2016 DIESEL Supplement

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owner.ford.com  ford.ca

April 2015

First Printing

Diesel Supplement

Power Stroke

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Litho in U.S.A.

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GC3J 19A285 AA

image4image5The information contained in this publication was correct at the time of going to print. In the interest of continuous development, we reserve the right to change specifications, design or equipment at any time without notice or obligation. No part of this publication may be reproduced, transmitted, stored in a retrieval system or translated into any language in any form by any means without our written permission. Errors and omissions excepted.

© Ford Motor Company 2015

All rights reserved.

Part Number: 20150323155017

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Table of Contents

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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  40

Maintenance

Under Hood Overview  43

Engine Oil Check  44

Engine Coolant Check  46

Changing the Engine Air Filter  51

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Vehicle Care

Cleaning the Engine  54

Cleaning the Exhaust  54

Capacities and Specific-

ations

Engine Specifications  55

Motorcraft Parts  55

Capacities and Specifications  56

Scheduled Maintenance

General Maintenance Information  60

Normal Scheduled Maintenance  63

Special Operating Conditions Scheduled

Maintenance  66

Scheduled Maintenance Record  73

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Introduction

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ABOUT THIS SUPPLEMENT

This supplement acquaints you with the Power Stroke diesel engine. It provides recommendations on engine care, operating procedures, special equipment and specifications of the Power Stroke engine. Make sure you keep this supplement with the vehicle.

For complete vehicle information, refer to your Owner’s Manual.

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 and 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.

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Ford may discontinue models or change specifications without any notice and without incurring obligations.

Warnings

WARNING

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Throughout this guide, you will find warnings identified by the warning symbol. Warnings remind you to be

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especially careful to reduce the risk of personal injury.

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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 497 mi (800 km) before towing a trailer. Make sure you use the specified engine oil. See Capacities and Specifications (page 56).

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 44).

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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Introduction

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A high-pressure fuel rail for each cylinder bank (2 total)

Numerous high-pressure pipes from the high-pressure pump to the rails, and rails to the injectors

The fuel and water separator removes both water and impurities from the fuel. The engine-mounted filter filters finer impurities from the diesel fuel. The engine-mounted fuel filter and the fuel and water separator filter should be changed at the recommended service interval or when indicated by the information display LOW FUEL PRESSURE message. Refer to the scheduled maintenance information in this supplement for more information.

The fuel and water separator should be drained at regular intervals (recommended at every oil change) or when indicated by the information display and water in fuel indicator light. See Fuel Quality (page 15).

Proper fuel filter maintenance and prompt water draining when the water in fuel light illuminates is essential to prevent injection equipment damage. Ignoring the water in fuel light can cause your vehicle to go into a reduced power mode.

A frame-mounted electric fuel pump located inside the fuel and water separator draws fuel from the fuel tank to provide pressurized fuel to the engine. The fuel pump contains a pressure relief valve for overpressure protection in the event of restricted flow.

The fuel injection system is controlled through the powertrain control module.

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Engine protection mode

Ford diesel engines are equipped with engine protection and emission control systems. These systems monitor critical temperatures and pressures, and modify engine operation accordingly. These modified engine performance characteristics are normal.

If these modified engine performance characteristics persist for an extended period and either the service engine soon or powertrain malfunction, reduced power, electronic throttle control light is illuminated, have the system checked by an authorized dealer.

Service engine soon

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Powertrain malfunction, reduced power, electronic throttle control

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Lubrication system

It is important to change the engine oil at the recommended service intervals to maintain oil viscosity. Extending the oil and filter change interval beyond the recommended interval can negatively affect engine performance, fuel economy and engine life. See Engine Oil Check (page 44).

Fast start glow plug system

The diesel engine glow system consists of:

Eight glow plugs (one per cylinder)

Glow Plug Control Module

Engine Coolant Temperature sensor

Barometric pressure sensor

Environmental temperature sensor

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Introduction

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The powertrain and glow plug control modules electronically control the glow plug system. After you switch the ignition on the glow plug control module immediately energizes the glow plugs. The glow plug control module using the engine coolant temperature, barometric pressure sensor and environmental temperature sensor will determine how long the glow plugs stay energized. The required time for the glow plugs to be energized decreases as the coolant temperature, barometric pressure and environmental temperature increase.

Glow Plug

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Engine and secondary cooling system

The cooling system contains a primary cooling loop to cool the engine and a secondary cooling loop to cool the transmission, charge air, and fuel. The coolant serves three primary purposes: to provide heat transfer, freeze point protection, and corrosion protection using additives.

