instrument cluster FORD SUPER DUTY 2009 2.G Diesel Supplement Manual

Introduction
2
Instrument Cluster
7
Driving
11
Roadside Emergencies
23
Cleaning
29
Maintenance and Specifications
32
Scheduled Maintenance: General Information
59
Scheduled Maintenance: E-Series
66
Scheduled Maintenance: F-Super Duty
83
Scheduled Maintenance: Special Information
100
Motorcraft Premium Gold Coolant change record 101
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Table of Contents
1
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)

•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.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Introduction
4

WARNING LIGHTS
E-Series
F-Super Duty w/manual transmission
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Instrument Cluster
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F-Super Duty w/automatic transmission
Harley-Davidson
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.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Instrument Cluster
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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.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Instrument Cluster
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Engine oil pressure:
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 due to blockage in the air intake system.
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.
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 only):
Indicates the amount of pressure in
the engine. Driving with your
pointer continuously at the high end
of the scale may damage the engine.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Instrument Cluster
10

•use of biodiesel, up to and including 5% Biodiesel (B5)
•use of high sulfur diesel fuel
If you are operating your vehicle under any of these conditions, change
engine oil and filter every 5,000 miles (8,000 km).
AIR FILTER RESTRICTION GAUGE AND AIR FILTER
REPLACEMENT
Air filter restriction gauge:
The restriction gauge, located on
the upper housing of the air filter
assembly, measures the vacuum
inside the air filter. The more the air
filter is restricted (dirty, clogged),
the higher the vacuum reading
Check the air filter restriction gauge
whenever the hood is raised to
perform general engine maintenance
at least every 7,500 miles (12,000 km). If the vehicle is operated in
extremely dusty conditions, check and reset the gauge at least every
500 miles (800 km), or two weeks, whichever comes first.
Change the air filter when the gauge reads near the “change filter” line
and the chamber is filled with yellow. Engine performance and fuel
economy are adversely affected when the maximum restriction is
reached.
Blowing-out the air filter element with compressed air is not
recommended as the compressed air may damage the filter paper.
Note:It is not possible to determine the level of filter clogging by visual
appearance alone. A filter which appears to be dirty may actually have
several thousand miles (kilometers) of life remaining.
Always use the underhood air filter restriction gauge to
determine when the air filter element needs to be changed. The
warning light on the instrument cluster should not be used
exclusively for determining when the air filter element needs
changing.
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Maintenance and Specifications
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After installation of the new filter
element, reset the gauge by pressing
the reset button on top of the
gauge.
Note:Vehicle operation in heavy
snowfall or extreme rain conditions
may feed excessive amounts of
snow/water into the air intake
system. This could plug/soak the air
filter with snow and may cause the
engine to lose power and possibly
shut down. Either of these conditions may cause the CHECK AIR
FILTER message to appear in the message center.
You may not need to change the air filter and the vehicle may be driven
up to 200 miles (320 km) under the following conditions:
•Snow:At the earliest opportunity, open the hood and clear all the
snow and ice from the air filter housing inlet (do NOT remove the air
filter) and reset the air filter restriction gauge.
•Wet:The air filter will dry after about 15–30 minutes at highway
speeds. At the earliest opportunity, open the hood and reset the air
filter restriction gauge.
The air filter warning message on the instrument cluster may be used, in
addition to the underhood restriction gauge, to monitor the condition of
the air filter element. Refer to theEngine air filterwarning light in this
chapter of the supplement.
Air filter replacement:
When replacing the air filter element, use the Motorcraft air filter
element listed inMotorcraft Part Numberslater in this chapter.
WARNING:To reduce the risk of vehicle damage and/or
personal burn injuries do not start your engine with the air filter
removed and do not remove it while the engine is running.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Maintenance and Specifications
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