fuel filter FORD SUPER DUTY 2011 3.G Diesel Supplement Manual
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WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 500 miles (800 km) before towing a
trailer. Make sure you use the specified engine oil by checking the engine
oil specification chart underEngine oilin theMaintenance and
Specificationschapter.
Do not add friction modifier compounds or special break-in oils during
the first few thousand miles (kilometers) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The diesel engine fuel system is a pressurized two-stage filtration system
and consists of:
•a frame-mounted diesel fuel conditioner module (DFCM) with an
electric fuel pump and water drain,
•an engine-mounted secondary fuel filter,
•a fuel injector for each cylinder (8 total),
•a high-pressure fuel pump,
•a high-pressure fuel rail for each cylinder bank (2 total) and
•numerous high-pressure pipes from the high-pressure pump to the
rails, and rails to the injectors.
The DFCM 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 DFCM filter should be changed at the recommended service interval
or when indicated by the message centerLOW FUEL PRESSURE
message. Refer to thescheduled maintenance informationin this
supplement for more information.
Introduction
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The DFCM should be drained at regular intervals or when indicated by
the message center message and water in fuel indicator light. SeeFuel
filter/water separatorin theMaintenance and Specificationschapter.
The fuel injection system is controlled through the powertrain control
module (PCM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump
located inside the DFCM and provides pressurized fuel to the engine.
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.
Lubrication system
It is important to change the engine oil at the recommended service
intervals to maintain oil viscosity. Extending the oil and filter change
interval beyond the recommended interval can negatively affect engine
performance, fuel economy and engine life. Refer toEngine oilin the
Maintenance and Specificationschapter.
Fast start glow plug system
The diesel engine glow system consists of:
•eight glow plugs (one per cylinder)
•the glow plug control module (GPCM)
•engine coolant temperature (ECT) sensor
•barometric pressure (BARO) sensor
•environmental temperature sensor
Introduction
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Water in fuel:
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 DFCM 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 DFCM. Refer
toFuel filter/water separatorin theMaintenance and Specifications
chapter 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.
Note:Draining the water separator with the engine running will allow air
to enter the fuel system and cause engine problems.
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.
Low/contaminated diesel exhaust fluid:
With the key in the on position, this
light will illuminate if the exhaust
fluid is contaminated and/or low.
SeeDiesel exhaust fluidin the
Maintenance and Specifications
chapter for more information.
GAUGES
Engine boost gauge:
Indicates the amount of manifold air
pressure in the engine.
Instrument Cluster
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If the vehicle’s speed is limited or the vehicle has entered an
idle-only mode
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.
Cold weather starting
It is recommended that the engine block heater be used for starting
when the temperature is -10°F (-23°C) or colder. Refer toEngine block
heater (if equipped)in theDrivingchapter of theOwner’s Guide.
When operating in cold weather, use Motorcraftcetane improvers or
non alcohol-based cetane improvers from a reputable manufacturer.
Do not crank the engine for more than 10 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (off) and wait
30 seconds before trying again.
WARNING:Do not use starting fluid, such as ether, in the air
intake system (see air filter decal). Such fluid could cause
immediate explosive damage to the engine and possible personal injury.
WARNING:Do not add gasoline, gasohol or alcohol to diesel
fuel. This practice creates a serious fire hazard and causes
engine performance problems.
1. Turn the key to on without turning the key to start.Do not start the
engineuntil the glow-plug pre-heat indicator
turns off.
2. When the glow plug pre-heat
indicator turns off, turn the key to
start, then release the key as soon
as the engine starts. The glow plugs
may remain on for a period of time after engine start. If the engine is not
started before the glow plug activation time ends, the glow plugs will
need to be reset by turning the key to off.
3. After the engine starts,allow it to idle for about 15 seconds. This
is to protect the engine. Do not increase engine speed until the oil
pressure gauge indicates normal pressure.
Driving
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ENGINE IDLE SHUTDOWN (IF EQUIPPED)
Your vehicle may be equipped with an engine idle shutdown system. This
system will automatically shut down your engine when it has been idling
in P (Park) or N (Neutral) for five minutes (parking brake set) or
15 minutes (parking brake not set). When the engine idle shutdown
process has started:
•A chime will sound and the message center will displayENGINE
TURNS OFF IN 30(seconds) and start counting down.
•The 5 or 15 minute timer can be restarted by changing the position of
the accelerator pedal, brake pedal or the park brake within the final
30 seconds.
•When the timer reaches zero, the engine shuts down and the message
center will displayENGINE TURNED OFF.
•One minute after the engine has shut down, the electrical system will
simulate key off, even though the ignition is still in the on position,
initiating normal accessory delay period.
•The ignition must be moved to the off position to reset the system
before restarting the vehicle.
Note:The engine idle shutdown idle timer will not start if:
•The engine is operating in power take-off (PTO) mode.
•The engine coolant temperature is below 60°F (16°C).
•The exhaust emission control device (DPF) is regenerating.
STOPPING THE ENGINE
Turn the ignition to the off position.
To prolong engine life (especially after extended high speed, high
ambient temperature, or high GVW/GCW operation), it is recommended
that a hot engine be idled for 3-5 minutes which will allow the
turbocharged engine to cool down.
COLD WEATHER OPERATION
Changing to a lighter grade engine oil also makes starting easier under
these conditions. Refer toEngine oil specificationsin theMaintenance
and Specificationschapter of this supplement.
