engine FORD SUPER DUTY 2015 3.G Diesel Supplement Manual

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional information
display messages shown, base information display messages similar)
None
Refill exhaust fluid
Approximately 500
miles (805 km) left
before exhaust fluid tank is empty
Exhaust Fluid Range
500 miles (805 km)
None
Refill exhaust fluid
Approximately 99
Miles (159 km) left
before exhaust fluid tank is empty
In 99 Miles (159 km)
Speed Limited to 50
MPH (80 km/h)
Exhaust Fluid Empty
None
Refill exhaust fluid
0 Miles (0 km) –
exhaust fluid tank is empty
Speed Limited to 50
MPH (80 km/h)Upon Restart
Exhaust Fluid Empty
Speed is limited to
50 MPH. (80 km/h)
Refill exhaust fluid
Vehicle restarted
with exhaust fluid tank empty
Speed Limited To 50
MPH (80 km/h)
Exhaust Fluid Empty
-
Refill exhaust fluid
This occurs 200
Miles (322 km) after the vehicle reaches the 0 mile (0 km)
exhaust fluid range
Engine Idled Soon
Exhaust Fluid Empty
Engine is limited toidle ONLY
Refill exhaust fluid
This occurs when
the exhaust fluid is empty and:
Engine Idled-See
Owner ’s Manual
Exhaust Fluid Empty The vehicle’s diesel
fuel tank is refueled or,
the engine is shut off for 10 minutes or,
the engine is idling with the parking
brake engaged for 60 minutes.
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Filling the Diesel Exhaust Fluid (DEF)
tank
WARNINGS
Make sure that Diesel Exhaust Fluid
(DEF) does not come into contact
with eyes, skin or clothing. Should
any DEF contact your eyes, flush them with
plenty of water and contact a physician.
Clean affected skin with soap and water.
If any DEF is swallowed, drink plenty of
water and contact a physician immediately 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. Note:
Do not put DEF in the fuel tank. This
can cause engine damage not covered by
your vehicle ’s warranty.
Note: Immediately wipe away any DEF that
has spilled on painted surfaces with water
and a damp cloth to prevent damage to the
paint.
Your vehicle is equipped with a DEF tank
with a blue-capped filler port located next
to the diesel fuel fill inlet. The tank can be
filled using a nozzle at a DEF filling station
(similar to fuel fill) or using a DEF bottle
with a spout. We recommend Motorcraft®
DEF bottles since they are designed to be
spill proof and will stop the flow of DEF
when the tank is full. You can use other
aftermarket bottles, but they should have
a seal on the spout and an internal vent
tube to achieve best fill performance and
prevent overfilling. Overfilling your DEF
tank can cause damage to the tank. For
your DEF tank capacity. See Technical
Specifications (page 57). You can purchase Diesel Exhaust Fluid
(DEF) at an authorized dealer, most
highway truck stops or you can contact
roadside assistance for help in finding a
retailer that sells DEF. See the Customer
Assistance chapter in the Owner
’s Manual
for more information. In addition, there is
a government website locator for DEF at
the following web address to find the
nearest location to purchase DEF:
http://www.afdc.energy.gov/afdc/
locator/def. Use only DEF certified by the American
Petroleum Institute (API) such as
Motorcraft® DEF or equivalent meeting
Ford specification WSS-M99C130-A
and/or ISO 22241. Look for API certification
trademark shown here. Your vehicle
’s
warranty will not cover repairs resulting
from the use of non-certified diesel
exhaust fluid products.
Maintaining the purity of DEF is important
to avoid malfunctions in the selective
catalytic reduction system.
If you remove the DEF for tank repair, you
cannot use the same fluid to refill the tank.
You can no longer guarantee the purity of
the DEF.
To fill the DEF tank in cold climates, see
filling the Diesel Exhaust Fluid (DEF) tank
in cold climates later in this section or see
an authorized dealer.
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Diesel Exhaust Fluid (DEF) bottle fill with
spout
The following procedure applies to
Motorcraft® Diesel Exhaust Fluid (DEF) or
similar diesel exhaust fluid 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 you align the arrow
above the nut 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 your vehicle
by turning the blue cap
counterclockwise. Do not put DEF in
the fuel tank. This can cause engine
damage not covered by your vehicle ’s
warranty. 3. Lift and hold the DEF container,
without tipping, and insert the spout
into the DEF filler port until the small
black seal on the spout completely
seats into the filler port. 4.
