engine FORD SUPER DUTY 2023 Service Manual

STARTING AND STOPPING THEENGINE – FREQUENTLY ASKEDQUESTIONS - GASOLINE,VEHICLES WITH: PUSH BUTTONSTART
Why is the engine speed high whenI am starting the engine?
•The speed at which the engine idlesimmediately after starting is optimizedto minimize vehicle emissions andmaximize cabin comfort and fueleconomy.
Why does the engine not crank?
•You can only attempt to start theengine for a limited amount of timebefore the starting system temporarilydisables. If you exceed the starting timelimit, a message may appear and youcannot attempt to start the engine forat least 15 minutes.
Why do I experience differentdriving characteristics?
•If you disconnect the battery, yourvehicle may exhibit some unusualdriving characteristics forapproximately 5.0 mi (8 km) after youreconnect it. This is because the enginemanagement system must realignitself with the engine. You candisregard any unusual drivingcharacteristics during this period.
Why can I not start the engine?
If you cannot start the engine after 3attempts, wait 10 seconds and do thefollowing:
1.Fully press the brake pedal or theclutch pedal.
Note:Make sure that the parking brake isapplied.
Note:Make sure that the transmission is inpark (P) or neutral (N).
2.Fully press the accelerator pedal andhold it there.
3.Press the push button ignition switch.
Note:The engine cranks for a short periodof time and then it stops.
4.Release the accelerator pedal.
5.Press the push button ignition switch.
Why does the system not detect apassive key?
•If the system does not detect a passivekey and you are unable to start theengine, insert the passive key into thebackup position and press the pushbutton ignition switch to start theengine. See Accessing the PassiveKey Backup Position (page 209).
STARTING AND STOPPING
THE ENGINE VIDEOS
Push-Button Start: F-Series Diesel
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FUEL AND REFUELING
PRECAUTIONS
WARNING: Fuels can cause seriousinjury or death if misused or mishandled.
WARNING: Fuel may containbenzene, which is a cancer-causingagent.
Follow these guidelines when refueling:
•Extinguish all smoking materials andany open flames before refueling yourvehicle.
•Switch the engine off before refueling.
•Automotive fuels can be harmful orfatal if swallowed. Fuel is highly toxicand if swallowed can cause death orpermanent injury. If fuel is swallowedimmediately call a physician, even if nosymptoms are immediately apparent.The toxic effects of fuel may not beapparent for hours.
•Avoid inhaling fuel vapors. Inhaling fuelvapor can lead to eye and respiratorytract irritation. In severe cases,excessive or prolonged breathing offuel vapor can cause serious illness andpermanent injury.
•Avoid getting fuel in your eyes. If yousplash fuel in your eyes, immediatelyremove contact lenses, if worn, flushwith water for 15 minutes and seekmedical attention. Failure to seekproper medical attention could lead topermanent injury.
•Fuels can be harmful if absorbedthrough the skin. If you splash fuel onyour skin, clothing or both, promptlyremove contaminated clothing andthoroughly wash your skin with soapand water. Repeated or prolonged skincontact causes skin irritation.
•Be particularly careful if you are takingAntabuse or other forms of Disulfiramfor the treatment of alcoholism.Breathing fuel vapors could cause anadverse reaction, serious personalinjury or sickness. Immediately call aphysician if you experience any adversereactions.
FUEL QUALITY
SELECTING THE CORRECT FUEL -GASOLINE
Your vehicle operates on regular unleadedgasoline with a minimum pump (R+M)/2octane rating of 87.
Some fuel stations, particularly those inhigh altitude areas, offer fuels posted asregular unleaded gasoline with an octanerating below 87. The use of these fuelscould result in engine damage that will notbe covered by the vehicle Warranty.
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For best overall vehicle and engineperformance, premium fuel with an octanerating of 91 or higher is recommended. Theperformance gained by using premium fuelis most noticeable in hot weather as wellas other conditions, for example whentowing a trailer. See Towing a Trailer(page 365).
Do not be concerned if the enginesometimes knocks lightly. However, if theengine knocks heavily while using fuel withthe recommended octane rating, contactan authorized dealer to prevent any enginedamage.
We recommend Top Tier detergentgasolines, where available to help minimizeengine deposits and maintain optimalvehicle and engine performance.
For additional information, visitwww.toptiergas.com.
Note:Use of any fuel for which the vehiclewas not designed can impair the emissioncontrol system, cause loss of vehicleperformance, and cause damage to theengine which may not be covered by thevehicle Warranty.
