engine FORD SUPER DUTY 2008 2.G Diesel Supplement Manual

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
Your new diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.A special procedure for turning off the diesel engine is in
theDrivingchapter. It is important to read and understand this
material in order to maintain the best service life for your
engine.
This guide will acquaint you with the 6.0L/6.4L Power Stroke diesel
engine. It provides recommendations on engine care and operating
procedures. For complete vehicle information, also refer to theOwner’s
Guideincluded with the vehicle. It also describes equipment and gives
specifications for equipment that was in effect when this guide was
approved for printing, and should be considered a permanent part of the
vehicle.
Some aftermarket products may cause severe engine/transmission
and/or exhaust system damage; refer to theWhat is not covered
section inThe new vehicle limited warranty for your vehicle
chapter of your vehicle’sWarranty Guidefor more information.
Your vehicle’s Powertrain Control Systems can detect and store
information about vehicle modifications that increase horsepower
and torque output such as whether or not performance-enhancing
powertrain components commonly referred to as “performance
chips” have been used. This information cannot be erased and
will stay in the system’s memory even if the modification is
removed. The Information can be retrieved by Ford Motor
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.
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Important notice
Ford vehicles are suitable for producing ambulances only if equipped
with the Ford ambulance preparation package. In addition, Ford urges
ambulance manufacturers to follow the recommendation of theFord
Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book
(and pertinent supplements) and theQualified 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
overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with the Ford ambulance preparation
package, inspect the information plate on the driver’s side door pillar.
Contact the manufacturer of your vehicle to determine whether the
ambulance manufacturer’s followed Ford’s recommendations.
WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 500 miles (800 km) before towing a
trailer. Make sure you use the specified engine oil by checking the engine
oil specification chart underEngine oilin theMaintenance and
Specificationschapter.
Do not add friction modifier compounds or special break-in oils during
the first few thousand miles (kilometers) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The Diesel engine fuel system consists of:
•On E-Series vehicles (6.0L engine),a Fuel Conditioner Module
(FCM) mounted on the driver-side of the transmission case
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•On F-Super Duty vehicles (6.4L engine),a frame-mounted
Horizontal Fuel Conditioner Module (HFCM)
•an engine-mounted secondary fuel filter
•a unit injector for each cylinder
The FCM/HFCM acts as a primary fuel filter/water separator which
removes both water and impurities from the fuel. The engine-mounted
fuel filter and the FCM/HFCM filter should be changed at the
recommended service interval. Refer to thescheduled maintenance
informationin this supplement for more information.
The FCM/HFCM should be drained at regular intervals or when the
WATER IN FUEL light illuminates in the instrument cluster (E-Series) or
when the WATER IN FUEL message appears in the message center
(F-Super Duty).
The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM) and Fuel Injection Control Module (FICM) (6.0L
engine only).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. 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
Check Engine (
) or Powertrain malfunction/Reduced
power/Electronic throttle control light (
) is illuminated, seek
service from your authorized dealer.
Lubrication system
Extended oil change intervals can negatively affect engine performance,
fuel economy and engine life. Refer to the engine oil specification chart
located underEngine oil specificationsin theMaintenance and
Specificationschapter of this supplement.
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On E-Series vehicles (6.0L engine),it is important to change the
engine oil at the recommended service intervals, because oil viscosity is
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 plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM energizes the glow
plugs immediately after the ignition
is placed in the ON position, then determines how long the glow plugs
will be on according to the EOT and BARO sensors. The required time
for the glow plugs to be energized decreases as the engine oil
temperature and barometric pressure increase.
Engine cooling system
The engine cooling system contains an engine oil cooler which is
mounted in the center valley of the engine. The cooler’s function is to
regulate engine oil temperature.
Fuel and turbocharger cooling system (F-Super Duty only)
The fuel and turbocharger cooling system contains a cooler which is
mounted on the turbo interstage U-tube on the left side of the engine.
The cooler’s function is to regulate engine fuel temperature and cool the
electronics that support the turbocharger. You may hear the auxiliary
coolant pump running up to 10 minutes after the ignition is turned OFF
in hot weather or if you are towing heavy loads. This is to control the
temperature of the turbocharger.
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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 at too high a vehicle speed for the selected
transmission gear.
If your vehicle is equipped with a manual transmission,refer to
Manual transmission shift speedsin theDrivingchapter of your
Owner’s Guidefor maximum vehicle shift speeds in various gears. Do
not exceed 4,000 rpm. Maximum engine governed speed is 3,700 rpm.
Excessive rpm can only be achieved by manually downshifting at too
high of a vehicle speed.