Diesel fuel is adjusted seasonally for cold temperatures. Diesel fuel which
has not been properly formulated for the ambient conditions may form
wax crystals which can clog the fuel filters. At temperatures below 20°F
(–7°C), if the engine starts, stalls after a short time, and then will not
Driving
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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
1 4full. 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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•Try to keep the fuel tank full as much as possible at the end of
operation to prevent condensation in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level. Also, if necessary, make sure to follow the engine oil and
filter change schedule found under theSpecial operating conditions
section listed in thescheduled maintenance information.
•At temperatures of -10°F (-23°C) or below, it is recommended that
you use an engine block heater to improve cold engine starting.
•If operating in arctic temperatures of -20°F (-29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling in cold weather can cause
a buildup of heavy deposits of carbon and rust which can cause engine
damage.
The following cold weather idling guidelines must be followed:
•Avoid idling the engine for more than 10 minutes at a time.
•Use Motorcraftcetane improvers or non alcohol-based cetane
improvers from a reputable manufacturer.
•Maintain the engine cooling system properly.
•Avoid shutting the engine down after an extensive idling period
(10 minutes or more). Drive the vehicle for several miles with the
engine at normal operating temperatures under a moderate load.
•Consider using an engine block heater.
•For extended idle times use an approved idle speed increase device.
Winter operating tips for Arctic operation -20°F (-29°C) and below
The following information is provided as a guideline only, and is not
intended to be the only source of possible solutions in resolving extreme
cold temperature issues.
Starting aids:
The use of the factory engine block heater (if equipped) (refer to
Engine block heaterin theDrivingchapter of theOwner’s Guide) will
assist in engine starting in extreme cold ambient temperatures.
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IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
F-Super Duty
1. Engine oil dipstick
2. Automatic transmission dipstick
3. Brake fluid reservoir
4. Power distribution box
5. Batteries
6. Engine cooling system coolant reservoir (primary high-temperature
cooling system)
7. Power steering fluid reservoir
8. Engine oil fill
9. Engine-mounted fuel filter assembly
10. Secondary cooling system coolant reservoir
11. Air filter assembly
12. Air filter restriction gauge
13. Windshield washer fluid reservoir
1135234
57691012118
Maintenance and Specifications
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engine designed to use only Ultra Low Sulfur Diesel fuel may
result in damage to engine emission control devices and the
aftertreatment system, potentially rendering the vehicle
inoperable. Engine damage from using the improper type of fuel
is not covered under your warranty.
Vehicles with engines configured for use with high sulfur diesel fuel will
only be made available for sale in countries where ULSD fuel is generally
not available or mandated by the government. Vehicles originally sold in
a ULSD fuel market that are subsequently exported to non-ULSD fuel
markets will need to be retrofitted (at the customer’s expense) in order
to be reliably operated on non-ULSD fuel.
Diesel fuel is adjusted seasonally for cold temperature. For best results
at temperatures below 20°F (-7°C), it is recommended to use a diesel
fuel which has been seasonally adjusted for the ambient temperature.
SeeCold weather operationin theDrivingchapter of this supplement.
BIODIESEL
This vehicle may be operated on diesel fuels containing up to 20%
biodiesel, also known as B20.
To help achieve acceptable engine performance and durability when
using biodiesel in your vehicle:
•Confirm the biodiesel content of the fuel to be B20 (20% biodiesel) or
less
•Only use biodiesel fuel of good quality that complies with industry
standards
•Follow the recommended service maintenance intervals section in the
Schedule Maintenancechapter.
•Do not store biodiesel fuel in the fuel tank for more than 1 month
•Consider changing brands or reducing biodiesel content if you have
cold temperature fuel gelling issues
•Do not use raw oils, fats or waste cooking greases
Use of biodiesel in concentrations greater than 20% may cause damage
to your vehicle, including engine and/or exhaust after-treatment
hardware (exhaust catalyst and particulate filter) failures. Concentrations
greater than 20% can also cause fuel filter restrictions that may result in
a lack of power and / or damage to fuel system components, including
fuel pump and fuel injector failures.
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Many of the world’s automakers approved the World-wide Fuel Charter
that recommends diesel fuel specifications to provide improved
performance and emission control system protection for your vehicle.
Diesel fuel that meets the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about fuel that meets the World-wide
Fuel Charter.
Do not blend used engine oil with diesel fuel under any
circumstances.Blending used oil with the fuel will significantly increase
your vehicle’s exhaust emissions and reduce engine life due to increased
internal wear.
Diesel fuel conditioner
Additives that will improve fuel cetane numbers may be used to
verify/enhance fuel quality. Use Motorcraftor an equivalent cetane
booster & performance improver as listed in theMaintenance product
specifications and capacitiessection in this chapter. The customer
warranty may be void from using additives that do not meet or exceed
Ford specifications.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/system. Use Motorcraftor an
equivalent anti-gel & performance improver as listed in theMaintenance
product specifications and capacitiessection in this chapter. The
customer warranty may be void from using additives that do not meet or
exceed Ford specifications.
Note:These ultra-low sulfur formulations are designed to meet the
emissions standards for the 6.7L engine and is backward compatible as
well (i.e., can be used in Ford 7.3L, 6.9L, 6.4L and 6.0L diesel engines in
Ford vehicles).
Fueling tips
Truck stops have pumps and nozzles designed for larger, heavy-duty
trucks. When refueling at truck stops: if the nozzle shuts off repeatedly
when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter change or if
you run out of fuel) the engine will purge the trapped air as it runs. To
purge the air sooner: prior to engine start, prime system by turning the
key to on for 30 seconds then to off. Repeat this several times. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low cetane
Maintenance and Specifications
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