jumper cable from the negative
(-) terminal of the booster battery.
- Remove the end of the jumper cable from the positive (+)
terminal of the booster battery.
- Remove the end of the jumper cable from the positive (+)
terminal of the dead battery.
DIESEL ENGINE DRIVING TIPS
Prevent overspeeding of the engine when going down long
and steep gFades. The governor control of the powertrain
control module (peM) has no control over engine speed
when it is being pushed by the loaded or unloaded vehicle.
Operate in a gear that wHl not permit engine overspeed. Do
not permit engine speed to exceed redline on tachometer.
DIESEL ENGINE DRIVING HPS
NOTE: Operating the ,engine beyond the governed speed
can severe damqge.
-RECOMMENDED SHIFT SPEEDS - MANUA'l TRANSMISSION
UPSHIJ;TS; NORM'Al ACCELERATION F-25l1/350 F,Super Duty
GeaJ Change Shin Speed
Ftrstlo Second 10 mph (16km/h) 10,mph (.16 kmlh)
Second to Third (40 Iynlh) 20 mph (32.kriJ/h)

Third to Fourth 30 mph (48 km/h) 40 mph <?'\ kmlh)
.'
-
Fourth to 0,0, 45 mph (72 krn/h) 45 mph (721m/h)
fplAXlfplUM DOWNS,HIFT SI'"EEpS' F-25l1/35D FSuper Duty
Gear Chang,e Shih Speed
, Overdrive to Fourth 5O'mph (96'kmlh) 55 mph (88 kmlll)
..... - ,-
Fourth to Third 45 mph (72 km/h) 35 mph km/h)
"

