2009 Ford E150 Super Duty Passenger Diesel Supplement 2nd Printing
2009 Ford E150 Super Duty Passenger Manual
2009 Ford E150 Super Duty Passenger manual content summary:
- 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 1
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 © 2008 Ford Motor Company 1 2009 Econoline (eco) Supplement, 2nd Printing USA (fus - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 2
Company, Ford of Canada, and service and repair facilities when servicing your vehicle. This information may be used to determine if repairs will be covered by warranty. Ford may discontinue models or change specifications without any notice and without incurring obligations. 2 2009 Econoline (eco - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 3
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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 4
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 the scheduled maintenance information in - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 5
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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 6
the temperature of the turbocharger. 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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 7
Instrument Cluster WARNING LIGHTS E-Series F-Super Duty w/manual transmission 7 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 8
Cluster F-Super Duty w/automatic transmission Harley-Davidson Note: Some warning lights are reconfigurable telltale (RTT) indicator lights and will illuminate in the message center display and function the same as the warning light. 8 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 9
for water-contaminated diesel fuel to be pumped into your tank. Your vehicle's 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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 10
use the underhood restriction gauge to determine when the air filter element needs to be changed. The vehicle may be driven with the engine air filter message on or when the underhood air filter restriction gauge has moved to the CHANGE FILTER mark for up to 200 miles (320 km) without damaging - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 11
and vehicle driving conditions change as you drive. This is to be expected as being normal to the operation of your vehicle. High levels of fan noise might also be heard when your engine is first started, and should normally decrease after driving for a short time. 11 2009 Econoline (eco - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 12
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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 13
. 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 chapter of this supplement. Diesel fuel is adjusted seasonally for cold temperatures. Diesel fuel which has not - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 14
with either an FCM or HFCM which recirculates fuel from the engine to help prevent fuel filter clogging. Your vehicle is also equipped with a bypass relief valve, located in the fuel tank pick-up boot, which provides fuel flow to the engine if the fuel pickup should become plugged. To allow the - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 15
extreme cold temperature issues. Starting aids: The use of the factory engine block heater (refer to Engine block heater [if equipped] in the Driving chapter of the Owner's Guide) and oil pan heaters (aftermarket) will assist in engine starting, in extreme cold ambient temperatures. WARNING: Do not - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 16
to produce "coking" or "wet stacking", which is common to all diesel engines when idling for extended periods during cold ambient temperatures. • Your vehicle may have a factory option for a Stationary Elevated Idle Control (SEIC) through dash-mounted Upfitter switches will allow the operator to - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 17
. • Do not modify the winter grille cover. The winter grille cover does not block some sections of the front of the vehicle because these openings are needed to provide enough airflow to the radiator and air cooler in extremely cold temperatures. 17 2009 Econoline (eco) Supplement, 2nd Printing USA - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 18
aftermarket electrical loads operated during engine warm up may impact the performance of the Rapid heat supplemental heater. 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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 19
Maximum lbs. (kg) trailer weight lbs. (kg) E-350 Regular Van (9500 GVWR) 6.0L 3.55 16000 (7257) 9500 (4309) 6.0L 4.10 20000 (9072) 10000 (4536) E-350 Extended/RV Van (9500 GVWR) 6.0L 3.55 16000 (7257) 9400 (4264) 6.0L 4.10 20000 (9072) 10000 (4536) E-350 Regular Wagon (12-passenger) (8950 GVWR) 6.0L - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 20
Engine Rear axle ratio Maximum GCWR Maximum lbs. (kg) trailer weight lbs. (kg) GVWR E-350 Cutaway with Dual Rear Wheels (DRW) 20000 (9072) 10000 (4536) GVWR E-350 Cutaway with Dual Rear Wheels (DRW) 20000 (9072) 10000 (4536) GVWR E-450 Cutaway 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 21
tow package; see rear axle label to identify actual vehicle content. Engine Integrated hitch rating The standard integrated hitch has two ratings depending on mode of operation: • Weight carrying - requires a draw bar and hitch ball. The draw bar supports all the vertical tongue load of the trailer - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 22
beyond the maximum tongue weight exceeds the limit of the towing system and could result in vehicle structural damage, loss of vehicle control and personal injury. * Trailer hitch adapter is available from Ford dealers (Part number: 5C3Z-19H282-A). 22 2009 Econoline (eco) Supplement, 2nd Printing - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 23
Set the parking brake on both vehicles. Note: This vehicle has two frame-mounted batteries located on the passenger side frame rail, behind the front passenger door. A battery positive (+) jumper stud is located on the frame rail behind the rear most battery box. 23 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 24
