light FORD SUPER DUTY 2011 3.G Diesel Supplement Manual

The DFCM should be drained at regular intervals or when indicated by
the message center message and water in fuel indicator light. SeeFuel
filter/water separatorin theMaintenance and Specificationschapter.
The fuel injection system is controlled through the powertrain control
module (PCM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump
located inside the DFCM and provides pressurized fuel to the engine.
The fuel pump contains a pressure relief valve for overpressure
protection in the event of restricted flow.
Engine protection mode
Ford diesel engines are equipped with engine protection and emission
control systems. These systems monitor critical temperatures and
pressures, and modify engine operation accordingly. These features are
intended to modify engine performance characteristics. If these modified
engine performance characteristics persist for an extended period or the
service engine soon
or powertrain malfunction/reduced
power/electronic throttle control light
is illuminated, seek service
from your authorized dealer.
Lubrication system
It is important to change the engine oil at the recommended service
intervals to maintain oil viscosity. Extending the oil and filter change
interval beyond the recommended interval can negatively affect engine
performance, fuel economy and engine life. Refer toEngine oilin the
Maintenance and Specificationschapter.
Fast start glow plug system
The diesel engine glow system consists of:
•eight glow plugs (one per cylinder)
•the glow plug control module (GPCM)
•engine coolant temperature (ECT) sensor
•barometric pressure (BARO) sensor
•environmental temperature sensor
Introduction
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WARNING LIGHTS
Base cluster with standard measure shown; metric and optional
similar
Note:Some warning lights are reconfigurable telltale (RTT) indicator
lights and will illuminate in the message center display and function the
same as the other warning lights.
Glow plug pre-heat indicator:
With the key in the on position, this
light will illuminate if glow plug heat
is necessary as a starting aid. Wait until the light goes off before starting.
Refer toCold weather startingin theDrivingchapter of this
supplement. After the engine starts, the light should turn off. The light
should always illuminate at least momentarily when the engine is cold
and the ignition is turned to on.
04CHCHEF
RPMx1000
0204
060801001
2
01
4
0160
km/hMPH
Instrument Cluster
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Water in fuel:
During refueling, it is possible 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 DFCM 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 DFCM. Refer
toFuel filter/water separatorin theMaintenance and Specifications
chapter of this supplement for the drain procedure. Allowing water to
stay in the system could result in extensive damage to, or failure of, the
fuel injection system.
Note:Draining the water separator with the engine running will allow air
to enter the fuel system and cause engine problems.
WARNING: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.
Low/contaminated diesel exhaust fluid:
With the key in the on position, this
light will illuminate if the exhaust
fluid is contaminated and/or low.
SeeDiesel exhaust fluidin the
Maintenance and Specifications
chapter for more information.
GAUGES
Engine boost gauge:
Indicates the amount of manifold air
pressure in the engine.
Instrument Cluster
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ENGINE IDLE SHUTDOWN (IF EQUIPPED)
Your vehicle may be equipped with an engine idle shutdown system. This
system will automatically shut down your engine when it has been idling
in P (Park) or N (Neutral) for five minutes (parking brake set) or
15 minutes (parking brake not set). When the engine idle shutdown
process has started:
•A chime will sound and the message center will displayENGINE
TURNS OFF IN 30(seconds) and start counting down.
•The 5 or 15 minute timer can be restarted by changing the position of
the accelerator pedal, brake pedal or the park brake within the final
30 seconds.
•When the timer reaches zero, the engine shuts down and the message
center will displayENGINE TURNED OFF.
•One minute after the engine has shut down, the electrical system will
simulate key off, even though the ignition is still in the on position,
initiating normal accessory delay period.
•The ignition must be moved to the off position to reset the system
before restarting the vehicle.
Note:The engine idle shutdown idle timer will not start if:
•The engine is operating in power take-off (PTO) mode.
•The engine coolant temperature is below 60°F (16°C).
•The exhaust emission control device (DPF) is regenerating.
STOPPING THE ENGINE
Turn the ignition to the off position.
To prolong engine life (especially after extended high speed, high
ambient temperature, or high GVW/GCW operation), it is recommended
that a hot engine be idled for 3-5 minutes which will allow the
turbocharged engine to cool down.