Third to Second I:! 26 (40 km{h) 20 O1Ph (3Um/h)
.
Second to First \5 mph'(2Hmlh) 10 mph (16km/h)
*WARNING - Downshift at lower speeds when driving
on slippery surfaces.
GENERAL MAINTENANCE INFORMATION
The Scheduled Maintenance Services in lhe Maintenance
Schedule (SerVice Guide) are required b.ecause 'they are
considered essential to the life and performance of your
vehicle.
Use only recommended fuel, lubricants, fluids and seri e
parts conforrningto Ford specifications. Motorcraft parts
are designed and built for best performance in your vehicle.
Using these, parts for replacement is your assurance that
Ford-built quality stays in your vehicle.
Washing the Diesel Engine
NOTE: Never wash the engine when it is warm, hot or
running. Spraying water or other cleaning fluids OR a
warm engine can seriously damage the engine's fuel
system. When washing the engine, the air cleaner must
be in place to prevent water from splashing into the
engine.
16
17
GENERAL MAINTENANCE INFORMATION
Fuel Requirements
The Direct Injection Power Stroke diesel engine is designed
to use low sulfur number l-D or 2-D diesel fuel only. At
temperatures below 20
0
P [-7C], number I-D or winter
blend number 2-D fuel is recommended. (See Cold Weather
Operation in the Index.)
NOTE: Do not add gasoline, gasohol or alcohol to diesel
fuel. Damage to the fuel injection system may result.
NOTE: It should not be neressary to add any aftennarket
additives to yourfueltank ifyou use a properly formulated diesel
fuel that meets !heAS1M D 975 industry specification.
Aftennarket additives can damage !he injector system 0f engine.
NOTE: Under no circumstances should used engine oil be
blended with diesel fuel. Blending used oil with the fuel will
significantly increase your vehicle's exhaust emissions and
reduce engine life due to increased internal wear.
NOTE: For vehicles equipped with optional dual fyel
tanks, do not allow one fuel tank to run dry before
switching tanks. Running the fuel tank dry will cause air
to enter the fuel system thereby stalling the engine.
Longer than normal cranking time may be required to
restart the engine. If you run out of fuel while the vehicle
is in motion, immediately tum on the hazard warning
flashers.
NOTE: Do not crank the engine for more than 30
seconds at a time as damage to the starter motor may
result. If the engine fails to start in 30 seconds, turn the
key to the OFF position and wait 30 seconds before
trying again.
NOTE: Truck stops have pumps and nozzles designed
for larger, heavy-duty trucks. When refueling at truck
stops: if the nozzle shuts off repeatedly when refueling,
wait 5-10 seconds; then use a slower rate of flow (don't
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter
change Or if you run out of fuel) the engine will purge the
trapped air as it runs. The engine may run rough and
produce white smoke while air is in the system. This is
normal and should correct itself in a short time.
18
GENERAL MAINTENANCE INFORMATION
NOTE: An engine that suddenly becomes noisy after a
fuel fill could be using substandard fuel (i.e., high water
content or low octane rating or gasoline in the fuel).
Whenever possible, diesel fuel should be purchased from
a reputable station which sells a large amount of diesel
fuel.
Care should be taken whenever diesel fuel is stored. Use
only clean, approved containers which will prevent the entry
of dirt or water.
NOTE: Diesel fuel mllst not be stored in a ga1lvanized
container. The fuel will dissolve the zinc in a galvanized
container. The zinc will then remain in solution until it is
run through the engine where it will be deposited in the
fuel injectors causing expensive-to-repair damage.
Changing Fuel Filter
Removal
1. Using a screwdriver or bar, remove fuel filter cap. Fuel
filter element will come out with cap.
2. Remove and discard bevel gasket. Carefully clean
mating surfaces.
3. Press in on fuel filter element locking tabs, to separate
element from cap.
Installation
NOTE: The engine will not run properly if the fuel
filter is not installed in housing.
1. Apply a coating of clean d,iesel fuel to new bevel gasket
and install onto fuel filter housing gland.
2. Install new fuel filter element onto cap. Place new fuel
filter element and cap into fuel filter housing. Allow fuel
to soak into fuel filter element. Tighten cap onto fuel
filter housing until cap contacts the aluminum housing.
19
GENERA-L MAINTENANCE INFORMATION
Fuel with more than average impurities may require
changing filters at shorter intervals.
After changing the fuel filter, the engine will purge the
trapped air as it is run. Engine may run rough and smoke
until the air is completely eliminated.
GENERAL MAINTENANCE INFORMATION
Checl<ing Engine Oil Level
Because it is nonna.1 to add some oil between oil changes,
have your engine oil level checked each time you stop for
fuel or check it yourself. To check the engine oil level
consistently and accurately the following procedure is
recommended:
FUEL FILTER
OIL
DIPSTICK
20 21
GENERAL MAINTENANCE INFORMATION
I. Have engine at normal operating temperature (at least
into the NORMAL range on the engine coolant
temperature gauge).
2. Park vehicle on level surface.
3. Turn off engine and open hood.
4. Allow at least 20 minutes after engine shutdown to
assure that oil contained in the upper parts of the engine
has returned to the oil pan.
S. Protecting yourself from engine heat, pull out the
dipstick, wipe it clean and reinsert fully.
6. Read oil level on both sides of dipstick and use highest
level (reading) for the actual engine oil level.
7. Maintain the oil level between the FULL and ADD
marks on the dipstick by adding oil as required. The
distance between the ADD and FULL marks on the
dipstick represents two quarts (1.9 liters). Do not
overfill If the oil level exceeds the FULL mark, oil
consumption may result.
Engine Oil Specifications
NOTE: 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 changed no later than 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.
