2003 FORD SUPER DUTY 7.3L Diesel Engine Owners Manual

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.
Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
•towing a trailer over 1,600 km (1,000 miles)
•sustained, high speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation during hot
weather-above 32°C [90°F]).
•frequent or extended idling (over 10 minutes per hour of normal
driving).
•operating in severe dust conditions.
•frequent, short trips of 16 km (10 miles) or less during freezing
weather
If you are operating your vehicle under any of these conditions, observe
the following service procedures:
•Change engine oil and filter every 5,000 km (3,000 miles).
•Use Motorcraft oil or an equivalent oil conforming to Ford
Specification WSS-M2C171–C or API categories CH-4, CH-4/SJ,
CH-4/SL or DHD-1. If CH-4 oil is not available, CG-4 is acceptable..
For more information refer theSevere Duty Maintenance Schedulein
the“Service Guide”.
REPLACING THE AIR FILTER ELEMENT
When replacing the air filter element, use the Motorcraft air filter
element listed. Refer toLubricant and Maintenance Materials
Specificationsin this supplement.
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Failure to use the correct air filter element may result in severe
engine damage.
1. Remove air filter element from the housing, taking care to prevent dirt
from falling into the engine air intake.
2. Clean the air filter housing and cover to ensure good sealing.
3. Install a new air filter element. Be careful not to crimp the filter edges
between the air filter housing and cover. This could cause damage to the
air filter element and possible severe damage to the engine.
When servicing the air filter, always be sure that the rubber
water drain hose is not kinked or obstructed. 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 engine is equipped with a combination fuel filter/water separator
located in the“V”of the engine.
•E-Series
•F-250/350/450/550, Excursion
Water should be drained from the
filter bowl whenever the warning
light comes on or every 8 000 km
(5 000 miles). The WATER IN FUEL light will come on when
approximately 100 cc (0.2 pints) of water accumulates in the separator.
Replace the fuel filter with Motorcraft Part No. FD-4596 (Ford Part No.
F81Z-9N184–AA).
Fuel filter/water separator drain procedure
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the fuel filter/water separator. Fuel may ignite if separator is
drained while the engine is running or vehicle is moving.
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2. Open the hood. Place an
appropriate container under the
filter drain under the vehicle.
3. Locate the fuel filter drain valve. If necessary, remove the engine
appearance cover. Refer toEngine Compartmentin theService points
chapter.
4.On F-Series and Excursion
models,open fuel filter drain valve
by turning clockwise. Allow to drain
for approximately 25 seconds or
until clean fuel is observed. Close
filter drain valve by turning
counterclockwise until firmly seated.
DRAIN
CLOSE
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4.On E-Series models,open fuel filter drain valve by pulling on the
release handle. Allow to drain for approximately 25 seconds or until
clean fuel is observed. Close filter drain valve by resetting handle to
original position.
5. Verify that the fuel filter drain valve is closed. If removed, install the
engine appearance cover.
6. Close the hood and remove the container from under the vehicle.
7. 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.
ENGINE COOLANT
Checking engine coolant
The concentration and level of engine coolant should be checked at the
mileage intervals listed in the scheduled maintenance guide. The coolant
concentration should be maintained at 50/50 coolant and water, which
equates to a freeze point of -36°C (-34°F). Coolant concentration
testing is possible with a hydrometer or antifreeze tester (such as the
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Rotunda Battery and Antifreeze Tester, 014–R1060). The level of coolant
should be maintained at the“cold full”of“cold fill range”level in the
coolant reservoir. If the level falls below, add coolant per the instructions
in theAdding Engine Coolantsection.
Your vehicle was factory-filled with a 50/50 engine coolant and water
concentration. If the concentration of coolant falls below 40% or above
60%, the engine parts could become damaged or not work properly.A
50–50 mixture of coolant and water provides the following:
•freeze protection down to -36°C (-34°F).
•boiling protection up to 129°C (265°F).
•protection against rust and other forms of corrosion.
•enables calibrated gauges to work properly.
When the engine is cold, check the level of the engine coolant in the
reservoir.
•The engine coolant should be at the“cold fill level”or within the“cold
fill range”as listed on the engine coolant reservoir (depending upon
application).
•Refer to the scheduled maintenance guide for service interval
schedules.
•Be sure to read and understandPrecautions when servicing your
vehiclein your owner guide.
If the engine coolant has not been checked at the recommended interval,
the engine coolant reservoir may become low or empty. If the reservoir is
low or empty, add engine coolant to the reservoir. Refer toAdding
engine coolantin this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant, antifreeze or windshield washer fluid outside of its specified
function and vehicle location.
Vehicles with Diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors cause the additives in the
coolant to“wear out”in a shorter time. For vehicles equipped with green
coolant, Ford recommends an interim service interval performed at 12
months or 24,000 km (15,000 miles), whichever occurs first. Add
237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 to the
cooling system. For vehicles with extensive idling time, add 237–295 ml
(8–10 oz.) of coolant additive FW-16 after every 500 hours of operation.
