check engine FORD SUPER DUTY 2009 2.G Diesel Supplement Manual

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.
•For vehicles with manual transmissions,the clutch pedalmustbe
fully depressed in order for the starter to operate.
•For vehicles with automatic transmissions,the gearshift lever
must be in P (Park) or N (Neutral) in order for the starter to operate.
•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(F-Super Duty) or refer to theJump startingsection
in theRoadside Emergencieschapter of this supplement (E-Series).
If engine cranks but won’t start
Prolonged starter cranking (in excess of 30 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, charge air cooler, A/C condenser and/or oil
cooler.
•Driving with frozen coolant.
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•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.
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.
MOTORCRAFT PART NUMBERS
Item Ford Part Number
Engine oil filter FL-2016
Air filter - E-Series* FA-1804
Air filter - F-Super Duty* FA-1886
Fuel filter kit - E-Series
(2 included - engine and frame rail
mounted)FD-4606
Fuel filter kit - F-Super Duty
(2 included - engine and frame rail
mounted )FD-4609
Battery (2 Required) BXT-65-750
* Always use the authorized Motorcraft air filter listed.Failure to use
the correct air filter may result in severe engine damage.
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scheduled maintenance and should only be done using the same fluid
required to finish the maintenance procedure, or a Ford approved
flushing chemical.
Engine Emissions label
Emissions information appears on the Engine Emissions label on the
engine valve cover. This decal identifies engine displacement and
provides certain engine specifications.
Any modification of the emissions control system could create liability
under federal law (U.S.) if made prior to sale and registration, under the
laws of some states if made thereafter. Further, federal law prohibits
vehicle manufacturers, dealers and other persons engaged in the
business of repairing, servicing, selling, leasing or trading motor vehicles
as well as fleet operations from knowingly removing or rendering an
emissions control system inoperative after sale and delivery to an
ultimate purchaser. In Canada, modifications of the emissions control
system could create liability under applicable federal or provincial laws.
Genuine Ford Parts and Service
When planning your maintenance services, consider your Ford dealership
for all your vehicle’s needs.
Get the most from your service and maintenance visits
There are a lot of reasons why your Ford 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
Ford 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.
Factory Authorized Systems Checks
In the event that your vehicle experiences a component related concern,
please contact your Ford dealership. The Ford Motor Company Trained
Technicians who work at Ford dealerships are specifically trained to
understand your vehicle.
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A proper repair begins with a thorough system check. A Factory
Authorized Systems Check can ONLY be found at a Ford dealership. In
some circumstances, the technician may need to request your
authorization to perform additional operations to determine the final
diagnosis. The technician’s goal is to ensure that your vehicle is fixed
right the first time, at the best value to you.
The following list represents several of the Factory Authorized Systems
Checks available at participating Ford dealers:
•Air Conditioning
•Service Engine Soon Light
•All Wheel Drive and4X4
•Automatic Transmission
•Engine Cooling and Cabin Heating
•Steering and Suspension
•Charge/Start/Battery
•Wheel Alignment
•Anti-Lock Brake System
Genuine Ford and Motorcraft Replacement Parts
Ford dealerships stock Ford and Motorcraft branded replacement parts.
These parts meet or exceed Ford Motor Company’s specifications, and
we stand behind them. Maintenance parts installed at your Ford
dealership carry a nationwide, 12 months, 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 Ford
dealers can offer.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional 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.
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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 lubricants used.
Maximum oil change interval (E-Series)
❑Normal schedule: 7,500 miles (12,000 km) or 6 months, whichever occurs first.❑Special Operating Conditions: 5,000 miles (8,000 km), 6 months or 200 hours of engine operation, see appropriate sched-
ule.
Maximum oil change interval (F-Super Duty)
❑Normal schedule: 10,000 miles (16,000 km) or 6 months, whichever occurs first.❑Special Operating Conditions: 5,000 miles (8,000 km), 6 months or 200 hours of engine operation, see appropriate sched-
ule.
Maximum fuel filter change interval (E-Series)
❑Normal schedule: 15,000 miles (24,000 km) or 12 months, whichever occurs first.❑Special Operating Conditions: 10,000 miles (16,000 km) or 400 hours of engine operation, see appropriate schedule.
Maximum fuel filter change interval (F-Super Duty)
❑Normal schedule: 20,000 miles (32,000 km) or 24 months, whichever occurs first.❑Special Operating Conditions: 10,000 miles (16,000 km) or 400 hours of engine operation, see appropriate schedule.
