mileage 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.
Introduction
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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. The system automatically injects diesel
exhaust fluid (DEF) into the exhaust system to enable proper SCR
function.
Importance of maintaining the DEF level
In order for the SCR system to operate properly, the DEF level must be
maintained. Generally, the DEF tank should be filled during the oil
change service interval. See thescheduled maintenance informationin
this supplement for more information. However, certain conditions or
driving styles, such as trailer towing or fast rates of acceleration, will
require the refilling of the DEF tank more often.
The engine control unit will monitor the amount of fluid available in the
DEF tank. Running a system check in the message center will indicate
whether the DEF level is ok or if it is less than 1/2 full. A message will
automatically be displayed in the message center when the DEF level is
low and needs to be refilled. When you see this message you should refill
your tank. SeeMessage centerin theInstrument Clusterchapter of
yourOwner’s Guidefor message center functions. For instructions on
refilling your DEF tank, seeFilling the DEF tanklater in this section.
DEF warning messages and vehicle operations
WARNING:Diesel Exhaust Fluid (DEF) must be refilled when
low or replaced when contaminated or the vehicle speed will be
speed limited to 55 mph (89 km/h) and then 50 mph (80 km/h). In
these conditions, drive with caution and refill DEF immediately. If the
DEF becomes empty or contaminated fluid is not replaced, the vehicle
will become limited to idle speed only once stopped. In these
conditions, be cautious where you stop the vehicle because you may
not be able to drive long distances and will not be able to maintain
highway speeds until DEF is refilled or replaced.
Your vehicle’s message center will display a series of messages regarding
the amount of DEF available. A systems check will display messages
indicating the amount of DEF available (OK or under
12full) or will
produce a warning message that displays the mileage (kilometers)
remaining as the fluid in the DEF tank nears empty. For more
information on warning messages, see theMessage centersection in the
Instrument Clusterchapter of yourOwner’s Guide.
Maintenance and Specifications
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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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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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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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Ford Motor Company has recommended maintenance intervals for
various parts and component systems based upon engineering testing.
Ford Motor Company relies upon this testing to determine the most
appropriate mileage for replacement of oils and fluids to protect your
vehicle at the lowest overall cost to you and recommends against
maintenance schedules that deviate from the scheduled maintenance
information.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraftor Ford-authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult yourWarranty Guidefor complete warranty information.
Non Ford-approved chemicals or additives are not required for factory
recommended maintenance. In fact, Ford Motor Company recommends
against the use of such additive products unless specifically
recommended by Ford for a particular application.
Oils, fluids and flushing
In many cases, fluid discoloration is a normal operating characteristic of
the chemical compound and may not necessarily demonstrate that a fluid
needs to be changed. Oils and fluids identified in this guide should be
changed at the specified interval or in conjunction with a repair. Flushing
is a viable way to change fluid for many vehicle sub-systems during
scheduled maintenance and should only be done using the same fluid
required to finish the maintenance procedure, or a Ford-approved
flushing chemical.
Genuine Ford parts and service
When planning your maintenance services, consider your Ford dealership
for all your vehicle’s needs.
Get the most from your service and maintenance visits
There are a lot of reasons why your Ford dealership is a great way to
help keep your vehicle running great.
Convenience
To make your service visit even more convenient, in many cases, you’ll
find extended evening hours and Saturday hours. How’s that for quality
service?
Scheduled Maintenance Guide
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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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Perform the services noted in the following table at the specified
time/mileage (km) period either within 3,000 miles (5,000 km) of the
OIL CHANGE REQUIRED message appearing in the message center or
when the time/mileage (km) reading indicates service is due.
Example #1:The OIL CHANGE REQUIRED message comes on at
18,751 miles (30,177 km); perform the 22,500 mile (36,000 km) fuel
filter replacement.
Example #2:The OIL CHANGE REQUIRED message hasnotcome on
but the odometer reads 22,500 miles (36,000 km); perform the fuel filter
replacement. (i.e., Intelligent Oil Life Monitor™ was reset at 15,000 miles
[24,000 km].)
Every 15,000 miles
(24,000 km), 600 hours of
engine operation or as
indicated by the instrument
cluster message centerInspect engine and secondary cooling
system concentration (freeze-point
protection), additive strength
(corrosion inhibitor), coolant level and
hoses
Every 22,500 miles
(36,000 km) or as indicated by
the instrument cluster
message center, whichever
comes firstReplace engine- and frame-mounted
fuel filters
At 45,000 miles (72,000 km) Replace air inlet foam filter
1
Every 60,000 miles
(96,000 km)Replace front wheel bearing grease
and grease seal on 4x2 vehicles (if
non-sealed bearings are used)
At 90,000 miles (144,000 km) Inspect accessory drive belt(s)
2
At 100,000 miles (160,000 km) Change rear axle fluid (Dana axles
only; refer toSpecial operating
conditions)
3
At 105,000 miles (168,000 km)
or 72 monthsChange engine coolant and secondary
coolant4
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Maintenance schedule log
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