coolant level FORD SUPER DUTY 2011 3.G Diesel Supplement Manual

The glow plug system is
electronically controlled by the PCM
and GPCM. The GPCM energizes the
glow plugs immediately after the
ignition is turned on and kept on as determined by the GPCM using the
ECT, BARO and environmental temperature sensor. The required time
for the glow plugs to be energized decreases as the coolant temperature,
barometric pressure and environmental temperature increase.
Engine and secondary cooling system
The cooling system contains an engine cooling loop to cool the engine
and a secondary cooling loop to cool the transmission, exhaust gas
recirculation (EGR), charge air and fuel. The coolant serves three
primary purposes: to provide heat transfer, freeze point protection, and
corrosion protection using additives.
Vehicles with diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors may cause the additives in
the coolant to “wear out” in a shorter time. Refer to theSpecial
operating conditionssection for more information about coolant
additives and coolant change intervals. Operating the engine with
insufficient coolant and/or coolant additive can cause severe engine
damage.
Selective catalytic reduction (SCR) system
Your vehicle is equipped with a selective catalytic reduction (SCR)
system to help reduce emission levels of oxides of nitrogen from the
exhaust of the diesel engine. This system relies on the use of diesel
exhaust fluid (DEF) which must be replenished at certain intervals.
Failure to maintain proper DEF levels or if the DEF becomes
contaminated will result in vehicle speed limitations and/or result in the
vehicle entering an idle-only mode. SeeSelective catalytic reduction
(SCR) systemin theMaintenance and Specificationschapter for more
information.
Speed control (if equipped)
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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restart, the fuel filter(s) may be clogged. For best results in cold
weather, use a diesel fuel which has been formulated for the ambient
conditions. If you have been using biodiesel, you may need to use a fuel
with lower biodiesel content, try another brand, or discontinue using
biodiesel.
Your vehicle is equipped with a diesel fuel conditioner module (DFCM)
which recirculates fuel from the engine to help prevent fuel filter
clogging. Your vehicle is also equipped with a bypass relief valve, located
in the fuel tank pick-up boot, which provides fuel flow to the engine if
the fuel pickup should become plugged. To allow the bypass valve to
function and avoid engine fuel starvation during cold weather operation
of 32°F (0°C) or below, it is recommended that the fuel level in your
tank should not be allowed to drop below
14full. This will help prevent
air from entering the fuel system and stalling the engine.
Your vehicle is equipped with a an SCR system which uses diesel exhaust
fluid (DEF) to operate properly. DEF must be replenished at certain
intervals. When filling the vehicle’s DEF tank in cold weather, special
care must be taken to prevent damage to the DEF tank. For proper cold
weather fill procedure, seeSelective Catalytic Reduction (SCR) System
in theMaintenance and Specificationschapter.
In cold weather below 32°F (0°C), the engine will slowly increase to a
higher idle speed if left idling in P (Park). As the engine warms-up, the
engine sound level will decrease due to the activation of PCM-controlled
sound reduction features.
If your vehicle is operated in a heavy snow storm or blowing snow
conditions, the engine air induction may become partially clogged with
snow and/or ice. If this occurs, the engine may experience a significant
reduction in power output. At the earliest opportunity, clear all the snow
and/or ice away from inside the air filter assembly. Remove the air
cleaner cover and the pleated paper filter, leaving the foam filter in and
remove any snow or ice. Ensure the foam filter is installed correctly in
place. Remove any debris, snow and/or ice on the foam filter by brushing
the surface with soft brush. Do not use water, solvents, or a hard brush
for cleaning the foam filter.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they are in
optimum condition.
•Use the proper coolant solution at the concentration recommended to
protect the engine against damage from freezing.
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3. Reconnect both fuel lines.
Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
The system will need to be purged of air after removal/changing of the
filter. SeePurging air from the fuel system after DFCM and
engine-mounted fuel filter replacementfollowing.
Purging air from the fuel system after DFCM and engine mounted
fuel filter replacement
Turn the ignition key to on for 30 seconds, then turn it to off. Do this a
total of six times in a row to purge any trapped air from the fuel system.
After filter service, a no start or rough running engine may indicate that
air is entering the system through the filter bowl seal or drain. Make sure
the drain is tight.
ENGINE OIL
Checking the engine oil level
Because it is normal to add some oil between oil changes, check your
engine oil level each time you stop for fuel. To check the engine oil level
consistently and accurately, the following procedure is recommended:
1. Have engine at normal operating temperature (at least into the
NORMAL range on the engine coolant temperature gauge).
2. Park the vehicle on a level surface, then turn off the engine and open
the hood.
3. Allow at least20 minutesafter engine shutdown to ensure that the
oil contained in the upper parts of the engine has returned to the oil
pan.
