1999 FORD E SERIES relay

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
4

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

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
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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
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