1999 FORD E SERIES fuel filter

DIESEL ENGINE INFORMATION
The diesel engine fuel system consists of:
²a frame-mounted electric fuel supply pump
²an engine mounted fuel filter/water separator
²a fuel restriction sensor
²a 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 ªService Guideº for more
information. The filter bowl should be drained at regular intervals or
when the ªWATER IN FUELº 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).
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 and fuel economy.
The turbocharger, which is supplied pressurized oil, is also used to
actuate an exhaust backpressure warm-up system (if equipped).
Pressurized oil returning to the turbocharger is routed to the exhaust
backpressure actuator. During exhaust backpressure operation, the
engine's sound will be altered and you may notice a change in engine
performance while it's engaged. This function occurs only during cold
weather warm-up cycle.
Diesel information
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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.
The air filter element should be
replaced when the yellow band on
the 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, reset the restriction
gauge by pressing the button the
end of the gauge.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
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WAIT TO START
With the key in the ON position, the
WAIT TO START light will illuminate
if glow plug heat is necessary as a
starting aid. Wait until the light goes
off before starting. The light should
always illuminate briefly, when the ignition key is in the ON position. If
the light does not illuminate, there may be a problem. Refer to the
Startingchapter in this guide. 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 fuel filter/water separator has a significant quantity of water in
it.
If the light illuminates when the engine is running, stop the vehicle as
soon as safely possible, shut off the engine, then drain the filter bowl.
Refer to theGeneral maintenancechapter for 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.
WAIT
TO
START
WATER
IN
FUEL
Warning lights
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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 grade engine oil also makes starting easier under
these conditions.
At temperatures below ±7ÉC (20ÉF), Number 2±D diesel fuel may thicken
enough to clog the fuel filter. Your engine is equipped with a fuel
filter/heater/water/separator to keep the wax melted which will help
prevent fuel filter clogging. However, if the engine starts but stalls after a
short time and will not restart, the fuel filter may be clogged. For best
results in cold weather, use Number 1±D diesel fuel or ªwinterizedº
Number 2±D diesel fuel which has an additive to minimize wax
formation.
Your vehicle is also equipped with a bypass relief valve, located on the
in-tank fuel sending unit, which provides fuel flow to the engine if the
fuel pickup should become plugged by ice or wax. To allow this bypass
valve to function and avoid engine fuel starvation, it is recommended
that, during cold weather operation 0ÉC (32ÉF) or below, the fuel level in
your tank should not be allowed to drop below 1/4 full. This will help
prevent air from entering the fuel system and stalling the engine.
An auxiliary PCM 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 for improving cab heat.
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.
Starting
10

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.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low octane
rating or gasoline in the fuel). 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.
Diesel fuel must not be stored in a galvanized 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.
General maintenance information
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CHANGING FUEL FILTER
Removal
1. Remove fuel filter cap by turning
counterclockwise. 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
The engine will not run properly if the fuel filter is not installed
in housing.
1. Apply a coating of clean diesel 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.
Fuel with more than average impurities may require more frequent filter
changing intervals.
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21

After changing the fuel filter, the engine will purge the trapped air as it
runs. Engine may run roughly and smoke until the air is completely
eliminated.
ENGINE OIL
Checking 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.
4. Allow at least20 minutesafter engine shutdown to assure that the oil
contained in the upper parts of the engine has returned to the oil pan.
5. 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 ADD and OPERATING RANGE on the
dipstick by adding oil as required. The distance from ADD to
OPERATING RANGE on the dipstick represents 1.9L (2 quarts). Do not
overfill. If the oil level exceeds OPERATING RANGE, oil consumption
may result.
General maintenance information
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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.
Changing engine oil and filter
Change your oil and filter according to the ªService Guideº. Change more
frequently if your vehicle operation includes extended periods of idling
or low-speed operation, driving for a long time in cold temperatures or
driving short distances. See the following section ªEngine Lubrication for
Severe Service Operationº for all severe duty restrictions.
Use Ford Engine Oil Filter Part No. F4TZ-6731±A (FL±1995) or
equivalent. These filters protect your engine by filtering harmful,
abrasive or sludge particles. The FL±1995 filters particles significantly
smaller than most available ªwill fitº filters.
To replace, use an oil filter wrench to unscrew the filter from the oil
cooler fitting. Turn it horizontally to let excess oil drain off, and remove.
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 base.Then tighten another 1±1/4 to 2 turns.Fill
the crankcase and run the engine to check for leaks.
Continuous contact with USED motor oil has caused cancer in
laboratory mice. Protect your skin by washing with soap and
water.
APISERVICECG-4/SHSAE15W-40
General maintenance information
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