warning FORD SUPER DUTY 2011 3.G Diesel Supplement Manual

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional message
center messages shown, base message center messages similar)
Distance/DEF Level
or ActionCluster MessageCustomer Requested
ActionsVehicle Actions
Full TankExhaust Fluid
Level OKDrive normally None
Below
12TankExhaust Fluid
Under
12FullDrive normally None
800 Miles (1287 km)Exhaust Fluid
Range 800 miles
(1287 km)Refill exhaust fluid None
300 Miles (483 km)Exhaust Fluid
Range 300 miles
(483 km)Refill exhaust fluid None
99 Miles (159 km)In 99 Miles
(159 km) Speed
Limited to
55 MPH (89 km/h)
Exhaust Fluid
EmptyRefill exhaust fluid None
*0 Miles (0 km)Speed Limited to
55 MPH (89 km/h)
Max Upon Restart
Exhaust Fluid
EmptyRefill exhaust fluid None
Maintenance and Specifications
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Low DEF Warnings and Actions — Instrument Cluster Messages (Optional message
center messages shown, base message center messages similar)
Distance/DEF Level
or ActionCluster MessageCustomer Requested
ActionsVehicle Actions
RestartSpeed Limited To
55 MPH (89 km/h)
Exhaust Fluid
emptyRefill exhaust fluid
On vehicle restart, speed
is limited to 55 MPH.
(89 km/h
*No action occurs until
restart.
*200 Miles (322 km)In 200 Miles
(322 km) Speed
Limited to
50 MPH (80 km/h)
Exhaust Fluid
EmptyRefill exhaust fluid
RestartSpeed Limited To
50 MPH (80 km/h)
Exhaust Fluid
EmptyRefill exhaust fluidOn vehicle restart, speed
is limited to 50 MPH
(80 km/h).
**No action taken until
vehicle is refueled
**100 Miles (161 km)Engine Idled Upon
Refuel Exhaust
Fluid EmptyRefill exhaust fluid
Diesel Tank FillEngine Idled-See
Owner’s Manual
Exhaust Fluid
EmptyRefill exhaust fluidEngine limited to idle
ONLY
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Filling the DEF tank
Your vehicle is equipped with a DEF tank with a blue-capped filler port
located next to the diesel fuel fill inlet. The tank can be filled using a
nozzle at a DEF filling station (similar to fuel fill) or using a DEF bottle
with a spout. MotorcraftDEF bottles are recommended as they are
designed to be spill proof and will stop the flow of DEF when the tank is
full. Other aftermarket bottles can be used, but they should have a seal
on the spout and an internal vent tube to achieve best fill performance
and prevent overfilling. Overfilling your DEF tank can cause damage to
the tank.
Note:Do not put DEF in the fuel tank. This can cause engine damage
not covered by your vehicle’s warranty.
Note:Immediately wipe away any DEF that has spilled on painted
surfaces with water and a damp cloth to prevent damage to the paint.
You can purchase DEF at your authorized dealer, most highway truck
stops or you can contact roadside assistance for help in finding a retailer
that sells DEF. See theCustomer Assistancechapter in theOwner’s
Guidefor more information. In addition, there is a government website
locator for DEF at the following web address that can be used to find the
nearest location to purchase DEF: http://www.afdc.energy.gov/afdc/
locator/def.
Use only DEF certified by the
American Petroleum Institute (API)
such as MotorcraftDEF or
equivalent meeting Ford specification
WSS-M99C130-A and/or ISO 22241.
Look for API certification trademark
shown here. Repairs resulting from
the use of non-certified DEF
products may not be covered by your vehicle’s warranty.
Maintaining the purity of DEF is important to avoid malfunctions in the
SCR system.
If DEF is removed from the tank for repair work, etc., the same DEF
must not be used to refill the tank as its purity is no longer guaranteed.
WARNING:Make sure that DEF does not come into contact
with eyes, skin or clothing. Should DEF contact your eyes, flush
them with plenty of water and contact a physician. Clean affected skin
with soap and water. If DEF is swallowed, drink plenty of water and
contact a physician immediately.
