FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS
AND MAINTENANCE
On January 1, 1978, Federal regulation 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
10,000 lbs. (4,536 kg) GVWR.
Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use, or
(2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
•Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
•Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer’s specifications.
The complexity of the diesel engine makes it so the owner is discouraged
from attempting to perform maintenance other than the services
described in this supplement.
If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged or disconnected air 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.
•check engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
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FUELING
WARNING:Do not use starting fluid such as ether or gasoline
in the diesel air intake system. Such fluids can cause immediate
explosive damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) 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
Air purge procedure
Turn the key on for 30 seconds, then turn off. Repeat the procedure six
times.
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or when
the ignition is turned to START the lights become dim or go out, the
battery connections may be loose or corroded, or the battery may be
discharged. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to START, this may also
indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds.Wash hands after handling.
•The gearshift lever must be in P (Park) or N (Neutral) in order for
the starter to operate.
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•Try operating the starter switch several times. Should the switch be
corroded, this operation may clean the contacts or make the switch
temporarily operable until you can reach the dealer.
•If all electrical connections are tight and you need assistance to start,
refer toJump startingin theRoadside Emergencieschapter of your
Owner’s Guide.
If engine cranks but won’t start
Prolonged starter cranking (in excess of 10 seconds) could cause
damage to 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 empty
tank.
•Leaving the ignition key turned to on for over two minutes without
starting may make starting difficult because the glow plugs will cease
activation. Reset the system by turning the ignition key to off and
then back to on again.
If the engine runs hot
The following could cause the engine to overheat:
•Lack of coolant.
•Dirty cooling system.
•Plugged radiator fins, A/C condenser and/or oil cooler.
•Malfunctioning fan drive.
•Driving with frozen coolant.
•Sticking thermostat.
•Overloading or pulling heavy trailers during hot weather.
•Grill or radiator air blockage.
•Slipping or missing drive belt.
•Plugged or very dirty air filter.
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If fuses burn out
Burned-out or blown fuses usually indicate an electrical short-circuit,
although a fuse may occasionally burn out from vibration. Insert a second
fuse. If this fuse immediately burns out and you cannot locate the cause,
return your vehicle to your dealer for a circuit check.
WARNING:Replacement fuses and circuit breakers must always
be the same rating as the original equipment shown. Never
replace a fuse or circuit breaker with one of a higher rating. Higher
rated fuses or circuit breakers could allow circuit overloading in the
event of a circuit malfunction, resulting in severe vehicle damage or
personal injury due to fire.
Refer to theOwner’s Guidefor replacement of fuses.
Selective catalytic reduction (SCR) system speed limit and
Idle-only modes
If the vehicle’s speed is limited or in an idle-only mode, the SCR system
may be limiting the vehicle’s functions due to low or contaminated diesel
exhaust fluid (DEF). Check the DEF. SeeSelective catalytic reduction
(SCR) systemin theMaintenance and Specificationschapter for more
information.
MOTORCRAFTPART NUMBERS
Item Ford Part Number
Engine oil filter FL-2051
Foam pre-filter FA-1907
* Air filter FA-1902
Fuel filter kit (2 included - engine
and frame rail mounted )FD-4615
Battery (2 Required) BXT-65-750
* Always use the authorized Motorcraftair filter or an equivalent
replacement part.Failure to use the correct air filter may result
in severe engine damage.
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MAINTENANCE PRODUCT SPECIFICATIONS AND CAPACITIES
Item Capacity Ford part nameFord part number /
Ford specification or
specification
Engine coolant
(primary high-
temperature cooling
system loop)*29.4 quarts
(27.8L)MotorcraftSpecialty
Orange Engine CoolantVC-3-B (US)
CVC-3-B (Canada) /
WSS-M97B44-D
Engine coolant additive
(primary high-
temperature cooling
system loop)48.0 oz. (1.4L) per
addition if
requiredMotorcraftSpecialty
Orange Engine Coolant
RevitalizerVC-12 /
—
Engine coolant additive
(secondary cooling
system)16 oz. (473 mL)
per addition if
required
Engine cooling system
cleaner1 quart (946 mL)
MotorcraftPremium
Cooling System FlushVC-1 /
—
Secondary cooling
system cleaner22.0 oz. (651 mL)
Engine coolant
(secondary cooling
system*)11.7 quarts
(11.1L)MotorcraftSpecialty
Orange Engine CoolantVC-3-B (US)
CVC-3-B (Canada) /
WSS-M97B44-D
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Item Capacity Ford part nameFord part number /
Ford specification or
specification
Engine oil (includes
filter change)13.0 quarts
(12.4L)•MotorcraftMotor Oil
10W30 Super Duty
•MotorcraftMotor Oil
15W40 Super Duty
•MotorcraftMotor Oil
5W40 Super Duty
•MotorcraftMotor Oil
0W30 Super Duty•XO-10W30–QSD /
WSS-M2C171–E
•XO-15W40-QSD /
WSS-M2C171-E
•XO-5W40-5QSD /
WSS-M2C171-E
•CXO-0W30-LAS12 /
WSS-M2C171-D
Diesel Exhaust Fluid
(DEF) — Pick-up5 gallons (18.9L)
MotorcraftDiesel
Exhaust FluidPM-27-G /
WSS-M99C130-A
Diesel Exhaust Fluid
(DEF) — Chassis Cab6 gallons (22.7L)
Cetane Booster &
Performance Improver—MotorcraftCetane
Booster & Performance
ImproverPM-22-A (US)
PM-22-B (Canada) /
—
Anti-Gel &
Performance Improver—MotorcraftAnti-Gel &
Performance ImproverPM-23-A (US)
PM-23-B (Canada) /
—
Fuel tank — Pick up
regular cab long box
and all short box26 gallons (98.4L) — —
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Item Capacity Ford part nameFord part number /
Ford specification or
specification
Fuel tank — Pick Up
long box (except
regular cab)37.5 gallons
(142.0L)——
Fuel tank — Chassis
cab (midship)28 gallons
(106.0L)——
Fuel tank — Chassis
cab (aft of axle)40 gallons
(151.4L)——
Fuel tank — Dual
tanks40 gallon (151.4L)
and
28 gallon (106.0L)——
Automatic transmission
fluidRefer toOwner’s Guide
* Use only the recommended coolant for topping off and coolant changes. Using any other coolant
may result in vehicle damage.
