2004 FORD F250 engine

EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with applicable
exhaust emission standards. To make sure that the catalytic converter and
other emission control components continue to work properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
•Have the items listed in yourScheduled Maintenance Guide
performed according to the specified schedule.
The scheduled maintenance items listed in theScheduled Maintenance
Guideare essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of theService engine soonlight, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By law,
vehicle owners and anyone who manufactures, repairs, services, sells,
leases, trades vehicles, or supervises a fleet of vehicles are not permitted to
intentionally remove an emission control device or prevent it from working.
Information about your vehicle’s emission system is on the Vehicle
Emission Control Information Decal located on or near the engine. This
decal identifies engine displacement and gives some tune up specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
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On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When theCheck
engine/Service engine soonlight illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause yourCheck
engine/Service engine soonlight to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck engine/Service engine soonlight should turn off. (A
driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck engine/Service engine soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If yourCheck engine/Service engine
soonlight is on, refer to the description in theWarning lights and
chimessection of theInstrument Clusterchapter. Your vehicle may not
pass the I/M test with theCheck engine/Service engine soonlight on.
If the vehicle’s powertrain system or its battery has just been serviced, the
on-board diagnostics system is reset to a“not ready for I/M test”condition.
To ready the on-board diagnostics system for I/M testing, a minimum of 30
minutes of city and highway driving is necessary as described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
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CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCONAT F.
Check the fluid level when it is at ambient temperature, 20°–80°F
(-7°–25°C):
1. Check the fluid level on the dipstick. It should be between the arrows
in the FULL COLD range. Do not add fluid if the level is within this
range.
2. If the fluid level is low. Add fluid to bring fluid level up to be between
the arrows in the FULL COLD range.
3. Start the engine.
4. While the engine idles, turn the steering wheel left and right several
times.
5. Turn the engine off.
6. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
7. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the“MAX”line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
MAX
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TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to yourScheduled Maintenance Guidefor scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
Low fluid level
Do not drive the vehicle if the fluid
level is at the bottom of the dipstick
and the ambient temperature is
above 10°C (50°F).
ADD COLD HOT DO NOT ADD
DON'T ADD IF IN CROSSHATCHED AREA  CHECK WHEN HOT IDLING IN PARK
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If an overfill occurs, excess fluid
should be removed by a qualified
technician.
An overfill condition of
transmission fluid may cause
shift and/or engagement
concerns and/or possible
damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
Automatic transmission fluid filter (if equipped)
The TorqShift automatic
transmission is equipped with a
serviceable external fluid filter
mounted on the frame rail. Refer to
theScheduled Maintenance Guide
for service intervals.
To replace the transmission filter:
1. Shut off the engine.
2. Unscrew filter housing.
3. Replace filter with a new authorized Motorcraft filter element. Refer to
theMotorcraft part numberschart in this chapter.
4. Reinstall housing and check transmission fluid level using procedure in
this section.
ADD COLD HOT DO NOT ADD
DON'T ADD IF IN CROSSHATCHED AREA  CHECK WHEN HOT IDLING IN PARK
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AIR FILTER MAINTENANCE
Refer to the scheduled maintenance guide for the appropriate intervals
for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer toMotorcraft part numbersin this chapter.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
Changing the air filter element
1. Loosen the clamp that secures
the air filter element in place.
2. Carefully separate the two halves
of the air filter housing.
3. Remove the air filter element
from the open end of the air filter
housing.
4. Install a new air filter element, ensuring the arrow on the top half of
the air filter housing lines up with the notch on the bottom half of air
filter housing. Be careful not to crimp the filter element edges between
the air filter housing. This could cause filter damage and allow
unmetered air to enter the engine if not properly seated.
5. Replace the two halves of the air filter housing and secure the clamp.
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MOTORCRAFT PART NUMBERS
Component* 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve
1
Battery (Standard) BXT-65-650 BXT-65-650
Battery (Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum
2
Automatic Transmission Filter3——
1The PCV valve is a critical emission component. It is one of the items
listed in theScheduled Maintenance Guideand is essential to the life
and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.
2For spark plug replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
3Only available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
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REFILL CAPACITIES
FluidFord Part
NameApplication Capacity
Front axle Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-250/350
(Dana 60 axle)2.7L (5.8 pints)
F-350/450/550
(Dana 60 axle)2.7L (5.8 pints)
Rear axle Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantF-250 /350
(10.50 inch
axle)
1
3.3L (6.9 pints)
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantF-350/450
(DANA 80)
14.0L (8.5 pints)
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-550
(Dana S135)11.6L (24.5
pints)
Brake fluid (and
clutch fluid-if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or
step (for clutch)
on reservoir
Engine coolant
2Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)5.4L V8 engine
with A/C25.0L (26.4
quarts)
6.8L V10 engine 26.0L (27.5
quarts)
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