FORD SUPER DUTY 2011 3.G Diesel Supplement Manual

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.
Maintenance and Specifications
51
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

4. Remove and install a new foam
filter if needed according to the
service interval indicated in the
scheduled maintenance
informationin this guide. If the
foam filter is not being replaced, be
sure the existing foam filter is in
place.
5. Install a new air filter element. be
sure that the groove seal on the
pleated paper filter traps both sides
of the vertical partition of the air
box.
6. Replace the air filter housing
cover and secure the clamps. Be
careful not to crimp the filter
element edges between the air filter
housing and cover and ensure that
the tabs on the edge are properly
aligned into the slots.
7. Reconnect the mass air flow sensor electrical connector to the inlet
tube. Make sure the locking tab on the connector is in the “locked”
position.
Maintenance and Specifications
52
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

DIESEL EXHAUST SYSTEM: OXIDATION CATALYST/DIESEL
PARTICULATE FILTER SYSTEM
Your vehicle is equipped with a diesel particulate filter (DPF). The DPF
is an inline filter in the exhaust system which reduces carbon emissions
by trapping exhaust particles before they reach the tailpipe. The DPF
looks similar to a traditional exhaust catalyst, except larger, and is part
of the exhaust system under the vehicle. The DPF is coupled to a diesel
oxidation catalyst, that reduces the amount of harmful exhaust emitted
from the tailpipe. As soot gathers in the system it begins to restrict the
filter. The soot gathered inside the filter needs to be periodically cleaned.
The soot can be cleaned in two different ways; passive regeneration and
active regeneration. Both methods occur automatically and require no
actions from the driver/operator. During either one of these regeneration
methods you may notice an increase/change in exhaust noise/tone. At
certain times, the message center will display various messages related
to the DPF. SeeMessage centerin theInstrument Clusterchapter in
theOwner Guidefor more information.
Passive regeneration
In passive regeneration, the exhaust constituents / temperature are at an
appropriate level where some soot can be reduced or oxidized (burned)
thus cleaning the filter. This method occurs naturally as a result of
normal engine operating conditions (at varying levels due to drive
patterns).
Active regeneration
Once the DPF is full of exhaust particles, the engine control module will
command the exhaust system to clean the DPF through a process called
active regeneration. Active regeneration requires the engine computer to
raise the exhaust temperature to eliminate the particles. During cleaning,
the particles are converted to harmless gasses, and the DPF will then be
clean and ready to continue trapping exhaust particles.
The regeneration process operates more efficiently when the vehicle is
safely operated at least 30 mph (48 km/h) with a steady pedal for
approximately 20 minutes to complete the process. The frequency and
duration of regeneration will fluctuate as both are determined by how
you drive your vehicle, outside air temperature, and altitude. For most
driving, regeneration frequency will vary from 100 - 600 miles (161 -
966 km) between occurrences and each occurrence will last from 9 -
20 minutes. The duration of regeneration is usually reduced if a constant
speed above 30 mph (48 km/h) is maintained.
Maintenance and Specifications
53
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

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.
Maintenance and Specifications
54
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

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
55
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use, or
(2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
•Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
•Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer’s specifications.
The complexity of the diesel engine makes it so the owner is discouraged
from attempting to perform maintenance other than the services
described in this supplement.
If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged or disconnected air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•check engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
Maintenance and Specifications
56
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

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.
Maintenance and Specifications
57
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

•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.
If engine cranks but won’t start
Prolonged starter cranking (in excess of 10 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, A/C condenser and/or oil cooler.
•Malfunctioning fan drive.
•Driving with frozen coolant.
•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.
Maintenance and Specifications
58
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

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.
Selective catalytic reduction (SCR) system speed limit and
Idle-only modes
If the vehicle’s speed is limited or in an idle-only mode, the SCR system
may be limiting the vehicle’s functions due to low or contaminated diesel
exhaust fluid (DEF). Check the DEF. SeeSelective catalytic reduction
(SCR) systemin theMaintenance and Specificationschapter for more
information.
MOTORCRAFTPART NUMBERS
Item Ford Part Number
Engine oil filter FL-2051
Foam Pre-filter FA-1907
*Air filter F A-1902
Fuel filter kit (2 included - engine
and frame rail mounted )FD-4615
Battery (2 Required) BXT-65-750
* Always use the authorized Motorcraftair filter or an equivalent
replacement part.Failure to use the correct air filter may result
in severe engine damage.
Maintenance and Specifications
59
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

MAINTENANCE PRODUCT SPECIFICATIONS AND CAPACITIES
Item Capacity Ford part nameFord part number /
Ford specification or
specification
Engine coolant
(primary high-
temperature cooling
system loop)*29.4 quarts
(27.8L)MotorcraftSpecialty
Orange Engine Coolant
with bittering agent (US)
/
MotorcraftSpecialty
Orange Engine Coolant
(Canada)VC-3-B (US)
CVC-3-B (Canada) /
WSS-M97B44-D
Engine coolant additive48.0 oz. (1.4L) per
addition if
requiredMotorcraftSpecialty
Orange Engine Coolant
RevitalizerVC-12 /
—
Engine cooling system
cleaner1 quart (946 mL)MotorcraftCoolant
System Iron CleanerVC-9 /
—
Secondary cooling
system cleaner22.0 oz. (651 mL)MotorcraftPremium
Cooling System FlushVC-1 /
—
Secondary cooling
system*11.7 quarts
(11.1L)MotorcraftSpecialty
Orange Engine Coolant
with bittering agent (US)
/
MotorcraftSpecialty
Orange Engine Coolant
(Canada)VC-3-B (US)
CVC-3-B (Canada) /
WSS-M97B44-D
Maintenance and Specifications
60
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)