engine FORD SUPER DUTY 2022 Workshop Manual

WHAT IS THE SELECTIVE
CATALYTIC REDUCTION
SYSTEM
The selective catalytic reduction system
helps reduce emission levels of oxides of
nitrogen from the exhaust system.
HOW DOES THE SELECTIVE
CATALYTIC REDUCTION
SYSTEM WORK
The selective catalytic reduction system
injects diesel exhaust fluid into the exhaust
system to enable correct selective catalytic
reduction system function.
SELECTIVE CATALYTIC
REDUCTION SYSTEM
PRECAUTIONS
WARNING: Keep diesel exhaust
fluid out of reach of children. Avoid
contact with skin, eyes or clothing. In
case of contact with your eyes, flush
immediately with water and get prompt
medical attention. In case of contact
with your skin, clean immediately with
soap and water. If you swallow any
diesel exhaust fluid, drink plenty of
water, call a physician immediately. WARNING:
Only refill the diesel
exhaust fluid tank in a well ventilated
area. When you remove the diesel
exhaust fluid tank filler cap or a diesel
exhaust fluid container cap, ammonia
vapors may escape. Ammonia 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. WARNING:
Diesel exhaust fluid
must be refilled when low or replaced
when contaminated or your vehicle
speed becomes limited to
50 mph
(80 km/h). In these conditions, drive with
caution and refill diesel exhaust fluid
immediately. If the diesel exhaust fluid
becomes empty or contaminated and
fluid is not replaced, your vehicle
becomes limited to engine idle only once
stopped. In these conditions, be cautious
where you stop your vehicle because you
may not be able to drive long distances
or maintain highway speeds until you
refill or replace the diesel exhaust fluid. WARNING:
Tampering with or
disabling the selective catalytic
reduction system results in severe
vehicle performance limitation including
eventual speed limiting to
5 mph
(8 km/h).
Note: Do not put diesel exhaust fluid in the
fuel tank. This can cause damage that your
vehicle Warranty may not cover.
Selective catalytic reduction systems are
sensitive to contamination of the diesel
exhaust fluid. Maintaining the purity of the
fluid is important to avoid system
malfunctions. If you remove or drain the
diesel exhaust fluid tank, do not use the
same fluid to refill the tank. The system
has a sensor to monitor fluid quality.
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Driving without refilling, replacing
contaminated diesel exhaust fluid, or
having the selective catalytic reduction
system repaired results in the following
actions as required by the California Air
Resources Board (CARB) and the U.S.
Environmental Protection Agency (EPA):
•
Within a preset distance to empty,
speed is limited upon vehicle restart.
Prior to this occurring a message
appears in the information display.
• Further vehicle operation without
refilling or replacing contaminated
diesel exhaust fluid causes the engine
to enter an idle-only condition. This
only occurs upon vehicle refueling,
vehicle idling in park for 1 hour, or
engine shutdown for 10 minutes or
more and is indicated by a message in
the information display indicating
required actions to resume normal
operation. It is required to add a
minimum of 1.0 gal (3.8 L) of diesel
exhaust fluid to the tank to exit the
idle-only condition, but your vehicle is
still in the speed-limiting mode until
you refill the tank completely.
Note: For vehicle speed limiting or idle-only
condition, normal vehicle operation resumes
when you refill the diesel exhaust fluid tank
or repair the contaminated system. If the
system is contaminated or inoperative, have
your vehicle checked as soon as possible. SELECTIVE CATALYTIC
REDUCTION SYSTEM
REQUIREMENTS Only use diesel exhaust fluid that is
certified by the American Petroleum
Institute (API).
You can purchase diesel exhaust fluid at
an authorized dealer, or contact roadside
assistance for help in finding a retailer that
sells diesel exhaust fluid.
Note:
Non-certified diesel exhaust fluid use
can cause damage that your Warranty may
not cover
SELECTIVE CATALYTIC
REDUCTION SYSTEM
GUIDELINES
• Diesel exhaust fluid is non-flammable,
non-toxic, colorless and water-soluble
liquid.
