light FORD SUPER DUTY 2011 3.G Diesel Supplement Manual

•Do not mix with recycled coolant unless from a Ford-approved
recycling process (seeUse of recycled engine coolantsection).
WARNING:To reduce the risk of personal injury, make sure the
engine is cool before unscrewing the coolant pressure relief cap.
The cooling system(s) are under pressure; steam and hot liquid can
come out forcefully when the cap is loosened slightly.
Add the proper mixture of coolant and distilled water to the cooling
system(s) by following these steps:
1. Before you remove the cap, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the cap. Slowly
turn cap counterclockwise until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
Engine and secondary cooling system refill procedure
The following procedure should be used when refilling the engine or
secondary cooling systems after it has been drained or become extremely
low.
1. Remove the pressure relief cap from the engine or secondary coolant
reservoir as previously outlined.
2. Slowly add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
3. Reinstall the pressure relief cap.
4. Start and run the engine at 2,000 rpm for 2 minutes.
5. Shut engine off, and remove the pressure relief cap as previously
outlined.
6. If required, add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
7. Engine cooling system: Repeat Step 3 until the coolant level has
stabilized (is no longer dropping after each step) AND the upper radiator
hose at the radiator is warm to the touch (indicating that the engine
thermostat is open and coolant is flowing through the radiator).
Secondary cooling system: Repeat Step 3 until the coolant level has
stabilized (is no longer dropping after each step) AND the lower
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1. Locate the mass air flow sensor
electrical connector on the air inlet
tube. This connector will need to be
unplugged.
Unlock the locking clip on the
connector, then squeeze and pull
the connector off of the air inlet
tube.
2. Release the four clamps that
secure the cover to the air filter
housing. Push the air filter cover
forward (away from you) and up
slightly to release it.
3. Remove the air filter element from the air filter housing.
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When the engine control module detects that the DPF is nearly full of
particulates and that the vehicle is not being operated in a manner to
allow effective automatic cleaning, the message center will display
several messages guiding the vehicle operator to drive to clean the DPF.
If the vehicle is operated in a manner to allow effective automatic
cleaning, the message center will display CLEANING EXHAUST FILTER,
which is the normal regeneration process. SeeMessage centerin the
Instrument Clusterchapter of theOwner Guidefor more information.
Filter service/maintenance
Over time a slight amount of ash will build up in the DPF which is not
removed during the regeneration process. The DPF may need to be
removed for ash cleaning at approximately 120,000 miles (193,000 km)
or greater (actual mileage can vary greatly depending upon
engine/vehicle operating conditions) and replaced with a new or
remanufactured (ash cleaned) part. The filter may need to be replaced
at approximately 250,000 miles (400,000 km) depending upon
engine/vehicle operating conditions. In both cases the engine control
system will set a service light
to inform you to bring the vehicle to
the dealer for service.
If there are any issues with the oxidation catalyst/DPF system a service
light
orwill be set by the engine control system to inform
you to bring the vehicle into a dealership for service.
Resonator/Tailpipe assembly maintenance
The diesel resonator tail-pipe assembly is a uniquely functioning device
that accompanies the Oxidation Catalyst/DPF assembly. The assembly
serves multiple functions. First it serves as an acoustic device to
attenuate exhaust noise. Second it provides an exit path for the exhaust
from the vehicle. It also is designed to help control the temperature of
the exhaust during DPF regeneration events. The visible holes in each
leg of the twin tip and the holes under the shield just inboard of the
right rear tire(s) are functional. The holes need to be kept clear of
mud/debris or foreign material to maintain proper function of the
exhaust system. Clean and remove debris or foreign material if present
as needed. Spraying with a hose during regular washing of vehicle should
help keep holes clean and clear of debris or foreign material.
Note:Additions of aftermarket devices or modifications to the exhaust
system can reduce the effectiveness of the exhaust system as well as cause
damage to the exhaust system and/or engine. These actions may also affect
the vehicle’s warranty. See theWarranty Guidefor more information.
