tow FORD SUPER DUTY 2015 3.G Diesel Supplement Manual

Introduction
About This Supplement.................................3
Instrument Cluster
Gauges..................................................................8
Warning Lamps and Indicators...................8
Starting and Stopping the Engine
Starting a Diesel Engine...............................10
Switching Off the Engine..............................13
Engine Idle Shutdown
...................................13
Engine Block Heater.......................................14
Fuel and Refueling
Fuel Quality
.......................................................15
Selective Catalytic Reduction System............................................................21
Refueling...........................................................29
Emission Control System
...........................30
Fuel Tank Selector Switch..........................36
Brakes
General Information......................................37
Towing
Towing a Trailer...............................................38
Roadside Emergencies
Fuel Shutoff.....................................................39
Jump Starting the Vehicle...........................39
Maintenance
Under Hood Overview..................................42
Engine Oil Check............................................43
Engine Coolant Check
..................................45
Changing the Engine Air Filter...................50 Vehicle Care
Cleaning the Engine......................................54
Cleaning the Exhaust...................................54
Capacities and Specific-
ations
Engine Specifications
...................................55
Motorcraft Parts
.............................................55
Technical Specifications
..............................57
Scheduled Maintenance
General Maintenance Information
..........59
Normal Scheduled Maintenance.............62
Special Operating Conditions Scheduled Maintenance................................................65
Scheduled Maintenance Record
...............71
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Super Duty (TFA) , enUSA Table of Contents

ABOUT THIS SUPPLEMENT
This supplement will acquaint you with the
Power Stroke diesel engine. It provides
recommendations on engine care and
operating procedures. For complete vehicle
information, also refer to your Owner
’s
Manual included with the vehicle. It also
describes equipment and gives
specifications for equipment that was in
effect when this guide was approved for
printing, and should be considered a
permanent part of the vehicle.
Note: Your vehicle ’s powertrain control
systems can detect and store information
about vehicle modifications that increase
horsepower and torque output such as
whether or not performance-enhancing
powertrain components commonly referred
to as performance chips have been used.
This information will stay in the system ’s
memory cannot be erased even if the
modification is removed. Ford Motor
Company, Ford of Canada, Ford of Mexico
and service or repair facilities can retrieve
this information when servicing your vehicle.
Ford Motor Company may use this
information to determine if your warranty
covers any needed repairs.
Note: Some aftermarket products may
cause severe engine/transmission and/or
exhaust system damage; refer to your
warranty information for more information.
Your new diesel engine will feel, drive and
function somewhat differently than a
gasoline engine. Therefore it is very
important that you read and thoroughly
familiarize yourself and others operating
the vehicle with this guide. A special
procedure for turning off the diesel engine
is in the Starting and Stopping the Engine
chapter, See Starting a Diesel Engine
(page 10). It is important to read and
understand this material in order to
maintain the best service life for your
engine. Ford may discontinue models or change
specifications without any notice and
without incurring obligations.
Warnings WARNING
Throughout this guide, you will find
warnings identified by the warning
symbol. Warnings remind you to be
especially careful to reduce the risk of
personal injury. Breaking-In Your Vehicle
Your vehicle does not need an extensive
break-in. Try not to drive continuously at
the same speed for the first 1000 miles
(1600 kilometers) of new vehicle
operation. Vary your speed to allow parts
to adjust themselves to other parts.
Drive your new vehicle at least 500 miles
(800 kilometers) before towing a trailer.
Make sure you use the specified engine oil.
See Technical Specifications (page 57).
Do not add friction modifier compounds
or special break-in oils during the first few
thousand miles (kilometers) of operation,
since these additives may prevent piston
ring seating. See Engine Oil Check (page
43
).
Diesel Engine Information
The diesel engine fuel system is a
pressurized two-stage filtration system
and consists of:
• A frame-mounted Fuel and Water
Separator primary filter with an electric
fuel pump and water drain
• An engine-mounted secondary fuel
filter
• A fuel injector for each cylinder (8
total)
• A high-pressure fuel pump
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Super Duty (TFA) , enUSA Introduction