COLD WEATHER OPERATION
Changing to a lighter grade engine oil also makes starting easier under
these conditions. Refer toEngine oil specificationsin theMaintenance
and Specificationschapter of this supplement.
Diesel fuel is adjusted seasonally for cold temperatures. Diesel fuel which
has not been properly formulated for the ambient conditions may form
wax crystals which can clog the fuel filters. At temperatures below 20°F
(–7°C), if the engine starts, stalls after a short time, and then will not
Driving
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ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•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 MotorcraftEngine Shampoo and Degreaser (ZC-20) 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.
Cleaning
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SCHEDULED MAINTENANCE
The scheduled maintenance services in thescheduled maintenance
informationof this supplement 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. Motorcraftparts 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 STATES/CANADA/PUERTO RICO/U.S. VIRGIN
ISLANDS AND OTHER LOCALES)
Use only Ultra Low Sulfur (15 ppm Sulfur Maximum) number 1-D
or 2-D diesel fuel (also known as ULSD) in your 6.7L diesel
engine.The engine and exhaust system were designed to only use this
fuel. Look for theULTRA-LOW SULFUR HIGHWAY DIESEL FUEL
(15 ppm Sulfur Maximum)label on fuel pumps when purchasing your
fuel.
Using low sulfur diesel fuel (16-500 ppm) or high sulfur diesel
fuel (greater than 500 ppm) in a diesel engine designed to use
only Ultra Low Sulfur Diesel fuel will cause certain emission
components to malfunction which may also cause the service
engine soon
light to illuminate indicating an emissions-
related concern.
Diesel fuel is adjusted seasonally for cold temperature. For best results
at temperatures below 20°F (-7°C), it is recommended to use a diesel
fuel which has been seasonally adjusted for the ambient conditions. See
Cold weather operationin theDrivingchapter of this supplement.
FUEL REQUIREMENTS - CHOOSING THE RIGHT FUEL: VEHICLES
OPERATED WHERE ULTRA LOW SULFUR DIESEL FUEL IS NOT
REQUIRED
For the engine to operate reliably on low sulfur or high sulfur diesel fuel,
the engine must be a high sulfur configured engine or a ULSD
fuel-configured engine that has been retrofitted for high sulfur diesel fuel
use.
Use only a 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 fuel (greater than 500 ppm) in a diesel
Maintenance and Specifications
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5. Once the level in the DEF bottle
has stopped dropping, return the
container to the vertical position
slightly below the DEF filler port
and let any DEF drain out of the
spout. DO NOT try to continue to
add DEF to the tank by shaking or
repositioning the container to
induce flow. This may cause spilling
and overfill the tank. Overfilling the
DEF tank can cause damage to the
tank.
Once the spout has drained, remove the spout from the DEF filler port
and install the blue cap on the DEF filler port.
7. Remove the spout from the DEF container and install the cap back on
the bottle.
8. If the container is empty, discard the empty container and spout, or
recycle if possible. If there is some DEF left in the container, retain it
and the spout for later use. Store the spout to ensure it is kept clean.
9. Wipe away any DEF that has spilled on painted surfaces with water
and a damp cloth.
•DEF filling station nozzle fill:
Filling the DEF tank using a nozzle is similar to a normal fuel fill. The
nozzle will shut off automatically when the tank is full. Do not continue
to fill the tank as this may cause spilling and overfill the tank which can
cause damage.
Note:Some filling station nozzles may prevent filling of your DEF tank
due to a magnetic mechanism in the nozzle. This is not a problem with
your vehicle. To refill your tank either locate another filling station or
use a bottle to refill the tank.
Filling the DEF tank in cold climates
DEF will freeze below 12°F (-11°C); however, your vehicle is equipped
with an automatic preheating system which allows the DEF system to
operate below 12°F (-11°C). When the vehicle is not in operation for an
extended period of time with temperatures at or below 12°F (-11°C), the
DEF tank could freeze. If the tank is OVERFILLED and freezes, it could
be damaged, therefore DO NOT OVERFILL.
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To prevent overfilling of the DEF tank when filling with a bottle, Ford
recommends using MotorcraftDEF. Additionally, if the message center
indicatesEXHAUST FLUID UNDER 1/2 FULL, you should only add a
MAXIMUM of 2 gallons (6.7L) of DEF to the tank to prevent freeze
damage due to overfilling. If the message center indicatesEXHAUST
FLUID LEVEL OK, do not add DEF.