GENERAL MAINTENANCE INFORMATION
For normal or severe service, use Motorcraft oil or an
equivalent oil conforming to Ford Specification WSS
M2C171-C or API Service categories CG-4ISH. Do not use
oils labeled with only one of the following category
designations; SG, SH, CE, CF-4, or CG-4, as they could
cause engine damage.
Engine oils with improved fuel economy prQperties (energy
conserving) are currently available. If you use an energy
conserving oil, be sure it meets the recommended Ford
Specification, API service categories and SAE viscosity
grades listed in the Specifications chart. Some energy
conserving oils do not meet the requirements necessary for
your diesel engine.
SAE VISCOSITY GRADES
F' -20 -10 0 10 20 30 40 50 60 70 80 90100
I I ! I I I I I I I I I I
I ( I I I I I I I I I I I I
C' -30 -25 -20 -15 -10 -5 0 5 10 152025 30 35 40
EXPECTED TEMPERATURE RANGE
"
5W-30
OW-30
Heavy duty trailer tow 01 ambients above 50'F requires
15W-40 all
The use of correct oil viscosities (thickness) for diesel
engines is important for satisfactory operation (especially in
cold weather). Determine which oil viscosity best suits the
temperature range you expect to enc01mter for the next
service intervaL
23
22
GENERAL MAINlfENANCE INFORMATiON
Oil Identification Symbol
A symbol has been developed by the
American Petroleum Institute (API) to
help you seiect the proper engine oil. It
will be included on the oil container you
purchase. The top section of the symbol
shows the- oil perfonnance by the API
designation. This shc>1Ild 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.
Changing Engine Oil and Filter
Change your oil and filter according to the Scheduled
Maintenance. Change more frequently if your vehicle
operation includes extended periods of idling or low-speed
operation, t,owing trailers, driving for a long time in cold
temperatures or driving short distances. See the followmg
sectioh "Engine Lubrication for Severe Service Operation"
for all severe duty restrictions.
Use Ford Engine Oil Filter Part No. F4TZ-673 I-A
(FL 1995) OJ: equivalent. These- filters protect your engine by
filtering harmful, abrasive or sludge particles. The FL 1995
filters particles significantly smaller than most available
"will fit" filters.
To replace, use an oil filter wrench to unscrew the filter from
the oil cooler fitting. Tum it horizontally to let excess oil
drain off, and remove.
WARNING - Do not handle a hot oil filter with bare
hands.
Clean the filter mounting area on the oil cooler, lightly coat
the gasket surface of the new filter with clean engine oil and
hand tighten until the gasket contacts the l!>ase. Then
tighten another 1-114 to 2 turns. Fill the crankcase and run
the engine to check for leaks.
WARNING - Continuous contact with USED motor oil
has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water.
24
GENERAL MAINTENANCE INFORMATION
Engine Lubrication for Severe Service Operation
When operating your vehicle for trailer towing over long
distances over 1,000 miles [1,600 km], sustained high speed
driving at Gross Vehicle Weight Rating (maximum loaded
weight for vehicle operation) during hot weather (over 90F
[32C]), frequent or extended idling (over 10 minutes per
hour of normal driving), opeFation in severe dust conditions,
or frequent short trips (l0 miles [16 km]) during freezing
weather, the following procedures should be followed:
1
Change engine oil and filter every 3,000 miles
(5,000 km).
Use Motorcraft oil or an equivalent oil conforming to
Ford Specification ESR-M2CI71-C or API categories
CG-41SH. Do not use oils labeled with only one of the
following category designations', SG, SH CE, CF-4 or
CG-4, as they could cause engine damage.
For more information refer to Severe Duty Maintenance
Schedule ,in the Maintenance Schedule (Service Guide).
Replacing Air Cleaner Filter
NOTE: The original air cleaner filter element provided
with your vehicle has been specially formulated to
provide protection against engine water ingestion.
When replacing the element, use Motorcraft Filter or
its equivalent. Refer to Lubricant and Maintenance
Materials Specifications in this supplement.
Failure to use the correct filter may result in severe
1
engine damage when driving through deep water and/or
encountering unusually heavy precipitation conditions.
Remove air filter element, take care to prevent dirt from
J
falling into the engine air intake. Before installing the new
filter element, clean both the top and bottom surfaces of the
element, and clean the air cleaner tray and cover to ensure
good sealing.
25
GENERArL MAINTENANCE INFORMATION
NOTE: After replaCing the air cleaner be sure that the
rubber water dn!in hose is not kinked under the tray. If
so, unkink it so that it hangs free. Failure to do so may
result in severe engine damage when driving through
deep water and/or encountering unusually heavy
precipitation<conditions.
Fuel Filter/Water Separator
The Power Stroke diesel engine is equipped winh a
combination fuel filter/water separator located in the "V" of
the engine. A WATER IN FUEL indicator light is provided
on the instrument pl\nel to alert the operator. The light
should glow when the ignition switch is in the START
position to indicate proper light and water sensor function.
If the light glows continuously while the engine is running,
the water must be drained from the filter bowl as soon as
practical to prevent damage to the fuel injection system.
Water should be drained from the filter bowl whenever the
warning light comes on or every 5,000 miles (8,000 km).
The WATER IN FUEL light will come on when
approximately 0.2 pints (100 cc) of water accumulates in
the separator.
NOTE: Replace fuel filter element with Motorcraft
Part No. FD-4595-A (Ford Part No. F4TZ-9N184-B).
Fuel Filter/Water Separator Orain Procedure
1. Stop the vehicle and shut off the engine.
WARNING - The vehicle must be stopped with the
engine off when draining the filter bowl. Fuel may ignite