While filling, the fluid level in the bottle
will continually drop. 25
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Contaminated Diesel Exhaust Fluid
(DEF) or inoperative Selective
Catalytic Reduction system
Selective catalytic reduction
systems are sensitive to
contamination of the Diesel
Exhaust Fluid (DEF). USE ONLY API or ISO
22241 CERTIFIED DIESEL EXHAUST FLUID
(DEF). If the selective catalytic reduction
system becomes contaminated or
inoperative, the Diesel Exhaust Fluid (DEF)
light will illuminate and exhaust fluid
system fault messages will appear in the
information display.
Continued driving without replacing DEF
or having the selective catalytic reduction
system repaired will result in the following
actions as required by the California Air
Resources Board (CARB) and 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
information display.
• 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 information display
indicating required actions to resume
normal operation.
For either vehicle speed limiting or idle-only
condition, normal vehicle operation will
resume when you repair the contaminated
system. To service a contaminated or
inoperative system, see an authorized
dealer. Diesel Exhaust Fluid (DEF) guidelines
and information
•
Use only Diesel Exhaust Fluid 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 once
it is emptied.
• Avoid spilling DEF on painted surfaces,
carpeting or plastic components.
Immediately wipe away any DEF that
has spilled with a damp cloth and
water. If it has already crystallized, use
warm water and a sponge.
• Store DEF out of direct sunlight and in
temperatures between 23°F (-5°C) —
68°F (20°C).
• DEF will freeze below 12°F (-11°C).
• Do not store the DEF bottle in your
vehicle. If it leaks it could cause
damage to interior components or
release an ammonia odor inside your
vehicle.
• DEF is non-flammable, non-toxic,
colorless and water-soluble liquid.
• Do not dilute DEF with water or any
other liquid.
• An ammonia odor may be smelled
when the cap is removed or during
refill. Refill DEF in a well ventilated
area.
Typical Diesel Exhaust Fluid (DEF)
Usage
The charts below illustrate approximate
Diesel Exhaust Fluid (DEF) usage for the
given distances traveled under various
driving conditions and when using the
power take off. Your usage may vary
depending on: driving style, trailer towing,
loaded vehicle weight, weather, idle time,
PTO usage.
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Chassis cab (non–Power Take Off)
Steady highwaydriving
Normal driving
Trailer towing /
aggressive or city driving
Driving style
7800 miles (12553km) – 9300 miles (14967 km)
4700 miles (7564
km) – 7800 miles (12553 km)
1700 miles (2736
km) – 4700 miles (7564 km)
Diesel Exhaust Fluid
(DEF) usage Chassis cab (with Power Take Off)
Cont. PTO usage — Min. PTO usage
PTO usage
0 miles (0 km) — 7800 miles (12553 km)
Diesel Exhaust Fluid
(DEF) usage
REFUELING
Fueling Tips 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. 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
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.
An engine that suddenly becomes noisy or
operates poorly after a fuel fill could be
using substandard fuel (for example, high
water content, low cetane rating or
gasoline in the fuel). You should purchase
diesel fuel from a reputable station that
sells a large amount of diesel fuel.
Use only clean, approved containers that
will prevent the entry of dirt or water
whenever you store diesel fuel.
Diesel fuel must not be stored in a
galvanized container. The fuel will dissolve
the zinc in the galvanized container. The
zinc will then remain in the fuel. If you run
the contaminated fuel through the engine,
the zinc will deposit in the fuel injectors
causing expensive-to-repair damage.
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Diesel fuel dispensing nozzle fill rate
Your truck is equipped with a fuel fill pipe
that is able to accept fuel up to 20 gallons
per minute from an 11⁄8 fuel-dispensing
nozzle. Pumping fuel at greater flow rates
may result in premature nozzle shut-off or
spit back.
Fuel filler cap
WARNINGS
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. If you do not use the proper fuel filler
cap, excessive pressure or vacuum
in the fuel tank may damage the fuel
system or cause the fuel cap to disengage
in a collision, which may result in possible
personal injury. Note:
If you must replace the fuel filler cap,
replace it with a fuel filler cap 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
Motorcraft® fuel filler cap is not used.
