clock FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

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
rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of diesel fuel.
Care should be taken whenever diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
the solution until it is run through the engine where it will be deposited
in the fuel injectors causing expensive-to-repair damage.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from a 1
18fuel dispensing nozzle. Pumping fuel
at greater flow rates may result in premature nozzle shut-off or spitback.
Fuel filler cap
Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise until it spins off.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 of a turn until it clicks at least once.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The vehicle warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraftfuel filler cap is not used.
WARNING:The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait
until it stops before completely removing the fuel filler cap. Otherwise,
fuel may spray out and injure you or others.
Maintenance and Specifications
25
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

WARNING:Refill DEF in a well-ventilated area. When opening
the cap on the DEF tank or bottle containing DEF, ammonia
vapors may escape. The vapors can be irritating to skin, eyes and
mucous membranes. Inhaling ammonia vapors can cause burning to the
eyes, throat and nose and cause coughing and watery eyes.
To fill the DEF tank, see your authorized dealer or do the following
(before filling the DEF tank in cold climates, seeFilling the DEF tank
in cold climateslater in this section):
•DEF bottle fill with spout:
The following procedure applies to MotorcraftDEF or similar DEF
bottles; for other brands or bottle types, refer to the instructions on the
bottle label.
1. Remove the cap from the DEF
container. Remove the spout from
the bottle and insert the straw end
into the bottle. Ensure that the
arrow above the nut is aligned with
the bottle handle and the small tube
end extends into the far corner of
the bottle. Twist the spout nut on
the container until it is tight.
2. Open the DEF filler port on the
vehicle by turning the blue cap
counterclockwise.
Maintenance and Specifications
31
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

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.
Maintenance and Specifications
37
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

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
39
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

Installation – DFCM filter
1. Install the new filter into the filter bowl tabs and replace the seal on
the DFCM header (top portion of DFCM). Refer toMotorcraft part
numberslater in this chapter for the fuel filter kit part number.
2. Reinstall the lower portion of the
housing by slowly turning it
clockwise onto DFCM housing,
allowing fuel to soak into the fuel
filter element. Tighten the lower
housing until it contacts the
mechanical stop.
Note:The engine will not run properly if the DFCM fuel filter is not
installed in the housing or if the filter bowl is not tightened to the
mechanical stop.
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.
Removal - Engine-mounted fuel filter
The engine-mounted fuel filter is a plastic disposable cartridge. To
remove it, do the following:
1. Disconnect both fuel lines by
squeezing the connector tabs and
pulling the lines straight off.
Note:Although the fuel system is
not fully pressurized when the
vehicle is off, some residual
pressure may remain in the fuel
system since it can take some
time for the pressure to
completely bleed off. Therefore, it
is recommended to place a shop
rag below the filter connectors to absorb the small amount of fuel that
will drain.
Maintenance and Specifications
40
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

2. Rotate the filter counterclockwise
until the peg aligns with the release
slot.
3. Pull the filter straight out from the bracket and discard the filter.
Installation – Engine-mounted fuel filter
1. Install the new filter into the filter bracket. Turn the filter clockwise to
lock it in place.
2. 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 and the filter bowl has been tightened to the
mechanical stop.
Maintenance and Specifications
41
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

•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.
•Do not mix with recycled coolant. We do not recommend the
use of recycled coolant in vehicles equipped with Motorcraft
Speciality Engine Coolant, since a Ford approved recycling
process is not yet available.
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.
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. 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.
5. 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.
6. Reinstall the pressure relief cap.
7. Start and run the engine at 2,000 rpm for 2 minutes.
8. Shut engine off, and remove the pressure relief cap as previously
outlined.
9. 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.
Maintenance and Specifications
47
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)