if separator is drained while the engine is running or
vehicle is moving.
NOTE: Diesel fuel can damage asphalt and other
surfaces.
26
GENERAL MAINTENANCE INFORMAlilON
2. Open the'hood. Place an appropriate contaiper under the
filter drain under the ,vehicle.
DRAIN
TUBE tH
CLEAR n
CONTAINER -D
DRAINING FUEL RLTER
F-Series models:
3. Open filter drain valve by turning clockwise. Allow to
drain for approximately 25 seconds or until clean fuel is
observed. Close dralin valve by turning
counterclockwise until firmly seated.
27
GENERAL MAINTENANCE INFORMATION
rfl
FUEL FILTERJlNATER SEPARATOR
Econoline models:
3. Open filter drain valve by pulling valve release handle
(see illustration). Allow to drain for approximately 25
seconds or until clean fuel is observed. Close drain valve
by resetting handle to original position.
GENERAL MAINTENANCE INFORMATION
All models:
4. Verify that the fuel drain is closed. Close the hood and
remove the container from under the vehiele. It is your
responsibility to properly dispose of the waste in
accordance with all federal, state and local
requirements.
5. Restart the engine and check WATER IN FUEL
indicator light. The light should not glow. If it continues
to glow, have fuel system checked and repaired.
28 29
GENERAL MAINTENANCE INFORMATION
Replacing Coolant
When refilling the coolant system either as part of the
regular mainteniUlce (48 mos. or 50,000 miles, whichever
comes first and then every 36 mos. or 30,000 miles,
whicheve-r comes first), or due to service performed, adhere
to the following instructions:
1. Drain and flush the cooling system to remove dirt
deposits, oil, rust particles.
2. Add four (4) pints of supplemental coolant additive
FW-15, directly to the cooling system.
NOTE: 8-10 ounces of supplemental coolant additive
FW-15 should be added at 15,000 mile to
maintain proper concentration.
3. Fill the coolant reservoir with the specified coolant!
water mixture until the level stabilizes at the top hose
fitting. Replace and tighten cap.
NOTE: Fill the radiator when cold. Level the coolant in
the coolant bottle.
NOTE: A coolant mixture of 50% coolant concentrate
and 50% water is recommended to maintain best overall
performance. To avoid damaging the engine and radiator,
the coolant concentrate should not exceed 60%.
4. Reinstall the coolant bottle cap.
5. Start and idle engine until the radiator upper hose is
warm (approximately 10-15 minutes). If the hose does
not get warm then repeat at a higher engine speed.
6. Immediately shut off engine. Cautiously remove coolant
bottle cap and add coolant to Cold Fill mark.
Upon subsequent engine operation t.he coolant will
expand and flow into the recovery bottle during engine
warmup and the coolant will contract and flow back into
the engine during engine cool down.
GENERAL MAINTENANCE INFORMATION
FSERIES
ECONOLINE
30
31
GENERAL MAINTENANCE INFORMATrON
Checking Coolant Level
Check coolant level in coolant reservoir bottle at least once
a month, only when the engine is cool. Fill to within the
"Cold Fill Level" range noted on the reservoir as required
with a 50/50 mixture of coolant concentrate and water.
NOTE: A coolant mixture of 50% coolant concentrate
and 50% water is recommended to maintain best overall
performance. A 60/40 antifreeze to water ratio is
acceptable for extremely Gold climates, but must be
returned to a 50/50 ratio at the end of the winter season.
NOTE: Vehicles with diesel engines typically are uSed to
carry heavy loads and accumulate mileage rapidly. 111ese
two factors cause the additives in the coolant to "wear
out" in a shorter time. Ford recommends an illterim
service interval performed at 12 months or 15,000 miles
(24,000 km), whichever occurs first. Add 8 to 10 ounces
(235 to 295 ml) of supplemental coolant additive FW-15
to the cooling system. For vehicles with extensive idling
time, add 8 to 10 ounces of coolant additive FW-15 after
every 500 hours of operation.
NOTE: Operating engine with insufficient coolant and/
or coolant additive can caUse severe engine damage.
WARNING - Failure to follow these instructions could
result in serious personal jnjury from hot coolant or
steam blowout and/or damage to the cooling system or
engine. Never remove the coolant bottle cap under any
circumstances while the engine is operating. Switch off
the engine and wait until it has cooled. Wrap a thick
cloth around the cap and turn it slowly while the
pressure is relieved. Step back while the pressure is
released from the coo}'ing system. When you are sure all
the pressure has been released, still with a cloth - turn
and remove it. Stand clear of the opening. Hot coolant
may splash out.
Whenever coolant level checks are made, check condition of
coolant bottle cap rubber seal. Make sure it is clean and free
of any dirt particles. Rinse off with water, if necessary. When
replacing cap on coolant bottle, also make sure coolant bottle
neck seat is clean. Check that overflow hose is not kinked.
-'I
GENERAL MAINTENANCE INFORMATION
Coolant Specification
Use only a permanent-type coolant that meets Ford
Specification ESE-M97B44-A such as Ford Premium
Cooling System Fluid E2FZ-19549-AA. Do not use alcohol
or methanol antifreeze or mix them with the specified
coolant.
NOTE: Use of the wrong coolant may cause radiator
and/or engine damage.
Plain water may be used in an emergency, but replace it with
the specified coolant as soon as possible t.o avoid damage to
the system. With only water in the system, do not let the
engine run hot or remain parked in temperatures below 32F
[OC].
Coolant Conditioner (Liquid)
A supplement coolant additive FW-15 has been added to the
coolant in this engine.
This additive aids in the prevention of rust and scale buildup
on the internal parts of the cooling system. Prevention of
rust and scale buildup allows for proper dissipation of heat
generated by combustion
See the maintenance schedules for recommended intervals.
EMISSION CONTROL SYSTEM(S) LAWS
