FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

After installation of the new filter
element, reset the gauge by pressing
the reset button on top of the
gauge.
Note:Vehicle operation in heavy
snowfall or extreme rain conditions
may feed excessive amounts of
snow/water into the air intake
system. This could plug/soak the air
filter with snow and may cause the
engine to lose power and possibly
shut down.
The following actions are recommend after operating the vehicle up to
200 miles (320 km) in heavy snowfall or extreme rain:
•Snow:At the earliest opportunity, open the hood and clear all the
snow and ice from the air filter housing inlet (do NOT remove the
foam filter) and reset the air filter restriction gauge.
•Extreme rain:The air filter will dry after about 15–30 minutes at
highway speeds. At the earliest opportunity, open the hood and reset
the air filter restriction gauge.
Air filter replacement:
When replacing the air filter element, use the Motorcraftair filter
element listed inMotorcraft part numberslater 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.
Failure to use the correct air filter element may result in severe
engine damage.
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1. Locate the mass air flow sensor
electrical connector on the air inlet
tube. This connector will need to be
unplugged.
Unlock the locking clip on the
connector, then squeeze and pull
the connector off of the air inlet
tube.
2. Release the four clamps that
secure the cover to the air filter
housing. Push the air filter cover
forward (away from you) and up
slightly to release it.
3. Remove the air filter element from the air filter housing.
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4. Remove and install a new foam
filter if needed according to the
service interval indicated in the
scheduled maintenance
informationin this guide. If the
foam filter is not being replaced, be
sure the existing foam filter is in
place.
5. Install a new air filter element. be
sure that the groove seal on the
pleated paper filter traps both sides
of the vertical partition of the air
box.
6. Replace the air filter housing
cover and secure the clamps. Be
careful not to crimp the filter
element edges between the air filter
housing and cover and ensure that
the tabs on the edge are properly
aligned into the slots.
7. Reconnect the mass air flow sensor electrical connector to the inlet
tube. Make sure the locking tab on the connector is in the “locked”
position.
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DIESEL EXHAUST SYSTEM: OXIDATION CATALYST/DIESEL
PARTICULATE FILTER SYSTEM
Your vehicle is equipped with a diesel particulate filter (DPF). The DPF
is an inline filter in the exhaust system which reduces carbon emissions
by trapping exhaust particles before they reach the tailpipe. The DPF
looks similar to a traditional exhaust catalyst, except larger, and is part
of the exhaust system under the vehicle. The DPF is coupled to a diesel
oxidation catalyst, that reduces the amount of harmful exhaust emitted
from the tailpipe. As soot gathers in the system it begins to restrict the
filter. The soot gathered inside the filter needs to be periodically cleaned.
The soot can be cleaned in two different ways; passive regeneration and
active regeneration. Both methods occur automatically and require no
actions from the driver/operator. During either one of these regeneration
methods you may notice an increase/change in exhaust noise/tone. At
certain times, the message center will display various messages related
to the DPF. SeeMessage centerin theInstrument Clusterchapter in
theOwner Guidefor more information.
Passive regeneration
In passive regeneration, the exhaust constituents / temperature are at an
appropriate level where some soot can be reduced or oxidized (burned)
thus cleaning the filter. This method occurs naturally as a result of
normal engine operating conditions (at varying levels due to drive
patterns).
Active regeneration
Once the DPF is full of exhaust particles, the engine control module will
command the exhaust system to clean the DPF through a process called
active regeneration. Active regeneration requires the engine computer to
raise the exhaust temperature to eliminate the particles. During cleaning,
the particles are converted to harmless gasses, and the DPF will then be
clean and ready to continue trapping exhaust particles.
The regeneration process operates more efficiently when the vehicle is
safely operated at least 30 mph (48 km/h) with a steady pedal for
approximately 20 minutes to complete the process. The frequency and
duration of regeneration will fluctuate as both are determined by how
you drive your vehicle, outside air temperature, and altitude. For most
driving, regeneration frequency will vary from 100 - 500 miles (161 -
805 km) between occurrences and each occurrence will last from 9 -
20 minutes. The duration of regeneration is usually reduced if a constant
speed above 30 mph (48 km/h) is maintained.
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When the engine control module detects that the DPF is nearly full of
particulates and that the vehicle is not being operated in a manner to
allow effective automatic cleaning, the message center will display
DRIVE TO CLEAN EXHAUST FILTERfor base message center and
Drive to Clean Exhaust Systemfor the optional message center,
guiding the vehicle operator to drive in order to clean the DPF. If the
vehicle is operated in a manner to allow effective automatic cleaning, the
message center will display a cleaning exhaust filter message, which is
the normal regeneration process. SeeMessage centerin theInstrument
Clusterchapter of theOwner Guidefor more information.
