2004 FORD E SERIES air filter

•engine oil temperature (EOT) sensor
•barometric 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 toManual
transmission shift speedsin 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.
Air filter restriction gauge, E-Series
The restriction gauge, located on
the clean-air side of the air cleaner
upper housing, shows if the air filter
is clogged. Refer toEngine
CompartmentinService points
chapter.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
5

The air filter element should be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when maximum restriction
is reached. After servicing the air
filter element, reset the restriction
gauge by pressing the button on the
end of the gauge.
Air filter restriction gauge, F-250/350/450/550 & Excursion
The restriction gauge, located on
the upper housing of the air cleaner
assembly, monitors the condition of
the air filter element in two ways:
First, the colored indictor inside the
gauge highlights the percentage that
the air filter element is clogged with
dust or contaminants. Refer to
Engine CompartmentinService
Pointschapter.
Second, the gauge contains an electrical switch which illuminates a
warning light on the instrument cluster when the air filter element is
100% clogged. Refer toF-250/350/450/550, ExcursioninWarning
Lightschapter.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance. If the vehicle is operated in
extremely dusty conditions, check the gauge at least every 800 km (500
miles), or two weeks, whichever comes first.
The air filter element must be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when the maximum
restriction is reached.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
6

Blowing-out the air filter element with compressed air is not
recommended as the compressed air may damage the filter paper.
Note:It is not possible to determine the level of filter clogging by visual
appearance alone. A filter which appears to be dirty may actually have
several thousand kilometers (miles) of life remaining.
Always use the underhood air filter restriction gauge or engine
air filter warning light on the instrument cluster to determine
when the air filter element needs to be changed.
After servicing the air filter element,
reset the restriction gauge by
pressing the button on the end of
the gauge.
Note:If the vehicle is operated in a heavy snow storm, in blowing snow
or the vehicle is equipped with a snowplow, the engine air filter element
may become partially clogged with snow and/or ice. If this occurs, the air
filter restriction gauge will move to the CHANGE FILTER mark and the
engine may experience a significant reduction in power output. The
vehicle may be driven under these conditions for up to 160 km (100
miles) without damage to the engine or related components.
At the earliest opportunity, clear all snow and ice from the air induction
system and replace the air filter element, or remove the element and dry
it out. Reset the restriction gauge by pressing the button on the end of
the gauge.
The air filter warning light on the instrument cluster may be used, in
addition to the underhood restriction gauge, to monitor the condition of
the air filter element. Refer to theWarning Lightschapter.
Diesel information
7

WATER IN FUEL
•E-Series
•F-250/350/450/550, Excursion
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.
ENGINE AIR FILTER (F-250/350/450/550 & EXCURSION)
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The vehicle may be driven with the engine air filter warning light
illuminated for up to 400 km (250 miles) without damaging the engine or
related components. However, the air filter elementmustbe replaced at
the earliest opportunity. Refer toAir filter restriction gaugein the
Diesel informationchapter for more information.
Warning lights
9

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.
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. Refer toEngine Oil Specificationsin theGeneral
maintenance informationchapter.
At temperatures below–7°C (20°F), 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“winterized”
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 0°C (32°F) 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.
In cold weather below 0°C (32°F) your Diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). The sound of the engine
may change also, as an exhaust device engages to improve heater
performance and reduce exhaust smoke.
Starting
11

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.
Refer toAir filter restriction gaugein theDiesel informationchapter
and Engine air filter in theWarning lightschapter for more information.
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.
Starting
12

Do not use fuel intended for agricultural use (agricultural fuel is
dyed red), home heating oil or any Diesel fuel not intended for
highway use. Damage to the fuel injection system or engine can
occur if an improper fuel is used.
Do not add gasoline, gasohol or alcohol to Diesel fuel. This practice
creates a serious fire hazard and engine performance problems.
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated Diesel fuel that meets the ASTM D
975 industry specification. Aftermarket additives can damage the injector
system or engine.
Do not blend used engine oil with Diesel fuel under any circumstances.
Blending used oil with the fuel will significantly increase your vehicle’s
exhaust emissions and reduce engine life due to increased internal wear.
Do not crank the engine for more than 30 seconds at a time as
damage to the starter motor may result.
If the engine fails to start in 30 seconds, turn the key to the OFF
position and wait 30 seconds before trying again.
Truck stops have pumps and nozzles designed for larger, heavy-duty
trucks. When refueling at truck stops: if the nozzle shuts off repeatedly
when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter change or if
you run out of fuel) the engine will purge the trapped air as it runs. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low cetane
rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of Diesel fuel.
Care should be taken whenever Diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
solution until it is run through the engine where it will be deposited in
the fuel injectors causing expensive-to-repair damage.
General maintenance information
27

CHANGING FUEL FILTER
Removal—F-250/350/450/550 and Excursion
1. Remove the engine appearance
cover.
2. Remove the fuel filter cap by
turning counterclockwise.
3. Remove and discard old fuel filter
element and fuel filter o-ring.
4. Carefully clean the mating
surfaces.
Removal — E-Series
1. Remove the engine appearance cover.
2. Disconnect the battery ground cable, then all electrical connectors,
vacuum tubes and fasteners as necessary for removal.
3. Release the four retaining clamps on the air cleaner assembly, then lift
the air cleaner cover and remove the air cleaner(s).
4. Loosen the clamp on the air inlet tube, then disconnect the air inlet
tube from the resonator.
5. Remove the three bolts on the turbocharger heat shield, then the
turbocharger heat shield.
6. Remove the bolt and resonator from the vehicle.
General maintenance information
28