other accessories off. Connecting the jumper cables 1. Connect the positive (+) jumper cable to the positive (+) jumper stud located on the passenger side frame rail of the disabled vehicle. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery. 24 2009 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 25
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. 25 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 26
cause an explosion of the gases 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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 27
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's battery. 27 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 28
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. 28 2009 Econoline (eco) Supplement, 2nd Printing USA - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 29
) on all parts that require cleaning and pressure rinse clean. • Never wash or rinse the engine while it is running; water in the running engine may cause internal damage. • Cover the highlighted areas to prevent water damage when cleaning the engine. • E-Series 29 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 30
maintain proper function of the exhaust system. Clean and remove debris or foreign material if present as needed. Spraying with a hose during regular washing of vehicle should help keep holes clean and clear of debris or foreign material. 30 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 31
particulate filter (DPF). The diesel oxidation catalytic converter and/or the DPF heats up to a high temperature after only a short period of engine operation and can stay hot even after the engine is turned off. Failure to follow these instructions may result in personal injury. 31 2009 Econoline - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 32
steering fluid reservoir 6. Brake fluid reservoir 7. Engine coolant reservoir 8. Air filter assembly 9. Engine oil dipstick 10. Power distribution box The Fuel Conditioner Module (FCM) is located on the driver-side of the vehicle next to the transmission case. 32 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 33
) 5. Engine oil fill 6. Engine oil filter 7. Engine-mounted fuel filter assembly 8. Engine oil dipstick 9. Fuel coolant reservoir 10. 11. 12. 13. Brake fluid reservoir Power distribution box (behind engine coolant reservoir) Engine coolant reservoir Power steering fluid reservoir 33 2009 Econoline - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 34
. Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. FUEL REQUIREMENTS - CHOOSING THE RIGHT FUEL: VEHICLES OPERATED WHERE ULTRA LOW SULFUR DIESEL FUEL IS REQUIRED (UNITED - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 35
diesel fuel not intended for highway use. 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. 35 2009 Econoline - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 36
Ultra Low Sulfur Diesel fuel increases the likelihood of engine oil dilution with fuel which may lead to major engine damage. Engine damage from using the improper type of fuel is not covered under your warranty. Vehicles with 6.4L engines configured for use with high sulfur diesel fuel will only be - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 37
emissions and reduce engine life due to increased internal wear. Many of the world's automakers approved the World-wide Fuel Charter that recommends diesel fuel specifications to provide improved performance and emission control system protection for your vehicle. 37 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 38
. 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 change or if you run out of fuel) the engine will purge the - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 39
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. 39 2009 Econoline (eco) Supplement, 2nd Printing USA - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 40
information. Refer to Motorcraft Part Numbers later in this chapter for the fuel filter replacement part number. This part number includes filters and seals for both the engine-mounted and frame-mounted filters. 1. Stop the vehicle and shut off the engine. 40 2009 Econoline (eco) Supplement, 2nd - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 41
is closed and latched, then remove the container 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. 41 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 42
(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 surfaces. Removal - HFCM filter 1. Remove the fuel filter cap by turning counterclockwise. 42 2009 Econoline (eco) Supplement, 2nd Printing - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 43
and Specifications 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Removal - Engine-mounted fuel filter • E-Series • F-Super Duty 1. Remove the fuel filter cap by turning counterclockwise. 43 2009 Econoline (eco) Supplement, 2nd Printing USA (fus - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 44
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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 45
to Ford specification WSS-M2C171-E or API service categories CJ-4 or CJ-4/SM. It is important to use these oils because they are compatible with the emission control equipment of your vehicle to meet the more stringent emission standards. The use of correct oil viscosities for diesel engines is - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 46
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 46 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 47
Changing engine oil and filter Change your oil and filter according to the scheduled maintenance information in this supplement. Change more frequently if your vehicle operation includes extended at Gross Vehicle Weight Rating (maximum loaded weight for vehicle operation) 47 2009 Econoline (eco - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 48
