2005 FORD SUPER DUTY fuel cap

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
Your new diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the 6.0L Power Stroke diesel engine. It
provides recommendations on engine care and operating procedures. For
complete vehicle information, also refer to theOwner’s Guideincluded
with the vehicle. It also describes equipment and gives specifications for
equipment that was in effect when this guide was approved for printing,
and should be considered a permanent part of the vehicle.
Some aftermarket products may cause severe engine and/or
transmission damage. There are various manufacturers offering
devices to increase turbocharger boost, exhaust brakes to
increase stopping/hauling capacity or other such devices to
increase the power/torque of the Power Stroke engine. Many
owners’ past experience with these products has been very poor.
Severe powertrain damage may result from the use of these
aftermarket products which will not be covered by the Ford
warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if equipped
with the Ford ambulance preparation package. In addition, Ford urges
ambulance manufacturers to follow the recommendation of theFord
Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book
(and pertinent supplements) and theQualified Vehicle Modifiers
Guidelines. Using a Ford vehicle without the Ford ambulance
preparation package to produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
Introduction
Introduction
2

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

Removal - HFCM filter (F-Super Duty/Excursion)
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 - FCM filter (E-Series)
1. Remove the fuel filter cap by
turning counterclockwise.
Maintenance and Specifications
33

2. Remove and discard the old fuel
filter element.
3. Carefully clean the mating
surfaces.
Removal - Engine-mounted fuel filter
•F-Super Duty/Excursion
•E-Series
1. Remove the fuel filter cap by turning counterclockwise.
Maintenance and Specifications
34

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. FD–4604)
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.
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.
Maintenance and Specifications
35

A symbol has been developed by the
American Petroleum Institute (API)
to help you select the proper engine
oil. It will be included on the oil
container you purchase. The top
section of the symbol shows the oil
performance by the API designation.
This should match the owner guide recommendation. The center section
will show the SAE viscosity grade. The lower section will state energy
conserving if the oil has proven fuel saving capabilities.
Changing engine oil and filter
Change your oil and filter according to theGeneral Owner’s
Informationsection of this supplement. Change more frequently if your
vehicle operation includes extended periods of idling or low-speed
operation, driving for a long time in cold temperatures or driving short
distances. See the following sectionEngine lubrication for severe
service operationfor all severe duty restrictions.
Use Ford Engine Oil Filter Part No. 3C3Z-6731–AA (FL–2016) or
equivalent. These filters protect your engine by filtering harmful,
abrasive or sludge particles. The FL–2016 filters particles significantly
smaller than most available“will-fit”filters.
To replace the filter,
1. Unscrew the oil filter cap and wait a few seconds for the oil to drain
through the built-in drain valve.Note:The filter should be changed
before reinstalling the oil pan drain plug.
2. Reinstall and tighten the oil filter cap.
Do not handle a hot oil filter with bare hands.
Continuous contact with USED motor oil has caused cancer in
laboratory mice. Protect your skin by washing with soap and
water.
Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
•towing a trailer over 1,600 km (1,000 miles)
Maintenance and Specifications
37

REFILL CAPACITIES
Component Capacity
Cooling system127.5 quarts (26.0L)
Engine oil215.0 quarts (14.2L)
Fuel tank (F-250/350/450/550) Refer to yourOwner’s
Guide
Fuel tank (Excursion) 44.0 gallons (166.6L)
Fuel tank (E-Series) Refer to yourOwner’s
Guide
Radiator cap 16 psi (110 kPa)
Manual transmission
35.8 quarts (5.5L)
Automatic transmission Refer to yourOwner’s
Guide
1Includes heater and 5.0 quarts (4.7L) in coolant recovery.
2Includes 1 quart (1.0L) 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
Maintenance and Specifications
48

Company’s specifications, and we stand behind them. Maintenance parts
installed at your Ford or Lincoln Mercury dealership carry a nationwide,
12 months, 12,000 mile parts and labor limited warranty. Your dealer can
give you details.
Value Shopping for Your Vehicle’s Maintenance Needs
Your dealership recognizes the competitive landscape of maintenance and
light repair automotive services. With factory-trained technicians, and
one-stop service from routine maintenance like oil changes and tire
rotations to repairs like brake service, check out the value your Ford and
Lincoln Mercury dealers can offer.
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, 6 months or 200 hours of
engine operation, see appropriate schedule.
Check every month:
•Check function of all interior and exterior lights
•Check tires for wear and adjust air pressure (including spare tire)
•Check engine oil level
•Check windshield washer 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 that externally-mounted spare tire is tight (see Owner’s Guide)
General Owner’s Information
52