2002 Ford Excursion 7.3L Diesel Supplement 2nd Printing

2002 Ford Excursion Manual

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  • 2002 Ford Excursion | 7.3L Diesel Supplement 2nd Printing - Page 1
    Diesel information Warning lights Starting Driving tips General maintenance information Scheduled maintenance Minor troubleshooting guide Capacities and specifications Service translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the
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    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
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    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. WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known
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    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 "Service Guide" for
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    transmission gear. For maximum vehicle speed in various gears, refer to the "Transmission shift speed" chart 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
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    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. AIR FILTER GAUGE FILTER CHANGE FILTER CHANGE The air filter element should be replaced when the colored band on the
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    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
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    diesel fuel to be IN pumped into your tank. Your vehicle fuel system is equipped with a fuel 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
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    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
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    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
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    , 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. 11
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    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
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    the following shift speed charts: Upshifts when accelerating (recommended for best fuel economy) 6-speed transmission Shift from: shift to LO when at a stop. Use 2H or 4H for 4WD equipped vehicles. Downshift at lower speeds when driving on slippery surfaces. TRAILER TOWING Refer to your "Owner Guide
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    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 Maximum Trailer
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    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. Do not exceed
  • 2002 Ford Excursion | 7.3L Diesel Supplement 2nd Printing - Page 16
    SCHEDULED MAINTENANCE The Scheduled Maintenance Services in the Service Guide 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
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    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
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    General maintenance information CHANGING FUEL FILTER Removal - F-Series Super Duty and Excursion only 1. Remove the engine appearance cover. 2. Remove the fuel filter cap by turning counterclockwise. 3. Remove and discard old fuel filter element and fuel filter o-ring. 4. Carefully clean the mating
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    maintenance information 7. Remove the fuel filter cap by turning counterclockwise. 8. Remove and discard old fuel filter element and fuel filter o-ring. 9. Carefully clean the mating surfaces. Installation - F-Series Super Duty and Excursion only The engine will not run properly if the fuel filter
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    . 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
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    engine coolant temperature gauge). 2. Park the vehicle on a level surface, then turn off the engine and open the hood. 3. Allow at least 20 minutes after 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
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    , be sure it meets the recommended Ford Specification, API service categories and SAE viscosity grades listed in the Lubricant and Maintenance Materials Specifications chart. Some energy conserving oils do not meet the requirements necessary for your diesel engine. SAE VISCOSITY GRADES * Preferred
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    "will fit" filters. To replace, use an oil filter wrench to unscrew the filter from the oil cooler fitting. Turn it horizontally to let excess oil drain off, and remove. Do not handle a hot oil filter with bare hands. Clean the filter mounting area on the oil cooler, lightly coat the gasket
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    not use oils labeled with only one of the following category designations, SG, SH, CE, CF-4 or CG-4, as they could cause engine damage. For more information refer the Severe Duty Maintenance Schedule in the "Service Guide". REPLACING THE AIR FILTER ELEMENT When replacing the air filter element, use
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    000 miles). The WATER IN FUEL FUEL light will come on when approximately 100 cc (0.2 pints) of water accumulates in the separator. Replace the fuel filter with Motorcraft Part No. FD-4596 (Ford Part No. F81Z-9N184-AA). Fuel filter/water separator drain procedure 1. Stop the vehicle and shut off the