) • use of high sulfur diesel fuel If you are operating your vehicle under any of these conditions, change engine oil and filter every 5,000 miles (8,000 km). AIR FILTER RESTRICTION GAUGE AND AIR FILTER REPLACEMENT Air filter restriction gauge: The restriction gauge, located on the upper housing of - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 49
element listed in Motorcraft Part Numbers later in this chapter. WARNING: To reduce the risk of vehicle damage and/or personal burn injuries do not start your engine with the air filter removed and do not remove it while the engine is running. 49 2009 Econoline (eco) Supplement, 2nd Printing - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 50
filter element may result in severe engine damage. • E-series air filter: 1. Disconnect the hoses from the air filter outlet tube. 2. Loosen the clamp and disconnect the air filter the air filter cover 5. Remove the air filter. 6. To install, reverse the removal procedure. 50 2009 Econoline (eco) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 51
from the housing. Failure to follow this instruction may result in damage to the air filter housing, air filter seal and engine. 3. When installing the air filter, first make certain the bottom of the air filter is positioned to the inboard side of the stop feature located in the bottom of the air - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 52
(ash cleaned) part. The filter may need to be replaced at approximately 250,000 miles (400,000 km) depending upon engine/vehicle operating conditions. In both cases the engine control system will set a service light ( ) to inform you to bring the vehicle to the dealer for service. If there are - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 53
particulate filter (DPF). The diesel oxidation catalytic converter and/or the DPF heats up to a high temperature after only a short period of engine operation and can stay hot even after the engine is turned off. Failure to follow these instructions may result in personal injury. EMISSION CONTROL - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 54
became effective governing the noise emission on trucks over 10,000 lbs. (4,536 kg) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Guide, are applicable to complete chassis cabs over - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 55
while air is in the fuel system; this is normal and should stop after a short time. MINOR TROUBLESHOOTING GUIDE Air purge procedure Turn the key on for 30 seconds, then turn off. Repeat procedure four or five times. If the engine won't crank Turn on the headlights. If the lights are dim, do not go - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 56
the starter motor. • Check the fuel gauge. You may be out of fuel. If the gauge shows that there is fuel in the tank, the trouble may be in the electrical system or the fuel system. If equipped with an auxiliary tank, be sure that the tank control switch is set for the tank with fuel and not on an - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 57
malfunction, resulting in severe vehicle damage or personal injury due to fire. Refer to the Owner's Guide for replacement of fuses. MOTORCRAFT PART NUMBERS Item Ford Part Number Engine oil filter FL-2016 Air filter - E-Series* FA-1804 Air filter - F-Super Duty* FA-1886 Fuel filter kit - E-Series FD - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 58
Engine coolant additive Engine coolant flush Fuel coolant F-Super Duty Engine oil (includes filter change) Fuel tank Manual transmission fluid Automatic transmission fluid 1 2 Capacity 27.5 quarts (26.0L) 29.6 quarts (28.0L)1 - - 2.0 quarts (1.9L) 15.0 quarts (14.2L)2 Ford part name Ford part - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 59
GUIDE Vehicle Identification Number (VIN): Owner Name: Address: Note: Use only a 6.4L diesel engine that has been configured for use with high sulfur diesel fuel in markets with diesel fuel that has sulfur content greater than 15 ppm. Using low sulfur diesel fuel (16-500 ppm) or high sulfur diesel - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 60
or for the service of components affecting emission control must be equivalent to genuine Ford Motor Company parts in performance and durability. It is the owner's responsibility to determine the equivalency of such parts. Please consult your Warranty Guide for complete warranty information. Non - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 61
after sale and delivery to an ultimate purchaser. In Canada, modifications of the emissions control system could create liability under applicable federal or provincial laws. Genuine Ford Parts and Service When planning your maintenance services, consider your Ford dealership for all your vehicle - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 62
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 dealers can offer. WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW? Owner Checks and Services Refer to Mileage - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 63
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 engine operation, see appropriate schedule. Maximum fuel filter change - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 64
and exterior lights tires for wear and adjust air pressure (including spare tire) that holes in the tail-pipe of the exhaust system are clear of debris-the holes/slots are functional (F-Super Duty) engine oil level windshield washer fluid level and drain fuel filter/water separator Check every six - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 65
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 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 66
, frequently asked questions and much more. The website location is at: www.ford.com in the U.S. or www.ford.ca in Canada. Then go to the vehicles and service pick at the web site. 7,500 miles (12,000 km) ❑ Change engine oil and replace oil filter ❑ Rotate tires, inspect tires for wear and measure - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 67
RO#: DATE: P&A CODE: MILEAGE: 30,000 miles (48,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted mounted fuel filters ❑ Rotate tires, inspect tires for wear and measure tread depth and inspect wheel ends for endplay and noise (vehicles with dual rear wheels - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 68