Federal law prohibits vehicle manufacturers, dealers and
other persons engaged in the business of repairing,
servicing, selling, leasing or trading motor vehicles as well
as fleet operations from knowingly removing or rendering
emission control system(s) inoperative. Further,
modifications of the emission control system(s) could create
liability on the part of the individual owners under the laws
of some states. In Canada, modifications of the emission
control system(s) could create liability under applicable
Federal or Provincial laws.
32
33
II
~
EMISSION CONTROL SYSTEM(S) LAWS
NOTE: Do not remove or alter the original equipment
floor covering or iusulation between it and the metal
floor of the vehicle. The floor covering and insulation
protect occupants of the vehicle from engine and exhaust
system heat and noise. On vehicles with no original
equipment floor covering insulation, do not carry
passengers in a manner that permits prolonged skin
contact with the metal floor. Provide adequate insulation.
NOISE EMISSIONS WARRANTY, PROHIBITED
TAMPERING ACTS AND MAINTENANCE
On January l, 1978, Federal regulations became effective
governing the noise emission on trucks over 10,000 lbs.
(4,536 kg) GVWR (Gross Vehicle Weight Rating). The
following statements concerning prohibited tampering acts
and maintenance, and the noise warranty found in the
Warranty Facts Booklet, are applicable to complete chassis
cabs over 10,000 lbs. GVWR.
TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
Federal law prohibits the following acts Qr the causing
thereof: (1) The removal or renderiug inoperative by any
person other than for purposes of maintenance, repair
or rreplacement of any device or element of design
incorporated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate purchaser
or while it is in use, or (2) the use of the vehicle after such
device or element of design has been removed or rendered
inoperative by any person.
Among those acts which the U.S. Environmental Protection
Agency may presume to constitute tampering are the acts
listed below:
Removal of hood blanket, fender aprou absorbers, fender
apron barriers, underbody noise shields or acoustically
absorptive material.
Tampering or rendering inoperative the engine speed
governor, so as to allow engine speed to exceed
ffi
,i 34 ,,"Ufactum'S spedfications.
NOISE EMISSIONSWARRANTY, PROHIBITED
TAMPERING ACTS AND MAINTENANCE
Removal of air duct, air intake choke or silencer, air
cleaner and/or air cleaner element.
Removal or rendering inoperative exhaust system
II
components including the inlet pipe, muffler, outlet pipe,
resonator or diffuser.
Removal of the fan shrOUd. Removal or rendering
inoperative the fan clutch.
MAINTENANCE
Instructions for maintenance and service of the noise
control system have been included in the Scheduled
Maintenance Services and in the General Maintenance
Checklist in the Maintenance Schedule (Service Guide). To
further help JDinimize noise emissions degradation
throughout the life of the vehicle, Ford Motor Company
recommends that this vehicle should be operated in the
manner described within the Owner's Guide.
Caution should be exercised by the owner when installing
replacement parts to be sure that a tampering act (as
outlined above) is not committed. Note any inspection
.and service performed in the Maintenance Schedule
(Service Guide).
Ii
,I
I
II 1 35
MAlNTENANCE
Vehicle Emi,ssions Control Information (VECI)
Emissions information appears on the VECI decal on bhe
right-hand engine valve cover. This decal identifies' engine
displacement and provides cert.1in engine specifications.
ELECTRICAL
SYSTEM
CAUTION
~ ~ : ' ~ ~ I
E
:::
-
EMISSION
LABEL
36
MAINTENANCE
Scheduled Maintenance Services
The Maintenance Schedule (Service Guide) details bhe
maintenance services which are to be performed at the
indicated intervals, following the procedures in the Ford
Service Manual. Maintenance service adjustments must
conform to specifications contained in this supplement,
those published in the Ford Truck Perfomlance
Specifications Manual, and those shown on the VECI decal
on the engine valve cover. Refer to your Warranty Facts
Booklet for complete warranty information.
Any modification of the emission control systems could
create liability under federal law (U.S.) if made prior to the
first sale and registration, and under the laws of some states jf
made thereafter. Further, federal law prohibits vehicle
manufacturers, dealers and other persons engaged in the
business of repairing, servicing, selling, leasing, or trading
motor vehicles as well as fleet operations from knowingly
removing or rendering an emission control system
inoperative after sale and delivery to an ultimate purchaser. In
Canada, modifications of the emission control system could
create liability under applicable federal or provincial laws.
NOTE: Idling the engine for extended periods will
accumulate more hours of use on your vehicles than is
actually indicated by the mileage odometer.
Consequently, the odometer reading can be often
misleading when determining the right time to change
your engine oil and filter.
If you are using your Ford vehicle in a manner which
allows it to remain stationary while the engine is running
for long periods (door to door delivery, taxi, police, power!
utility company trucks, or similar duty), then Ford
recommends you increase the frequency ofoil and filter
changes to an interval equivalent to 200 ENGINE HOURS
of use. Since most vehicles are not equipped with
hourmeters, it may be necessary fur you to approximate
your idle time and plan oiJAjlter changes accordingly.
Although the diesel engine is more technically complex than
the gasoline engine, it is also relatively more trouble-free. The
owner is discouraged from attempting to perfOml maintenance
other than that described in this Owner Guide Supplement.
37
~ i
MINOR TROUBLESHOOTING GUIDE
Many difficulties in engine performance can be corrected by
