air condition FORD SUPER DUTY 2012 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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STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F (0°C), the use of the correct grade engine
oil is essential for proper operation. Refer toEngine oil specifications
in theMaintenance and Specificationschapter for more information.
Your vehicle may be equipped with a cold weather starting strategy that
prevents severe engine damage by assisting in engine lubrication
warm-up. In extremely cold ambient temperatures, this strategy activates
and prevents the accelerator pedal from being used for 30 seconds after
starting the vehicle. By not allowing the accelerator pedal to be used, the
engine oil is allowed to properly lubricate the bearings preventing engine
damage due to lack of proper lubrication. After the 30 second warm-up
period, the accelerator pedal will be operational again as long as the
pedal is not being pressed when the 30 second time limit expires. When
starting the engine in extremely cold temperatures (-15°F [–26°C]), it is
recommended to allow the engine to idle for several minutes before
driving the vehicle.
Ensure the gearshift lever is in P (Park) and the parking brake is fully
set before you turn the key. Do not press the accelerator during starting.
Engine-driven cooling fan (fan clutch)
Your vehicle is equipped with an engine driven cooling fan drive (also
called a fan clutch). This fan drive changes the fan speed to match the
vehicle’s changing cooling air flow requirements. Fan speed, fan noise
level and fuel consumption all will increase based on the driving
conditions that include trailer towing, hill climbing, heavy loads, high
speed and high ambient temperature, individually or in combination.
The fan drive is designed to provide the minimum fan speed (and
resulting minimum fan noise and fuel consumption) required to meet the
ever changing vehicle cooling air flow requirements. You will hear the
amount of fan noise increasing and decreasing as the engine power
requirements and vehicle driving conditions change as you drive. This is
to be expected as being normal to the operation of your vehicle. High
levels of fan noise might also be heard when your engine is first started,
and should normally decrease after driving for a short time.
Driving
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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
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. Do not use alcohol based additives to correct fuel gelling. This
may result in damage to the fuel injectors/system. Use the proper
anti-gel & performance improver product as listed in theMaintenance
product specifications and capacitiessection in theMaintenance and
Specificationschapter.
Your vehicle is equipped with a diesel fuel conditioner module (DFCM)
which recirculates fuel from the engine to help prevent fuel filter
clogging. To 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 may 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
Driving
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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.
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.
Idle control:
•Your vehicle may have a factory option for a stationary elevated idle
control (SEIC) through dash-mounted upfitter switches will allow the
operator to elevate the idle rpm for extended idle periods, as well as
aftermarket equipment such as PTO operation. This feature must be
configured even if ordered from the factory. See your authorized
dealer for required upfitting.
Operation in snow and rain
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 recommended after operating the vehicle up to
200 miles (320 km) in 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.
Note:Removal of the foam filter degrades vehicle performance during
snow and hot weather conditions.
•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.
Refer toAir filter and restriction gaugein theMaintenance and
Specificationschapter of this supplement for more information.
Driving
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specifications. Outside of North America, use fuels meeting EN590 or
equivalent local market standard. Aftermarket additives can damage the
injector system or engine. Repairs to correct the effects of using an
aftermarket product in your fuel may not be covered by your warranty.
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 the system by turning
Maintenance and Specifications
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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.
As the DEF level nears empty, the
DEF warning symbol will be
displayed and chimes will sound
with the messages starting at
500 miles (805 km) remaining
before DEF is depleted. The
warning symbol and messages will
continue until the DEF tank is
refilled.
Continued driving without refilling will result in the following actions as
required by the California Air Resources Board (CARB) and /or U.S.
Environmental Protection Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon vehicle restart. Prior to this occurring a message will
appear in the message center.
•Further vehicle operation without refilling your DEF tank will cause
the engine to enter an idle-only condition. This will only occur upon
vehicle refueling or extended idle and will be indicated by a message
in the message center indicating required actions to resume normal
operation. It is required to add a minimum of 0.5 gallons (1.9L) of
DEF to the tank to exit the idle-only condition, but the vehicle will
still be in the speed limiting mode until the tank is refilled completely.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the DEF tank is refilled.
Note:When filling the DEF tank from empty, there may be a short delay
before detecting the increased level of DEF. This must occur before full
power is returned.
Maintenance and Specifications
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To prevent overfilling of the DEF tank when filling with a bottle, Ford
recommends using MotorcraftDEF. Additionally, if the message center
indicatesEXHAUST FLUID UNDER 1/2 FULL, you should only add a
MAXIMUM of 2 gallons (6.7L) of DEF to the tank to prevent freeze
damage due to overfilling. If the message center indicatesEXHAUST
FLUID LEVEL OK, do not add DEF.