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. EMISSION CONTROL SYSTEM
Diesel Exhaust System: Oxidation
Catalyst And Diesel Particulate
Filter System (If Equipped)
Your vehicle is equipped with a diesel
particulate filter. The diesel particulate
filter is an inline filter in the exhaust system
that reduces carbon emissions by trapping
exhaust particles before they reach the
tailpipe. The diesel particulate filter looks
similar to a traditional exhaust catalyst,
except larger, and is part of the exhaust
system under the vehicle. The filter couples
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. You
need to periodically clean the soot that
gathers inside the filter. You can clean the
soot in two different ways, passive
regeneration and active regeneration. Both
methods occur automatically and require
no actions from the driver. During either
one of these regeneration methods, you
may notice a change in exhaust tone. At
certain times, the information display will
display various messages related to the
diesel particulate filter. See the Information
Displays chapter in the Owner Guide for
more information.
Passive regeneration
In passive regeneration, the exhaust
system temperature and constituents
automatically clean the filter, or reduce
the soot level, by burning (oxidizing) the
soot. Cleaning occurs naturally because of
normal engine operating conditions (at
varying levels, due to driving patterns).
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Diesel particulate filter maintenance
You must properly maintain your diesel
particulate filter in order for it to function
properly. Do not disregard the EXHAUST
OVERLOADED DRIVE TO CLEAN and
EXHAUST AT LIMIT DRIVE TO CLEAN
NOW
maintenance messages otherwise
system damage could result that your
warranty may not cover.
Failure to perform active or Operator
Commanded Regeneration when
instructed could result in a clogged diesel
particulate filter. If your diesel particulate
filter fills beyond the regeneration
threshold, your vehicle will disable the
ability for active and Operator
Commanded Regeneration. This could
result in irreversible damage to the filter
requiring replacement that your warranty
may not cover. If your vehicle is not
equipped with Operator Commanded
Regeneration, check with your dealer for
availability.
Once the diesel particulate filter is full of
exhaust particles, the engine control
module will command the exhaust system
to clean the filter 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
convert to harmless gasses. Once cleaned
the diesel particulate filter will then be
ready to continue trapping exhaust
particles.
The regeneration process operates more
efficiently when you safely operate your
vehicle 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
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. You can usually
reduce the duration of regeneration if you
maintain a constant speed above 30 mph
(48 km/h).
When the engine control module detects
that the diesel particulate filter is nearly
full of particulates and you are not
operating your in a manner to allow
effective automatic cleaning, the
information display will display
EXH
OVERLOADED DRIVE TO CLEAN for
base information display and Exhaust
Overloaded Drive to Clean for the
optional information display. These
messages appear as a reminder for you to
drive in order to clean the diesel particulate
filter. If you operate your vehicle in a
manner to allow effective automatic
cleaning, the information display will
display a cleaning exhaust filter message,
which is the normal regeneration process.
See the Information Displays chapter of
the Owner Guide for more information.
You can also choose Operator
Commanded Regeneration to clean the
exhaust system at this point. See How to
start Operator Commanded Regeneration
later in this chapter.
If you are not able to drive in a manner that
allows effective automatic cleaning (active
regeneration) or you choose to perform
regeneration of the diesel particulate filter
(cleaning) while at idle (stationary), then
Operator Commanded Regeneration
would need to be performed. See Operator
Commanded Regeneration later in this
chapter.
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Operator Commanded Regeneration
(If Equipped)
If your vehicle is operated with significant
stationary operation, low speed drive
cycles less than 25 mph, short drive cycles,
a drive time is less than 10 - 15 minutes or
the vehicle does not fully warm up, passive
and active regeneration may not
sufficiently clean the diesel particulate
filter system. Operator Commanded
Regeneration allows you to manually start
regeneration of the diesel particulate filter
at idle (while stationary) to clean the filter.
If you are not sure whether your vehicle is
equipped with this feature, contact an
authorized dealer.
When to perform Operator Commanded
Regeneration
Use the Operator Commanded
Regeneration feature when the EXH
OVERLOADED DRIVE TO CLEAN
message appears in the information
display and:
• the operator is not able to drive in
manner that allows effective
automatic cleaning (active
regeneration),
• or the operator instead wishes to
manually start regeneration (cleaning)
of the diesel particulate filter while the
vehicle is idle (stationary).
