2004 Ford Excursion Diesel Supplement 2nd Printing

2004 Ford Excursion Manual

2004 Ford Excursion manual content summary:

  • 2004 Ford Excursion | Diesel Supplement 2nd Printing - Page 1
    mechanical including photocopying, recording or by any information storage and retrieval 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 © 2003 Ford
  • 2004 Ford Excursion | Diesel Supplement 2nd Printing - Page 2
    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
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    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
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    , fuel economy and engine life. Refer to the engine oil specification chart located under Engine oil specifications in the Maintenance 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
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    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
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    Instrumentation Instrumentation E-SERIES EXCURSION & F-SUPER DUTY (EXCEPT HARLEY-DAVIDSON) H 40 60 80 00 20 40 60 KM/H RPMX1000 H C H C L F E DIESEL FUEL ONLY 20 0 MPH SELECT RESET TOW HAUL PRN D 321 F-SUPER DUTY HARLEY-DAVIDSON 6
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    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
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    CHANGE FILTER mark 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 (if equipped) in this section of the supplement for more information. Transmission
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    to the Engine air filter warning light in this section of the supplement. Check the air filter restriction gauge whenever the hood is raised to perform general engine maintenance at least every 12,000 km (7,500 miles). If the vehicle is operated in extremely dusty conditions, check the gauge at
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    Instrumentation 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 AA AIR FILTER REST restriction is reached. Blowing-out the air filter CHANGE FILTER 75% element with
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    replace the filter. Reset filter restriction gauge after changing the air filter element. 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 Engine air filter warning
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    , 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
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    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 Maintenance and Specifications section of this supplement. At temperatures below -7°C (20°F), Number 2-D diesel fuel
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    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. Engine block heater (if equipped) Refer to the Driving chapter in the Owner's Guide. DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED
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    Driving Trailer towing tables - E-Series Engine Maximum GCWR Maximum kg (lbs.) trailer weight kg (lbs.) E-350 Regular Van (9500 GVWR) 6.0L 3.55 7257 (16000) 4400 (9700) 6.0L 4.10 9072 ( (20000) 4536 (10000) E-350/E-450 Cutaway and Chassis Cab 6.0L 4.10 9072 (20000) 4536 (10000) Rear axle ratio 15
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    9072 (20000) 4988 (11000) 4x4 9072 (20000) 4990 (11000) 6.0L 6.0L Engine 3.73 3.73 Rear axle ratio F-250 Maximum GCWR Maximum kg (lbs.) trailer weight kg (lbs.) Vehicles without fifth wheel 6.0L All 9072 (20000) 5670 (12500) Regular Cab Pickup 4x2 with manual transmission and fifth wheel 6.0L All
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    6.0L All 9072 (20000) 5941 (13100) Crew Cab Pickup 4x4 with manual transmission and fifth wheel 6.0L All 9072 (20000) 4671 (10300) Crew Cab Pickup 4x4 with automatic transmission and fifth wheel 6.0L All 9072 (20000) 4807 (10600) Engine Rear axle ratio F-350 Regular Cab Single Rear Wheel Pickup
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    20000) 6078 (13400) 4x4 with manual transmission and fifth wheel 6.0L All 9072 (20000) 5851 (12900) 4x4 with automatic transmission and fifth wheel 6.0L All 9072 (20000) 5897 (13000) F-350 SuperCab Single Rear Wheel Pickup Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs
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    ) 5895 (13000) 4x4 with fifth wheel All 9072 (20000) 5714 (12600) 6.0L 6.0L Engine F-350 Crew Cab Single Rear Wheel Pickup Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) Vehicles without fifth wheel 6.0L All 9072 (20000) 5670 (12500) 4x2 with manual transmission and fifth
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    Cab Single Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) 4x2 with manual transmission 6.0L All 9072 (20000) 5759 (12700) 4x2 with automatic transmission 6.0L All 9072 (20000) 5804 (12800) 4x4 6.0L All 9072 (20000) 5579 (12300) 20
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    Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) 4x2 with manual transmission 6.0L All 9072 (20000) 5623 (12400) 4x2 with automatic transmission 6.0L All 9072 (20000) 5668 (12500) 4x4 with manual transmission 6.0L All 9072 (20000) 5442
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    Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) 4x2 with automatic transmission 6.0L All 9072 (20000) 5579 (12300) 4x4 with manual transmission 6.0L All 9072 (20000) 5306 (11700) 4x4 with automatic transmission 6.0L All 9072 (20000) 5352
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    (26000) 7891 (17400) 4.88 13608 (30000) 9705 (21400) 6.0L (with high capacity trailer tow package) Crew Cab Chassis Cab 4x4 with manual transmission 6.0L All 11793 (26000) 7709 (17000) Crew Cab Chassis Cab 4x4 with automatic transmission 6.0L All 11793 (26000) 7756 (17100) Engine Rear axle ratio 23
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    YOUR VEHICLE (E-SERIES ONLY) F-Super Duty and Excursion vehicles equipped with the 6.0L diesel engine can be jump started using the same procedure as a gasoline engine; refer to your Owner's guide for the jump starting procedure. The gases around the battery can explode if exposed to flames, sparks
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    and remove any excessive corrosion before you attach the battery cables. Ensure that accessible vent caps are tight and level. 5. Turn the heater fan on in both vehicles to protect any electrical surges. Turn all other accessories off. Connecting the jumper cables 1. Connect the positive (+) jumper