E-Series 45,000 miles (72,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Rotate tires, inspect tires for wear and measure tread depth and inspect wheel ends for endplay and noise (vehicles with dual rear wheels should only rotate if unusual - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 69
(96,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Change automatic transmission fluid and filter on all vehicles equipped with the Torqshift transmission. Consult your dealer for particular requirements. Replace front wheel bearing grease - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 70
E-Series 75,000 miles (120,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Rotate tires, inspect tires for wear and measure tread depth and inspect wheel ends for endplay and noise (vehicles with dual rear wheels should only rotate if unusual - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 71
brake system. Inspect exhaust system and heat shields Inspect accessory drive belt(s) Inspect automatic transmission fluid level Perform multi-point inspection (recommended) DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: 97,500 miles (156,000 km) Change engine oil and replace oil filter Change - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 72
km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Change engine coolant (see Motorcraft Premium Gold Coolant ❑ Rotate tires, inspect tires for wear and measure tread depth Change Record) and inspect wheel ends for endplay and noise (vehicles with - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 73
(192,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Change automatic transmission fluid and filter on all vehicles equipped with the Torqshift transmission. Consult your dealer for particular requirements. Replace front wheel bearing grease - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 74
Series 135,000 miles (216,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Rotate tires, inspect tires for wear and measure tread depth and inspect wheel ends for endplay and noise (vehicles with dual rear wheels should only rotate if unusual - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 75
150,000 miles (240,000 km) ❑ Change engine oil and replace oil filter ❑ Replace engine- and frame-mounted fuel filters ❑ Replace accessory drive belt(s) (if not replaced in the last ❑ Replace front wheel bearing and wheel bearing grease seals ❑ Change Premium Gold coolant (see Motorcraft Premium - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 76
wheel ends for endplay and noise Every 10,000 miles (16,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (FCM) fuel filter (whichever comes first) Every 15,000 miles (24,000 km) or Check the Nitrite level of the coolant using Fleetguardா 600 hours of - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 77
miles (8,000 km), Change engine oil and replace filter 6 months or 200 hours of engine operation (whichever comes first) Every 5,000 miles (8,000 km) Check air filter restriction gauge (replace air filter as required or when air filter restriction gauge indicates) Inspect brake system Rotate tires - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 78
000 km), Change engine oil and replace filter 3 months or 200 hours of engine operation (whichever comes first) if vehicle is used for stationary operation Every 10,000 miles (16,000 km), Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (FCM) fuel filter (whichever - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 79
) As required Replace cabin air filter, if equipped Off-road operation Every 5,000 miles (8,000 km) or Change engine oil and replace filter 6 months Every 5,000 miles (8,000 km) Check air filter restriction gauge (replace air filter as required or when air filter restriction gauge indicates) Rotate - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 80
miles (8,000 km) or Change engine oil and replace filter 200 hours of operation (whichever comes first) Every 10,000 miles (16,000 km) or Replace engine-mounted fuel filter and chassis-mounted 400 hours of operation (which ever (FCM) fuel filter comes first) 80 2009 Econoline (eco) Supplement, 2nd - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 81
: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: P&A CODE: MILEAGE: 81 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 82
: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: P&A CODE: MILEAGE: 82 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 83
) DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: 10,000 miles (16,000 km) ❑ Change engine oil and replace oil filter ❑ Rotate tires, inspect tires for wear and measure tread depth ❑ ❑ ❑ DEALER VALIDATION: and inspect wheels for endplay and noise (vehicles with dual rear wheels should only - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 84
, suspension, tie rod ends, drive shaft, 4x4 front axle U-joints and U-joints Perform multi-point inspection (recommended) DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: 30,000 miles (48,000 km) ❑ Change engine oil and replace oil filter ❑ Rotate tires, inspect tires for wear and measure - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 85
rod ends, drive shaft, 4x4 front axle U-joints and U-joints (lubricate if equipped with Zerk fittings) Perform multi-point inspection (recommended) DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: 60,000 miles (96,000 km) ❑ Change engine oil and replace oil filter ❑ Rotate tires, inspect tires - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 86
, suspension, tie rod ends, drive shaft, 4x4 front axle U-joints and U-joints Perform multi-point inspection (recommended) DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: 90,000 miles (144,000 km) ❑ Change engine oil and replace oil filter ❑ Rotate tires, inspect tires for wear and measure - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 87