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GENERAL MAINTENANCE INFORMATION
Why maintain your vehicle?
This guide describes the scheduled maintenance required for your vehicle.
Carefully following this schedule helps protect against major repair
expenses resulting from neglect or inadequate maintenance and may also
help to increase the value of your vehicle when you sell or trade it.
It is your responsibility to see that all scheduled maintenance is performed
and that the materials used meet Ford engineering specifications as
identified in theMaintenance and Specificationschapter. 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 always recorded in this guide.
Your Ford dealer has factory-trained technicians who can perform the
required maintenance using genuine Ford parts. They are committed to
meeting your service needs and to assuring your continuing satisfaction.
Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To ensure the proper
performance of your vehicle and its emission control systems, it is imperative
that scheduled maintenance be completed at the designated intervals.
Your vehicle is equipped with the Intelligent Oil Life Monitor™ system
which displays a message in the message center at the proper oil change
service interval; this interval may be up to one year or 10,000 miles
(16,000 km). When ENGINE OIL CHANGE DUE or OIL CHANGE
REQUIRED appears in the message center display, it’s time for an oil
change; the oil change must be done within two weeks or 500 miles
(800 km) of the OIL CHANGE REQUIRED message appearing. The
Intelligent Oil Life Monitor™ must be reset after each oil change; refer to
theInstrument Clusterchapter.
If your message center is prematurely reset or becomes inoperative, you
should perform the oil change interval at six months, 5,000 miles
(8,000 km) or 200 engine hours from your last oil change.
Your vehicle is very sophisticated and built with multiple complex
performance systems. Every manufacturer develops these systems using
different specifications and performance features. That’s why it’s
important to rely upon your Ford dealership to properly diagnose and
repair your vehicle.
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Ford Motor Company has recommended maintenance intervals for various
parts and component systems based upon engineering testing. Ford Motor
Company relies upon this testing to determine the most appropriate
mileage for replacement of oils and fluids to protect your vehicle at the
lowest overall cost to you and recommends against maintenance schedules
that deviate from the scheduled maintenance information.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraftor Ford-authorized remanufactured
parts that are used for maintenance replacement 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 yourWarranty Guidefor complete warranty information.
Non Ford-approved chemicals or additives are not required for factory
recommended maintenance. In fact, Ford Motor Company recommends
against the use of such additive products unless specifically
recommended by Ford for a particular application.
Oils, fluids and flushing
In many cases, fluid discoloration is a normal operating characteristic of the
chemical compound and may not necessarily demonstrate that a fluid
needs to be changed. Oils and fluids identified in this guide should be
changed at the specified interval or in conjunction with a repair. Flushing is
a viable way to change fluid for many vehicle sub-systems during scheduled
maintenance and should only be done using the same fluid required to
finish the maintenance procedure, or a Ford-approved flushing chemical.
Genuine Ford parts and service
When planning your maintenance services, consider your dealership for
all your vehicle’s needs.
There are a lot of reasons why your dealership is a great way to help
keep your vehicle running great.
Convenience
To make your service visit even more convenient, in many cases, you’ll find
extended evening hours and Saturday hours. How’s that for quality service?
Factory-trained technicians
Service technicians participate in extensive factory-sponsored training to
help them become the experts on the operation of your vehicle. Many
participate in Ford-sponsored training to become certified. Ask your dealer
about the training and certification their technicians have received.
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Genuine Ford and Motorcraftreplacement parts
Dealerships stock Ford and Motorcraftbranded replacement parts.
These parts meet or exceed Ford Motor Company’s specifications, and
we stand behind them. Maintenance parts installed at your dealership
carry a nationwide, 12 month/12,000 mile (20,000 km) parts and labor
limited warranty. Your dealer can give you details.
Value shopping for your vehicle’s maintenance needs
Your dealership recognizes the competitive landscape of maintenance and
light repair automotive 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 dealers
can offer.
Owner checks and services
Certain basic maintenance checks and inspections should be performed
by the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in theOwner’s
Guide.
Any adverse condition should be brought to the attention of your dealer
or qualified 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 fluids used.
Maximum oil change interval
Normal schedule As indicated by the message center (do not
exceed one year or 10,000 miles [16,000 km])
Special operating
conditionsRefer toSpecial operating conditionslater in
this chapter
Maximum fuel filter change interval
Normal schedule 22,500 miles (36,000 km) or as indicated by the
message center (whichever comes first)
Special operating
conditionsRefer toSpecial operating conditionslater in
this chapter
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