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    Roadside emergencies 2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery. 3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery. 26
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    that surround the battery. 5. Ensure that the cables are clear of moving parts or any fuel delivery system, brake system or exhaust system parts. Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the engine of the disabled vehicle
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    they were connected. 1. Remove the jumper cable from the ground metal surface. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery. 2. Remove the jumper cable on the negative (-) connection of the booster vehicle
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    the jumper cable from the positive (+) jumper stud of the disabled vehicle. Reinstall the cap onto the jumper stud. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions. 29
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    • Take care when using a power washer to clean the engine. The high-pressure fluid could penetrate the sealed parts and cause damage. • Do not spray a hot engine with cold water to avoid cracking the engine block or other engine components. • Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on
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    Cleaning • E-Series 31
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    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
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    Maintenance and Specifications F-Super Duty/Excursion 1. Battery (dual batteries shown) 2. Air filter assembly 3. Power steering fluid reservoir 4. Clutch fluid reservoir (if equipped) 5. Brake fluid reservoir 6. Engine coolant reservoir 7. Engine oil dipstick 8. Engine-mounted fuel filter assembly
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    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. It should not be necessary to add any aftermarket additives to
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    - E-SERIES)/HORIZONTAL FUEL CONDITIONING MODULE (HFCM - F-SUPER DUTY/EXCURSION) - FUEL FILTER/WATER SEPARATOR HFCM - F-Super Duty/Excursion The vehicle is equipped with a Horizontal Fuel Conditioning Module (HFCM) located on the frame-rail under the driver-side floorboard near the transmission. 35
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    seals for both the engine-mounted and frame-mounted filters. 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
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    from under the vehicle. 5. Restart the engine and check WATER IN FUEL indicator light; it should not be illuminated. If it continues to illuminate, have the fuel system checked and repaired. Removal - HFCM filter (F-Super Duty/Excursion) 1. Remove the fuel filter cap by turning counterclockwise. 37
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    Maintenance and Specifications 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. 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating
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    Maintenance and Specifications Removal - Engine-mounted fuel filter • F-Super Duty/Excursion • 1. 2. 3. E-Series Remove the fuel filter cap by turning counterclockwise. Remove and discard the old fuel filter element. Carefully clean the mating surfaces. Installation - both The engine will not run
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    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
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    if the oil has proven fuel saving capabilities. Changing engine oil and filter Change your oil and filter according to the General Owner's Information section of this supplement. Change more frequently if your vehicle operation includes extended periods of idling or low-speed operation, driving for
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    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) • sustained, high speed driving at Gross Vehicle Weight Rating (maximum loaded weight for vehicle
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    deep water and/or encountering unusually heavy precipitation conditions. ENGINE COOLANT Checking engine coolant The concentration and level of engine coolant should be checked at the mileage intervals listed in the Scheduled Maintenance Guide. The coolant concentration should be maintained at 50/50
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    Maintenance and Specifications • Enables calibrated gauges to work properly. When the engine is cold, check the level of the engine coolant in the reservoir. • The engine coolant should be at the "cold fill level" or within the "cold fill range" as listed on the engine coolant reservoir (depending
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    corrosion protection of the engine coolant. For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add coolant to the coolant recovery reservoir when the engine is cool. Add the proper mixture of coolant and water to the "cold full" level. For all other
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    than 1.0 liter (1.0 quart) of engine coolant per month, have your dealer check the engine cooling system. Your cooling system may have a leak. Operating an engine with a low level of coolant can result in engine overheating and possible engine damage. Recycled engine coolant Ford Motor Company does
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    climates should use a 50/50 mixture of engine coolant and distilled water for optimum cooling system and engine protection. EMISSION CONTROL SYSTEM covering and insulation protect occupants of the vehicle from the engine and exhaust system heat and noise. On vehicles with no original equipment floor
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    inlet system or engine air filter element. • water in 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 or oil viscosity for climactic conditions
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    empty or during a fuel filter change), the engine will self-purge the trapped air once it starts running. The engine may run roughly and produce white smoke while air is in the fuel system; this is normal and should stop after a short time. MINOR TROUBLESHOOTING GUIDE If the engine won't crank Turn