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    container under the filter drain under the vehicle. 3. Locate the fuel filter drain valve. If necessary, remove the engine appearance cover. Refer to "Engine Compartment" in the Service points chapter. 4. On F-Series and Excursion models, open fuel filter drain valve by turning clockwise. Allow to
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    to original position. 5. Verify that the fuel filter drain valve is closed. If removed, install the engine appearance cover. 6. Close the hood and remove the container from under the vehicle. 7. Restart the engine and check WATER IN FUEL indicator light. The light should not glow. If it continues to
  • 2002 Ford Excursion | 7.3L Diesel Supplement 2nd Printing - Page 28
    as part of the regular maintenance (48 months, or 80 000 km [50 000 miles], whichever comes first and then every 36 months or 48 000 km [30 000 miles], whichever comes first), or due to service performed, adhere to the following instructions: 1. Drain and flush the cooling system to remove dirt
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    General maintenance information coolant to "wear out" in a shorter time. Ford recommends an interim service interval performed at 12 months or 24 000 km (15 000 miles), whichever occurs first. Add 237-295 ml (8-10 oz.) of supplemental coolant additive FW-16 to the cooling system. For vehicles with
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    repairing, servicing, selling, leasing or trading motor vehicles as well as fleet operations from unknowingly removing or rendering emission control system(s) inoperative. Further, modifications of the emission control system(s) could create liability on the part of the individual owners under the
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    January 1, 1978, Federal regulation became effective governing the noise emission on trucks over 4 536 kg (10 000 lbs.) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Facts Booklet, are
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    "Service Guide" for details of maintenance on your vehicle. If you are using your vehicle in a manner in which it will remain stationary (door to door service, taxi, etc.), then it is recommended that you change the engine oil every 200 engine hours as opposed to a mileage limit. Since most vehicles
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    the fuel filter/water separator. • a clogged fuel filter. • contaminated fuel. • air in the fuel system, due to loose connections. • an open or pinched sensor hose. • low engine oil level. • wrong fuel for climactic conditions. If these checks do not help you correct the engine performance problem
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    Minor troubleshooting guide IF THE ENGINE WON'T CRANK Turn on the headlights. If the lights are dim, do not go on at all or if when the ignition is turned to START the lights become dim or go out, the battery connections may be loose or corroded, or the battery may be discharged. If there is a
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    and you cannot locate the cause, return your vehicle to your dealer for a circuit check. Replacement fuses and circuit breakers must always be the same rating as the original equipment shown. Never replace a fuse or circuit breaker with one of a higher rating. Higher rated fuses or circuit breakers
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    ) Cooling system (Econoline) 1, 2 Engine oil 3 Fuel tank (F- Series) Fuel tank (Excursion) Fuel tank (Econoline) 4 Radiator cap Manual transmission 5 Automatic transmission 1 2 1 Capacity 31.0L (32.75 quarts) 28.5L (30.0 quarts) 14.2 L (15.0 quarts) Refer to Owner Guide 166.6L (44.0 gallons) 132.5L
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    Ford Part Ford Part Ford Name Number Specification Motorcraft Motor Oil 15W40 XO-15W40-QSD, WSS-M2C171-C, Super Duty, XO-10W30-QSD CH-4/SJ/SH 10W30 Super Duty F4TZ-6731-A (FL-1995) FA-1680 ES-E95AE9601-AA ES-E95AE9601-AA ESE-M97B44-A _ Engine Oil Engine Oil Filter (Use this filter Only) Air Filter
  • 2002 Ford Excursion | 7.3L Diesel Supplement 2nd Printing - Page 38
    2. Windshield washer fluid reservoir 3. Engine oil dipstick 4. Fuel filter/water separator drain valve release handle 5. Automatic transmission fluid dipstick 6. Air filter assembly 7. Engine oil filler 8. Air filter restriction gauge 9. Power steering fluid reservoir 10. Brake fluid reservoir 11
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    reservoir 3. Engine oil filler 4. Engine oil dipstick 5. Automatic transmission dipstick (if equipped) 6. Fuel filter drain valve 7. Clutch fluid reservoir (if equipped) 8. Brake fluid reservoir 9. Air filter restriction gauge 10. Air filter assembly 11. Power steering fluid reservoir 12. Windshield
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Introduction
2
Diesel information
4
Warning lights
7
Starting
9
Driving tips
12
General maintenance information
16
Scheduled maintenance
32
Minor troubleshooting guide
33
Capacities and specifications
36
Service points
38
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system or translation in whole or part is not permitted without written
authorization from Ford Motor Company. Ford may change the contents without
notice and without incurring obligation.
Copyright © 2000 Ford Motor Company
Table of contents
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