• In order for the system to operate
correctly you must maintain the diesel
exhaust fluid level.
• Do not overfill the diesel exhaust fluid
tank.
• Diesel exhaust fluid is corrosive.
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Action
Message
The diesel exhaust fluid is empty. You must replenish thediesel exhaust fluid to resume normal operation of your
vehicle. See Diesel Exhaust Fluid Capacity and Specific- ation (page 221).
DEF Level Low Speed
Limited to XX MPH/km/ h
The selective catalytic reduction system detects low exhaustfluid. The engine will eventually enter into an idle only mode.
You must replenish the diesel exhaust fluid to resume normal operation of your vehicle. See
Diesel Exhaust Fluid Capa-
city and Specification (page 221).
DEF Level Empty Engine
Idled Soon
The vehicle will enter into an idle only mode. You must
replenish the diesel exhaust fluid to resume normal operation of your vehicle. See
Diesel Exhaust Fluid Capacity and
Specification (page 221).
DEF Level Empty Engine
Idled See Manual
The selective catalytic reduction system detects a fault. Thevehicle ’s top speed will become limited in the displayed
distance and count down from this point. Have your vehicle checked as soon as possible.
DEF Fault Speed Limited
to XX MPH/km/h in XX mi/km
The selective catalytic reduction system detects a fault. The
vehicle ’s top speed will become limited upon restarting. Have
your vehicle checked as soon as possible.
DEF Fault Speed Limited
to XX MPH/km/h Upon Restart
The selective catalytic reduction system detects a fault. Thevehicle ’s top speed is limited. Have your vehicle checked as
soon as possible.
DEF Fault Speed Limited
to XX MPH/km/h
The selective catalytic reduction system detects a fault. The
engine will eventually enter into an idle only mode. Have your vehicle checked as soon as possible.
DEF Fault Engine Idled
Soon
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WHAT IS THE CATALYTIC
CONVERTER
The catalytic converter is part of your
vehicle's emissions system and filters
harmful pollutants from the exhaust gas.
CATALYTIC CONVERTER
PRECAUTIONS
WARNING: Do not park, idle or
drive your vehicle on dry grass or other
dry ground cover. The emission system
heats up the engine compartment and
exhaust system, creating the risk of fire. 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 catalytic converter.
The catalytic converter heats up to a very
high temperature after only a short
period of engine operation and stays hot
after the engine is switched off.
To avoid damaging the catalytic converter:
• Do not crank the engine for more than
10 seconds at a time.
• Do not run the engine with a spark plug
lead disconnected.
• Do not push-start or tow-start your
vehicle. Use booster cables. See Jump
Starting the Vehicle
(page 380).
• Use the correct fuel.
See Fuel and
Refueling (page 203).
• Do not switch the ignition off when your
vehicle is moving.
• Avoid running out of fuel.
• Have the items listed in scheduled
maintenance information performed
according to the specified schedule. Note:
Do not make any unauthorized
changes to your vehicle or engine. By law,
vehicle owners and anyone who
manufactures, repairs, or services a fleet of
vehicles are not permitted to intentionally
remove an emission control device or
prevent it from working.
CATALYTIC CONVERTER –
TROUBLESHOOTING
CATALYTIC CONVERTER –
WARNING LAMPS
Your vehicle has an on-board diagnostics
system that monitors the emission control
system. If any of the following warning
lamps illuminate, this may indicate that
the on-board diagnostics system has
detected an emission control system
malfunction. Continuing to drive your vehicle may cause
reduced power or the engine to stop.
Failure to respond to a warning lamp may
cause damage that your vehicle Warranty
may not cover. Have your vehicle checked
as soon as possible.