checking for any of the following conditions:
Plugged air inlet system. ,1,
Water in fuel'water separator.
Clogged fuel filter.
Contaminated fuel.
Air in fuel system, due to loose connections.
~
Open or pinched sensor hose.
Low oil fill level.
You may wish to check for any of these problems if your
vehicle suffers from difficult starting, rough idling,
excessive exhaust smoke, a decrease in performance and
excess fuel consumption.
I"
"
If these checks do not correct a problem, consult an
authorized dealer.
Most operating troubles that might be encountered with a
new or well-maintained vehicle will be of a minor nature.
Therefore, if you have trouble, look for some simple causes
rather thah malfunction of a major component. For instance,
loose or corroded battery connections are more likely than a
battery malfunction.
In many cases, operating troubles are coupled with outside
factors, such as climate conditions, road conditions, a
change of servicing or fueling source, or change of drivers.
Fueling
TIle diesel engine is designed to use low sulfur Number I-D
or 2-D diesel fuel only. Use of off road "high" sulfur fuel
can damage the catalytic converter and violates federal
emissions laws.
At temperatures below 200P (-7C), Number 2-D diesel fuel
may thicken enough to clog the fuel filter. This is usually caused
by the naturally-occurring paraffin in diesel fuel turning to wax
as it gets colder. Your engine is equipped with a fuel heater to
help prevent fuel filter clogging. However, if the engine starts
but stalls out after a short time and win not restart, the fuel filter
may be clogged. For best results in cold weather use number 1
D diesel fuel or "winterized" number 2-D diesel fuel.
38
~
MINOR TROUBLESHOOTING GUIDE
WARNING - Do not use starting fluid such as ether or
gasoline in the diesel air intake system. Such fluids can
cause immediate explosive damage to the engine and
possible personal injury.
NOTE: Do not add gasoline, gasohol or alcohol to diesel
fuel. Damage to the fuel injection system may result.
NOTE: 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.
NOTE: Truck stops have pumps and nozzles designed
for larger heavy-duty trucks. When refueling at truck
stops: if the nozzle shuts off repeatedly when refuelim.g,
wait 5- 10 seconds; then use a slower rate of flow (don't
depress the nozzle trigger as far).
Take care not to run your diesel vehicle out of fuel. It will
I'
allow air to enter the fuel system and will make restarting
difficult. Longer than normal cranking times may be
required.
If air is allowed to enter the fuel system (during fuel filter
change or if vehicle nms out of fuel), the engine will self
purge the trapped air as it is run. TIle engine may run
rough and produce white smoke while air is in the system.
This is normal and should stop in a short time.
I f E n g i n ~ Won't Crank
I,
Switch on the headlights. If lights are dim or do not go on,
or' if when ignition key is turned to START, the lights
become dim or go out, the battery cable connections may
be loose or corroded, or the battery may be discharged.
39
MINOR TROUBLESHOOTING GUIDE
Another indication of loose battery connections or low
battery cha_r.ge is a stuttering or clicking noise from the
engine compartment when the ignition lock cylinder is
turned to START. Check connections at battery posts, cable
connection to engine ground point, and at starter relay
tenninals. Make sure relay bracket is fastened securely to
mounting surface. If starter relay clicks (no stuttering), but
starter does not crank, check connections at starter tenninal.
If a discharged battery is suspected, have it checked and
corrected.
For vehicles with manual transmissions, the clutch pedal
must be fully depressed in order for the starter to operate.
For vehicles with automatic transmissions, the gearshift
lever must be in Park or Neutral in order for the starter to
operate.
Try operating the starter switch several times. Should the
switch be corroded, this operation may clean the contacts
or make the switch temporarily operable until you can
reach the dealer.
If all electrical connections are tight and you need
assistance to start, see Jump Starting Procedures on
page 13.
If Eng,ine Cranks But Won't Start
NOTE: Prolonged starter cranking (in excess of 30
seconds) could cause damage to the starter motor.
Check the f u ~ l gauge.. You may be out of fuel. If the gauge
shows that there is fuel in the tank, the trouble may be in
the electrica:I system or the fuel system. If equipped with
an auxiliilry tank, be sure that tank control switch is set
for the tank with fuel and not at an empty tank.
Leaving the ignition key ON for over two minutes
without starting may make starting difficult because the
glow plugs will cease activation. Reset the system by
turning the ignition key to OFF and then back to ON
again.
40
l
I
I
'I..
M1NOR TROUBLESHOOTING GUIDE
If Engine Runs Hot
The following items could cause the engine to overheat:
Lack of coolant.
Dirty cooling system.
Driving with frozen coolant.
Sticking thennostat.
Overloading or pulling heavy trailers during hot weather.
Grill or radiator air blockage.
Slipping or missing drive belt.
If Fuses Burn Out
Burned-out Or blown fuses usually indicate an electrical
short-circuit, although a fuse may occasionally bum out
from vibration. Insert a second fuse. If this fuse
immediately bums out and you cannot locate the cause,
return your vehicle to your dealer for a circuit check.
WARNING - Replacement fuses and circuit breakers
must always be the same rating as the original
equipment shown in the following illustration. Never
replace a fuse or circuit breaker with one of a higher
rating. Higher rated fuses or circuit breakers could
allow circuit overloading in the event of a circuit
malfunction, resulting in severe vehicle damage or
personal injury.
Fuse Replacement
Refer to Owner Guide for replacement of fuses.
41
____
Component,
I
u.s. Metric
Cooling System (including heater) (a)