Vehicles with diesel engines typically are used to carry heavy loads and accumulate mileage rapidly. These two factors may cause the additives in the coolant to wear out in a shorter time. You can find more information about coolant additives and coolant change intervals in the coolant chapter. See Engine Coolant Check (page 46). Operating the engine with insufficient coolant or coolant additive can cause severe engine damage.

Diesel Particulate Filter system

Your vehicle is equipped with a diesel particulate filter in the exhaust system. The diesel particulate filter reduces carbon emissions by trapping exhaust particulates (soot) before they reach the tailpipe. You must properly maintain your diesel

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particulate filter in order for it to function properly. Regeneration of the diesel particulate filter occurs automatically during operation above 4 mph (7 km/h) and requires no actions from the driver. If you do a lot of idling or stop and go driving, pay attention to maintenance messages that alert you when you need to drive to clean the diesel particulate filter, or perform operator commanded regeneration. See Emission Control System (page 30).

Selective catalytic reduction system

Your vehicle is equipped with a selective catalytic reduction system designed to reduce emission levels of nitrogen oxides from the exhaust of your diesel engine. This system relies on the use of Diesel Exhaust Fluid (DEF) that you must replenish at certain intervals. Failure to maintain proper DEF levels or if the DEF becomes contaminated will result in vehicle speed limitations or result in your vehicle entering an idle-only mode. See Selective Catalytic Reduction System (page 21).

Speed control

If your vehicle speed goes outside a predetermined range from the set speed, the RSM (Resume) function will not reset your vehicle speed. You will need to reset your vehicle speed with the SET+ or SET-button after reaching the desired speed using the accelerator pedal.

Minor Troubleshooting Guide

If the engine won’t crank WARNING

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Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after

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handling.

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Introduction

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Turn on the headlights. If the lights are dim, do not go on at all or when the ignition is turned to START the lights become dim or go out, the battery connections may be loose or corroded, or the battery may be discharged. If there is a clicking or stuttering sound coming from the engine compartment when you turn the key to START, this may also indicate a loose or corroded battery connection.

Check the battery connections at the battery posts, cable connection to the engine grounding point and at the starter connection.

If you suspect a discharged battery, have it checked and corrected.

The gearshift lever must be in P (Park) or N (Neutral) in order for the starter to operate.

Try operating the starter switch several times. This operation may clean potentially corroded contacts or make the switch temporarily operable until you can reach the dealer.

If all electrical connections are tight and you need assistance to start, refer to Jump Starting in the Roadside Emergencies chapter of your Owner’s Manual.

If engine cranks but won’t start

Prolonged starter cranking (in excess of 10 seconds) could cause damage to the starter motor or the high-pressure fuel pump.

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Check the fuel gauge. You may be out of fuel. If the gauge shows that there is fuel in the tank, the trouble may be in the electrical system or the fuel system. If equipped with an auxiliary tank, be sure that the tank control switch is set for the tank with fuel and not on an empty tank.

Leaving your ignition key turned to on for over two minutes without starting may make starting difficult because the glow plugs will cease activation.

Reset the system by turning the ignition key to off and then back to on again.

Note: If the system is out of fuel and the engine will not start, do not continue cranking the engine. Continued cranking can damage the high-pressure fuel pump.

If the engine runs hot

The following could cause the engine to overheat:

Lack of coolant

Dirty cooling system.

Plugged radiator fins, A/C condenser and/or oil cooler

Malfunctioning fan drive

Driving with frozen coolant

Sticking thermostat

Overloading or pulling heavy trailers during hot weather

Grill or radiator air blockage

Slipping or missing drive belt

Plugged or very dirty air filter

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Introduction

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If fuses burn out

WARNING

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Replacement fuses and circuit

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breakers must always be the same

rating as the original equipment shown. Never replace a fuse or circuit breaker with one of a higher rating. Higher rated fuses or circuit breakers could allow circuit overloading in the event of a circuit malfunction, resulting in severe vehicle damage or personal injury due to fire.

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Burned-out or blown fuses usually indicate an electrical short-circuit, although a fuse may occasionally burn out from vibration. Insert a second fuse. If this fuse immediately burns out and you cannot locate the cause, return your vehicle to your dealer for a circuit check.

Refer to the Owner’s Manual for

replacement of fuses.

Selective catalytic reduction system speed limit and Idle-only modes

If the vehicle’s speed is limited or in an idle-only mode, the selective catalytic reduction system may be limiting the vehicle’s functions due to low or contaminated DEF. Check the DEF. See

Selective Catalytic Reduction System (page 21).