Contaminated DEF or inoperative SCR system
SCR systems are sensitive to
contamination of the DEF. USE
ONLY API or ISO 22241 CERTIFIED
DIESEL EXHAUST FLUID. If the
SCR becomes contaminated or
inoperative, the DEF light will
illuminate and exhaust fluid system
fault messages will appear in the
message center.
Continued driving without replacing DEF or having the SCR system
repaired will result in the following actions as required by the California
Air Resources Board (CARB) and /or U.S. Environmental Protection
Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon restart. Prior to this occurring a message will appear in
the message center.
•Further vehicle operation without replacing contaminated DEF will
cause the engine to enter an idle-only condition. This will only occur
upon vehicle refueling, vehicle idling in park for 1 hour, or engine
shutdown for 10 minutes or more and will be indicated by a message
in the message center indicating required actions to resume normal
operation.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the contaminated system is repaired.To
service a contaminated or inoperative system, see your
authorized dealer.
DEF guidelines and information
•Use only DEF that carries the trademark: American Petroleum
Institute (API) certified DEF or ISO 22241.
•Do not put DEF in the diesel fuel tank.
•Do not overfill the DEF tank.
•Do not re-use the DEF container or nozzle once it is emptied.
Maintenance and Specifications
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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).
3. Rotate the drain counterclockwise
until the O-ring is visible. Allow the
DFCM to drain for approximately
25 seconds or until clean fuel is
observed. Rotate the drain clockwise
to tighten it. If no liquid drains, the
drain may be clogged. Have the
DFCM serviced by your authorized
dealer.
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4. Make sure that the drain valve is fully tightened, then remove the
container from under the vehicle.
Note:A loose drain valve can allow air to enter the fuel system and
cause drivetrain issues. The engine will not operate properly. be sure
that the drain valve is fully tightened.
5. Restart the engine. TheWATER IN FUEL DRAIN FILTERor
WATER IN FUEL DRAIN FILTER SEE MANUALmessage and light
should not be illuminated. If they continues to illuminate, have the fuel
system checked and repaired.
LOW FUEL PRESSURE MESSAGE
The engine is equipped with a low fuel pressure detection system. If the
message center displays:LOW FUEL PRESSUREthe following
explains why and what to do:
•Cold start or cold operation (below 32°F (0°C): If this message
appears during a cold start or during cold operation up to 10 minutes
after the initial cold start, monitor the message center. If it disappears
and does not re-appear after the engine has fully warmed up, the low
fuel pressure message is most likely caused by waxed or gelled fuel.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/systems. Use an anti-gel additive
as listed inMaintenance product specifications and capacities
section in this chapter. The customer warranty may be void from using
additives that do not meet or exceed Ford specifications.
If the low fuel pressure message persistently appears after re-fueling
during the cold start and cold operation conditions defined previously
and then disappear when the engine has fully warmed up, consider
different fuel sources.
•Low fuel operation: If the message appears when the vehicle is warm
and during low fuel tank level operation, i.e. the tank level is at or
very near empty, refuel the vehicle and operate the vehicle. If the
message reappears after fueling, see below. If the message does not
come back, the low fuel pressure condition was due to low fuel levels
in the fuel tank.
•
Normal operation: If the message appears during normal operation when
the vehicle / engine is fully warm, and fuel level is not low, the fuel
filters must be changed regardless of the maintenance schedule interval.
•If replacement of the fuel filter does not remedy the low fuel pressure
message during normal operation as defined above, take the vehicle to
your authorized dealer.
Maintenance and Specifications
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AIR FILTER RESTRICTION GAUGE AND AIR FILTER
REPLACEMENT
Air filter restriction gauge:
The restriction gauge, located on
the upper housing of the air filter
assembly, measures the vacuum
inside the air filter. The more the air
filter is restricted (dirty, clogged),
the higher the vacuum reading
Check the air filter restriction gauge
whenever the hood is raised to
perform general engine maintenance
at least every 7,500 miles (12,000 km). If the vehicle is operated in
extremely dusty conditions, check and reset the gauge at least every
500 miles (800 km), or two weeks, whichever comes first.
Change the air filter when the gauge reads near the “change filter” line
and the chamber is filled with yellow. Engine performance and fuel
economy are adversely affected when the maximum restriction is
reached.
Blowing-out the air filter element with compressed air is not
recommended as the compressed air may damage the filter paper.
Note:It is not possible to determine the level of filter clogging by visual
appearance alone. A filter which appears to be dirty may actually have
several thousand miles (kilometers) of life remaining.
Use the underhood air filter restriction gauge to determine when
the air filter element needs to be changed.
Maintenance and Specifications
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