Ford F250 Crew cab 4.4 2003 Owner's Manual

Table of contents

Introduction

Diesel information

Warning lights

Starting

Driving tips

General maintenance information

Scheduled maintenance

Minor troubleshooting guide

Capacities and specifications

Service points

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Introduction

California Proposition 65 Warning: Diesel engine exhaust, some

of its constituents, and certain vehicle components contain or may emit chemicals known to the State of California to cause cancer or 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 Power Stroke (7.3L DIT) Diesel engine. It provides recommendations on engine care and operating procedures. For complete vehicle information, also refer to the Owner Guide included 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 7.3L 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 the

Ford Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book (and pertinent supplements) and the Qualified 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 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.

Introduction

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.

WARNINGS

Throughout this guide, you will find warnings. Warnings remind you to be especially careful to avoid 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. See Engine oil in the General Maintenance Information chapter for more information on oil usage.

Diesel information

DIESEL ENGINE INFORMATION

The Diesel engine fuel system consists of:

• a frame-mounted electric fuel supply pump

• an engine mounted fuel filter/water separator

• a fuel restriction sensor

• a unit injector for each cylinder

The combination fuel filter/water separator removes both water and impurities from the fuel. The filter should be changed at the recommended service interval. Refer to the scheduled maintenance guide for more information. The filter bowl 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).

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 and fuel economy.

Pressurized oil from the turbocharger is also used to actuate an exhaust backpressure warm-up system (if equipped). Pressurized oil from the turbocharger is routed to the exhaust backpressure actuator. During exhaust backpressure operation, the engine’s sound will be altered and you may notice a change in engine performance while it’s engaged. This function occurs only during cold weather warm-up cycle.

Fast start glow plug system

The glow plug system consists of:

• eight glow plugs

• the glow plug relay

Diesel information

• engine oil temperature (EOT) sensor

• barometric pressure (BARO) sensor

The glow plug system is electronically controlled by the PCM. The PCM 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 cooling system contains an engine oil cooler which is mounted to the side of the cylinder block. 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.

For maximum vehicle speed in various gears, refer to Manual transmission shift speeds in the Driving tips chapter. Do not exceed 3,600 rpm. Maximum engine governed speed is 3,000–4,000 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.

Air filter restriction gauge, E-Series

The restriction gauge, located on the clean-air side of the air cleaner upper housing, shows if the air filter is clogged. Refer to Engine Compartment in Service points chapter.

Diesel information

The air filter element should be

replaced when the colored band on the gauge reaches the CHANGE

FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air filter element, reset the restriction gauge by pressing the button on the end of the gauge.

Air filter restriction gauge, F-250/350/450/550 & Excursion

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

Engine Compartment in Service Points 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 F-250/350/450/550, Excursion in Warning Lights chapter.

Check the air filter restriction gauge whenever the hood is raised to perform general engine maintenance. 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.

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.

Diesel information

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 or engine air filter warning light on the instrument cluster to determine when the air filter element needs to be changed.

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 replace the air filter element, or remove the element and dry it out. Reset the restriction gauge by pressing the button on the end of the gauge.

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 the Warning Lights chapter.

Warning lights

E-SERIES

F–250/350/450/550, EXCURSION

WAIT TO START

• E-Series

• F-250/350/450/550, Excursion

With the key in the ON position, the WAIT TO START light will illuminate if glow plug heat is necessary as a starting aid. Wait until the light goes off before starting. The light should always illuminate briefly, when the ignition key is in the ON position. If the light does not illuminate, there may be a problem. Refer to the Starting chapter in this guide. After the engine starts, the light should remain off.

The light should always illuminate at least momentarily when the engine is cold and the ignition is turned to ON. If it does not illuminate, the glow plug system should be checked and repaired promptly to avoid difficulty in cold starting.

Warning lights

WATER IN FUEL

• E-Series

• F-250/350/450/550, Excursion

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 fuel filter/water separator 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 filter bowl. Refer to the General maintenance chapter for 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 (F-250/350/450/550 & EXCURSION)

The engine air filter warning light illuminates when the air filter restriction gauge reaches the CHANGE FILTER mark.

The vehicle may be driven with the engine air filter warning light illuminated 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 to Air filter restriction gauge in the Diesel information chapter for more information.

Starting

STARTING THE ENGINE

Read all starting instructions carefully before you start your vehicle.

For temperatures below 0°C (32°F), 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

Do not crank the engine for more than 30 seconds at a time as starter damage may occur. If the engine fails to start, turn the key to 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.

Do not add gasoline, gasohol or alcohol to Diesel fuel. This practice creates a serious fire hazard and causes engine performance problems.

1. Make sure all vehicle occupants have buckled their safety belts. For more information on safety belts and their proper usage, refer to Seating and safety restraints chapter in the owner guide.

2. Make sure the headlamps and vehicle accessories are off.

3. Turn the key to the ON position. When the WAIT TO START light goes off, turn the key to START. (For Canadian vehicles, the daytime running lamps will be on if the parking brake is not applied and the key is turned to ON.)

• E-Series

• F-250/350/450/550, Excursion

Starting

4. When the engine starts, release the key. The glow plugs will continue to be activated for up to two minutes. If the engine is not started before the activation ceases, the glow plug system must be reset by turning the ignition key to OFF.