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Instrument Cluster

GAUGES

Cluster shown in standard measure. Metric

similar.

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E163169

AEngine boost gauge

Engine Boost Gauge

Indicates the amount of manifold air pressure in the engine

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WARNING LAMPS AND INDICATORS

The following warning lamps and indicators will alert you to a vehicle condition that may become serious. Some lamps will light when you start your vehicle to make sure they work. If any lamps remain on after starting your vehicle, refer to the respective system warning lamp for further information.

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Instrument Cluster

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Note: Some warning indicators appear in the information display and function the same as a warning lamp but do not display when you start your vehicle.

Diesel Engine Brake

Lights when you switch the engine brake on. See (page 37).

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Diesel Exhaust Fluid (DEF) (If

Equipped)

With the key in the on position, lights when the DEF is

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E163176 contaminated, low or someone has tampered with the DEF system. See

Selective Catalytic Reduction System (page 21).

Glow Plug Pre-Heat

With the key in the on position, lights when the glow plug heat is necessary as a starting aid.

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Wait until the light goes off before starting.

See Starting a Diesel Engine (page 10).

After you start the engine, the light should turn off. When the engine is cold, the light should always light for a short period.

If the water in fuel lights when the engine is running, stop your vehicle as soon as safely possible, shut off the engine, then drain the fuel and water separator. See Fuel Quality (page 15). Allowing water to stay in the fuel system, after the water in fuel indicator lights, could result in extensive damage or failure of the fuel injection system.

WARNING

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Do not drain the fuel and water separator while the engine is running. Fuel may ignite if the separator is

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drained while the engine is running or the vehicle is moving.

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Note: Do not drain the fuel and water separator while the engine is running. Air will enter into the fuel system causing the engine not to operate properly.

Water In Fuel

During refueling, it is possible for

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you to pump

water-contaminated diesel fuel

into your fuel tank. Your vehicle’s fuel

system is equipped with a fuel filter and

water separator to remove water from the

fuel. The water in fuel indicator lights when

the fuel and water separator has a

significant quantity of water in it and

requires immediate draining.

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Starting and Stopping the Engine

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STARTING A DIESEL ENGINE

Note: Do not press the accelerator during starting.

Read all starting instructions carefully before you start your vehicle.

For temperatures below 32°F (0°C), the use of the correct grade engine oil is essential for proper operation. Refer to Engine oil specifications for more information. See Capacities and Specifications (page 56).

Your vehicle may be equipped with a cold weather starting strategy that prevents severe engine damage by assisting in engine lubrication warm-up. In extremely cold ambient temperatures, this strategy activates and prevents the accelerator pedal from being used for 30 seconds after starting your vehicle. A message will appear in the information display as your vehicle warms up. By not allowing the accelerator pedal to be used, the engine oil is allowed to properly lubricate the bearings preventing engine damage due to lack of proper lubrication. After the 30 second warm-up period, the accelerator pedal will be operational again and a message will appear informing you the vehicle is ok to drive.

When starting the engine in extremely cold temperatures -15°F (-26°C), it is recommended to allow the engine to idle for several minutes before driving the vehicle.

Before starting the engine check the following:

Make sure all occupants have fastened their safety belts.

Make sure the headlamps and electrical accessories are off.

Make sure the parking brake is on.

Make sure the gearshift lever is in P (Park).

Turn the ignition key to the on position.

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Cold Weather Starting

WARNINGS

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Do not use starting fluid, such as ether, in the air intake system (see air filter decal). Such fluid could

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cause immediate explosive damage to the engine and possible personal injury.

Do not add gasoline, gasohol, alcohol or Kerosene to diesel fuel. This practice creates a serious fire hazard

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and causes engine performance problems.

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It is recommended that the engine block heater be used for starting when the temperature is -9°F (-23°C) or colder. Refer to Engine block heater later in this chapter for more information.

When operating in cold weather, Motorcraft® cetane improvers or non-alcohol-based cetane improvers from a reputable manufacturer may be used as needed.

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 position 3 (off) and wait 30 seconds before trying again.

Turn the key to on without turning the key to start. Do not start the engine until the

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glow-plug indicator turns off.

When the glow plug pre-heat indicator turns off, turn the key to start and release the key as soon as the engine starts. After starting the engine, the glow plugs may remain on for a period. If you do not start the engine before the glow plug activation

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Starting and Stopping the Engine

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time ends, you will need to reset the glow plugs by turning the key to off. 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.