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.
Note: Using a fuel that has more than
average impurities may require you to
replace the fuel filter more frequently than
the service interval specifies.
Note: You will need to purge the system of
air after removal or changing of the filter.
See purging air from the fuel system later
in this chapter.
Purging air from the fuel system
Turn the ignition key to on for 30 seconds,
then turn it to off. Do this 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 you tightened the filter bowl to the
mechanical stop.
SELECTIVE CATALYTIC
REDUCTION SYSTEM
Your vehicle is equipped with a selective
catalytic reduction system to help reduce
emission levels of oxides of nitrogen from
the exhaust of the diesel engine. The
system automatically injects Diesel
Exhaust Fluid (DEF) into the exhaust
system to enable proper selective catalytic
reduction function. Importance of maintaining the
Diesel Exhaust Fluid (DEF) level
In order for the selective catalytic reduction
system to operate properly, the DEF level
must be maintained. Generally, the DEF
tank should be filled during the oil change
service interval. See General
Maintenance Information (page 59).
However, certain conditions or driving
styles, such as trailer towing or fast rates
of acceleration, will require the refilling of
the DEF tank more often.
The engine control unit will monitor the
amount of fluid available in the DEF tank.
Running a system check in the information
display will indicate whether the DEF level
is ok or if it is less than 1/2 full. A message
will display in the information display when
the DEF level is low and needs to be
refilled. When you see this message, you
should refill your tank. See the Information
displays chapter of your Owner ’s Manual
for information display functions. For
instructions on refilling your DEF tank, see
filling the Diesel Exhaust Fluid (DEF) tank
in this supplement.
Diesel Exhaust Fluid (DEF)
warning messages and vehicle
operations WARNINGS
Diesel Exhaust Fluid (DEF) must be
refilled when low or replaced when
contaminated or your vehicle speed
will be speed limited to 50 mph (80 km/h).
In these conditions, drive with caution and
refill DEF immediately. If the DEF becomes
empty or contaminated and fluid is not
replaced, your vehicle will become limited
to idle speed only once stopped. In these
conditions, be cautious where you stop
your vehicle because you may not be able
to drive long distances and will not be able
to maintain highway speeds until you refill
or replace the DEF.
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Super Duty (TFA) , enUSA Fuel and Refueling

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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Super Duty (TFA) , enUSA Fuel and RefuelingE163176

Pick-up (3.31 axle ratio)
Steady highwaydriving
Normal driving
Trailer towing /
aggressive or city driving
Driving style
9600 miles (15450km) – 10000 miles (16093 km) +
7100 miles (11426
km) – 9600 miles (15450 km)
4100 miles (6598
km) – 7100 miles (11426 km)
Diesel Exhaust Fluid
(DEF) usage Pick-up (3.55 axle ratio)
Steady highwaydriving
Normal driving
Trailer towing /
aggressive or city driving
Driving style
8100 miles (13036km) – 9700 miles (15611 km)
5800 miles (9334
km) – 8100 miles (13036 km)
2800 miles (4506
km) – 5800 miles (9334 km)
Diesel Exhaust Fluid
(DEF) usage Pick-up (3.73 axle ratio)
Steady highwaydriving
Normal driving
Trailer towing /
aggressive or city driving
Driving style
7300 miles (11748
km) – 8900 miles (14323 km)
5050 miles (8127
km) – 7300 miles (11748 km)
2050 miles (3299
km) – 5050 miles (8127 km)
Diesel Exhaust Fluid
(DEF) usage Pick-up (4.30 axle ratio)
Steady highwaydriving
Normal driving
Trailer towing /
aggressive or city driving
Driving style
6300 miles (10139km) – 7900 miles (12714 km)
4100 miles (6598
km) – 6300 miles (10139 km)
1100 miles (1770 km)
– 4100 miles (6598 km)
Diesel Exhaust Fluid
(DEF) usage
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Super Duty (TFA) , enUSA Fuel and Refueling

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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Super Duty (TFA) , enUSA Fuel and Refueling