Operator Commanded Regeneration
precautions and safe exhaust position WARNING
Failure to comply with the following
instructions for Operator
Commanded Regeneration may
result in fire, serious injury, death and/or
property damage. Before you start operator commanded
regeneration, do the following: •
Place your vehicle in
P (Park) with the
parking brake set on stable, level
ground
• You must park your vehicle outside of
any structure
• Your vehicle must be 10 – 15 feet (3 –
5 meters) away from any obstructions
and must be away from materials that
can easily combust or melt (for
example, paper, leaves, petroleum
products, fuels, plastics and other dry
organic material)
• Make sure there is a minimum of 1/8
tank of fuel
• Make sure all fluids are at proper levels
Make sure that the louvers (holes) located
at the tip of the exhaust are also clear of
any obstructions as they are used to
introduce fresh air into the tailpipe to cool
the exhaust gas as it leaves. See Cleaning
the Exhaust
(page 54).
How to start Operator Commanded
Regeneration WARNING
Stay clear of exhaust tip during
regeneration. You or others can be
burned.
Note:
You cannot use the Operator
Commanded Regeneration until the diesel
particulate filter load percentage has
reached 100% (Full). The diesel particulate
filter load percentage will fluctuate up and
down when driving your vehicle due to active
and passive regenerations.
Note: During the use of Operator
Commanded Regeneration, you may
observe a light amount of white smoke. This
is normal. You cannot use the Operator
Commanded Regeneration if the
service engine soon light is
illuminated.
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Information display procedure
Start with your vehicle engine fully warmed
and then press the Info button on the
steering wheel until the information display
reads one of the following choices:
• EXHST XX% FULL CLEAN? Y/N
• EXHAUST FULL CLEAN? Y/N
Answer yes to this prompt and then follow
the prompts regarding exhaust position as
needed to initiate Operator Commanded
Regeneration. Be sure to understand each
prompt. If you are not sure what is being
asked by each prompt, contact an
authorized dealer. The display will confirm
the operation has started and when it has
finished.
If the diesel particulate filter is near or at
saturation, a message requesting
permission to initiate filter cleaning will
display
EXH AT LIMIT CLEAN? Y/N.
Answer yes to this prompt and then follow
the prompts regarding exhaust position as
needed to initiate Operator Commanded
Regeneration. Be sure to understand each
prompt. If you are not sure what is being
asked by each prompt, contact an
authorized dealer. The display will confirm
the operation has started and when it has
finished. You can also drive to clean the
filter. See Active regeneration earlier in this
chapter. When the system is at the point
of oversaturation, the service
engine soon light will illuminate
and the following message
EXH OVER
LIMIT SERVICE NOW will appear . You
will not be able to allow cleaning. You
must have your vehicle serviced by an
authorized dealer. Once operator commanded regeneration
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 Operator
Commanded Regeneration 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 diesel
particulate filter, ambient temperature,
and altitude, Operator Commanded
Regeneration may last from 10 to 25
minutes.
How to interrupt or cancel Operator
Commanded Regeneration
If you need to cancel the Operator
Commanded Regeneration, pressing the
brake, accelerator, or shutting off the
vehicle will stop the procedure. Depending
on the amount of time you allowed the
Operator Commanded Regeneration to
operate, soot may not have had sufficient
time to be eliminated, but the exhaust
system and exhaust gas may still be hot.
If you shut your vehicle off during Operator
Commanded Regeneration, you will notice
turbo flutter. This is a normal consequence
caused by shutting off a diesel engine
during boosted operation and is considered
normal.
Filter service and maintenance
Over time, a slight amount of ash will build
up in the diesel particulate filter, which is
not removed during the regeneration
process. The filter may need to be removed
for ash cleaning at approximately 120,000
miles (193,000 km) or greater (actual
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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
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 diesel
particulate filter system a service light will
be set by the engine control system to
inform you to bring your vehicle into an
authorized dealer for service. Powertrain fault indicator or
Service engine soon
Resonator and Tailpipe assembly
maintenance WARNINGS
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. 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 WARNINGS
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. 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 or engine. These actions
may also affect your vehicle ’s warranty. See
the Warranty Guide for more information.
The diesel resonator tail-pipe assembly is
a uniquely functioning device that
accompanies the diesel particulate filter
assembly. The tail-pipe 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 your vehicle. It also helps
control the temperature of the exhaust
during diesel particulate filter 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. You need to keep the holes
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 your
vehicle should help keep holes clean and
clear of debris or foreign material.
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