Note: If the engine does not start it may have ingested excessive air. See the Workshop Manual for the correct procedure on removing excessive air from the fuel line.

Cold Weather Operation

Note: Idling in cold weather does 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.

Changing to a lighter grade engine oil also makes starting easier under these conditions. Refer to Engine oil specifications. See Capacities and Specifications (page 56).

Diesel fuel is adjusted seasonally for cold temperatures. Diesel fuel which has not been properly formulated for the ambient conditions may gel which can clog the fuel filters. One indication that the fuel filter(s) may be clogged is if the engine starts, stalls after a short time, and then does not restart. If you have been using biodiesel, you may need to use a fuel with lower biodiesel content, try another brand, or discontinue using biodiesel. Do not use alcohol based additives to correct fuel gelling. This may result in damage to the fuel injectors and system. Use the proper anti-gel and performance improvement product. See Capacities and Specifications (page 56).

Your vehicle is equipped with a fuel and water separator that recirculates fuel from the engine to help prevent fuel filter clogging. To avoid engine fuel starvation during cold weather operation of 32°F (0°C) or below, we recommended that the fuel level in your tank should not drop below 1⁄4 full. This helps prevent air from entering the fuel system and stalling the engine.

Your vehicle is equipped with a selective catalytic reduction system that uses Diesel Exhaust Fluid (DEF) to operate properly. You need to replenish your vehicle’s DEF at certain intervals. When filling your vehicle’s DEF tank in cold weather, you must take special care to prevent damage to the tank. See Selective Catalytic Reduction System (page 21).

In cold weather below 32°F (0°C), the engine may slowly increase to a higher idle speed if left idling in P (Park). As the engine warms-up, the engine sound level decreases due to the activation of PCM-controlled sound reduction features.

If you operate your vehicle in a heavy snowstorm or blowing snow conditions, snow and ice can clog the engine air induction. If this occurs, the engine may experience a significant reduction in power output. At the earliest opportunity, clear all the snow and/or ice away from inside the air filter assembly. Remove the air cleaner cover and the pleated paper filter, leaving the foam filter in and remove any snow or ice. Make sure you install the foam filter correctly in place. Remove any debris, snow or ice on the foam filter by brushing the surface with soft brush. Once you have cleared all of the debris, reinstall the air filter and assembly.

Do not use water, solvents, or a hard brush for cleaning the foam filter.

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Starting and Stopping the Engine

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WARNING

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To reduce the risk of vehicle damage and/or personal burn injuries do not start your engine with the air filter

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removed and do not remove it while the engine is running.

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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 protecting 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 the Special operating conditions section listed in the scheduled maintenance information

At temperatures of -9°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

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The following cold weather idling guidelines are recommended:

You can use Motorcraft® cetane improvers or non-alcohol-based cetane improvers from a reputable manufacturer as needed.

Maintain the engine cooling system properly.

Avoid shutting the engine down after an extensive idling period. Drive your 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.

Winter Operating Tips for Arctic Operation -20°F (-29°C) and Below

The following information is a guideline only and is not to be the only source of possible solutions in resolving extreme cold temperature issues.

Starting Aids

WARNING

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Do not use starting fluid, such as ether, in the air intake system (see air filter decal). Such fluid could

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cause immediate explosive damage to the engine and possible personal injury.

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The use of the factory engine block heater assists in engine starting in extreme cold ambient temperatures. Refer to Engine block heater in the Starting and Stopping the Engine chapter of your Owner’s Manual.

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Starting and Stopping the Engine

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Idle Control  Operation in Standing Water

Your vehicle may have a factory option for a stationary elevated idle control through dash-mounted upfitter switches that allows the operator to elevate the idle rpm for extended idle periods, as well as aftermarket equipment such as PTO operation. You must configure this feature 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 or water into the air intake system. This could plug the air filter with snow and may cause the engine to lose power and possibly shut down.

We recommend the following actions after operating your vehicle up to 199 mi (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 your vehicle performance during snow and hot weather conditions.

Extreme rain: The air filter dries after about 15–30 minutes at highway speeds. At the earliest opportunity, open the hood and reset the air filter restriction gauge.

Refer to Air filter and restriction gauge in the Maintenance chapter for more information. See Changing the Engine Air Filter (page 51).

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Ingestion of water into the diesel engine can result in immediate and severe damage to the engine. If driving through water, slow down to avoid splashing water into the intake. If the engine stalls, and you suspect ingestion of water into the engine, do not try to restart the engine. Consult your dealer for service immediately.