5. 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 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 to Engine Oil Specifications in the General maintenance information chapter.

At temperatures below –7°C (20°F), Number 2–D Diesel fuel may thicken enough to clog the fuel filter. Your engine is equipped with 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 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 in-tank fuel sending unit, 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 0°C (32°F) or below, the fuel level in your 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). The sound of the engine may change also, as an exhaust device engages to improve heater performance and reduce exhaust smoke.

Starting

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.

Refer to Air filter restriction gauge in the Diesel information chapter and Engine air filter in the Warning lights chapter 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. Follow the cylinder compression test procedure outlined in the Workshop Manual, then check the engine oil for contamination.

Engine block heater (if equipped)

Refer to the Starting chapter in your Owner Guide.

Driving tips

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.

MANUAL TRANSMISSION SHIFT SPEEDS

Do not overspeed the engine when going downhill or steep grades. If equipped, use the tachometer and do not allow engine speed to exceed the redline area. Operating the engine beyond the recommended speeds can cause severe engine damage.

If your vehicle is an F-Series equipped with a manual transmission, your vehicle has an electronic operating strategy which protects the engine system when the engine is operating with high coolant temperatures; fueling to the engine will be modified to prevent damage to the engine. Some power loss may be experienced if the vehicle is overloaded.

Driving tips

Upshift and downshift according to the following shift speed charts:

Upshifts when accelerating

(recommended for best fuel economy)

6-speed transmission

Shift from: Transfer case position

2H or 4H 4L

LO-1 8 km/h (5 mph) 3 km/h (2 mph)

1-2 16 km/h (10 mph) 6 km/h (4 mph) 2-3 32 km/h (20 mph) 13 km/h (8 mph) 3-4 48 km/h (30 mph) 19 km/h (12 mph)

(Overdrive)

64 km/h (40 mph) 24 km/h (15 mph)

Maximum downshift speeds

6-speed transmission

Shift from: Transfer case position (if equipped)

2H or 4H 4L

(Overdrive) - 4

72 km/h (45 mph) 26 km/h (16 mph) 4-3 56 km/h (35 mph) 19 km/h (12 mph) 3-2 32 km/h (20 mph) 13 km/h (8 mph) 2-1 8 km/h (5 mph) 3 km/h (2 mph)

1-LO Only shift to LO when at a stop.

Use 2H or 4H for 4WD equipped vehicles.

Downshift at lower speeds when driving on slippery surfaces.

(if equipped)

Driving tips

TRAILER TOWING

Refer to your Owner Guide for full details on towing a trailer.

E-Series trailer towing tables

Your vehicle may tow a class I, II or III trailer provided the maximum trailer weight is less than or equal to the maximum trailer weight listed for your engine and rear axle ratio on the following charts.

GCWR (Gross Combined Weight Rating)/Trailer Weights

Rear axle

ratio

Maximum GCWR-kg

(lbs.)

E-350 Regular Van (9500 GVWR)

3.55 7258 (16000) 4400 (9700) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Regular Van (Crew) (9500 GVWR)

3.55 7258 (16000) 4309 (9500) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Extended Van (9400 GVWR)

3.55 7258 (16000) 4354 (9600) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Extended Van (Crew) (9400 GVWR)

3.55 7258 (16000) 4264 (9400) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Regular Wagon (8 passenger) (8700 GVWR)

3.55 7258 (16000) 4264 (9400) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Regular Wagon (12 passenger) (8700 GVWR)

3.55 7258 (16000) 4218 (9300) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Extended Wagon (12 passenger) (9300 GVWR)

3.55 7258 (16000) 4173 (9200) 5.52 (60)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Extended Wagon (15 passenger) (9400 GVWR)

3.55 7258 (16000) 4128 (9100) 5.52 (60)

Trailer Loaded

Trailer Weight -

kg (lbs.)

Maximum Frontal

Area Of

Trailer-m

(ft2)

Driving tips

GCWR (Gross Combined Weight Rating)/Trailer Weights

Rear axle

ratio

Maximum GCWR-kg

(lbs.)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-350 Cutaway and Chassis Cab (all wheelbases, all GVWRs)

4.10 9072 (20000) 4536 (10000) 5.52 (60)

E-450 and E-550 (all wheelbases, all GVWRs)

All 9072 (20000) 4536 (10000) 5.52 (60)

For high altitude operation reduce GCWR by 2% per 300 meters (1 000 ft) elevation. To determine the maximum trailer weight designed for your particular vehicle as equipped, follow the section Calculating the load your vehicle can tow/carry earlier in this chapter.

Your vehicle’s load capacity is designated by weight, not by volume, so you cannot necessarily use all available space when loading a vehicle.

Distribute the load so that only 10 to 15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch.

Towing a trailer places an additional load on your vehicle’s engine, transmission, axle, brakes, tires and suspension. Inspect these components carefully after any towing operation.

Trailer Loaded

Trailer Weight -

kg (lbs.)

Maximum Frontal

Area Of

Trailer-m

(ft2)

Do not exceed the GVWR or the GAWR specified on the certification label.

Towing trailers beyond the maximum recommended gross trailer weight could result in engine damage, transmission/axle damage,

structural damage, loss of control and personal injury.

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