Do not use:
•Diesel fuel.
•Fuels containing kerosene or paraffin.
•Fuel containing more than 15% ethanolor E85 fuel.
•Fuels containing methanol.
•Fuels containing metallic-basedadditives, including manganese-basedcompounds.
•Fuels containing the octane boosteradditive, methylcyclopentadienylmanganese tricarbonyl (MMT).
•Leaded fuel, using leaded fuel isprohibited by law.
The use of fuels with metallic compoundssuch as methylcyclopentadienylmanganese tricarbonyl, which is amanganese-based fuel additive, will impairengine performance and affect theemission control system.
SELECTING THE CORRECT FUELFOR COLD WEATHER
Choosing the Right Fuel: VehiclesOperated Where Ultra Low SulfurDiesel Fuel Is Required (UnitedStates/Canada/Puerto Rico/U.S.Virgin Islands And Other Locales)
Note:Your Warranty will not cover damagecaused by using an improper type of fuel orfuel additive.
Note:Do not blend used engine oil withdiesel fuel under any circumstances.Blending used oil with the fuel significantlyincreases your vehicle’s exhaust emissionsand reduce engine life due to increasedinternal wear.
We recommend Top Tier diesel fuel whereavailable to help minimize engine depositsand maintain optimal vehicle and engineperformance.
For additional information, visitwww.toptiergas.com.
You should use ultra-low sulfur diesel fueldesignated as number 1-D or 2-D with amaximum of 15-ppm sulfur in your dieselvehicle. You can operate your vehicle ondiesel fuels containing up to 20%biodiesel, also known as B20. These fuelsshould meet the ASTM D975 diesel or theASTM D7467 B6-B20 biodiesel industryspecifications. Outside of North America,use fuels meeting EN590 or equivalentlocal market standard.
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Using low-sulfur diesel fuel(16-500 ppm) or high-sulfurdiesel fuel (greater than 500ppm) in your diesel engine will causecertain emission components tomalfunction which could also cause theservice engine soon light to illuminateindicating an emissions-related concern.
Diesel fuel is adjusted seasonally for coldtemperature. For best results attemperatures below 19°F (-7°C), werecommend using a diesel fuel which hasbeen seasonally adjusted for the ambientconditions.
Choosing the Right Fuel: VehiclesOperated Where Ultra Low SulfurDiesel Fuel Is Not Required
For the engine to operate reliably onlow-sulfur or high-sulfur diesel fuel, theengine must be a factory-built high-sulfurengine (available as a dealer order optionfor select markets) or an ultra-low sulfurdiesel fuel configured engine that has beenretrofitted for high-sulfur diesel fuel usingauthorized dealer service parts. Failure touse retrofit components other than thoseavailable through your authorized dealerresults in coolant system damage, engineoverheating, selective catalyst reductionsystem or diesel particulate filter damageand possible base engine damage.
Use only a diesel engine configured for usewith high-sulfur diesel fuel in markets withdiesel fuel that has sulfur content greaterthan 15 ppm. Using low-sulfur diesel fuel(16–500 ppm) or high-sulfur diesel fuel(greater than 500 ppm) in a diesel enginedesigned to use only ultra-low sulfur dieselfuel could result in damage to engineemission control devices and the aftertreatment system, potentially renderingthe vehicle inoperable.
Vehicles with engines configured for usewith high-sulfur diesel fuel are onlyavailable for sale in countries whereultra-low sulfur diesel fuel is generally notavailable or mandated by the government.Vehicles originally sold in an ultra-lowsulfur diesel fuel market that aresubsequently exported to non-ultra lowsulfur diesel fuel markets will need to beretrofitted at the customer’s expense usingFord authorized dealer service parts inorder to be reliably operated on non-ultralow sulfur diesel fuel.
Biodiesel
WARNING: Do not mix diesel withgasoline, gasohol or alcohol. This couldcause an explosion.
Note:Do not use home heating oil,agricultural fuel, raw fats and oils, wastecooking greases, biodiesel greater than 20%or any diesel not intended for highway use.Damage to the fuel injection system, engineand exhaust catalyst, and diesel particulatefilter can occur if you use an improper fuel.Red dye is used to identify fuels intendedfor agricultural and non-highway use.
You can operate your vehicle on dieselfuels containing up to 20% biodiesel, alsoknown as B20.