Contaminated DEF
SCR systems are sensitive to
contamination of the DEF. USE
ONLY API or ISO 22241 CERTIFIED
DIESEL EXHAUST FLUID. If the
system becomes contaminated, the
DEF light will illuminate and
contaminated exhaust fluid
messages will appear in the message
center.
Continued driving without refilling will result in the following actions as
required by the U.S. Environmental Protection Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon restart. Prior to this occurring a message will appear in
the message center.
•Further vehicle operation without replacing contaminated DEF will
cause the engine to enter an idle-only condition. This will only occur
upon vehicle refueling and will be indicated by a message in the
message center indicating required actions to resume normal
operation.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the contaminated system is repaired.To
service a contaminated SCR system, see your authorized dealer.
DEF guidelines and information
•Use only DEF that carries the trademark: American Petroleum
Institute (API) certified DEF or ISO 22241.
•Do not put DEF in the diesel fuel tank.
•Do not overfill the DEF tank.
•Do not re-use the DEF container or nozzle once it is emptied.
•Avoid spilling DEF on painted surfaces, carpeting or plastic
components. Immediately wipe away any DEF that has spilled with a
damp cloth and water. If it has already crystallized, use warm water
and a sponge.
Maintenance and Specifications
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•Store DEF out of direct sunlight and in temperatures between 23°F
(-5°C) — 68°F (20°C).
•DEF will freeze below 12°F (-11°C).
•Do not store DEF bottle in vehicle. If it leaks it could cause damage to
interior components or release an ammonia odor inside the vehicle.
•DEF is non-flammable, non-toxic, colorless and water-soluble liquid.
•Do not dilute DEF with water or any other liquid.
•An ammonia odor may be smelled when the cap is removed or during
refill. Refill DEF in a well ventilated area.
FUEL FILTER/WATER SEPARATOR
Diesel Fuel Conditioner Module (DFCM)
The vehicle is equipped with a diesel fuel conditioning module (DFCM)
located on the frame-rail under the driver-side floorboard near the
transmission
Water should be drained from the
module assembly whenever the
warning light comes on and the
message center directs you to drain
the water separator. This will occur when approximately 0.32 pints (150
ml) of water accumulates in the module. If water level is allowed to
exceed this level, the water may be passed through to the engine and
may cause fuel injection equipment damage.
Draining the DFCM
1. Stop the vehicle andshut offthe engine.
WARNING:The vehicle must be stopped with the engine off
when draining the DFCM. Fuel may ignite if the separator is
drained while the engine is running or vehicle is moving.
Note:Air will enter into the fuel system if the DFCM is drained while
the system is running. The engine will not operate properly if air enters
the system.
2. Locate the DFCM and place an appropriate container under the drain
port (see illustration).
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3. Rotate the drain counterclockwise
until the O-ring is visible. Allow the
DFCM to drain for approximately
25 seconds or until clean fuel is
observed. Rotate the drain clockwise
to tighten it.
4. Make sure that the drain valve is fully tightened, then remove the
container from under the vehicle.
Note:A loose drain valve can allow air to enter the fuel system and
cause drivetrain issues. The engine will not operate properly. be sure
that the drain valve is fully tightened.
5. Restart the engine. TheWATER IN FUEL DRAIN FILTERor
WATER IN FUEL DRAIN FILTER SEE MANUALmessage and light
should not be illuminated. If they continues to illuminate, have the fuel
system checked and repaired.
LOW FUEL PRESSURE MESSAGE
The engine is equipped with a low fuel pressure detection system. If the
message center displays:LOW FUEL PRESSUREthe following
explains why and what to do:
•Cold start or cold operation (below 32°F (0°C): If this message
appears during a cold start or during cold operation up to 10 minutes
after the initial cold start, monitor the message center. If it disappears
and does not re-appear after the engine has fully warmed up, the low
fuel pressure message is most likely caused by waxed or gelled fuel.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/systems. Use an anti-gel additive
as listed inMaintenance product specifications and capacities
section in this chapter. The customer warranty may be void from using
additives that do not meet or exceed Ford specifications.
If the low fuel pressure message persistently appears after re-fueling
during the cold start and cold operation conditions defined previously
and then disappear when the engine has fully warmed up, consider
different fuel sources.
Maintenance and Specifications
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