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FUELING
WARNING:Do not use starting fluid such as ether or gasoline
in the diesel air intake system. Such fluids can cause immediate
explosive damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
MINOR TROUBLESHOOTING GUIDE
Air purge procedure
Turn the key on for 30 seconds, then turn off. Repeat the procedure six
times.
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or when
the ignition is turned to START the lights become dim or go out, the
battery connections may be loose or corroded, or the battery may be
discharged. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to START, this may also
indicate a loose or corroded battery connection.
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.
•The gearshift lever must be in P (Park) or N (Neutral) in order for
the starter to operate.
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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.
Genuine Ford and Motorcraftreplacement parts
Ford dealerships stock Ford and Motorcraftbranded 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.
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
❑Normal schedule: As indicated by the instrument cluster message center❑Special Operating Conditions: Consult specific operating condition for maintenance recommendation.
Maximum fuel filter change interval
❑Normal schedule: 22,500 miles (36,000 km) or as indicated by the instrument cluster message center, whichever occurs
first.
❑Special Operating Conditions: 15,000 miles (24,000 km) or 600 hours of engine operation, see appropriate schedule.
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Coolant change interval
❑6 years or 105,000 miles (168,000 km) - change coolant (whichever comes first) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
❑After initial change - change coolant every 3 years or 45,000 miles (72,000 km) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
❑Use coolant specified in theOwner’s Guideunder theMaintenance and Specificationschapter
❑For special operating conditions, seeSpecial Operating Conditionsat the end of this section
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
❑Check engine oil level
❑Check windshield washer fluid level
❑Check and drain fuel filter/water separator
❑Check air filter restriction gauge
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 and secondary cooling system concentration (freeze-point protection), additive strength (corrosion inhibitor),
coolant level and hoses
❑Check battery connections and clean if necessary
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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Multi-point inspection
In order to keep your vehicle running right, it is important that you have
the systems on your vehicle checked regularly. This can help identify any
potential issue before there are any problems. Ford Motor Company
suggests the following multi-point inspection to be performed at every
scheduled maintenance interval as the way to ensure your vehicle keeps
running right.
NORMAL SCHEDULED MAINTENANCE AND LOG
For your convenience, your vehicle is equipped with a message center
which calculates the proper oil change service interval. You should
perform the engine oil change as indicated by the instrument cluster
message center. The message center will display ENGINE OIL CHANGE
SOON or OIL CHANGE REQUIRED to indicate when an oil change is
needed. The engine oil change service needs to be completed within two
weeks or 500 miles (800 km) after the OIL CHANGE REQUIRED
message is displayed. Your oil change service interval can be up to one
year or 10,000 miles (16,000 km). Reset your Intelligent Oil Life
Monitor™ after each engine oil and filter change; refer to the
Instrument Clusterchapter of the owner guide.
If your message center is prematurely reset or becomes inoperative, you
should perform the oil change interval at six months, 5,000 miles
(8,000 km) or 200 hours from your last oil change.
Multi-point inspection - recommended at every visit
❑Check and top-up fluid levels: brake, engine coolant reservoir, secondary low-temperature cooling system reservoir, automatic
transmission, power steering, window washer.
❑Inspect tires for wear and check air pressure, including spare.
❑Check exhaust system for leaks, damage, loose parts and foreign materials.
❑Check that holes in the tail-pipe of the exhaust system are clear of debris; the holes/slots are functional
❑Check battery performance.
❑Check operation of horn, exterior lamps, turn signals and hazard warning lights.
❑Check radiators, coolers and heater and air conditioning hoses.
❑Inspect windshield washer spray and wiper operation.
❑Check windshield for cracks, chips and pitting.
❑Inspect for oil and fluid leaks.
❑Inspect air filter.
❑Check shocks and struts and other suspension components for leaks and damage.
