2003 FORD SUPER DUTY service interval

DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•an engine-mounted secondary fuel filter
•frame-mounted Horizontal Fuel Conditioner Module (HFCM)
•a unit injector for each cylinder
The HFCM acts as a primary fuel filter/water separator which removes
both water and impurities from the fuel. The engine-mounted fuel filter
and the HFCM filter should be changed at the recommended service
interval. Refer to theScheduled maintenance guidesection of this
manual for more information.
The HFCM should be drained at
regular intervals or when the
WATER IN FUEL 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) and Fuel Injection Control Module (FICM).
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, fuel economy and
engine life. Refer to the engine oil specification chart located under
Engine oil specificationsin theGeneral maintenance information
chapter.
Diesel information
4

Removal - Engine-mounted fuel filter
1. Remove the fuel filter cap by
turning counterclockwise.
2. Remove and discard the old fuel
filter element.
3. Carefully clean the mating
surfaces.
Installation-both
The engine will not run properly if the fuel filter is not installed
in housing.
1. Install the new fuel filter and cap seal (from Ford Part No.
3C3Z-9N184–CA) into the fuel filter housing.
2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run roughly and smoke until the air
is completely eliminated.
Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
ENGINE OIL
Checking the 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.
3. 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.
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27

4. Protecting yourself from engine
heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
6. 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.
Engine oil specifications
To help achieve proper engine performance and durability, it is important
that only engine lubricating oils of the proper quality are used in your
Diesel engine and that the engine oil is changedno laterthan the
recommended interval. Diesel engines require specially formulated oil to
resist contamination. Proper quality oils also provide maximum efficiency
of the crankcase ventilating system which reduces air pollution.
For normal or severe service, use Motorcraft oil or an equivalent oil
conforming to Ford Specification WSS-M2C171–D or API Service
categories CI-4, CI-4/SL or DHD-1. If CI-4 oil is not available, CH-4 is
acceptable..
Engine oils with improved fuel economy properties (energy conserving)
are currently available. If you use an energy conserving oil, be sure it
meets the recommended Ford Specification,APIservice categories and
SAE viscosity grades listed in the Lubricant and Maintenance Materials
Specifications chart. Some energy conserving oilsdo notmeet the
requirements necessary for your Diesel engine.
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28

* Heavy duty trailer towing with ambient temperatures above 10°C
(50°F) requires 15W-40 engine oil.
The use of correct oil viscosities for Diesel engines is important for
satisfactory operation. Determine which oil viscosity best suits the
temperature range you expect to encounter for the next service interval.
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 scheduled maintenance guide.
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
Engine lubrication for severe service operationfor all severe duty
restrictions.
Use Ford Engine Oil Filter Part No. 3C3Z-6731–AA (FL–2016) or
equivalent. These filters protect your engine by filtering harmful,
abrasive or sludge particles. The FL–2016 filters particles significantly
smaller than most available“will-fit”filters.
General maintenance information
29

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 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. Replace the engine coolant
initially after five years or 100,000 miles and three years or 50,000 miles
thereafter. Vehicles equipped with the yellow 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.
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32

Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To assure the proper
performance of your vehicle and its emission control systems, it is
imperative that scheduled maintenance be completed at the designated
intervals.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraft or Ford authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult your Warranty Guide for complete warranty information.
Quality Care - one stop for all your maintenance needs
When you need maintenance for your Ford, Lincoln or Mercury vehicle,
there’s only one name to remember: Quality Care, available at your Ford
and Lincoln Mercury dealership. From scheduled maintenance to more
complicated repair work, nobody knows your car or truck better. Protect
your investment by choosing Quality Care service.
The right people
The difference is factory training and equipment, which means nobody is
more qualified to work on your Ford, Lincoln or Mercury than our
Quality Care service technicians. They’ll fix it right the first time.
The right parts
From headlights to taillights and everything in between, nothing fits like
an original. With Quality Care service, you’ll get the parts made
especially for your car or truck–genuine Ford and Motorcraft
parts.
The right prices
Our commitment to quality extends to pricing as well as service. Your
Ford and Lincoln Mercury Dealership offers competitive prices on
Genuine Ford and Motorcraft
parts and services, making Quality Care a
great value.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed by
the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in the Owner’s Guide.
General Owner’s Information
48

Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
Maximum Oil Change Interval:
Normal Schedule: 7,500 miles or 6 months, whichever occurs first.
Special Operating Conditions: 5,000 miles or 6 months, see appropriate
schedule.
Check every month:
•Check function of all interior and exterior lights
•Check tires for wear and proper air pressure
•Check engine oil fluid level
•Check windshield washer solvent fluid level
•Check and drain fuel filter/water separator
Check every six months:
•Check lap/shoulder belts and seat latches for wear and function
•Check air pressure in spare tire
•Check that externally-mounted spare tire is tight (see Owner’s Guide)
•Check power steering fluid level
•Check washer spray, wiper operation and clean all wiper blades
•Check parking brake for proper operation
•Check and lubricate all hinges, latches and outside locks
•Check and lubricate door rubber weatherstrips
•Check and clean body and door drain holes
•Check safety warning lamps (brake, ABS, air bag, safety belt) for
operation
•Check cooling system fluid level and coolant strength
•Check battery connections and clean if necessary
•Check clutch fluid level, if equipped
General Owner’s Information
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NORMAL SCHEDULE
The following section contains the“Normal Schedule.”This schedule is
presented at specific mileage intervals with exceptions noted.
Additional information available on the Web
To learn more about the importance of routine and dealer-performed
maintenance on your vehicle, please visit the Ford Customer Service
website. You’ll also find important warranty information, customer
assistance, technical expertise, frequently asked questions and much
more. The website location is at: www.ford.com/
Then go to the service pick at the web site.
12,000 km (7,500 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Inspect engine air filter
24,000 km (15,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Inspect engine air filter
•Replace engine- and frame-mounted fuel filters
•Inspect steering linkage, suspension and, if equipped, driveshaft and
ball joints
•Inspect engine cooling system and hoses
•Inspect brake system
•Inspect exhaust system and heat shields
•Check wheels for end play and noise
•Inspect and lubricate 4x2 ball joints (except F-450/F-550)
•Inspect and lubricate steering idler arms
•Replace cabin air filter, if equipped
•Inspect half-shaft boots, if equipped
36,000 km (22,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
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