Biodiesel fuel is a chemically convertedproduct from renewable fuel sources, suchas vegetable oils, animal fats and wastecooking greases.
To help achieve acceptable engineperformance and durability when usingbiodiesel in your vehicle:
•Confirm the biodiesel content of thefuel to be B20 (20% biodiesel) or less.
•Only use biodiesel fuel of good qualitythat complies with industry standards.
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•Follow the recommended servicemaintenance intervals. See GeneralMaintenance Information (page 594).
•Do not store biodiesel fuel in the fueltank for more than 1 month.
•Consider changing brands or reducingbiodiesel content if you have coldtemperature fuel gelling issues or afrequently appearing LOW FUELPRESSURE message.
Use of biodiesel in concentrations greaterthan 20% can cause damage to yourvehicle, including engine and/or exhaustafter-treatment hardware (exhaustcatalyst and particulate filter) failures.Concentrations greater than 20% can alsocause fuel filter restrictions that couldresult in a lack of power or damage to fuelsystem components, including fuel pumpand fuel injector failures.
We recommend SAE 5W-40 oil for fuelswith greater than 5% biodiesel (B5). Formore information about oil changeintervals and other maintenance whenoperating on biodiesel. See SpecialOperating Conditions ScheduledMaintenance (page 603).
Look for a label on the fuel pump toconfirm the amount of biodiesel containedin diesel fuel. Ask the service stationattendant to confirm the biodiesel contentof diesel fuel, if you do not see a label onthe fuel pump.
If you plan to park or store your vehicle formore than 1 month, then you should emptyyour vehicle fuel tank of biodiesel fuel. Youshould fill the tank with a purepetroleum-based diesel fuel and run yourvehicle for a minimum of 30 minutes.
Note:Degraded or oxidized biodiesel candamage fuel system seals and plastics andcorrode steel parts.
During cold weather, if you have problemsoperating on biodiesel, you may need touse diesel fuel with lower biodieselcontent, try another brand or discontinuethe use of biodiesel.
Diesel Fuel Additives
It should not be necessary to add anyaftermarket additives to your fuel if youuse a high-quality diesel fuel that conformsto ASTM industry specifications.Aftermarket additives can damage the fuelinjector system or engine.
Use Motorcraft® cetane booster or anequivalent cetane booster additive if yoususpect fuel has low cetane. UseMotorcraft® anti-gel and performanceimprover or an equivalent additive if thereis fuel gelling.
Do not use alcohol-based additives toimprove cetane quality, to prevent fuelgelling or any other use. The use of alcoholadditives could result in damage to the fuelinjectors and system.
Your Warranty may not cover repairsneeded to correct the effects of using anaftermarket product that does not meetour specifications in your fuel.
RUNNING OUT OF FUEL
FILLING A PORTABLE FUELCONTAINER
WARNING: Flow of fuel through afuel pump nozzle can produce staticelectricity. This can cause a fire if you arefilling an ungrounded fuel container.
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Use the following guidelines to avoidelectrostatic charge build-up, which canproduce a spark, when filling anungrounded fuel container:
•Only use an approved fuel container totransfer fuel to your vehicle. Place thecontainer on the ground when filling it.
•Do not fill a fuel container when it isinside your vehicle (including the cargoarea).
•Keep the fuel pump nozzle in contactwith the fuel container when filling it.
•Do not use a device that holds the fuelpump nozzle lever in the fill position.
ADDING FUEL FROM A PORTABLEFUEL CONTAINER
WARNING: Do not pry open thefuel tank filler valve. This could damagethe fuel system. Failure to follow thisinstruction could result in fire, personalinjury or death.
WARNING: Do not dispose of fuelin the household refuse or the publicsewage system. Use an authorized wastedisposal facility.
When refueling the vehicle fuel tank froma fuel container, do the following:
1.Fully open the fuel filler door.
2.Turn the fuel filler capcounterclockwise and remove it.
3.Add fuel to your vehicle from the fuelcontainer.
4.To replace the fuel filler cap, turn itclockwise until you feel a strongresistance and it clicks.
5.Fully close the fuel filler door.
Note:If your vehicle runs out of fuel add aminimum of 1.3 gal (5 L) of fuel to restartthe engine.
Note:You may need to switch the ignitionfrom off to on several times after refuelingto allow the fuel system to pump the fuelfrom the tank to the engine. Whenrestarting, cranking time takes a fewseconds longer than normal.