Note:You can also choose OCR to clean the exhaust system at this
point. SeeHow to start operator commanded regeneration (OCR)
later in this chapter.
If the operator is not able to drive in manner that allows effective
automatic cleaning (active regeneration) or the operator instead wishes
to perform regeneration of the DPF (cleaning) while at idle (stationary),
then OCR (operator commanded regeneration) will need to be
performed. SeeOperator commanded regeneration (OCR)following.
Note:Do not disregard theDRIVE TO CLEAN EXHAUST FILTERor
Drive to Clean Exhaust Systemmaintenance message for extended
periods of time. Failure to perform active or operator commanded
regeneration (OCR) (if equipped) when instructed may result in a
clogged DPF. If your DPF fills beyond what can be safely regenerated,
active regeneration and OCR will be disabled. This could cause
irreversible damage to the DPF, requiring service and possible
replacement that may not be covered by your warranty.
Operator commanded regeneration (OCR) (if equipped)
If your vehicle is operated with significant stationary operation, passive
and active regeneration may not sufficiently clean the DPF system. OCR
allows you to manually start regeneration of the diesel particulate filter
(DPF) at idle (while stationary) to clean the DPF. If you are not sure
whether your vehicle is equipped with this feature, contact your
authorized dealer.
When to perform OCR
Use the OCR feature when theDRIVE TO CLEAN EXHAUST FILTER
message appears in the message center and:
•the operator is not able to drive in manner that allows effective
automatic cleaning (active regeneration),
•or the operator instead wishes to manually start regeneration
(cleaning) of the DPF while the vehicle is idle (stationary).
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OCR precautions and safe exhaust position
WARNING:Failure to comply with the following instructions for
operator commanded regeneration (OCR) may result in fire,
serious injury, death and/or property damage.
Before you start OCR, observe/do the following:
•Place the vehicle in P (Park) with the parking brake set on stable,
level ground.
•The vehicle must not be parked in a structure.
•The vehicle must be 10 – 15 feet (3 – 5 meters) away from any
obstructions,
•and must be away from materials that can easily combust or melt such
as: paper, leaves, petroleum products, fuels, plastics and other dry
organic material, such as grass.
•Make sure there is a minimum of 1/8 tank of fuel.
•Make sure all fluids are at proper levels.
Make sure that the louvers (holes) located at the tip of the exhaust are
also clear of any obstructions as they are used to introduce fresh air into
the tailpipe to cool the exhaust gas as it leaves. SeeExhaustunder the
Cleaningchapter for more information.
How to start operator commanded regeneration (OCR)
WARNING:Stay clear of exhaust tip during regeneration. You or
others can be burned.
Note:OCR will not be allowed until DPF load percentage has reached at
least 80%. The DPF load percentage will fluctuate up and down when
driving your vehicle due to active and passive regenerations.
Note:OCR will not be allowed to operate if the service engine soon
light
is illuminated
Note:During the use of OCR, you may observe a light amount of white
smoke. This is normal.
Note:During stationary PTO operation, OCR will change the engine speed
to 2,000 or 2,400 rpm (depending on vehicle application), therefore it is
recommended you exit PTO mode before starting OCR. During mobile PTO
use, OCR is not necessary; regeneration will function normally.
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Base message center procedure
1. Start with the vehicle engine fully warmed.
2. Press the Info button on the steering wheel until the message center
reads one of the following choices:
•EXHST XX% FULL CLEAN Y/NorEXHAUST FILTER FULL:If
the DPF needs cleaning and the vehicle is warmed up, a message
requesting permission to initiate filter cleaning is displayed. Answer
yes to this prompt and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished.
•DRIVE TO CLEAN EXHAUST FILTER+EXH OVERLOADED
CLEAN? Y/N+
: If the vehicle is warmed up, a message
requesting permission to initiate filter cleaning is displayed. Answer
yes to this prompt and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished. You can also drive to clean the
filter. SeeActive regenerationearlier in this chapter.
•EXH OVERLOADED CLEAN? Y/N+REDUCED ENGINE POWER
+
: When the system is at this point of oversaturation you will not
be able to allow cleaning. The vehicle must be serviced by an
authorized dealer.
3. Once OCR starts, the engine’s rpm will rise to approximately 2,000 -
2,400 rpm and the cooling fan will increase speed; you will hear a change
in audible sound due to the fan and engine speed increase.
It is not necessary to open the hood on the engine compartment. Once
OCR is complete, the engine rpm and fan will return to normal idling.
The exhaust system will remain very hot for several minutes even after
regeneration is complete. Do not reposition the vehicle over materials
that could burn until the exhaust system has had sufficient time to
cool. Depending on the amount of soot collected by the DPF, ambient
temperature, and altitude, OCR may last from 10 to 25 minutes.
