change time 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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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.
•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, especially in cold weather,
can cause a buildup of deposits which can cause engine damage.
The following cold weather idling guidelines are recommended:
•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. 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.
Driving
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CHANGING THE ENGINE-MOUNTED AND DFCM FUEL FILTERS
Your vehicle is equipped with two fuel filters; one is mounted on top of
the driver’s side of the engine and the second filter, inside the DFCM, is
mounted on the frame rail under the driver-side floorboard near the
transmission. Both filters should be replaced at the same time. Regular
fuel filter changes are an important part of engine maintenance; failing to
keep with the scheduled maintenance could lead to engine performance
issues and/or fuel injection system damage. Refer to thescheduled
maintenance informationof this supplement for more information.
Refer toMotorcraft part numberslater in this chapter for the fuel filter
replacement part number. This part number includes filters and seals for
both the engine-mounted and frame-mounted filters.
Removal - DFCM filter
The DFCM filter is located in the lower portion of the DFCM housing.
1. Drain the DFCM. SeeFuel filter/water separatorearlier in this
chapter.
To install the new DFCM filter, seeInstallation – DFCM filterlater in
this section.
2. Remove the lower portion of the
DFCM housing (filter bowl) by
turning it counterclockwise using a
32 mm socket.
Note:Depending on the amount
seal swelling, removal of the filter
bowl may be noisy and require some
effort. Replace the seal prior to
reinstalling the filter/bowl to
improve assembly.
3. Remove and discard the old fuel filter element.
4. Carefully clean the mating surfaces using a lint-free rag.
Maintenance and Specifications
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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.
6. Maintain the oil level within the
crosshatch area on the dipstick by
adding oil as required. Do not
overfill the oil past the maximum
line as depicted by the arrow.
Engine oil specifications
To help achieve acceptable engine performance and durability, it is
important that only engine oils of good quality are used in your diesel
engine and it is changed at the recommended interval. For normal or
severe service, use Motorcraftoil or an equivalent oil conforming to
Ford specifications as listed in theMaintenance product specifications
and capacitiessection in this chapter or API service categories CJ-4 or
CJ-4/SM. It is important to use these oils because they are compatible
with the emission control equipment of your vehicle to meet the more
stringent emission standards.
The use of correct oil viscosities for diesel engines is important for
satisfactory operation. Determine which oil viscosity best suits the
temperature range you expect to encounter for the next service interval
from the following SAE viscosity grade chart.
Maintenance and Specifications
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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.
•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 with Motorcraft Premium Cooling
System Flush 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 with Motorcraft Premium
Cooling System Flush 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 messageCOOLANT CHANGE
REQUIREDat this time.
Refer toMaintenance product specifications and capacitiesin this
chapter for the proper coolant.
Maintenance and Specifications
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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 - 500 miles (161 -
805 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
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Base message center procedure
1. Start with the vehicle engine fully warmed.
2. Press the Info button on the steering wheel until the message center
reads one of the following choices:
•EXHST XX% FULL CLEAN Y/NorEXHAUST FILTER FULL:If
the DPF needs cleaning and the vehicle is warmed up, a message
requesting permission to initiate filter cleaning is displayed. Answer
yes to this prompt and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished.
•DRIVE TO CLEAN EXHAUST FILTER+EXH OVERLOADED
CLEAN? Y/N+
: If the vehicle is warmed up, a message
requesting permission to initiate filter cleaning is displayed. Answer
yes to this prompt and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished. You can also drive to clean the
filter. SeeActive regenerationearlier in this chapter.
•EXH OVERLOADED CLEAN? Y/N+REDUCED ENGINE POWER
+
: When the system is at this point of oversaturation you will not
be able to allow cleaning. The vehicle must be serviced by an
authorized dealer.
3. Once OCR starts, the engine’s rpm will rise to approximately 2,000 -
2,400 rpm and the cooling fan will increase speed; you will hear a change
in audible sound due to the fan and engine speed increase.
It is not necessary to open the hood on the engine compartment. Once
OCR is complete, the engine rpm and fan will return to normal idling.
The exhaust system will remain very hot for several minutes even after
regeneration is complete. Do not reposition the vehicle over materials
that could burn until the exhaust system has had sufficient time to
cool. Depending on the amount of soot collected by the DPF, ambient
temperature, and altitude, OCR may last from 10 to 25 minutes.
Maintenance and Specifications
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Optional message center procedure
1. Start with the vehicle engine fully warmed.
2. From the main menu, select Gauge Mode and scroll through until one
of the following options appear:
•Exhaust xx% FullorExhaust Filter Full: If the DPF needs
cleaning and the vehicle is warmed up, you will be prompted to hold
OK to clean. Press OK and then follow the prompts regarding exhaust
position as needed to initiate OCR. Be sure to understand each
prompt. If you are not sure what is being asked by each prompt,
contact your authorized dealer. The display will confirm the operation
has started and when it has finished.
•Drive to Clean Exhaust System+Exhaust Filter Overloaded
+
: When the exhaust system is overloaded cleaning will be
allowed until a certain saturation level. If the vehicle is warmed up
and ready you will be prompted to hold OK to clean. Press OK and
then follow the prompts regarding exhaust position as needed to
initiate OCR. Be sure to understand each prompt. If you are not sure
what is being asked by each prompt, contact your authorized dealer.
The display will confirm the operation has started and when it has
finished. You can also drive to clean the filter. SeeActive
regenerationearlier in this chapter.
•Exhaust Filter Overloaded+Reduced Engine Power+
:
When the system is at this point of oversaturation you will not be able
to allow cleaning. The vehicle must be serviced by an authorized
dealer.
3. Once OCR starts, the engine’s rpm will rise to approximately 2,000 -
2,400 rpm and the cooling fan will increase speed; you will hear a change
in audible sound due to the fan and engine speed increase.
It is not necessary to open the hood on the engine compartment. Once
OCR is complete, the engine rpm and fan will return to normal idling.
The exhaust system will remain very hot for several minutes even after
regeneration is complete. Do not reposition the vehicle over materials
that could burn until the exhaust system has had sufficient time to
cool. Depending on the amount of soot collected by the DPF, ambient
temperature, and altitude, OCR may last from 10 to 25 minutes.
How to interrupt/cancel OCR
If OCR needs to be cancelled, pressing the brake, accelerator, or shutting
off the vehicle will stop OCR. Depending on the amount of time OCR was
allowed to operate, soot may not have had sufficient time to be
Maintenance and Specifications
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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
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