Maintenance and Specifications
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WARNING:Refill DEF in a well-ventilated area. When opening
the cap on the DEF tank or bottle containing DEF, ammonia
vapors may escape. The vapors can be irritating to skin, eyes and
mucous membranes. Inhaling ammonia vapors can cause burning to the
eyes, throat and nose and cause coughing and watery eyes.
To fill the DEF tank, see your authorized dealer or do the following
(before filling the DEF tank in cold climates, seeFilling the DEF tank
in cold climateslater in this section):
•DEF bottle fill with spout:
The following procedure applies to MotorcraftDEF or similar DEF
bottles; for other brands or bottle types, refer to the instructions on the
bottle label.
1. Remove the cap from the DEF
container. Remove the spout from
the bottle and insert the straw end
into the bottle. Ensure that the
arrow above the nut is aligned with
the bottle handle and the small tube
end extends into the far corner of
the bottle. Twist the spout nut on
the container until it is tight.
2. Open the DEF filler port on the
vehicle by turning the blue cap
counterclockwise.
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•Store DEF out of direct sunlight and in temperatures between 23°F
(-5°C) — 68°F (20°C).
•DEF will freeze below 12°F (-11°C).
•Do not store DEF bottle in vehicle. If it leaks it could cause damage to
interior components or release an ammonia odor inside the vehicle.
•DEF is non-flammable, non-toxic, colorless and water-soluble liquid.
•Do not dilute DEF with water or any other liquid.
•An ammonia odor may be smelled when the cap is removed or during
refill. Refill DEF in a well ventilated area.
FUEL FILTER/WATER SEPARATOR
Diesel Fuel Conditioner Module (DFCM)
The vehicle is equipped with a diesel fuel conditioning module (DFCM)
located on the frame-rail under the driver-side floorboard near the
transmission
Water should be drained from the
module assembly whenever the
warning light comes on and the
message center directs you to drain
the water separator. This will occur when approximately 0.32 pints (150
ml) of water accumulates in the module. If water level is allowed to
exceed this level, the water may be passed through to the engine and
may cause fuel injection equipment damage.
Draining the DFCM
1. Stop the vehicle andshut offthe engine.
WARNING:The vehicle must be stopped with the engine off
when draining the DFCM. Fuel may ignite if the separator is
drained while the engine is running or vehicle is moving.
Note:Air will enter into the fuel system if the DFCM is drained while
the system is running. The engine will not operate properly if air enters
the system.
2. Locate the DFCM and place an appropriate container under the drain
port (see illustration).
Maintenance and Specifications
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To change the engine oil and oil filter:
1. Unscrew the oil filter and oil pan drain plug and wait for the oil to drain.
Note:The oil pan drain plug only requires 1/4 turn to removal/install. A
3/8 inch socket drive may be used to assist with removal/installation, but be
careful not to over-tighten the plug during installation.
2. Replace the filter.
3. Reinstall the oil pan drain plug.
4. Refill the engine with new oil. For the proper capacity, see
Maintenance product specifications and capacitiesin this chapter.
5. Reset the Intelligent Oil Life Monitor™. SeeMessage centerin the
Instrument Clusterchapter for more information.
WARNING:Do not handle a hot oil filter with bare hands.
WARNING:Continuous contact with used motor oil has caused
cancer in laboratory mice. Protect your skin by washing with
soap and water.
Engine lubrication for severe service operation
The following conditions define severe operation for which engine
operation with SAE 5W-40 API CJ-4 is recommended. Oil and oil filter
change intervals will be determined by the Intelligent Oil Life Monitor™
as noted previously.
•
frequent or extended idling (over 10 minutes per hour of normal driving)
•low-speed operation/stationary use
•if vehicle is operated in sustained ambient temperatures below -10°F
(-23°C) or above 100°F (38°C)
•frequent low-speed operation, consistent heavy traffic less than
25 mph (40 km/h)
•operating in severe dust conditions
•operating the vehicle off road
•towing a trailer over 1,000 miles (1,600 km)
•sustained, high-speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation)
•
use of fuels with sulfur content other than ultra-low sulfur diesel (ULSD)
•use of high-sulfur diesel fuel
Maintenance and Specifications
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Adding coolant
When adding coolant, make sure it is a 50/50 mixture of coolant and
distilled water. Add the mixture to the coolant reservoir(s),when the
engine is cool, until the appropriate fill level is obtained.