4. Protecting yourself from engine heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
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ENGINE AND SECONDARY COOLING SYSTEM COOLANT
Checking engine coolant
The concentration (freeze point protection), additive strength (corrosion
inhibitor), and level of coolant should be checked at the mileage intervals
listed in thescheduled maintenance information.The coolant
concentration should be maintained at 50/50 coolant and water, which
equates to a freeze point of -36°C (-34°F). Coolant concentration testing
is possible with a hydrometer or antifreeze tester (such as the Rotunda
Battery and Antifreeze Tester, 0014–R1060). The level of coolant should
be maintained within the COLD FILL RANGE in the coolant reservoirs. If
the level falls below, add coolant per the instructions in theAdding
coolantsection.
Your vehicle was factory-filled with a 50/50 coolant and water
concentration. If the concentration of coolant falls below 40% or above
60%, the engine parts could become damaged or not work properly.A
50/50 mixture of coolant and water provides the following:
•freeze protection down to -36°C (-34°F).
•boiling protection up to 129°C (265°F).
•protection against rust and other forms of corrosion.
•
an accurate temperature readout from the engine coolant gauge.
When the engine is cold, check the level of coolant in the reservoirs. See
Identifying components in the engine compartmentfor the location of
the engine and secondary cooling system reservoirs.
•The coolant should be within the COLD FILL RANGE in the coolant
reservoirs.
•Refer to thescheduled maintenance informationfor service interval
schedules.
•Be sure to read and understandPrecautions when servicing your
vehiclein yourOwner’s Guide.
If the coolant has not been checked at the recommended interval, the
engine or secondary coolant reservoir may become low or empty. If
either reservoir is low or empty, add coolant to the reservoir(s). Refer to
Engine and secondary cooling system refill procedurein this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant or windshield washer fluid outside of its specified function and
vehicle location.
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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
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passenger side of the secondary radiator is warm to the touch
(indicating secondary thermostat is open and coolant is flowing
through the entire system).
8. Reinstall the pressure relief cap. Shut the engine off and let it cool.
9. Check the coolant level in the reservoir before you drive your vehicle
the next few times (with the engine cool).
10. If necessary, 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. After any coolant has been added, check the
coolant concentration. SeeEngine and secondary cooling system
coolantearlier. If the concentration is not 50/50 (protection to
–34°F/–36°C), drain some coolant and adjust the concentration. It may
take several drains and additions to obtain a 50/50 coolant concentration.
Whenever coolant has been added, the coolant level in the coolant
reservoir should be checked the next few times you drive the vehicle. If
necessary, add enough 50/50 concentration of coolant and distilled water
to bring the liquid level to the proper level.
Coolant refill capacity
To find out how much fluid your vehicle’s cooling system can hold, refer
toMaintenance product specifications and capacitiesin this chapter.
Coolant additives
At specific mileage intervals of 15,000 miles (24,000 km), as listed in the
scheduled maintenance informationchapter, the coolant additive
should be checked. The optional message center, if equipped, will also
display the messageCHECK COOLANT ADDITIVEat this time. The
purpose of checking is to verify the correct concentration (freeze point
protection) and additive strength (corrosion inhibitor) levels of the
coolant for maximum engine performance and protection. Three
products are available for ensuring the life and health of the coolant: two
test kits and a coolant inhibitor additive:
•Rotunda 328-00007 (Matthew’s Water CoolCheck) – Evaluates water
quality (hardness, chloride, and pH) for 50/50 mixture of coolant and
distilled water. Use distilled water. If distilled water is unavailable,
water meeting the requirements of Rotunda 328-00007, is sufficient
for vehicle use. Using water that fails to meet the requirements can
lead to coolant passage scaling and degrade the engine’s durability and
performance.
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•Rotunda 328-00008 (Antifreeze Coolant ELC Contamination Kit) –
Evaluates the coolant concentration (freeze point protection) and
additive strength (corrosion inhibitor) for overall coolant health. Note
that the first step is to verify that the vehicle’s coolant concentration
is in the window of 40 – 60%. If the concentration falls outside of that
window, the evaluation of the corrosion inhibitor strength will not be
valid. If the report results in a pass the cooling system does not show
excessive contamination. No action is required. If the report results as
insufficient, the corrosion inhibitor (additive) strength of the coolant
is too low. Add entire contents of one bottle of MotorcraftSpecialty
Orange Engine Coolant Revitalizer to the coolant reservoir. The
coolant can be recharged with this additive up to two times before the
coolant must be changed-out. When exchanging the full coolant
volume, the system must be flushed and refilled with distilled water
and coolant concentrate (MotorcraftSpecialty Orange Engine
Coolant).
•MotorcraftSpecialty Orange Engine Coolant Revitalizer – Additive to
boost the corrosion inhibitor level based upon the test results of the
Antifreeze Coolant ELC Contamination Kit. The revitalizer may be
added two times over the life of the coolant. If additional dosages are
required, the cooling system must be flushed and refilled with distilled
water and coolant concentrate (MotorcraftSpecialty Orange
Coolant).
Refer toMaintenance product specifications and capacitiesin this
chapter for the proper coolant and additive specifications.
Coolant change
At specific mileage intervals, as listed in thescheduled maintenance
information,the coolant should be changed. The optional message
center, if equipped, will also display the message COOLANT CHANGE
REQUIRED at this time.
Refer toMaintenance product specifications and capacitiesin this
chapter for the proper coolant.
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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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