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Optional message center procedure
1. Start with the vehicle engine fully warmed.
2. From the main menu, select Gauge Mode and scroll through until one
of the following options appear:
•Exhaust xx% FullorExhaust Filter Full: If the DPF needs
cleaning and the vehicle is warmed up, you will be prompted to hold
OK to clean. Press OK and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished.
•Drive to Clean Exhaust System+Exhaust Filter Overloaded
+
: When the exhaust system is overloaded cleaning will be
allowed until a certain saturation level. If the vehicle is warmed up
and ready you will be prompted to hold OK to clean. Press OK and
then follow the prompts regarding exhaust position as needed to
initiate OCR. Be sure to understand each prompt. If you are not sure
what is being asked by each prompt, contact your authorized dealer.
The display will confirm the operation has started and when it has
finished. You can also drive to clean the filter. SeeActive
regenerationearlier in this chapter.
•Exhaust Filter Overloaded+Reduced Engine Power+
:
When the system is at this point of oversaturation you will not be able
to allow cleaning. The vehicle must be serviced by an authorized
dealer.
3. Once OCR starts, the engine’s rpm will rise to approximately 2,000 -
2,400 rpm and the cooling fan will increase speed; you will hear a change
in audible sound due to the fan and engine speed increase.
It is not necessary to open the hood on the engine compartment. Once
OCR is complete, the engine rpm and fan will return to normal idling.
The exhaust system will remain very hot for several minutes even after
regeneration is complete. Do not reposition the vehicle over materials
that could burn until the exhaust system has had sufficient time to
cool. Depending on the amount of soot collected by the DPF, ambient
temperature, and altitude, OCR may last from 10 to 25 minutes.
How to interrupt/cancel OCR
If OCR needs to be cancelled, pressing the brake, accelerator, or shutting
off the vehicle will stop OCR. Depending on the amount of time OCR was
allowed to operate, soot may not have had sufficient time to be
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eliminated, but the exhaust system and exhaust gas may still be hot. If
the vehicle is shut off during OCR, you will notice turbo flutter. This is a
normal consequence caused by shutting off a diesel engine during
boosted operation and is considered normal.
Filter service/maintenance
Over time a slight amount of ash will build up in the DPF which is not
removed during the regeneration process. The DPF may need to be
removed for ash cleaning at approximately 120,000 miles (193,000 km)
or greater (actual mileage can vary greatly depending upon
engine/vehicle operating conditions) and replaced with a new or
remanufactured (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 any issues with the oxidation catalyst/DPF system a service
light
orwill be set by the engine control system to inform
you to bring the vehicle into your authorized dealer for service.
Resonator/Tailpipe assembly maintenance
The diesel resonator tail-pipe assembly is a uniquely functioning device
that accompanies the Oxidation Catalyst/DPF assembly. The assembly
serves multiple functions. First it serves as an acoustic device to
attenuate exhaust noise. Second it provides an exit path for the exhaust
from the vehicle. It also is designed to help control the temperature of
the exhaust during DPF regeneration events. The visible holes in each
leg of the twin tip and the holes under the shield just inboard of the
right rear tire(s) are functional. The holes need to be kept clear of
mud/debris or foreign material to 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.
Note:Additions of aftermarket devices or modifications to the exhaust
system can reduce the effectiveness of the exhaust system as well as
cause damage to the exhaust system and/or engine. These actions may
also affect the vehicle’s warranty. See theWarranty Guidefor more
information.
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WARNING:Failure to maintain the functional holes, in the
tailpipe section of the exhaust, clean and free of debris or
foreign material may result in the holes becoming blocked or plugged.
Do not modify or remove the tail-pipe section. Blocked or plugged
holes or removal/modification of the system could result in elevated
exhaust gas temperatures which may result in vehicle/property damage
or personal injury.
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Use special care when
working around the diesel oxidation catalytic converter and/or the
diesel 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 SYSTEM(S) LAWS
In the U.S. federal law and certain state laws prohibit removing or
rendering inoperative emission control system(s). Similar federal or
provincial laws may apply in Canada. Ford recommends against any
vehicle modification without determining applicable law.
WARNING:Do not remove or alter the original equipment floor
covering or insulation between it and the metal floor of the
vehicle. The floor covering and insulation protect occupants of the
vehicle from the engine and exhaust system heat and noise. On
vehicles with no original equipment floor covering insulation, do not
carry passengers in a manner that permits prolonged skin contact with
the metal floor. Provide adequate insulation. Failure to follow these
instructions may result in fire or personal injury.
Tampering with emissions control systems (including related sensors and
the diesel exhaust fluid (DEF) injection system) can result in reduced
engine power and the illumination of the service engine soon light
.
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