lock FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

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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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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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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ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray MotorcraftEngine Shampoo and Degreaser (ZC-20) on all
parts that require cleaning and pressure rinse clean.
•Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
•Cover the highlighted areas to prevent water damage when cleaning
the engine.
Cleaning
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EXHAUST
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.
WARNING:Failure to maintain the functional holes, in the
tailpipe section of the exhaust, clean and free of debris or
foreign material may result in the holes becoming blocked or plugged.
Do not modify or remove the tail-pipe section. Blocked or plugged
holes or removal/modification of the system could result in elevated
exhaust gas temperatures which may result in vehicle/property damage
or personal injury
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Use special care when
working around the diesel oxidation catalytic converter and/or the diesel
particulate filter (DPF). The diesel oxidation catalytic converter and/or
the DPF heats up to a high temperature after only a short period of
engine operation and can stay hot even after the engine is turned off.
Failure to follow these instructions may result in personal injury.
Cleaning
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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
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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
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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.
Maintenance and Specifications
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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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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
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