2004 FORD SUPER DUTY air filter

Water in fuel
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 HFCM 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 HFCM. Refer
toDraining the HFCM and changing the fuel filtersin the
Maintenance and specificationssection of this supplement for the
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
The engine air filter warning light
illuminates when the air filter
restriction gauge reaches the
CHANGE FILTER mark.
The condition should be verified by inspecting the underhood air filter
restriction gauge; the warning light is only a secondary indicator. Always
use the underhood air filter restriction gauge to determine when the air
filter element needs to be changed.
The vehicle may be driven with the engine air filter warning light
illuminated/or when the underhood air filter restriction gauge has moved
to the CHANGE FILTER mark for up to 400 km (250 miles) without
damaging the engine or related components. However, the air filter
element must be replaced at the earliest opportunity. Refer toAir filter
restriction gauge (if equipped)in this section of the supplement for
more information.
Instrumentation
7

Air filter restriction gauge (if equipped)
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
Maintenance and specifications
chapter.
•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 to theEngine air filterwarning light in this
section of the supplement.
Check the air filter restriction gauge whenever the hood is raised to
perform general engine maintenance at least every 12,000 km (7,500
miles). 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.
Instrumentation
8

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.
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 to
determine when the air filter element needs to be changed. The
warning light on the instrument cluster should not be used
exclusively for determining when the air filter element needs
changing.
Instrumentation
9

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 reset the restriction gauge by pressing the button on the end
of the gauge. If the air filter restriction gauge moves the CHANGE
FILTER mark after clearing snow and/or ice, then replace the filter.
Reset filter restriction gauge after changing the air filter element.
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 theEngine air filterwarning light in this
section of the supplement.
Instrumentation
10

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). As the engine warms-up,
the engine sound level will decrease due to the activation of
PCM-controlled sound reduction features.
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 and/or lose power.
Refer toAir filter restriction gaugeandEngine air filterin the
Instrumentationchapter 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.
Engine block heater (if equipped)
Refer to theDrivingchapter in your Owner Guide.
DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED)
If your vehicle is equipped with dual
fuel tanks, you will have a selector
control, located to the right of the
steering wheel, which allows you to
draw fuel from either tank. Your fuel
gauge will display the amount of
fuel in the currently selected tank.
Fuel level indication is delayed for several minutes when the tank
selector switch is actuated. Fuel level indication can be obtained
immediately by turning off and restarting the engine.
TRAILER TOWING
Refer to your Owner Guide for full details on towing a trailer.
Driving
13

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
F-SuperDuty/Excursion
1. Battery (dual batteries shown)
2. Air filter assembly
3. Power steering fluid reservoir
4. Clutch fluid reservoir (if equipped)
5. Brake fluid reservoir
6. Engine coolant reservoir
7. Engine oil dipstick
8. Engine-mounted fuel filter assembly
9. Engine oil filter
10. Engine oil filler
Maintenance and specifications
Maintenance and specifications
23

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.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1 1/8 inch fuel dispensing nozzle.
Pumping fuel at greater flow rates may result in premature nozzle
shut-off or spitback.
HORIZONTAL FUEL CONDITIONING MODULE (HFCM)
(FUEL FILTER/WATER SEPARATOR)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission.
Maintenance and specifications
25

Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 100 cc (0.2 pints) of water accumulates in the module.
Replace the fuel filters with Ford Part No. 3C3Z-9N184–CA. This part
number includes filters and seals for both the engine-mounted and
frame-mounted filters.
DRAINING THE HFCM AND CHANGING THE FUEL FILTERS
Your vehicle is equipped with two fuel filters; one mounted on top of the
engine and the other, the HFCM, mounted inside the frame rail under
the driver-side floorboard near the transmission. Both filters should be
replaced at the same time. The Motorcraft part number for the
replacement filters is FD-4604.
HFCM drain procedure
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the HFCM. Fuel may ignite if separator is drained while the
engine is running or vehicle is moving.
2. Locate the HFCM and place an
appropriate container under the
drain plug (see illustration).
3. Remove the drain plug, using a 6mm hex drive, by turning it
counterclockwise. Allow the HFCM to drain for approximately 25 seconds
or until clean fuel is observed. Install the drain plug by turning it
clockwise until it is firmly seated.
4. Verify that the drain plug is closed and sealed, then remove the
container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light; it
should not be illuminated. If it continues to illuminate, have the fuel
system checked and repaired.
Maintenance and specifications
26