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AUTOMATIC TRANSMISSION
PRECAUTIONS
WARNING: Apply the parking
brake, shift into park (P), switch the
ignition off and remove the key before
you leave your vehicle. Failure to follow
this instruction could result in personal
injury or death. WARNING:
Do not use tow/haul
when the road surface is slippery. Failure
to follow this instruction could result in
the loss of control of your vehicle. WARNING:
When your vehicle is
stationary, keep the brake pedal fully
pressed when shifting gears. Failure to
follow this instruction could result in
personal injury, death or property
damage. WARNING:
Do not apply the brake
pedal and accelerator pedal
simultaneously. Applying both pedals
simultaneously for more than a few
seconds will limit engine performance,
which may result in difficulty maintaining
speed in traffic and could lead to serious
injury.
AUTOMATIC TRANSMISSION
POSITIONS
PARK (P)
This position locks the driveline and
prevents the wheels from turning. Come
to a complete stop before putting your
vehicle into and out of park (P). REVERSE (R) WARNING:
Move the transmission
selector lever to reverse (R) only when
your vehicle is stationary and the engine
is at idle speed.
This position allows your vehicle to move
backward. Come to a complete stop
before shifting into and out of reverse (R).
NEUTRAL (N) WARNING:
In neutral (N) your
vehicle is free to roll.
This position allows your vehicle to roll
free. Hold the brake pedal down when in
this position.
Note: You can start your vehicle in this
position.
DRIVE (D)
Drive (D) is the normal driving position, and
allows automatic upshifts and downshifts
through all available gears.
MANUAL (M)
To select manual (M) mode, place the
gearshift in the manual (M) position.
This position allows you to change gears
up or down as preferred using the + or -
buttons on the shifter lever.
To return to the normal drive (D) position,
move the shifter into the drive (D) position.
SHIFTING YOUR VEHICLE INTO
GEAR
1. Fully press down on the brake pedal.
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2. Move the gearshift lever into the
desired gear.
3. When you finish driving, come to a complete stop.
4. Pull lever toward the driver and move the gearshift lever and securely latch
it in park (P).
MANUALLY SHIFTING GEARS
SHIFTING USING THE BUTTONS
ON THE SELECTOR LEVER
Pressing the manual (M) button on the
shifter allows you to select the gear you
prefer. Only the current gear displays. Press
the + button to upshift or the – button to
downshift. Return the transmission to a
different gearshift position to deactivate
manual control or press manual (M).
Your vehicle has a SelectShift Automatic
transmission gearshift lever. This gives you
the ability to change gears up or down,
without a clutch, as preferred.
Note: To prevent the engine from running
at too low an RPM, which could cause it to
stall, SelectShift still makes some
downshifts if it determines that you have
not downshifted in time. Although
SelectShift makes some downshifts for you,
it still allows you to downshift at any time
if it determines that damage to the engine
from over-revving does not occur.
Note: SelectShift does not automatically
upshift, even if the engine is approaching
the RPM limit. Shift manually by pressing
the
+ button. Note:
Engine damage could occur if you
maintain excessive engine revving without
shifting. BRAKE SHIFT INTERLOCK
WHAT IS BRAKE SHIFT
INTERLOCK
Brake shift interlock prevents you from
shifting out of park (P) when you have
switched the ignition on and not pressed
the brake pedal.
BRAKE SHIFT INTERLOCK
PRECAUTIONS
WARNING:
Do not drive your
vehicle until you verify that the
stoplamps are working. WARNING:
When doing this
procedure, you need to take the
transmission out of park (P) which
means your vehicle can roll freely. To
avoid unwanted vehicle movement,
always fully apply the parking brake prior
to doing this procedure. Use wheels
chocks if appropriate.
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POWER TAKE-OFF (IF EQUIPPED)
HOW DOES THE POWER TAKE-
OFF WORK
Auxiliary equipment called power take-off,
or PTO, is often added to the engine or
transmission to operate utility equipment.
Examples include a wheel-lift for tow
trucks, cranes, tools for construction or tire
service, and pumping fluids. PTO
applications draw auxiliary horsepower
from the powertrain, often while the
vehicle is stationary. In this condition, there
is limited cooling air flow through the
radiator and around the vehicle that
normally occurs when a vehicle is moving.