fuel filters Inspect fuel cooling system level, strength and hoses Inspect engine cooling system level, coolant strength and hoses Inspect brake pads/shoes/rotors/drums, brakes lines & hoses, and parking brake system Inspect exhaust system and heat shields Inspect accessory drive belt Change engine - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 88
lines & hoses, and parking brake system Replace front wheel bearing grease and grease seals on 4x2 wheel bearings (if non-sealed bearings) Inspect exhaust system and heat shields Inspect accessory drive belt Change automatic transmission fluid and filter on all vehicles equipped with the Torqshift - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 89
gauge, replace filter as required Replace accessory drive belt if not replaced in the last 100,000 miles (160,000 km) Change engine coolant and fuel coolant (refer to Motorcraft Premium Gold Engine Coolant Change Record) Replace front wheel bearing and wheel bearing grease seals on 4x2 vehicles (if - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 90
oil and replace filter 3 months or 200 hours of engine operation (whichever comes first) Every 10,000 miles (16,000 km), Change engine-mounted fuel filter and chassis-mounted 6 months or 400 hours of engine (HFCM) fuel filter operation (whichever comes first) Every 20,000 miles (32,000 km) or Check - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 91
hours of engine (HFCM) fuel filter operation (whichever comes first) Every 30,000 miles (48,000 km) Replace wheel bearing grease and grease seals on 4x2 wheel bearings (if non-sealed bearings) Every 60,000 miles (96,000 km) Change transfer case fluid (4x4 only) 91 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 92
oil and replace filter 6 months or 200 hours of engine operation (whichever comes first) Every 10,000 miles (16,000 km), Change engine-mounted fuel filter and chassis-mounted 6 months or 400 hours of engine (HFCM) fuel filter operation (whichever comes first) Every 20,000 miles (32,000 km) or Check - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 93
for stationary operation Every 5,000 miles (8,000 km), Change engine oil and replace filter 3 months or 200 hours of engine operation (whichever comes first) if vehicle is used for stationary operation Every 20,000 miles (32,000 km) or Check the Nitrite level of the coolant using Fleetguardா 800 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 94
,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (HFCM) fuel filter (whichever comes first) Every 30,000 miles (48,000 km) Replace wheel bearing grease and grease seals on 4x2 wheel bearings (if non-sealed bearings) 94 2009 Econoline (eco) Supplement - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 95
noise Inspect brake system pads and rotors Every 5,000 miles (8,000 km) or Change engine oil and replace filter 6 months Inspect and lubricate U-joints Every 10,000 miles (16,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (HFCM) fuel filter (whichever - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 96
noise Inspect brake system pads and rotors Every 5,000 miles (8,000 km) or Change engine oil and replace filter 6 months Inspect and lubricate U-joints Every 10,000 miles (16,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (HFCM) fuel filter (whichever - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 97
Scheduled Maintenance: F-Super Duty Sustained high-speed driving at Gross Vehicle Weight Rating (maximum loaded weight for vehicle operation) Every 5,000 miles (8,000 km) or Change engine oil and replace filter 6 months Every 5,000 miles (8,000 km) Rotate tires, inspect tires for wear and measure - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 98
comes first) Use of non-Ultra Low Sulfur Diesel (ULSD) fuel - Vehicles operated where ultra low sulfur diesel fuel is not required/not available Every 2,500 miles (4,000 km) or Change engine oil and replace filter 3 months (If using high sulfur fuel with more than 3000 ppm sulfur) Every 5,000 - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 99
: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: P&A CODE: MILEAGE: 99 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 100
: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: P&A CODE: MILEAGE: 100 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 101
(ash cleaned) part. The filter may need to be replaced at approximately 250,000 miles (400,000 km) depending upon ) to inform engine/vehicle operating conditions. In both cases the engine control system will set a service light ( you to bring the vehicle to the dealer for service. If there are - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 102
authorized dealer This section of the guide is designed to allow your Ford dealer, or Ford Auto Care service center or other qualified service technician to record that the recommended service was completed at the appropriate mileage intervals. Be sure to ask your service provider to record the type - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 103
Coolant ❑ 6 years or 100,000 miles (160,000 km) - change Motorcraft Premium Gold Engine Coolant (whichever comes first) ❑ After initial change - change Motorcraft Premium Gold Engine Coolant every 3 years or 50,000 miles (80,000 km) 103 2009 Econoline (eco) Supplement, 2nd Printing USA (fus) - 2009 Ford E150 Super Duty Passenger | Diesel Supplement 2nd Printing - Page 104
A CODE R.O.# Current mileage goes here => Add 50,000 miles to the current miles Next change due at this mileage => Or Today's date goes here => Add 3 years Date of next change => whichever comes first Dealer Stamp + 50,000 + 00 / 00 / 03 P & A CODE R.O.# 104 2009 Econoline (eco) Supplement, 2nd
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Introduction
2
Instrument Cluster
7
Driving
11
Roadside Emergencies
23
Cleaning
29
Maintenance and Specifications
32
Scheduled Maintenance: General Information
59
Scheduled Maintenance: E-Series
66
Scheduled Maintenance: F-Super Duty
83
Scheduled Maintenance: Special Information
101
Motorcraft Premium Gold Coolant change record
102
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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 © 2008 Ford Motor Company
Table of Contents
1
2009 Econoline
(eco)
Supplement, 2nd Printing
USA
(fus)