2004 FORD E SERIES air filter

7. Remove the fuel filter cap by
turning counterclockwise.
8. Remove and discard old fuel filter
element and fuel filter o-ring.
9. Carefully clean the mating
surfaces.
Installation—F-250/350/450/550 and Excursion
The engine will not run properly if the fuel filter is not installed
in housing.
1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring.
2. Install new fuel filter o-ring onto fuel filter element.
3. Install new fuel filter and o-ring into the fuel filter housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install engine appearance cover.
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.
Installation—E-Series
The engine will not run properly if the fuel filter is not installed
in housing.
General maintenance information
29

1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring.
2. Install new fuel filter o-ring onto fuel filter element.
3. Install new fuel filter and o-ring into the fuel filter housing.
4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
5. Install the resonator and resonator bolt.
6. Install the turbocharger heat shield, then the three bolts on the
turbocharger heat shield.
7. Connect the air inlet tube to the resonator, then tighten the clamp on
the air inlet tube.
8. Install the air cleaner(s), close the air cleaner cover, then close the
four retaining clamps on the air cleaner assembly.
9. Connect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for installation.
10. Install the engine appearance cover.
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 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.
General maintenance information
30

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.
General maintenance information
33

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.
General maintenance information
34

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
General maintenance information
36

VEHICLE EMISSIONS CONTROL INFORMATION (VECI)
Emissions information appears on
the VECI decal on the engine valve
cover. This decal identifies engine
displacement and provides certain
engine specifications.
SCHEDULED MAINTENANCE SERVICES
Refer to your scheduled maintenance guide for details of maintenance on
your vehicle.
If you are using your vehicle in a manner in which it will remain
stationary (door to door service, taxi, etc.), then it is recommended that
you change the engine oil every 200 engine hours as opposed to a
mileage limit. Since most vehicles are not equipped with hourmeters, it
may be necessary for you to approximate your time and plan engine oil
and filter changes accordingly.
Any modification of the emissions control system could create liability
under federal law (U.S.) if made prior to sale and registration, under the
laws of some states if made thereafter. Further, federal law prohibits
vehicle manufacturers, dealers and other persons engaged in the
business of repairing, servicing, selling, leasing or trading motor vehicles
as well as fleet operations from knowingly removing or rendering an
emissions control system inoperative after sale and delivery to an
ultimate purchaser. In Canada, modifications of the emissions control
system could create liability under applicable federal or provincial laws.
Scheduled maintenance
44

The complexity of the Diesel engine makes it so the owner is
discouraged from attempting to perform maintenance other than the
services described in this supplement.
If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
Do not use starting fluid such as ether or gasoline in the Diesel
air intake system. Such fluids can cause immediate explosive
damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your Diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
Minor troubleshooting guide
45

LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS
ItemFord Part
NameFord Part
NumberFord Specification
Engine OilMotorcraft
Motor Oil
15W40 Super
Duty, 10W30
Super DutyXO-15W40-QSD,
XO-10W30-QSDWSS-M2C171-C,
CH-4/SJ/SL, DHD-1
Engine Oil
Filter (Use this
filter Only)-F4TZ-6731-A
(FL-1995)-
Air Filter
(F-Series and
Excursion)
1- FA-1680 ES-E95AE-9601-AA
Air Filter
(E-Series)
(2 Required)- FA-1618 ES-E95AE-9601-AA
Battery
(2 Required)- BXT-65-750 -
Engine
Coolant
2
Motorcraft
Premium
Engine Coolant
(green-colored)VC-4–A (US)
or CXC-10
(Canada)ESE-M97B44–A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51–A1
Engine Coolant
Additive
3
Motorcraft
Heavy Duty
Cooling System
AdditiveFW-16 ESN-M99B169–A
Manual
TransmissionMotorcraft
MERCON
AT FXT-2–QDX MERCON

1Always use the authorized Motorcraft air filter listed.
Failure to use the correct air filter may result in severe engine
damage.
2Add the engine coolant type originally equipped with your vehicle.
3Use only when filling with Motorcraft Premium Engine Coolant
(green-colored).
Capacities and specifications
49