oil filter FORD SUPER DUTY 2008 2.G Diesel Supplement Manual

•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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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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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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FCM (E-Series) or an HFCM (F-Super Duty) which acts as a fuel
filter/water separator to keep the wax melted which will help prevent
fuel filter clogging. However, if the engine starts but stalls after a short
time and will not restart, the fuel filter(s) may be clogged. For best
results in cold weather, use Number 1–D diesel fuel or “winterized”
Number 2–D diesel fuel which has an additive to minimize wax
formation.
Your vehicle is also equipped with a bypass relief valve, located on the
fuel control module, which provides fuel flow to the engine if the fuel
pickup should become plugged by ice or wax. To allow the bypass valve
to function and avoid engine fuel starvation, it is recommended that,
during cold weather operation 32°F (0°C) or below, the fuel level in your
tank should not be allowed to drop below
14full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C), the engine will slowly increase to a
higher idle speed if left idling in P (Park). As the engine warms-up, the
engine sound level will decrease due to the activation of PCM-controlled
sound reduction features.
If your vehicle is operated in a heavy snow storm or blowing snow
conditions, the engine air induction may become partially clogged with
snow and/or ice. If this occurs, the engine may experience a significant
reduction in power output. At the earliest opportunity, clear all the snow
and/or ice away from inside the air filter assembly. Take the top off the
assembly, leaving the air filter in, and remove any snow or ice.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they are in
optimum condition.
•Use Motorcraft Premium Gold Engine Coolant solution at the
concentration recommended to protect the engine against damage
from freezing.
•Try to keep the fuel tank full as much as possible at the end of
operation to prevent condensation in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level. Also, if necessary, make sure to follow the engine oil and
filter change schedule found under theSpecial Operating Conditions
section in theScheduled Maintenance Guidechapter.
•At temperatures of -10°F (-23°C) or below, it is recommended that
you use an engine block heater to improve cold engine starting.
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•If operating in arctic temperatures of -20°F (-29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling in cold weather can cause
a buildup of heavy deposits of carbon and rust on valve stems causing
them to stick, which in turn, can cause valve train damage.
The following cold weather idling guidelines must be followed:
•Avoid idling the engine for more than 10 minutes at a time.
•Use Motorcraft Cetane improvers or non alcohol-based Cetane
improvers from a reputable manufacturer.
•Maintain the engine cooling system properly.
•Do not shut the engine down after an extensive idling period (10
minutes or more). Drive the vehicle for several miles with the engine
at normal operating temperatures under a moderate load to burn off
any accumulated carbon and varnish.
•Consider using an engine block heater.
•For extended idle times use an approved idle speed increase device.
Winter operating tips for Arctic operation -20°F (-29°C) and below
The following information is provided as a guideline only, and is not
intended to be the only source of possible solutions in resolving extreme
cold temperature issues.
Starting aids:
The use of the factory engine block heater (refer toUsing the engine
block heater [if equipped]in theDrivingchapter of theOwner’s
Guide) and oil pan heaters (aftermarket) will assist in engine starting, in
extreme cold ambient temperatures.
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.
Idle control:
For periods of extended idle, the throttle should be set at an rpm that is
sufficient to keep the engine at normal operating temperatures. This
action can reduce the amount of engine damaging deposits.
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•The engine contains a unique “Cold Weather - Idle up feature”
calibration strategy within the PCM. Under the appropriate conditions,
the strategy will automatically elevate the engine idle speed after 130
seconds of idling in cold ambient temperatures. For this feature to be
activated, the truck must be in P (Park) (for automatic transmission),
in neutral (for manual transmission) with the parking brake applied
and engine oil temperature below 158°F (70°C). This strategy raises
the rpm to a level that reduces the potential to produce “coking” or
“wet stacking”, which is common to all diesel engines when idling for
extended periods during cold ambient temperatures.
•On F-Super Duty vehicles,a factory option for Stationary Elevated
Idle Control (SEIC) through dash-mounted Upfitter switches will allow
the operator to elevate the idle rpm for extended idle periods, as well
as aftermarket equipment such as PTO operation. This feature must
be configured even if ordered from the factory. See your authorized
dealer for required upfitting.
Operation in snow
Vehicle operation in heavy snowfall or in dry loose snow that may swirl
around the front of the vehicle may feed excessive amounts of snow into
the air intake system. This could plug the air filter with snow and cause
the engine to stall and/or lose power.
Refer toAir filter and restriction gaugein theMaintenance and
Specificationschapter of this supplement for more information.
Operation in standing water
Ingestion of water into the diesel engine can result in immediate and
severe damage to the engine. If driving through water, slow down to
avoid splashing water into the intake. If the engine stalls, and ingestion
of water into the engine is suspected, do not try to restart the engine.
Consult your dealer for service immediately.
Engine block heater (if equipped)
Refer to theDrivingchapter in theOwner’s Guide.
Rapid Heat supplemental heating system (if equipped)
The optional Rapid Heat feature is an electrically powered device that is
designed to provide supplemental heat during engine warm up. For
maximum effectiveness mid to low blower speed is recommended during
initial warm up. When operating in automatic mode (when equipped) the
climate control unit will determine the appropriate blower speed for
existing conditions.
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IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
E-Series
1. Windshield washer fluid reservoir
2. Automatic transmission dipstick
3. Engine oil filler cap
4. Secondary fuel filter assembly (out of view)
5. Power 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.
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F-Super Duty
1. Windshield washer fluid reservoir
2. Batteries
3. Air filter assembly and restriction gauge
4. Automatic transmission dipstick (if equipped)
5. Engine oil fill
6. Engine oil filter
7. Engine-mounted fuel filter assembly
8. Engine oil dipstick
9. Fuel coolant reservoir
10. Brake fluid reservoir
11. Power distribution box (behind engine coolant reservoir)
12. Engine coolant reservoir
13. Power steering fluid reservoir
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than 5% biodiesel may be used. Use of biodiesel in concentrations
greater than 5% may cause damage to your vehicles fuel system
components such as fuel tank, fuel lines, fuel pump, fuel sender and fuel
injectors. Concentrations greater than 5% can also cause fuel filter
restrictions that may result in a lack of power and or fuel pump and fuel
injector failure.
Biodiesel fuel is a product that has been converted from renewable fuel
sources, including vegetable oil, animal fat and cooking oil. Raw or
refined vegetable oil, animal fat, cooking oil or recycled greases should
not be used.
Do not use home heating oil, agricultural fuel or any 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.
FUEL REQUIREMENTS - CHOOSING THE RIGHT FUEL: VEHICLES
OPERATED WHERE ULTRA LOW SULFUR DIESEL FUEL IS NOT
REQUIRED
For a 6.4L engine to operate reliably on low sulfur or high sulfur diesel
fuel, the 6.4L 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 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 fuel (greater than 500 ppm) in
a 6.4L diesel engine designed to use only 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 equipped with a 6.0L engine that are operated in a market that
does not require ULSD fuel may be operated on higher sulfur fuel
without any engine fuel system or emissions-related concerns.
Number 1-D or winter blend number 2-D fuel is recommended at
temperatures below 20°F (-7°C) (seeCold weather operationin the
Drivingchapter of this supplement). Diesel fuel containing no more
than 5% biodiesel may be used. Use of biodiesel in concentrations
greater than 5% may cause damage to your vehicles fuel system
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