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Table of contents
Introduction 2
Diesel information 4
Warning lights 7
Starting 9
Driving tips 12
General maintenance information 16
Scheduled maintenance 32
Minor troubleshooting guide 33
Capacities and specifications 36
Service points 38
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Introduction The following warning may be required by California law: California Proposition 65 Warning: Diesel engine exhaust, some of its constituents, and certain vehicle components contain or may emit chemicals known to the State of California to cause cancer or birth defects or other reproductive harm. 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 o
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Introduction 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. WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Certain fluids contained in vehicles and certain products of component contain or emit
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Diesel information DIESEL ENGINE INFORMATION The diesel engine fuel system consists of: ² a frame-mounted electric fuel supply pump ² an engine mounted fuel filter/water separator ² a fuel restriction sensor ² a unit injector for each cylinder The combination fuel filter/water separator removes both water and impurities from the fuel. The filter should be changed at the recommended service interval. Refer to the “Service Guide” for more information. The filter bowl should be drained at regular i
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Diesel information Fast start glow plug system The glow plug system consists of: ² eight glow plugs ² the glow plug relay ² engine oil temperature (EOT) sensor ² barometric pressure (BARO) sensor The glow plug system is electronically controlled by the PCM. The PCM 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 decre
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R E R T E L T I L F I F E E G E E G N G G N A A U U H H A A C C G G R R Diesel information Air filter restriction gauge The restriction gauge, located on the clean-air side of the air cleaner upper housing, shows if the air filter is clogged. Refer to “Engine Compartment” in Service Points chapter. The air filter element should be replaced when the colored band on the gauge reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reac
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Warning lights ECONOLINE F–250/350/450/550, EXCURSION WAIT TO START With the key in the ON position, the WAIT WAIT TO START light will illuminate if glow plug heat is necessary as a TO starting aid. Wait until the light goes START off before starting. The light should always illuminate briefly, when the ignition key is in the ON position. If the light does not illuminate, there may be a problem. Refer to the Starting chapter in this guide. After the engine starts, the light should remain off. Th
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Warning lights WATER IN FUEL During refueling, it is possible for WATER water-contaminated diesel fuel to be pumped into your tank. Your vehicle IN fuel system is equipped with a fuel 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 fuel filter/water separator has a significant quantity of water in it. If the light illuminates when the engine is running, stop
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Starting STARTING THE ENGINE Read all starting instructions carefully before you start your vehicle. For temperatures below 0°C (32°F), the use of the correct grade engine oil is essential for proper operation. If your vehicle is equipped with a manual transmission, make sure the parking brake is set fully before you turn the key. Depress the clutch pedal and place the gearshift in the neutral position. The clutch must be fully depressed in order to operate the starter. Do not press the accelera
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Starting 5. 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 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
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Starting Operation in standing water Ingestion of water into the diesel engine can result in immediate and severe damage to the engine. If driving through water, slow down to avoid splashing water into the intake. If the engine stalls, and ingestion of water into the engine is suspected, do not try to restart the engine. Consult your dealer for service immediately. Follow the cylinder compression test procedure outlined in the Workshop Manual, then check the engine oil for contamination. Engine
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Driving tips DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED) If your vehicle is equipped dual fuel tanks, you will have a selector control, located to the right of the steering wheel, which allows you to draw fuel from either tank. Your fuel gauge will display the amount of fuel in the currently selected tank. Fuel level indication is delayed for several minutes when the tank selector switch is actuated. Fuel level indication can be obtained immediately by turning off and restarting the engine. MA
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Driving tips Upshift and downshift according to the following shift speed charts: Upshifts when accelerating (recommended for best fuel economy) 6-speed transmission 1 Shift from: Transfer case position (if equipped) 2H or 4H 4L LO-1 8 km/h (5 mph) 3 km/h (2 mph) 1-2 16 km/h (10 mph) 6 km/h (4 mph) 2-3 32 km/h (20 mph) 13 km/h (8 mph) 3-4 48 km/h (30 mph) 19 km/h (12 mph) D 4- 64 km/h (40 mph) 24 km/h (15 mph) (Overdrive) 1 Maximum downshift speeds 6-speed transmission 2 Shift from: Transfer cas
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Driving tips Econoline trailer towing tables Your vehicle may tow a class I, II or III trailer provided the maximum trailer weight is less than or equal to the maximum trailer weight listed for your engine and rear axle ratio on the following charts. GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum Trailer weight Maximum Frontal Rear axle GCWR-kg range-kg (lbs.) Area Of ratio 2 2 (lbs.) (0-Maximum) Trailer-m (ft ) Regular Van E-350 3.55 7 258 (16 000) 4 536 (10 000) 5.52 (60) 4.10 9 0
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Driving tips Your vehicle’s load capacity is designated by weight, not by volume, so you cannot necessarily use all available space when loading a vehicle. Distribute the load so that only 10 to 15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch. Towing a trailer places an additional load on your vehicle’s engine, transmission, axle, brakes, tires and suspension. Inspect these components carefully after any towing operation. Do not e
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General maintenance information SCHEDULED MAINTENANCE The Scheduled Maintenance Services in the Service Guide 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. WASHING THE DIESEL ENGINE Never wash the engine when it is warm, hot or running. Spraying water or other cleaning flu
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General maintenance information 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 sy
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General maintenance information CHANGING FUEL FILTER Removal — F-Series Super Duty and Excursion only 1. Remove the engine appearance cover. 2. Remove the fuel filter cap by turning counterclockwise. 3. Remove and discard old fuel filter element and fuel filter o-ring. 4. Carefully clean the mating surfaces. Removal — Econoline only 1. Remove the engine appearance cover. 2. Disconnect the battery ground cable, then all electrical connectors, vacuum tubes and fasteners as necessary for removal. 3
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General maintenance information 7. Remove the fuel filter cap by turning counterclockwise. 8. Remove and discard old fuel filter element and fuel filter o-ring. 9. Carefully clean the mating surfaces. Installation — F-Series Super Duty and Excursion only The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean diesel fuel to the new fuel filter o-ring. 2. Install new fuel filter o-ring onto fuel filter element. 3. Install new fuel filter and o-
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General maintenance information Installation — Econoline only The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean diesel fuel to the new fuel filter o-ring. 2. Install new fuel filter o-ring onto fuel filter element. 3. Install new fuel filter and o-ring into the fuel filter housing. 4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into the fuel filter element. Tighten cap until it contacts the housing. 5. Install the