If you have to add more than 1.0 quart (1.0 liter) of coolant per month,
have your dealer check the cooling system. Your cooling system may
have a leak. Operating an engine with a low level of coolant can result in
engine overheating and possible engine damage.
Note:If coolant is added to bring the level within the COLD FILL
RANGE when the engine is not cold, the system will remain underfilled.
WARNING:Do not add coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
WARNING:Do not put coolant in the windshield washer fluid
container. If sprayed on the windshield, coolant could make it
difficult to see through the windshield.
•Do not mix coolants. Add the coolant type originally equipped
in your vehicle.Refer toMaintenance product specifications and
capacitiesin this chapter for the proper coolant type.
Note:Do not use stop leak pellets or cooling system sealants/additives
as they can cause damage to the engine cooling and/or heating systems.
This damage would not be covered under your vehicle’s warranty.
•A large amount of water without engine coolant may be added to the
engine cooling system only, in case of emergency, to reach a vehicle
service location. Avoid this procedure if delivery to the service location
requires heavy engine loads. In this instance, the cooling system(s)
must be drained, chemically cleaned with MotorcraftEngine Cooling
System Iron Cleaner, and refilled with a 50/50 mixture of coolant and
distilled water as soon as possible. Water alone (without coolant) can
cause damage from corrosion, overheating or freezing.DO NOTuse
this method for the secondary cooling system. The secondary cooling
system operates close to ambient temperature, and is susceptible to
freezing in any subfreezing environment, in the absence of coolant.
•
Do not use alcohol, methanol or brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol and
other liquids can cause engine damage from overheating or freezing.
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•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
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.
The following actions are recommend after operating the vehicle up to
200 miles (320 km) in heavy snowfall or extreme rain:
•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
foam filter) and reset the air filter restriction gauge.
•Extreme rain: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.
Air filter replacement:
When replacing the air filter element, use the Motorcraftair 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.
Failure to use the correct air filter element may result in severe
engine damage.
Maintenance and Specifications
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WARNING:Failure to maintain the functional holes, in the
tailpipe section of the exhaust, clean and free of debris or
foreign material may result in the holes becoming blocked or plugged.
Do not modify or remove the tail-pipe section. Blocked or plugged
holes or removal/modification of the system could result in elevated
exhaust gas temperatures which may result in vehicle/property damage
or personal injury.
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Use special care when
working around the diesel oxidation catalytic converter and/or the diesel
particulate filter (DPF). The diesel oxidation catalytic converter and/or
the DPF heats up to a high temperature after only a short period of
engine operation and can stay hot even after the engine is turned off.
Failure to follow these instructions may result in personal injury.
EMISSION CONTROL SYSTEM(S) LAWS
In the U.S. federal law and certain state laws prohibit removing or
rendering inoperative emission control system(s). Similar federal or
provincial laws may apply in Canada. Ford recommends against any
vehicle modification without determining applicable law.
WARNING:Do not remove or alter the original equipment floor
covering or insulation between it and the metal floor of the
vehicle. The floor covering and insulation protect occupants of the
vehicle from the engine and exhaust system heat and noise. On
vehicles with no original equipment floor covering insulation, do not
carry passengers in a manner that permits prolonged skin contact with
the metal floor. Provide adequate insulation. Failure to follow these
instructions may result in fire or personal injury.
NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS
AND MAINTENANCE
On January 1, 1978, Federal regulation became effective governing the
noise emission on trucks over 10,000 lbs. (4,536 kg) GVWR (Gross
Vehicle Weight Rating). The following statements concerning prohibited
tampering acts and maintenance, and the noise warranty found in the
Warranty Guide, are applicable to complete chassis cabs over
10,000 lbs. (4,536 kg) GVWR.
Maintenance and Specifications
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