GENERAL INFORMATION
Diesel Engine Braking
This feature increases engine braking at
higher engine speeds to provide better
grade descent control with less brake and
transmission wear and tear.
Press the button located on the
switch bank next to the audio
unit to switch the system on or
off.
A light will illuminate in the instrument
cluster when this feature is switched on.
You can use this feature with tow/haul to
provide further increased engine braking.
For more information on tow/haul, see
Automatic Transmission operation in your
Owner's Manual.
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Super Duty (TFA) , enUSA BrakesE171217

TOWING A TRAILER
Refer to your Owner
’s Manual for full
details on towing a trailer.
38
Super Duty (TFA) , enUSA Towing

5.
Reset the Intelligent Oil Life Monitor™.
See the Information Displays chapter
in the Owner's Manual for more
information.
Engine lubrication for severe service
operation
The following conditions define severe
operation for which engine operation with
SAE 5W-40 API CJ-4 is recommended. Oil
and oil filter change intervals will be
determined by the Intelligent Oil Life
Monitor™ as noted previously.
• Frequent or extended idling (over 10
minutes per hour of normal driving)
• Low-speed operation/stationary use
• If vehicle is operated in sustained
ambient temperatures below -10°F
(-23°C) or above 100°F (38°C)
• Frequent low-speed operation,
consistent heavy traffic less than 25
mph (40 km/h)
• Operating in severe dust conditions
• Operating the vehicle off road
• Towing a trailer over 1,000 miles (1,600
km)
• Sustained, high-speed driving at Gross
Vehicle Weight Rating (maximum
loaded weight for vehicle operation)
• Use of fuels with sulfur content other
than ultra-low sulfur diesel (ULSD)
• Use of high-sulfur diesel fuel
ENGINE COOLANT CHECK
Checking the Engine Coolant
When the engine is cold, check the
concentration and level of engine coolant
at the intervals listed in the scheduled
maintenance chapter. See Scheduled
Maintenance (page 59). Note:
Make sure that the level is between
the MIN and MAX marks on the coolant
reservoirs.
Note: Coolant expands when it is hot. The
level may extend beyond the MAX mark
Note: If the level is at the MIN mark, below
the MIN mark, or empty, add coolant
immediately. See
Adding Engine Coolant
in this chapter.
Note: The coolant concentration should be
maintained within 48% to 50%, which
equates to a freeze point between -30 °F
(-34 °C) and -34 °F (-37 °C).
Note: For best results, the coolant
concentration should be tested with a
refractometer such as Rotunda tool
300-ROB75240 available from your dealer.
Ford does not recommend the use of
hydrometers or coolant test strips for
measuring coolant concentrations.
Note: Automotive fluids are not
interchangeable. Do not use engine coolant
or antifreeze or windshield washer fluid
outside of its specified function and vehicle
location.
Adding Engine Coolant WARNINGS
Do not add engine coolant when the
engine is hot. Steam and scalding
liquids released from a hot cooling
system can burn you badly. Also, you can
be burned if you spill coolant on hot engine
parts. Do not put engine coolant in the
windshield washer fluid container. If
sprayed on the windshield, engine
coolant could make it difficult to see
through the windshield.
45
Super Duty (TFA) , enUSA Maintenance

Coolant Change
At specific mileage intervals, as listed in
the scheduled maintenance information,
the coolant should be changed. The
optional information display, if equipped,
will also display the message COOLANT
CHANGE REQUIRED at this time.
See Capacities and Specifications
(page 55). for the proper coolant.
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. CHANGING THE ENGINE AIR
FILTER
Air Filter Restriction Gauge WARNING
To reduce the risk of vehicle damage
and/or personal burn injuries do not
start your engine with the air filter
removed and do not remove it while the
engine is running. Note:
Operating your vehicle in heavy
snowfall or extreme rain conditions may
allow excessive amounts of snow or water
into the air intake system. This could plug
or soak the air filter that could cause the
engine to lose power or shut down. 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 you open the hood to perform
general engine maintenance or at least
every 7,500 miles (12,000 km). If you
operate your vehicle in extremely dusty
conditions, check and reset the gauge at
least every 500 miles (800 km), or two
weeks, whichever comes first. Change the
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Super Duty (TFA) , enUSA MaintenanceE163372