Econoline (b)
Enalne Oil (withe 2 auart fifter chanae)
3275 qrs.
30.0 qts.
14' qlS.
31.0 mers
28.5 liters
13.2 liters
Fuel Tank
F-Beries
Refer to Owner Guide
Econoline
35 gals. 132.5 liters
Radiator CaD
13 psi 90 kPa
Manual Transmission (c) 3.4qls. 3.2 liters
Au.tomatlc
15.7qts. 14.8lilers
Item
Ford Part
Nilme
Ford Part
Number
Ford
Specification
Engine Oil
Motorcraft Motor
Oil 15W40 Su per
Duty,10W30
Super Duty
XO-15W40-QSD
XO-10W30-QSD
WSS-M2C17-1-C
API-CG4/SH
Air Filler (.F-Series) Air FA-1605 E8-E95AE-9601-AA
Air Filler (Econoline)
2 Required
Air Filter FA-1618 ES-E95AE-9601-AA
Engine Oil Filler
Use this 2 quart filter ONLY
Oil Filter
F4TZ-6731-A
(FL 1995)
-
Engine Coolant
Premium
Cooling System
Fluid
E2FZ-19549-AA ESE-M9zB44-A
Engine Coolant Additive - FW-15 -
SPECI:FICATIONS AND REFILL CAPACITIES
Refill Capacities
aIncludes 5 quans (4.7 liters) in coolant recovery.
b Add 2,6 qts. (2.5L) if equipped with auxiliary heater option
c Use sy nlhelic Mercon (E6AZ-19582-B, ESR-M2C 163A2).
Light Bl:Jlb Specifications
lamp :Descrlpllon
Number 01
BUlbs Required
Trade No.
F-Serles Econoline
Wait to Start LigFtt
\