REFUELING
REFUELING SYSTEM OVERVIEW
Fuel filler door.A
Fuel cap.B
Fuel tank filler pipe.C
REFUELING YOUR VEHICLE
WARNING: When refueling alwaysshut the engine off and never allowsparks or open flames near the fuel tankfiller valve. Never smoke or use a cellphone while refueling. Fuel vapor isextremely hazardous under certainconditions. Avoid inhaling excess fumes.
WARNING: Fuel vapor burnsviolently and a fuel fire can cause severeinjuries.
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6.When the pump shuts off, wait fiveseconds, then raise the fuel pumpnozzle and slowly remove it.
7.Install the fuel filler cap by turning itclockwise until it clicks.
8.Fully close the fuel filler door.
Note: Do not attempt to start the engineif you have filled the fuel tank with incorrectfuel. Incorrect fuel use could cause damagenot covered by the vehicle Warranty. Haveyour vehicle immediately checked.
FUEL TANK CAPACITY
Advertised Capacity
The advertised capacity is the maximumamount of fuel that you can add to the fueltank after running out of fuel. Included inthe advertised capacity is an emptyreserve. The empty reserve is anunspecified amount of fuel that remainsin the fuel tank when the fuel gaugeindicates empty.
Note:The amount of fuel in the emptyreserve varies and should not be relied uponto increase driving range.
FUEL AND REFUELING –
TROUBLESHOOTING
FUEL AND REFUELING –WARNING LAMPS
If it illuminates when you aredriving, refuel as soon aspossible.
FUEL AND REFUELING – INFORMATION MESSAGES
ActionMessage
You may not have installed the fuel filler cap properly. At thenext opportunity, safely pull off of the road, remove the fuelfiller cap, align the cap properly and reinstall it.
Check Fuel Cap
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WHAT IS THE DIESEL
PARTICULATE FILTER
The diesel particulate filter is part of yourvehicle's emissions system and filtersharmful diesel particulates from theexhaust gas.
HOW DOES THE DIESEL
PARTICULATE FILTER WORK
The diesel particulate filter reducesemissions by trapping exhaust particlesbefore they reach the tailpipe. The systemmust periodically clean the exhaustparticles that gather inside the filter. Thisis carried out in three ways, passiveregeneration, active regeneration andmanual regeneration.
Passive Regeneration
In passive regeneration, the normalexhaust system temperature cleans thefilter by oxidizing the soot. Cleaning occursduring normal vehicle operating conditionsdue to driving patterns.
Active Regeneration
Once the diesel particulate filter is full,active regeneration raises the exhausttemperature to eliminate the particles.
When the engine control module detectsthat the diesel particulate filter is nearlyfull of particulates, and you are notoperating your vehicle in a manner to alloweffective regeneration, messages appearin the information display as a reminderfor you to drive your vehicle in order toclean the diesel particulate filter. If youdrive your vehicle in a manner to alloweffective regeneration, the informationdisplay shows a cleaning exhaust filtermessage.
DIESEL PARTICULATE FILTER
PRECAUTIONS
WARNING: Do not park or idle yourvehicle over dry leaves, dry grass or othercombustible materials. The regenerationprocess creates very high exhaust gastemperatures and the exhaust willradiate a considerable amount of heatduring and after regeneration and afteryou have switched the engine off. This isa potential fire hazard.
WARNING: When the ExhaustFilter Cleaning message appears in theinformation display, do not park nearflammable materials, vapors orstructures until filter cleaning iscomplete.
WARNING: The normal operatingtemperature of the exhaust system isvery high. Never work around or attemptto repair any part of the exhaust systemuntil it has cooled. Use special care whenworking around the diesel oxidationcatalytic converter or the dieselparticulate filter. The diesel oxidationcatalytic converter and the dieselparticulate filter heat up to very hightemperatures after only a short periodof engine operation and remain hot afteryou switch the engine off.
Note:Avoid running out of fuel.
Note: During regeneration at low speed orengine idle, you may smell a hot metallicodor and could notice a clicking metallicsound. This is due to high temperaturesreached during regeneration and is normal.
Note:Changes in the engine or exhaustsound may be heard during the regenerationprocess.
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Failure to perform active or manualregeneration when instructed could resultin a clogged diesel particulate filter. If thediesel particulate filter fills beyond theregeneration threshold, your vehicledisables the ability for active and manualregeneration. This could result inirreversible damage your vehicle Warrantymay not cover.
