2005 FORD SUPER DUTY engine oil

overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with the Ford ambulance preparation
package, inspect the information plate on the driver’s side door pillar.
Contact the manufacturer of your vehicle to determine whether the
ambulance manufacturer’s followed Ford’s recommendations.
WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,600 km (1,000 miles) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 800 km (500 miles) before towing a
trailer.
Do not add friction modifier compounds or special break-in oils during
the first few thousand kilometers (miles) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationssection of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•On F-Super Duty and Excursion vehicles,a frame-mounted
Horizontal Fuel Conditioner Module (HFCM)
•On E-Series vehicles,a Fuel Conditioner Module (FCM) mounted on
the driver-side of the transmission case
•an engine-mounted secondary fuel filter
•a unit injector for each cylinder
The FCM/HFCM acts as a primary fuel filter/water separator which
removes both water and impurities from the fuel. The engine-mounted
fuel filter and the FCM/HFCM filter should be changed at the
recommended service interval. Refer to theGeneral Owner’s
Informationsection of this supplement for more information.
Introduction
3

The FCM/HFCM should be drained
at regular intervals or when the
WATER IN FUEL light illuminates in
the instrument cluster.
The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM) and Fuel Injection Control Module (FICM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. The fuel pump
contains a pressure relief valve for overpressure protection in the event
of restricted flow.
Lubrication system
It is important to change the engine oil at the recommended service
intervals, because oil viscosity is important in maintaining the oil
pressure required to actuate the fuel injectors. Extended oil change
intervals can negatively affect engine performance, fuel economy and
engine life. Refer to the engine oil specification chart located under
Engine oil specificationsin theMaintenance and Specifcations
section of this supplement.
Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM 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.
Introduction
4

Engine cooling system
The cooling system contains an engine oil cooler which is mounted in the
center valley of the engine. 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.
On F-Super Duty vehicles equipped with a manual transmission,
refer toManual transmission shift speedsin theDrivingsection of
yourOwner’s Guidefor maximum vehicle speed in various gears. Do not
exceed 3,600 rpm. Maximum engine governed speed is 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.
Introduction
5

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F(0°C), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission,make sure
the parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission,ensure
the gearshift lever is in P (Park) and the parking brake is set before you
turn the key. Do not press the accelerator during starting.
Cold weather starting
When operating in cold weather, use a minimum of 45 Cetane Diesel fuel
or use Cetane Index improvers from a reputable manufacturer.
Do not crank the engine for more than 30 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (OFF) and wait
30 seconds before trying again.
Do not use starting fluid, such as ether, in the air intake system
(see air cleaner decal). Such fluid could cause immediate
explosive damage to the engine and possible personal injury.
Note:Do not add gasoline, gasohol or alcohol to diesel fuel. This
practice creates a serious fire hazard and causes engine performance
problems.
1. Turn the key to 4 (ON) without
turning the key to 5 (START).Do
not start the engineuntil the
glow-plug pre-heat indicator
turns off.
3
2
1
5
4
Driving
Driving
12

2. When the glow plug pre-heat
indicator turns off, turn the key to 5
(START), then release the key as
soon as the engine starts. The glow
plugs will continue to be activated for two minutes after the glow plug
pre-heat indicator
has turned off. If the engine is not started
before the glow plug activation time ends, the glow plugs will need to be
reset by turning the key to 3 (OFF).
3. 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 3 (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 theMaintenance
and Specificationssection of this supplement.
At temperatures below 20°F(–7°C), Number 2–D diesel fuel may thicken
enough to clog the fuel filter. Your vehicle is equipped with either an
FCM (E-Series) or an HFCM (F-Super Duty and Excursion) which acts
as 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(s) 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
fuel control module, 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 32°F(0°C) or below, the fuel level in your
tank should not be allowed to drop below
1⁄4full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C) your diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). As the engine warms-up,
Driving
13

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
E-Series
1. Windshield washer fluid reservoir
2. Automatic transmission dipstick
3. Engine oil filler cap
4. Secondary fuel filter assembly
5. Power steering fluid reservoir
6. Brake fluid reservoir
7. Engine coolant reservoir
8. Air filter assembly
The Fuel Conditioner Module (FCM) is located on the driver-side of the
vehicle next to the transmission case.
Maintenance and Specifications
Maintenance and Specifications
27

F-Super Duty/Excursion
1. Automatic transmission dipstick (if equipped)
2. Engine oil fill
3. Engine oil filter
4. Engine-mounted fuel filter assembly
5. Engine coolant reservoir
6. Brake fluid reservoir
7. Clutch fluid reservoir (if equipped)
8. Underhood relay box
9. Battery (dual batteries shown)
10. Power steering fluid reservoir
11. Air filter assembly
12. Engine oil dipstick
13. Windshield washer fluid reservoir
Maintenance and Specifications
28

The Horizontal Fuel Conditioner Module (HFCM) located on the
frame-rail under the driver-side floorboard near the transmission.
SCHEDULED MAINTENANCE
The scheduled maintenance services in theGeneral Owner’s
Informationsection of this supplement are required because they are
considered essential to the life and performance of your vehicle.
Use only recommended fuel, lubricants, fluids and service parts
conforming to Ford specifications. Motorcraft parts are designed and
built for best performance in your vehicle.
FUEL REQUIREMENTS
Choosing the right fuel
The engine is designed to use low sulfur number 1–Dor2–D Diesel fuel
only. At temperatures below -7°C (20°F), number 1–D or winter blend
number 2–D fuel is recommended. (SeeCold weather operationin the
Drivingchapter of this supplement.) Diesel fuel containing no more
than 5% of biodiesel may be used. Biodiesel fuel is a product derived
from renewable fuel sources such as vegatable oil, animal fat and cooking
oil.
Do not use home heating oil or any diesel fuel not intended for
highway use. Red dye is used to identify fuels intended for
agricultural and non-highway use. Damage to the fuel injection
system, engine and exhaust catalyst 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.
Fuel quality
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
Maintenance and Specifications
29