The aftermarket PTO system installer,
having the most knowledge of the final
application, is responsible for determining
whether additional chassis heat protection
or powertrain cooling is required, and
alerting the user to the safe and proper
operation.
Note: Use of auxiliary equipment that
exceeds the maximum Power Take-Off
(PTO) load specified in our Truck Body
Builders Layout Book can adversely affect
the performance of the powertrain system.
Refer to the Body Builders Layout Book for
instructions about the appropriate
installation of additional equipment.
For additional information, visit
www .f or dbb a s. c om/home .
WHAT IS THE SPLIT SHAFT
CAPABILITY
Split shaft capability is when the output
gear connects directly with the engine to
power your power takeoff (PTO), anytime
the engine is running. This feature is approved as a stationary
mobile power source, within the limits and
operating guidelines detailed in our Truck
Body Builders Layout Book. For additional
information, visit
www .f or dbb a s. c om/home .
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WARNING: If the parking brake is
fully released, but the brake warning
lamp remains illuminated, the brakes
may not be working properly. Have your
vehicle checked as soon as possible. WARNING:
Do not become
overconfident in the ability of four-wheel
drive vehicles. Although a four-wheel
drive vehicle may accelerate better than
a two-wheel drive vehicle in low traction
situations, it won't stop any faster than
two-wheel drive vehicles. Always drive
at a safe speed.
Truck and utility vehicles can differ from
some other vehicles. Your vehicle could be
higher to allow it to travel over rough
terrain without getting stuck or damaging
underbody components. The differences
that make your vehicle so versatile also
make it handle differently than an ordinary
passenger car. Always maintain steering
wheel control, especially in rough terrain.
Since sudden changes in terrain can result
in abrupt steering wheel motion, make sure
you grip the steering wheel from the
outside. Do not grip the spokes. Drive
cautiously to avoid vehicle damage from
concealed objects such as rocks and
stumps. Drive slower in strong crosswinds
which can affect the normal steering
characteristics of your vehicle. Be
extremely careful when driving on
pavement made slippery by loose sand,
water, gravel, snow or ice. Note:
Do not use four-wheel drive high or
four-wheel drive low mode on dry, hard
surfaced roads. Doing so can produce
excessive noise, increase tire wear and can
damage drive components. Four-wheel
drive high or four-wheel drive low modes
are for consistently slippery or loose
surfaces. Use of four-wheel drive low mode
on these surfaces could produce some
noise, such as occasional clunks, but should
not damage drive components. When
transitioning from consistently loose or
slippery surfaces, be sure the four-wheel
drive systems not mechanically blocked
once on dry, hard surfaced roads in
two-wheel drive high.
Parking WARNING:
If the parking brake is
fully released, but the brake warning
lamp remains illuminated, the brakes
may not be working properly. Have your
vehicle checked as soon as possible. WARNING:
Apply the parking
brake, shift into park (P), switch the
ignition off and remove the key before
you leave your vehicle. Failure to follow
this instruction could result in personal
injury or death.
On some four-wheel drive vehicles, when
the transfer case is in the neutral (N)
position, the engine and transmission
disconnects from the rest of the driveline.
Therefore, the vehicle is free to roll even if
the automatic transmission is in park (P)
or the manual transmission is in gear. Do
not leave the vehicle unattended with the
transfer case in the neutral (N) position.
Always set the parking brake fully and turn
off the ignition when leaving the vehicle.
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FOUR-WHEEL DRIVE
INDICATORS
Two-wheel Drive High
Momentarily illuminates when
you select two-wheel drive high.
Four-wheel Drive High Continuously illuminates when
you select four-wheel drive high.
Four-wheel Drive Low Continuously illuminates when
you select four-wheel drive low.
FOUR-WHEEL DRIVE DRIVING
HINTS
EMERGENCY MANEUVERS
In an unavoidable emergency situation
where a sudden sharp turn must be made,
remember to avoid over-driving your
vehicle (i.e. turn the steering wheel only as
rapidly and as far as required to avoid the
emergency). Excessive steering can result
in loss of vehicle control. Apply smooth
pressure to the accelerator pedal or brake
pedal when changes in vehicle speed are
required. Avoid abrupt steering,
acceleration and braking. This could result
in an increased risk of vehicle roll over, loss
of vehicle control and personal injury. Use
all available road surface to bring your
vehicle to a safe direction of travel.