(see scheduled maintenance guide). For vehicles equipped with yellow
coolant (Extended Life Coolant), the service interval is five years or
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100,000 miles and three years or 50,000 miles thereafter. Vehicles
equipped with the Extended Life Coolant do not require any additives.
Adding engine coolant
When adding coolant, make sure it is a 50/50 mixture of engine coolant
and distilled water. Add the mixture to the coolant reservoir,when the
engine is cool, until the appropriate fill level is obtained.
Do not add engine coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
Do not put engine coolant in the windshield washer fluid
container. If sprayed on the windshield, engine coolant could
make it difficult to see through the windshield.
The cooling system in your vehicle is filled with either green-colored
Motorcraft Premium Engine Coolant meeting Ford specification
ESE-M97B44–A or yellow-colored Motorcraft Premium Gold Engine
Coolant meeting Ford Specification WSS-M97B51–A1. To determine your
vehicle’s coolant type (color), check your coolant reservoir.
•Add Motorcraft Premium Engine Coolant (green-colored),
VC-4–A (U.S.) or CXC-10 (Canada) or Motorcraft Premium
Gold Engine Coolant (yellow-colored), VC-7–A, depending on
the type of coolant originally equipped in your vehicle.If you
are unsure which type of coolant your vehicle requires, check your
coolant reservoir or contact your local dealer.
•Do not add/mix an orange-colored, extended life coolant such
as Motorcraft Speciality Orange Engine Coolant, VC-2 (US) or
CXC-209 (Canada), meeting Ford specification WSS-M97B44–D
with the factory-filled coolant.Mixing Motorcraft Speciality Orange
Engine Coolant or any orange-colored extended life product with your
factory filled coolant can result in degraded corrosion protection.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
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•Do not use alcohol, methanol or brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
•Do not mix with recycled coolant unless from a Ford-approved
recycling process (seeUse of Recycled Engine Coolantsection).
For vehicles with overflow coolant systems with a non-pressurized cap
on the coolant recovery system, add coolant to the coolant recovery
reservoir when the engine is cool. Add the proper mixture of coolant and
water to the“cold full”level. For all other vehicles, which have a coolant
degas system with a pressurized cap, or if it is necessary to remove the
coolant pressure relief cap on the radiator of a vehicle with an overflow
system, follow these steps to add engine coolant.
To reduce the risk of personal injury, make sure the engine is
cool before unscrewing the coolant pressure relief cap. The
cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly.
1. Before you begin, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the coolant
pressure relief cap on the coolant reservoir (an semi-clear plastic bottle).
Slowly turn cap counterclockwise (left) until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
5. Fill the coolant reservoir slowly with the proper coolant mixture (see
above), to within the“cold fill range”or the“cold full”level on the
reservoir. If you removed the radiator cap in an overflow system, fill the
radiator until the coolant is visible and radiator is almost full.
6. Replace the cap. Turn until tightly installed. (Cap must be tightly
installed to prevent coolant loss.)
After any coolant has been added, check the coolant concentration see
Checking Engine Coolantsection). If the concentration is not 50/50
(protection to–34°F/–36°C), drain some coolant and adjust the
concentration. It may take several drains and additions to obtain a 50/50
coolant concentration.
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Whenever coolant has been added, the coolant level in the coolant
reservoir should be checked the next few times you drive the vehicle. If
necessary, add enough 50/50 concentration of engine coolant and
distilled water to bring the liquid level to the proper level.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant per
month, have your dealer check the engine cooling system. Your cooling
system may have a leak. Operating an engine with a low level of coolant
can result in engine overheating and possible engine damage.
Replacing coolant
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%.
When refilling the coolant system either as part of the regular
maintenance (refer to the scheduled maintenance guide), or due to
service performed, adhere to the following instructions:
1. Drain and flush the cooling system to remove dirt deposits, oil, rust
particles.
Note:When filling the system with Motorcraft Premium Engine Coolant
(green-colored) or equivalent meeting Ford specification
ESE-M97B44–A, a supplemental coolant additive is required. Refer to
Adding Coolantsection to determine the coolant type in your vehicle.
Add 1.89L (4 pints) of Motorcraft Heavy Duty Cooling System Additive
FW-16 or equivalent meeting Ford specification ESN-M99B169–A,
directly to the cooling system. An additional 237–295 ml (8–10 oz.) of
supplemental coolant additive FW-16 should be added at 24,000 km
(15,000 mile) intervals to maintain proper concentration.Do not use
this additive with yellow-colored coolant meeting Ford
specification WSS-M97B51–A1.
2. Fill the coolant reservoir with the specified coolant/water mixture until
the level stabilizes at the top hose fitting. Replace and tighten cap. Fill
the coolant bottle to the cold fill mark.
3. Reinstall the coolant bottle cap.
4. 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.
5. Immediately shut off engine. Allow engine to cool before removing
coolant bottle cap. Cautiously remove coolant bottle cap and add coolant
to Cold Fill mark.
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