fuel pump FORD SUPER DUTY 2009 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
filter filters finer impurities from the diesel 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.
F-Super Duty
E-Series
The FCM/HFCM should be drained at regular intervals or when the
WATER IN FUEL light illuminates in the instrument cluster.
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
service engine soon (
) or powertrain malfunction/reduced
power/electronic throttle control light (
) is illuminated, seek service
from your authorized dealer.
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Introduction
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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.
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)
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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Introduction
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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 on. 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
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 light 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 fuel filtersin the
Maintenance 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.
WARNING: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.
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Instrument Cluster
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The horizontal fuel conditioner module (HFCM) is located on the
frame-rail under the driver-side floorboard near the transmission.
SCHEDULED MAINTENANCE
The scheduled maintenance services in thescheduled maintenance
informationof this supplement are required because they are
considered essential to the life and performance of your vehicle.
Use only recommended fuel, lubricants, fluids and service parts
conforming to Ford specifications. Motorcraft parts are designed and
built for best performance in your vehicle.
FUEL REQUIREMENTS - CHOOSING THE RIGHT FUEL: VEHICLES
OPERATED WHERE ULTRA LOW SULFUR DIESEL FUEL IS
REQUIRED (UNITED STATES/CANADA/PUERTO RICO/U.S. VIRGIN
ISLANDS AND OTHER LOCALES)
Use only Ultra Low Sulfur (15 ppm Sulfur Maximum) number 1-D
or 2-D diesel fuel (also known as ULSD) in your 6.4L diesel
engine.The engine and exhaust system were designed to only use this
fuel. Look for theULTRA-LOW SULFUR HIGHWAY DIESEL FUEL
(15 ppm Sulfur Maximum)label on fuel pumps when purchasing your
fuel.
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 will cause certain emission
components to malfunction which may also cause the Service
Engine Soon(
)light to illuminate indicating an
emissions-related concern.
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).
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Maintenance and Specifications
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BIODIESEL
Diesel fuel containing no more than 5% biodiesel may be used. To help
achieve acceptable engine performance and durability, it is important to
only use biodiesel of good quality in your diesel engine. At a minimum,
the biodiesel should comply with ASTM D6751 or an equivalent
specification.
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.
Look for a label on the fuel pump to confirm the amount of biodiesel
contained in a diesel fuel. Biodiesel content is often indicated with the
letter “B” followed by the percent of biodiesel in the fuel. For example,
B5 indicates a fuel containing 5% biodiesel. Ask the service station
attendant to confirm the biodiesel content of a diesel fuel if you do not
see a label on the fuel pump.
Biodiesel should not be stored in the fuel tank for more than three
months. If your vehicle will be parked or stored for more than three
months, then your vehicle should be drained and filled with a diesel fuel
not containing biodiesel.
During cold weather, if you have problems operating on biodiesel, you
may need to use a diesel fuel with lower biodiesel content, try another
brand, or discontinue the use of biodiesel.
Biodiesel use may affect the recommended oil change intervals. Refer to
theSpecial Operating Conditionssection in theschedule
maintenance guidefor more information about oil change intervals and
other maintenance when operating on biodiesel.
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.
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Maintenance and Specifications
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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 with 6.4L engines configured for use with high sulfur diesel fuel
will only be made available for sale in countries where ULSD fuel is not
available or mandated by the government. Vehicles originally sold in a
ULSD fuel market that are subsequently exported to non-ULSD fuel
markets will need to be retrofitted (at the customer’s expense) in order
to be reliably operated on non-ULSD fuel.
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).
BIODIESEL
Diesel fuel containing no more than 5% biodiesel may be used. To help
achieve acceptable engine performance and durability, it is important to
only use biodiesel of good quality in your diesel engine. At a minimum,
the biodiesel should comply with ASTM D6751 or an equivalent
specification.
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.
Look for a label on the fuel pump to confirm the amount of biodiesel
contained in a diesel fuel. Biodiesel content is often indicated with the
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Maintenance and Specifications
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letter “B” followed by the percent of biodiesel in the fuel. For example,
B5 indicates a fuel containing 5% biodiesel. Ask the service station
attendant to confirm the biodiesel content of a diesel fuel if you do not
see a label on the fuel pump.
Biodiesel should not be stored in the fuel tank for more than three
months. If your vehicle will be parked or stored for more than three
months, then your vehicle should be drained and filled with a diesel fuel
not containing biodiesel.
During cold weather, if you have problems operating on biodiesel, you
may need to use a diesel fuel with lower biodiesel content, try another
brand, or discontinue the use of biodiesel.
Biodiesel use may affect the recommended oil change intervals. Refer to
theSpecial Operating Conditionssection in theschedule
maintenance guidefor more information about oil change intervals and
other maintenance when operating on biodiesel.
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 quality
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated diesel fuel that meets the ASTM D
975 industry specification. Aftermarket additives can damage the injector
system or engine. Repairs to correct the effects of using an aftermarket
product in your fuel may not be covered by your warranty.
Do not blend used engine oil with diesel fuel under any
circumstances.Blending used oil with the fuel will significantly increase
your vehicle’s exhaust emissions and reduce engine life due to increased
internal wear.
Many of the world’s automakers approved the World-wide Fuel Charter
that recommends diesel fuel specifications to provide improved
performance and emission control system protection for your vehicle.
Diesel fuel that meets the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about fuel that meets the World-wide
Fuel Charter.
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Maintenance and Specifications
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Diesel fuel conditioner
Additives that will improve fuel cetane numbers may be used to
verify/enhance fuel quality. Use Motorcraft Cetane Booster &
Performance Improver, PM-22-A (U.S.) / PM-22-B (Canada) or
equivalent. The customer warranty may be void from using additives that
do not meet or exceed Ford specifications.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/system. Use Motorcraft Anti-Gel &
Performance Improver, PM-23-A (U.S.) / PM-23-B (Canada) or
equivalent. The customer warranty may be void from using additives that
do not meet or exceed Ford specifications.
Note:This ultra-low sulfur formulation is designed to meet the emissions
standards for the 6.4L engine and is backward compatible as well (i.e.,
can be used in Ford 6.9L, 7.3L, and 6.0L diesel engines).
Fueling tips
If the engine fails to start in 30 seconds, turn the key to the off position
and wait 30 seconds before trying again.
Truck stops have pumps and nozzles designed for larger, heavy-duty
trucks. When refueling at truck stops: if the nozzle shuts off repeatedly
when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter change or if
you run out of fuel) the engine will purge the trapped air as it runs. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low cetane
rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of diesel fuel.
Care should be taken whenever diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
the solution until it is run through the engine where it will be deposited
in the fuel injectors causing expensive-to-repair damage.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1
18” fuel dispensing nozzle. Pumping
fuel at greater flow rates may result in premature nozzle shut-off or
spitback.
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Maintenance and Specifications
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