In the event of an emergency stop, avoid
skidding the tires and do not attempt any
sharp steering wheel movements. If your vehicle goes from one type of
surface to another (i.e. from concrete to
gravel) there can be a change in the way
your vehicle responds to a maneuver, i.e.
steering, acceleration or braking.
DRIVING IN SAND
When driving over sand, try to keep all four
wheels on the most solid area of the trail.
Avoid reducing the tire pressures but shift
to a lower gear and drive steadily through
the terrain. Apply the accelerator slowly
and avoid excessive wheel slip.
When driving at slow speeds in deep sand
under high outside temperatures, use a low
gear when possible. Low gear operation
can maximize the engine and transmission
cooling capability.
Avoid driving at excessive speed. This
causes vehicle momentum to work against
you and your vehicle could become stuck
to the point that assistance may be
required from another vehicle. Remember,
you may be able to back out the way you
came if you proceed with caution.
DRIVING THROUGH MUD AND
WATER
WARNING: Do not spin the wheels
at over 34 mph (55 km/h). The tires may
fail and injure a passenger or bystander.
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Mud
Be cautious of sudden changes in vehicle
speed or direction when you are driving in
mud. Even four-wheel drive vehicles can
lose traction in slick mud. If your vehicle
does slide, steer in the direction of the slide
until you regain control of your vehicle.
After driving through mud, clean off residue
stuck to rotating driveshafts and tires.
Excess mud stuck on tires and rotating
driveshafts can cause an imbalance that
could damage drive components.
Water
If you must drive through high water, drive
slowly. Traction or brake capability may
be limited. When driving through water,
determine the depth and avoid water
higher than the bottom of the hubs. If the
ignition system gets wet, your vehicle may
stall. Once through water, test the brakes.
Wet brakes do not stop your vehicle as
effectively as dry brakes. Drying improves
by applying light pressure to the brake
pedal while moving slowly.
Note:
Driving through deep water may
damage the transmission. If the front or rear
axle is submerged in water, the axle
lubricant and power transfer unit lubricant
should be checked and changed if
necessary.
DRIVING ON HILLY OR SLOPING
TERRAIN
Although natural obstacles may make it
necessary to travel diagonally up or down
a hill or steep incline, you should try to drive
straight up or straight down. Note:
Avoid turning on steep slopes or hills.
A danger lies in losing traction, slipping
sideways and possible vehicle roll over.
Whenever driving on a hill, determine
beforehand the route you can use. Do not
drive over the crest of a hill without seeing
what conditions are on the other side. Do
not drive in reverse over a hill without the
aid of an observer.
When climbing a steep slope or hill, start
in a lower gear rather than downshifting to
a lower gear from a higher gear once the
ascent has started. This reduces strain on
the engine and the possibility of stalling.
If your vehicle stalls, do not try to
turnaround because this could cause
vehicle roll over. It is better to reverse back
to a safe location.
Apply just enough power to the wheels to
climb the hill. Too much power can cause
the tires to slip, spin or lose traction,
resulting in loss of vehicle control.
Descend a hill in the same gear you would
use to climb up the hill to avoid excessive
brake application and brake overheating.
Do not descend in neutral. Disengage
overdrive or move the transmission
selector lever to a lower gear. When
descending a steep hill, avoid sudden hard
braking as you could lose control. The front
wheels have to be turning in order to steer
your vehicle.
Note: If your vehicle has anti-lock brakes,
apply the brakes steadily. Do not pump the
brakes.
DRIVING ON SNOW AND ICE WARNING: If you are driving in
slippery conditions that require tire
chains or cables, then it is critical that
you drive cautiously. Keep speeds down,
allow for longer stopping distances and
avoid aggressive steering to reduce the
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