2009 FORD SUPER DUTY fuel pressure

•On F-Super Duty vehicles (6.4L engine),a frame-mounted
Horizontal Fuel Conditioner Module (HFCM)
•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
filter filters finer impurities from the diesel fuel. The engine-mounted
fuel filter and the FCM/HFCM filter should be changed at the
recommended service interval. Refer to thescheduled maintenance
informationin this supplement for more information.
F-Super Duty
E-Series
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) (6.0L
engine only).
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.
Engine protection mode
Ford diesel engines are equipped with engine protection and emission
control systems. These systems monitor critical temperatures and
pressures, and modify engine operation accordingly. These features are
intended to modify engine performance characteristics. If these modified
engine performance characteristics persist for an extended period or the
service engine soon (
) or powertrain malfunction/reduced
power/electronic throttle control light (
) is illuminated, seek service
from your authorized dealer.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Introduction
4

Lubrication system
Extended oil change intervals can negatively affect engine performance,
fuel economy and engine life. Refer to the engine oil specification chart
located underEngine oil specificationsin theMaintenance and
Specificationschapter of this supplement.
On E-Series vehicles (6.0L engine),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.
On F-Super Duty vehicles (6.4L engine),it is important to change
the engine oil at the recommended service intervals to maintain oil
viscosity with the addition of the diesel particulate filter (DPF).
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.
Engine cooling system
The engine cooling system contains an engine oil cooler and an Exhaust
Gas Recirculation (EGR) cooler. The oil cooler’s function is to regulate
engine oil temperature. The EGR cooler function is to cool exhaust gases
before they are circulated back through the engine to reduce emissions.
Vehicles with diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors may cause the additives in
the coolant to “wear out” in a shorter time. Refer to the Special
Operating Conditions section for more information about coolant
additives and coolant change intervals. Operating the engine with
insufficient coolant and/or coolant additive can cause severe engine
damage.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Introduction
5

Cold weather starting
It is recommended that the engine block heater be used for starting
when the temperature is -10°F (-23°C) or colder. Refer toEngine block
heater (if equipped)in theDrivingchapter of theOwner’s Guide.
When operating in cold weather, use Motorcraft Cetane improvers or non
alcohol-based Cetane improvers from a reputable manufacturer.
Do not crank the engine for more than 10 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.
WARNING:Do not use starting fluid, such as ether, in the air
intake system (see air filter decal). Such fluid could cause
immediate explosive damage to the engine and possible personal injury.
WARNING: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 on without turning the key to start.Do not start the
engineuntil the glow-plug pre-heat indicator
turns off.
2. When the glow plug pre-heat
indicator turns off, turn the key to
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 off.
3. After the engine starts,allow it to idle for about 15 seconds. This
is to protect the engine. Do not increase engine speed until the oil
pressure gauge indicates normal pressure.
ENGINE IDLE SHUTDOWN (IF EQUIPPED)
Your vehicle may be equipped with an engine idle shutdown system. This
system will automatically shut down your engine when it has been idling
in P (Park) or N (Neutral) for five minutes (parking brake set) or
15 minutes (parking brake not set). When the engine idle shutdown
process has started:
•A chime will sound and the message center will displayENGINE
TURNS OFF IN XX30 seconds prior to shutdown and begins
counting down to zero.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Driving
12

Fuel filler cap
Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise until it spins off.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 of a turn until it clicks at least once.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The vehicle warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
WARNING:The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait
until it stops before completely removing the fuel filler cap. Otherwise,
fuel may spray out and injure you or others.
WARNING:If you do not use the proper fuel filler cap,
excessive pressure or vacuum in the fuel tank may damage the
fuel system or cause the fuel cap to disengage in a collision, which may
result in possible personal injury.
FUEL FILTER/WATER SEPARATOR
Fuel Conditioner Module (FCM - E-Series)
The vehicle is equipped with a Fuel Conditioning Module (FCM) located
on the driver-side of the vehicle next to the transmission case.
Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 0.2 pints (100 cc) of water accumulates in the module.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Maintenance and Specifications
39

Check every month
❑Check function of all interior and exterior lights❑Check tires for wear and adjust air pressure (including spare tire)
❑Check that holes in the tail-pipe of the exhaust system are clear of debris-the holes/slots are functional (F-Super Duty)
❑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 (seeOwner’s Guide)
❑Check power steering fluid level
❑Check washer spray, wiper operation and clean all wiper blades (replace as necessary)
❑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 engine cooling system level, coolant strength and hoses
❑Check fuel cooling system for fluid level and coolant strength (F-Super Duty)
❑Check battery connections and clean if necessary
❑Check clutch fluid level, if equipped
Retightening lug nuts
❑On vehicles equipped with single rear wheels, retighten the lug nuts to the specified torque at 500 miles (800 km) after
any wheel disturbance (tire rotation, changing a flat tire, wheel removal, etc.).
❑On vehicles equipped with dual rear wheels, retighten the wheel lug nuts to the specified torque at 100 miles (160 km),
and again at 500 miles (800 km) of new vehicle operation and after any wheel disturbance (tire rotation, changing a flat
tire, wheel removal, etc.).
❑Refer toWheel Lug Nut Torque Specificationin yourOwner’s Guidefor the proper lug nut torque specification.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: General Information
64

Multi-point Inspection
In order to keep your vehicle running right, it is important that you have
the systems on your vehicle checked regularly. This can help identify any
potential issue before there are any problems. Ford Motor Company
suggests the following multi-point inspection to be performed at every
scheduled maintenance interval as the way to ensure your vehicle keeps
running right.
Multi-point inspection - recommended at every visit
❑Check and top up fluid levels:❑brake❑coolant recovery reservoir❑fuel coolant recovery reservoir (F-Super Duty)❑manual and automatic transmission❑power steering❑window washer❑Inspect tires for wear and check air pressure, including spare.
❑Check exhaust system for leaks, damage, loose parts and foreign materials.
❑Check that holes in the tail-pipe of the exhaust system are clear of debris; the holes/slots are functional (F-Super Duty)
❑Check battery performance.
❑Check operation of horn, exterior lamps, turn signals and hazard warning lights.
❑Check radiator, coolers and heater and air conditioning hoses.
❑Inspect windshield washer spray and wiper operation.
❑Check windshield for cracks, chips and pitting.
❑Inspect for oil and fluid leaks.
❑Inspect air filter.
❑Check shocks and struts and other suspension components for leaks and damage.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: General Information
65