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EXCEPTIONS
In addition, there are several exceptions to the Normal Schedule. They
are listed below:
COOLANT CHANGE RECORD
Normal Vehicle Axle Maintenance
❑Rear axles and power take-off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design
axles are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is re-
quired or the axle assembly has been submerged in water. The axle and PTO lubricant should be changed anytime the axle
and PTO have been submerged in water. Non-synthetic rear axle lubricants should be replaced every 3,000 miles
(5,000 km) or 3 months, whichever occurs first, during extended trailer tow operation above 70°F (21°C) ambient and
wide open throttle for extended periods above 45 mph (72 km/h). The 3,000 mile (5,000 km) lube change interval may
be waived if the axle was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL-M2C192-A, part
number F1TZ-19580-B or equivalent. Add four ounces (118 mL) of additive friction modifier C8AZ-19B546-A (EST-
M2C118-A) or equivalent for complete refill of Traction-Lok rear axles. The axle lubricant should be changed anytime an
axle has been submerged in water.
F-450 and F-550 Axle Maintenance
❑Replace rear axle lubricant every 100,000 miles (160,000 km) under normal driving conditions on all F-450 and F-550
commercial applications. For F-450 and F-550 trucks operated at or near maximum Gross Vehicle Weights, the rear axle
lubricant should be replaced every 50,000 miles (80,000 km). In addition, this 50,000 mile (80,000 km) schedule
should be observed when the vehicles are operated under the Special Operating Conditions, where noted.
Diesel Particulate Filter (DPF)
❑The DPF may need to be removed for ash cleaning at approximately 120,000 miles (192,000 km) or greater (actual
mileage can vary greatly depending upon engine/vehicle operating conditions) and replaced with a new or remanufactured
(ash cleaned) part. The filter may need to be replaced at approximately 250,000 miles (400,000 km) depending upon
engine/vehicle operating conditions. In both cases the engine control system will set a service light (
) to inform
you to bring the vehicle to the dealer for service. If there are any issues with the oxidation catalyst/DPF system a service
light (
or) will be set by the engine control system to inform you to bring the vehicle into a dealership
for service.
Engine Coolant
❑6 years or 105,000 miles (168,000 km) - change coolant (whichever comes first) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
❑After initial change - change coolant every 3 years or 45,000 miles (72,000 km) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
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A
Additive
coolant .......................................60
Air cleaner filter ...................49, 59
Air filter restriction gauge .........49
B
Battery .........................................59
auxiliary battery .......................59
jumping a disabled battery ......17
Break-in period .............................3
C
Cleaning your vehicle
engine compartment ..........18–19
Coolant ....................................5, 60
refill capacities ..........................60
Coolant additive ..........................60
Cooler ............................................5
D
Diesel exhaust fluid (DEF) .......26
Diesel Particulate Filter
(DPF) ....................................53–54
E
Emergencies, roadside
jump-starting ............................17
Emission control system ......53–55
Engine ..........................................20
cleaning ...............................18–19
coolant .......................................60
diesel .......................................2–3
refill capacities ..........................60service points ............................20
starting after a collision ...........16
Engine fan .....................................8
Engine oil ....................4, 40, 42, 60
filter, specifications ..................59
refill capacities ..........................60
specifications ......................41, 60
Exhaust Fluid ..............................26
F
Fan, Engine Cooling
.....................8
Filter
fuel
.............................................37
Fuel
........................................14, 21
cap
.............................................25
capacity
.....................................60
dual tank selector switch
.........14
filling your vehicle with fuel
....25
filter, specifications
............37, 59
fuel pump shut-off switch
.......16
Fuel pump shut-off switch
.........16
Fuel separator
.......................35, 37
G
Gas cap (see Fuel cap)
..............25
Gauges
...........................................7
J
Jump-starting your vehicle
........17
L
Lights, warning and indicator
......6
Index
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