1999 FORD E SERIES ignition

Fast start glow plug system
The glow plug system consists of:
²eight glow plugs
²the glow plug relay
²engine oil temperature (EOT) sensor
²barometric 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 decreases as the engine oil temperature and
barometric pressure increase.
Engine cooling system
The 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 PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
For maximum vehicle speed in various gears, refer to the ªTransmission
shift speedº chart in theDriving tipschapter. Do not exceed 3,600 rpm.
Maximum engine governed speed is 3,000±4,000 rpm depending on
engine load. Excessive rpm can only be achieved by manually
downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause severe
engine damage.
Diesel information
5

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
8

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
Starting procedures are also shown on the vehicle visor. For
temperatures below 0ÉC (32ÉF), 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
accelerator during starting.
If your vehicle is equipped with an automatic transmission, ensure the
gearshift lever is in P (Park) and the parking brake is set before you turn
the key. Do not press the accelerator during starting.
COLD WEATHER STARTING
Do not crank the engine for more than 30 seconds at a time as starter
damage may occur. If the engine fails to start, turn the key to OFF and
wait 30 seconds before trying again.
Do not use starting fluid such as ether in the air intake system (see Air
Cleaner Decal). Such fluid could cause immediate explosive damage to
the engine and possible personal injury.
Do not add gasoline, gasohol or alcohol to diesel fuel. This practice
creates a serious fire hazard and causes engine performance problems.
1. Make sure all vehicle occupants have buckled their safety belts. For
more information on safety belts and their proper usage, refer toSeating
and safety restraintschapter in the owner guide.
2. Make sure the headlamps and vehicle accessories are off.
3. Turn the key to the ON position.
When the WAIT TO START light
goes off, turn the key to START.
(For Canadian vehicles, the daytime
running lamps will be on if the
parking brake is not applied and the key is turned to ON.)
4. When the engine starts, release the key. The glow plugs will continue
to be activated for up to two minutes. If the engine is not started before
the activation ceases, the glow plug system must be reset by turning the
ignition key to OFF.
WAIT
TO
START
Starting
9

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

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 block heater (if equipped)
Refer to theStartingchapter in your Owner Guide.
JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Do not push start your vehicle. You could damage the catalytic
converter.
Batteries contain sulfuric acid which burns skin, eyes, and
clothing.
Preparing your vehicle
Also see the label on the battery.
1. Use only a 12±volt supply to start your vehicle. If you connect your
battery to a 24±volt power supply you can damage your starter, ignition
system and other electrical components. Do not attach the jumper cables
to the glow plug relay as this could severely damage the glow plugs,
injector driver module and PCM.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle's electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure theydo nottouch. Set the parking brake on both vehicles
and stay clear of the engine cooling fan and other moving parts.
Starting
11

IF THE ENGINE WON'T CRANK
Turn on the headlights. If the lights are dim, do not go on at all or if
when the ignition is turned to START the lights become dim or go out,
the battery connections may be loose or corroded, or the battery may be
discharged. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to START, this may also
indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter relay terminals. Also, make
sure the relay bracket is securely fastened to its mounting surface.
If the starter relay clicks, but the starter does not crank, check the
connections at the starter terminal. If a discharged battery is suspected,
have it checked and corrected.
²For vehicles with manual transmissions, the clutch pedalmustbe fully
depressed in order for the starter to operate.
²For vehicles with automatic transmissions, the gearshift lever must be
in Park or Neutral in order for the starter to operate.
²Try 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.
²If all electrical connections are tight and you need assistance to start,
see ªJump Starting Your Vehicleº in theStartingchapter.
IF ENGINE CRANKS BUT WON'T START
Prolonged starter cranking (in excess of 30 seconds) could cause
damage to the starter motor.
²Check the fuel gauge. You may be out of fuel. If the gauge shows that
there is fuel in the tank, the trouble may be in the electrical system or
the fuel system. If equipped with an auxiliary tank, be sure that the
tank control switch is set for the tank with fuel and not on an empty
tank.
²Leaving 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.
Minor troubleshooting guide
34