Operating the engine beyond the governed speed can cause
severe engine damage.
Speed control (F-Super Duty only)
If vehicle speed goes outside a predetermined range from the set speed,
the RES (Resume) function will not reset vehicle speed. Vehicle speed
will need to be reset with the SET +/- button after reaching desired
speed using accelerator pedal.
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F-Super Duty w/automatic transmission
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.
Glow plug pre-heat indicator:
With the key in the ON position,
the
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. If it does not illuminate, the glow
plug system should be checked and repaired promptly to avoid difficulty
in cold starting.
Water in fuel:
E-Series
F-Super Duty
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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 RTT will illuminate when the ignition is turned to START (as part
of the light function check) and when the FCM/HFCM 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 FCM/HFCM.
Refer toDraining the FCM/HFCM and changing the engine and
vehicle fuel filtersin theMaintenance and Specificationschapter 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.
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.
Engine oil pressure (F-Super
Duty only):
Illuminates when the oil pressure
falls below the normal range. Refer
toEngine oilin theMaintenance
and Specificationschapter for more information.
Engine air filter (F-Super Duty only):
The engine air filter warning
message comes on in the message
center when the air filter restriction
gauge reaches the CHANGE FILTER
mark or if the air filter and/or
housing becomes packed with snow.
If airflow is restricted because of snow ingestion, the indicator will
remain on until snow is cleared from the housing, but the vehicle will
still be functional.
The air filter condition should be verified by inspecting the underhood
restriction gauge; the message is only a secondary indicator. Always use
the underhood restriction gauge to determine when the air filter element
needs to be changed.
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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 the engine.
However, the air filter element must be replaced at the earliest
opportunity. Refer toAir filter restriction gauge and air filter
replacementin theMaintenance and Specificationschapter for more
information.
GAUGES
Engine boost gauge (F-Super Duty):
Indicates the amount of pressure in
the engine. Driving with your
pointer continuously at the high end
of the scale may damage the engine.
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STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F (0°C), the use of the correct grade engine
oil is essential for proper operation. Refer toEngine oil specifications
in theMaintenance and Specificationschapter for more information.
If your vehicle is equipped with a manual transmission,make sure
the parking brake is fully set before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission,ensure
the gearshift lever is in P (Park) and the parking brake is fully set before
you turn the key. Do not press the accelerator during starting.
Engine-driven cooling fan (Fan clutch)
Your vehicle is equipped with an engine driven cooling fan drive (also
called a fan clutch). This fan drive changes the fan speed to match the
vehicle’s changing cooling air flow requirements. Fan speed, fan noise
level and fuel consumption all will increase based on the driving
conditions that include trailer towing, hill climbing, heavy loads, high
speed and high ambient temperature, individually or in combination. The
fan drive is designed to provide the minimum fan speed (and resulting
fan noise and fuel consumption) required to meet the ever changing
vehicle cooling air flow requirements. You will hear the amount of fan
noise increasing and decreasing as the engine power requirements 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.
Cold weather starting
It is recommended that the engine block heater be used for starting
when the temperature is -10°F (-23°C) or colder. Refer toUsing the
engine block heater (if equipped)in theDrivingchapter of the
Owner’s Guide.
When operating in cold weather, use a minimum of 45 Cetane Diesel fuel
or use Cetane improvers from a reputable manufacturer.
Do not crank the engine for more than 30 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (OFF) and wait
30 seconds before trying again.
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Do not use starting fluid, such as ether, in the air intake system
(see air filter decal). Such fluid could cause immediate explosive
damage to the engine and possible personal injury.
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 ON without turning the key to START.Do not start
the engineuntil the glow-plug pre-heat indicator
turns off.
2. When the glow plug pre-heat
indicator turns off, turn the key to
START, then release the key as soon
as the engine starts. The glow plugs
will continue to be activated for two minutes after the glow plug pre-heat
indicator
has turned off. If the engine is not started before the
glow plug activation time ends, the glow plugs will need to be reset by
turning the key to OFF.
3. After the engine starts, allow it to idle for about 15 seconds. Do not
increase engine speed until the oil pressure gauge indicates normal
pressure.
STOPPING THE ENGINE
Turn the ignition to 3 (OFF).
On E-Series vehicles:To prolong engine life (after extended high
speed or maximum GVW operation), it is recommended that a hot engine
be allowed to operate at low idle for about 7–10 minutes which would
allow sufficient time for the turbocharged engine to cool down.
On F-Super Duty vehicles: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.
At temperatures below 20°F (–7°C), Number 2–D diesel fuel may thicken
enough to clog the fuel filter. Your vehicle is equipped with either an
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