2004 FORD SUPER DUTY fuel filter

Removal - HFCM 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.
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.
Maintenance and specifications
27

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.
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
Maintenance and specifications
28

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 or oil viscosity 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
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or if
when the ignition is turned to START the lights become dim or go out,
the battery connections may be loose or corroded, or the battery may be
Maintenance and specifications
37

•Overloading or pulling heavy trailers during hot weather.
•Grill or radiator air blockage.
•Slipping or missing drive belt.
•Plugged or very dirty air cleaner element.
If fuses burn out
Burned-out or blown fuses usually indicate an electrical short-circuit,
although a fuse may occasionally burn out from vibration. Insert a second
fuse. If this fuse immediately burns out and you cannot locate the cause,
return your vehicle to your dealer for a circuit check.
Replacement fuses and circuit breakers must always be the same
rating as the original equipment shown. Never replace a fuse or
circuit breaker with one of a higher rating. Higher rated fuses or circuit
breakers could allow circuit overloading in the event of a circuit
malfunction, resulting in severe vehicle damage or personal injury due
to fire.
Refer to the“Owner Guide”for replacement of fuses.
MOTORCRAFT PART NUMBERS
Item Ford Part Number
Engine Oil Filter (Use this filter
Only)3C3Z-6731–AA (FL–2016)
Air Filter
1FA-1746
Battery (2 Required) BXT-65-750
1Always use the authorized Motorcraft air filter listed.Failure to use
the correct air filter may result in severe engine damage.
REFILL CAPACITIES
Component Capacity
Cooling system126.0L (27.5 quarts)
Engine oil214.2L (15.0 quarts)
Fuel tank (F-250/350/450/550) Refer to Owner Guide
Fuel tank (Excursion) 166.6L (44.0 gallons)
Radiator cap 110 kPa (16 psi)
Maintenance and specifications
39

Component Capacity
Manual transmission35.5L (5.8 quarts)
Automatic transmission Refer to Owner Guide
1Includes heater and 4.7L (5.0 quarts) in coolant recovery.
2Includes 1.0L (1 quart) in engine oil filter.
3Use Motorcraft MERCON
ATF, Motorcraft part number XT-2–QDX,
meeting Ford specification MERCON
.
BULB SPECIFICATIONS
Lamp descriptionNumber of bulbs
requiredTrade number
Wait to Start Light 1 194
Water-in-Fuel Light 1 194
Engine Temp. Light 1 194
LUBRICANT SPECIFICATIONS
ItemFord Part
NameFord Part
NumberFord
Specification
Engine OilMotorcraft
Motor Oil 15W40
Super Duty,
10W30 Super
Duty
1
XO-15W40-QSD,
XO-10W30-QSDWSS-M2C171-D,
CI-4/SL, DHD-1
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51–A1
Manual
TransmissionMotorcraft
MERCON
AT FXT-2–QDX MERCON

Automatic
transmissionRefer to Owner Guide
1Refer to the engine oil specification chart located underEngine oil
specificationsin theMaintenance and specificationssection of this
supplement.
Maintenance and specifications
40

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.
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
(replace as necessary)
General Owner’s Information
45

•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
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 minder, replace filter as required
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 minder, replace filter as required
•Replace engine- and frame-mounted fuel filters
•Inspect steering linkage, suspension and, if equipped, driveshaft and
ball joints
General Owner’s Information
46

•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
•Inspect and lubricate 4x4 front axle shaft u-joints
•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 minder, replace filter as required
48,000 km (30,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Inspect engine air filter minder, replace filter as required
•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
•Change automatic transmission fluid and external filter element
•Check wheels for end play and noise
•Inspect and lubricate 4x2 ball joints (except F-450/F-550)
•Inspect and lubricate steering idler arms
•Inspect and lubricate 4x4 front axle shaft u-joints
•Replace cabin air filter, if equipped
•Inspect half-shaft boots, if equipped
60,000 km (37,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter minder, replace filter as required
General Owner’s Information
47