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    Emergencies chapter of your Owner Guide (F-Super Duty and Excursion) or refer to the Jump starting section of this supplement (E-Series). If engine cranks but won't start Prolonged starter cranking (in excess of 30 seconds) could cause damage to the starter motor. • Check the fuel gauge. You may be
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    , resulting in severe vehicle damage or personal injury due to fire. Refer to the Owner Guide for replacement of fuses. MOTORCRAFT PART NUMBERS Item Engine Oil Filter (Use this filter Only) Air Filter1 Battery (2 Required) 1 Ford Part Number 3C3Z-6731-AA (FL-2016) FA-1746 BXT-65-750 Always use the
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    -A1 Engine Coolant (CA and OR (yellow-colored) only) Motorcraft XT-2-QDX MERCON௡ MERCON௡ ATF Refer to Owner Guide Engine Oil Engine coolant Manual Transmission Automatic transmission 1 Refer to the engine oil specification chart located under Engine oil specifications in the Maintenance and
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    Sales Representative or Service Advisor at your selling/servicing dealership. 2. If the inquiry or concern remains unresolved, contact the Sales Manager or Service Manager at the dealership. 3. If the inquiry or concern cannot be resolved at the dealership level, please contact the Ford Customer
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    594-4857 Fax: (313) 390-0804 E-mail: [email protected] In the Middle East and North Africa, contact: Ford Middle East and North Africa Customer Assistance Center API World Tower 17th Floor Sheikh Zayed Road Dubai, United Arab Emirates Telephone: 971-4-326084 Fax: 971-4-327299 E-mail: [email protected]
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    used meet Ford engineering specifications. Failure to perform scheduled maintenance specific in this guide will invalidate warranty coverage on parts affected by the lack of maintenance. Be sure receipts for completed maintenance are kept with the vehicle and confirmation of the work performed is
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    the proper performance of your vehicle and its emission control systems, it is imperative that scheduled maintenance be completed at the designated intervals. Ford strongly recommends the use of genuine Ford replacement parts. Parts other than Ford, Motorcraft or Ford authorized remanufactured
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    schedule. Check every month: • Check function of all interior and exterior lights • Check air pressure in all tires, including spare tire • Check tires for wear and proper air pressure • Check engine oil fluid level • Check windshield washer solvent fluid level • Check and drain fuel filter
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    • Rotate tires • Inspect engine air filter minder, replace filter as required • Replace engine- and frame-mounted fuel filters • Inspect steering linkage, suspension, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields 58
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    • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Change automatic transmission fluid and external filter element • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Replace cabin air filter, if
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    brake system • Inspect exhaust system and heat shields • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Replace cabin air filter, if equipped 84,500 km (52,500 miles) • Change engine oil and replace oil filter • Inspect engine air filter minder
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    brake system • Inspect exhaust system and heat shields • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Replace cabin air filter, if equipped 133,000 km (82,500 miles) • Change engine oil and replace oil filter • Inspect engine air filter minder
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    , driveshaft and u-joints • Change engine coolant • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Replace cabin air filter, if equipped 181
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    • Replace engine- and frame-mounted fuel filters • Inspect and lubricate steering linkage, ball joints, idler arms, suspension and, if equipped, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Change automatic
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    fuel filters • Inspect and lubricate steering linkage, ball joints, idler arms, suspension and, if equipped, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Replace accessory drive belt(s) • Change engine coolant
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    Change engine oil and replace filter Every 15,000 miles: Inspect and lubricate 4x2 ball joints and steering idler arms Every 30,000 miles: Lubricate 4x4 hub needle bearings Every 60,000 miles: Change transfer case fluid As required: Change manual transmission fluid Extensive idling and/or low-speed
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    engine oil and replace filter Every 15,000 miles: Lubricate 4x4 hub needle bearings Every 60,000 miles: Change transfer case fluid As required: Inspect and lubricate 4x2 ball joints and steering idler arms and linkage. Replace cabin air filter, if equipped Short trip in cold operating conditions
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    appropriate mileage intervals. Be sure to ask your service provider to record the type of service rendered (Normal or Special Operating Conditions - SOC) each time service is performed. Date: Mileage: Normal SOC Dealer's Stamp: Ǣ Ǣ See corresponding mileage in maintenance schedule for services
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    Owner 's Information YELLOW COOLANT CHANGE RECORD Date: 3 Years \ \ + Dealer's Stamp: 3 Next Date or Current Mileage: 50,000 Miles + 50,000 Next Mileage: Date: 3 Years \ \ + Dealer's Stamp: 3 Next Date or Current Mileage: 50,000 Miles + 50,000 Next Mileage: Date: 3 Years \ \ + Dealer
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Introduction
2
Instrumentation
6
Driving
12
Roadside emergencies
24
Cleaning
30
Maintenance and Specifications
32
General Owner’s Information
53
All rights reserved. Reproduction by any means, electronic or mechanical
including photocopying, recording or by any information storage and retrieval
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 © 2003 Ford Motor Company
Table of Contents
1