Motorcraft Premium Gold Engine Coolant change interval (E-Series)
❑6 years or 105,000 miles (168,000 km) - change Motorcraft Premium Gold Engine Coolant (whichever comes first)❑After initial change - change Motorcraft Premium Gold Engine Coolant every 3 years or 45,000 miles (72,000 km)
❑For special operating conditions, seeSpecial Operating Conditionsat the end of this section
Motorcraft Premium Gold Engine Coolant change interval (F-Super Duty)
❑6 years or 100,000 miles (160,000 km) - change Motorcraft Premium Gold Engine Coolant (whichever comes first)❑After initial change - change Motorcraft Premium Gold Engine Coolant every 3 years or 50,000 miles (80,000 km)
❑For special operating conditions, seeSpecial Operating Conditionsat the end of this section
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Check every month
❑Check function of all interior and exterior lights❑Check tires for wear and adjust air pressure (including spare tire)
❑Check that holes in the tail-pipe of the exhaust system are clear of debris-the holes/slots are functional (F-Super Duty)
❑Check engine oil level
❑Check windshield washer fluid level
❑Check and drain fuel filter/water separator
Check every six months
❑Check lap/shoulder belts and seat latches for wear and function❑Check that externally-mounted spare tire is tight (seeOwner’s Guide)
❑Check power steering fluid level
❑Check washer spray, wiper operation and clean all wiper blades (replace as necessary)
❑Check parking brake for proper operation
❑Check and lubricate all hinges, latches and outside locks
❑Check and lubricate door rubber weatherstrips
❑Check and clean body and door drain holes
❑Check safety warning lamps (brake, ABS, air bag, safety belt) for operation
❑Check engine cooling system level, coolant strength and hoses
❑Check fuel cooling system for fluid level and coolant strength (F-Super Duty)
❑Check battery connections and clean if necessary
❑Check clutch fluid level, if equipped
Retightening lug nuts
❑On vehicles equipped with single rear wheels, retighten the lug nuts to the specified torque at 500 miles (800 km) after
any wheel disturbance (tire rotation, changing a flat tire, wheel removal, etc.).
❑On vehicles equipped with dual rear wheels, retighten the wheel lug nuts to the specified torque at 100 miles (160 km),
and again at 500 miles (800 km) of new vehicle operation and after any wheel disturbance (tire rotation, changing a flat
tire, wheel removal, etc.).
❑Refer toWheel Lug Nut Torque Specificationin yourOwner’s Guidefor the proper lug nut torque specification.
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SPECIAL OPERATING CONDITIONS
Towing a trailer or using a camper or car-top carrier
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(FCM) fuel filter
Every 15,000 miles (24,000 km) or
600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 30,000 miles (48,000 km) or
1200 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL.) of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 45,000 miles (72,000 km) or
1800 hours of operation (whichever
comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
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Extensive idling and/or low-speed driving for long distances as in heavy
commercial use such as delivery, taxi, patrol or livery
Every 5,000 miles (8,000 km),
6 months or 200 hours of engine
operation (whichever comes first)Change engine oil and replace filter
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Inspect brake system
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Inspect and lubricate steering and suspension ball joints
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(FCM) fuel filter
Every 15,000 miles (24,000 km) or
600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL.) of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 30,000 miles (48,000 km) or
1200 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL.) of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 45,000 miles (72,000 km) or
1800 hours of operation (whichever
comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
As requiredReplace cabin air filter, if equipped
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
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Extensive idling if vehicle is used for stationary operation
Every 5,000 miles (8,000 km),
3 months or 200 hours of engine
operation (whichever comes first) if
vehicle is used for stationary
operationChange engine oil and replace filter
Every 10,000 miles (16,000 km),
400 hours of engine operation
(whichever comes first) if vehicle is
used for stationary operationChange engine-mounted fuel filter and chassis-mounted
(FCM) fuel filter
Every 15,000 miles (24,000 km) or
600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL.) of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 30,000 miles (48,000 km) or
1200 hours of operation (whichever
comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL.) of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 45,000 miles (72,000 km) or
1800 hours of operation (whichever
comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
Note:For vehicles that operate under severe service conditions such as
frequent or extended idle (over 10 minutes per hour of normal driving),
maintenance requirements need to be adjusted. This needs to be
considered when determining vehicle service intervals.
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
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Operating in dusty conditions such as unpaved or dusty roads
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Inspect and lubricate steering and suspension ball joints
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(FCM) fuel filter
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
As requiredReplace cabin air filter, if equipped
Off-road operation
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(FCM) fuel filter
Every 30,000 miles (48,000 miles)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 50,000 miles (80,000 km)Change rear axle lubricant (E–450 only)
As requiredInspect and lubricate steering and suspension ball joints
Inspect and lubricate U-joints
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