DIESEL PARTICULATE FILTER
REQUIREMENTS
The diesel particulate filter on your vehiclerequires periodic regeneration to maintainits correct function.
If your journeys meet one of the followingconditions:
•You drive only short distances.
•You frequently switch the ignition onand off.
•Your journeys contain a high level ofacceleration and deceleration.
You must carry out occasional trips withthe following conditions to assist theregeneration process:
•Drive your vehicle in more favorableconditions, which you will find at highervehicle speeds in normal driving, on amain road or freeway for a minimumof 20 minutes. This drive may includeshort stops that will not affect theregeneration process.
•Avoid prolonged idling and observespeed limits and road conditions.
•Do not switch the ignition off.
•Select a suitable gear to ideallymaintain engine speed between 1500and 3000 RPM.
DIESEL PARTICULATE FILTER
MANUAL REGENERATION
WHAT IS DIESEL PARTICULATEFILTER MANUAL REGENERATION
Diesel particulate filter manualregeneration allows you to manually startregeneration of the diesel particulate filterat idle to clean the filter.
Note:If you are not sure whether yourvehicle has this feature, contact yourauthorized dealer.
DIESEL PARTICULATE FILTERMANUAL REGENERATIONPRECAUTIONS
WARNING: Stay clear of theexhaust tailpipe during regeneration. Hotexhaust gases can burn you badly.
You may not be able to use manualregeneration if the service engine soonwarning lamp appears in the informationdisplay.
Note:During the use of manualregeneration, you may observe a lightamount of white smoke. This is normal.
DIESEL PARTICULATE FILTERMANUAL REGENERATIONREQUIREMENTS
You can use the manual regenerationfeature when a message appears in theinformation display and you are not ableto drive in a manner that allows effectiveautomatic active regeneration or if youchoose to manually start the regenerationof the diesel particulate filter while thevehicle is idle.
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Before you start manual regeneration, dothe following:
•Make sure the parking brake is on.
•Shift into park (P) on stable, levelground.
•Park your vehicle outside of anystructure.
•Park your vehicle 10–15 ft (3–5 m)away from any obstructions and awayfrom materials that can easily combustor melt, for example paper, leaves,petroleum products, fuels, plastics andother dry organic material.
•Make sure there is a minimum of 1/8tank of fuel.
•Make sure all fluids are at proper levels.
DIESEL PARTICULATE FILTERMANUAL REGENERATIONLIMITATIONS
You cannot use manual regeneration untilthe diesel particulate filter load percentagehas reached 100% or Full. The dieselparticulate filter load percentagefluctuates up and down when driving yourvehicle due to active and passiveregenerations.
If your vehicle is operated with significantstationary operation, low speed drivecycles less than 25 mph (40 km/h), shortdrive cycles, drive time less than 15 minutesor the vehicle does not fully warm up,passive and active regeneration may notsufficiently clean the diesel particulatefilter system.
Aftermarket devices or modifications tothe exhaust system may reduce theeffectiveness of the exhaust system aswell as cause damage to the exhaustsystem or engine. This may also degradevehicle performance and could lead toengine damage that may not be coveredby the vehicle Warranty.
STARTING DIESEL PARTICULATEFILTER MANUAL REGENERATION
Start with your vehicle engine and when ithas reached the normal operatingtemperature, press the information displaycontrol button on the steering wheel. SeeInstrument Cluster Display (page 143).
If the diesel particulate filter is near or atsaturation, a message requestingpermission to initiate filter cleaningappears in the information display. SeeDiesel Particulate Filter – InformationMessages (page 224). Answer yes to thisprompt and then follow the next promptsregarding exhaust position required toinitiate manual regeneration. Be sure tounderstand each prompt. If you are notsure what is being asked by each prompt,contact an authorized dealer. The displayconfirms the operation has started andwhen it has finished. You can also drive toclean the filter.
When the system is at the pointof oversaturation, themalfunction indicator lampilluminates and a message appears in theinformation display. You cannot initiatefilter cleaning. You must have your vehiclechecked as soon as possible.
Once manual regeneration starts, enginespeed increases and the cooling fan speedincreases. You will hear a change in audiblesound due to engine speed and cooling fanspeed increases.
It is not necessary to open the hood on theengine compartment. Once manualregeneration completes, the engine speedreturns to normal idling. The exhaustsystem remains very hot for severalminutes even after regeneration iscomplete. Do not reposition the vehicleover materials that could burn until the
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