194
Water-in-Fuel Light 1

194
Engine Temp. Lig/ll 1

194
Fuel 1

194
These bulbs are in ona assembly. If ona'bulb burns out, fhe total assembly must be
replaced. See your Ford Dealer
Lubricant and Maintenance Materials
Spe'cifications
SERVICE POINTS
F-Series
.

... w :5ClL_ <

a::...J!!!Z<",z _____

x

wl:ta>
Ii: ---.6'fTf f

;;:li






\)w.t
IrlL
ii: Ir ... fil




lL I.

wWw
"'t:o




U
.


:l:F
x
- '-,
,..-a: WW;t o;;!W



9 1-'"

N


0
t:-f\=


-\1r-
50
I:la:
E;::
- t-"UJoo!it
;;
1r!.2I-;jw,1

"'-"-w

Q
I
I
,
42
43
SERVICE POINTS
Econoline
o
!!G



lIl'"
,,,is
\5"'hd
w>
]t'"
OW
o.f3
'" 2 u

0
'"",


c




II:

",


f"''''



ac:

"I
g
Z:5
It


!.I


.lw

15"

_""2

i!:'"
"
... !!l

llli!:
5.
"

cr i

'"
44
IND,EX
A
Air Cleaner Restriction Gauge 6
B
Block Heater 12
Break-In, New Vehicle 2
C
Changing Fuel Filter : 19
Changing Engine Oil and Filter 24
Checking Coolant Level. 32
Checking Engine Oil Level... 21
Cold Engine, SlaTting Procedures 10
COLD WEATHER OPERATION 11
Engine Block Heater 12
Operation in Snow 12
Operation in Standing Water 12
Coolant Conditioner (Liquid) 33
Coolant Specifications 33
Cooling System Refill Capacities 42
D
DIESEL ENGINE DRIVING TIPS 16
DIESEL ENGINE INFORMATION , 3
Air Cleaner Restriction Gauge 6
Engine Governed Speed 5
Engine Oil Cooling System 5
Fast Start Glow Plug System 5
Lubrication System 4
Power Brakes 6
Driving Tips : 16
E
EMISSION CONTROL SYSTEM(S) LAWS 33
Engine Block Heater 12
Engine Coolant
Checking LeveJ 32
Conditioner (Liquid) 33
Refill Capacities 42
Replacing 30
Specification 33
45
. ,
INDEX (Cont'd)
Engine Governed Speed .5
Engine Information 3
Engine Lubrication for Severe Service Operation 25
Engine Oil Cooling System 5
Engine Oil Level, Checking 21
Engine Oil Refill Capacities 42
Engine Oil Specifications 22
F
Fast Start Glow Plug System 5
Filter Specifications : 42
Fuel FilterfWater Separator 26
Fuel FilterlWater Separator Drain Procedure 26
Fuel Biter Restriction Warning Light.. 7
Fuel Requirements 18
Fueling 37
Fuse Replacement .41
G
Gauges and Warning Lights 7
GENERAL MAINTENANCE INFORMATION 17
Changing Engine Oil and Filter 24
Changing Fuel FilterfWater Separator 19
Checking Coolant Level .32
Checking Engine Oil Level 21
Coolant Conditioner (Liquid) 33
Coolant Specification 33
Engine Lubrication for Severe Service Operation 25
Engine Oil Specifications 22
Fuel Filter/Water Separator 26
Fuel FilterfWater Separator Drain Procedure 26
Fuel Requirements 18
Oil Identification Symbol 24
Replacing Air Cleaner Filter 25
Replacing Coolant 30
I
IMPORTANT NOTICE F
Ford Vehicles Built With Turbochargers 2
INTRODUcrION 1'
46
...
INDEX (Cont'd)
J
ruMP STARTING 13
After the cables are connected 16
To connect the jumper cables 15
To remove the jumper cables 16
Use of jumper cables 14
L
Light Bulb Specifications 42
Lubrication System, Diesel Engine 4
Lubrication and Maintenance Materials
Specifications 42
M
MAINTENANCE 35
Scheduled Maintenance Services 37
Maintenance, Scheduled 37
MINOR TROUBLESHOOTING GUIDE 38
Fueling
Fuse replacement
If engine cranks but won't start
If engine runs hoL
If engine won't crank
If fuses bum out
N
NEW VEHICLE BREAK-IN
38
, 41
40
41
, 39
41
2
NOISE EMISSIONS WARRANTY, PROHIBITED
TAMPERING ACTS AND MAINTENANCE 34
NOTES AND -WARNINGS 2
o
I,
Oil Cooling System 5
Oil Identification Symbol 24
Oil Refill Capacities 42
Oil Specifications 22
I Operation In Snow 11
Operation In Standing Water 12
P
Power Brakes 6
47
INDEX (Cont'd}
- - ~
R
Replacing Air Cleaner Filter 25
Replacing Coolant. .30
Refill Capacities (Specifications) .42
S
Scheduled Maintenance Services 37
Service and Maintenance 17
SERVICE POINTS 43
SPECIFICATIONS AND REFILL CAPACITIES .42
Light Bulb Specifications .42
Refill Capacities 42
Specifications, Lubrication and Maintenance
Materials 42
STARTING PROCEDURES 9
Cold engine 10
Warm engine 11
STOPPING THE ENGlNE ll
T
Tampering with Noise Control System .34
Troubleshooting, minor 38
U
Use of Jumper Cables 14
V
Vehicle Break-In 2
Vehicle Emissions Control Information (VECI) 36
W
Wait to Start Light 7
WaFffi Engine, Starting Procedures 11
Warning Lights and Gauges 7
F u e ~ Filter Restriction Warning Light 7
Wait to Start Light 7
Water in Fuel Warning Light... 8
Warnings, Notes and 2
Washing the Diesel Engine 17
Water in Fuel Warning Light.. 7
48
~ I