Your fuel tank vents to the atmosphere by valves on top of the tank and through the fuel cap. If water reaches the top of the tank, the valves may pull water into the fuel tank. Water in the fuel can cause performance issues and damage the fuel injection system.

SWITCHING OFF THE ENGINE

Turn the ignition to the off position.

To prolong engine life (especially after extended high speed, high ambient temperature, or high GVW/GCW operation, such as heavy loads or heavy trailers), it is recommended that a hot engine be idled for 3-5 minutes. This allows the turbocharged engine to cool down. For more information on GVW/GCW, see the Load Carrying chapter in your Owner’s Manual.

ENGINE IDLE SHUTDOWN

Your vehicle may be equipped with an engine idle shutdown system. This system automatically shuts down your engine when it has been idling in P (Park) or N (Neutral) for five minutes (parking brake set) or 15 minutes (parking brake not set). When the engine idle shutdown process has started:

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Starting and Stopping the Engine

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A chime sounds and the information display will show ENGINE TURNS OFF IN 30 (seconds) and start counting down

You can restart the five or 15-minute timer by changing the position of the accelerator pedal, brake pedal or the park brake within the final 30 seconds

When the timer reaches zero, the engine shuts down and this message will appear in your information display

ENGINE TURNED OFF

One minute after the engine has shut down, the electrical system simulates key off, even though the ignition is still in the on position, initiating normal accessory delay period

You must move the ignition to the off position to reset the system before restarting your vehicle.

The engine idle shutdown idle timer does not start if:

The engine is operating in power take-off mode.

The engine coolant temperature is below 60°F (16°C).

The exhaust emission control device is regenerating.

The optional rapid heat feature is an electrically powered device that provides supplemental heat during engine warm up. During initial warm up, you should use a mid to low blower speed for maximum effectiveness. When operating in automatic mode (when equipped) the climate control unit determines the appropriate blower speed for existing conditions.

ENGINE BLOCK HEATER (If

Equipped)

Refer to the Starting and Stopping the

Engine chapter in your Owner’s Manual.

Rapid Heat Supplemental Heating

System

Note: Additional aftermarket electrical

loads operated during engine warm up may

affect the performance of the rapid heat

supplemental heater.

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Fuel and Refueling

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FUEL QUALITY

Fuel Requirements – Choosing The Right Fuel: Vehicles Operated Where Ultra Low Sulfur Diesel Fuel Is Required (United States/Canada/Puerto Rico/U.S. Virgin Islands And Other Locales)

Note: Your warranty will not cover damage caused by using an improper type of fuel or fuel additive.

Note: Do not blend used engine oil with diesel fuel under any circumstances. Blending used oil with the fuel will significantly increase your vehicle’s exhaust emissions and reduce engine life due to increased internal wear.

You should use Ultra-Low Sulfur Diesel fuel (also known as ULSD) designated as number 1-D or 2-D with a maximum of

15-ppm sulfur in your diesel vehicle. You may operate your vehicle on diesel fuels containing up to 20% biodiesel, also known as B20. These fuels should meet the ASTM D975 diesel or the ASTM D7467 B6-B20 biodiesel industry specifications. Outside of North America, use fuels meeting EN590 or equivalent local market standard.

Using low sulfur diesel fuel

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(16-500 ppm) or high sulfur diesel fuel (greater than 500

ppm) in your diesel engine will cause certain emission components to malfunction which may also cause the service engine soon light to illuminate indicating an emissions-related concern.

Diesel fuel is adjusted seasonally for cold temperature. For best results at temperatures below 20°F (-7°C), it is recommended to use a diesel fuel which has been seasonally adjusted for the ambient conditions.

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Fuel Requirements – Choosing The Right Fuel: Vehicles Operated Where Ultra Low Sulfur Diesel Fuel Is Not Required

For the engine to operate reliably on low-sulfur or high-sulfur diesel fuel, the engine must be a factory built high-sulfur engine (available as a dealer order option for select markets) or an ultra low sulfur diesel fuel configured engine that has been retrofitted for high-sulfur diesel fuel using Ford Motor Company dealer service parts. Failure to use retrofit components other than those available through your authorized dealer will result in coolant system damage, engine overheating, selective catalytic reduction system or diesel particulate filter damage and possible base engine damage.

Use only a diesel engine configured for use with high sulfur diesel fuel in markets with diesel fuel that has sulfur content greater than 15 ppm. Using low sulfur diesel fuel (16–500 ppm) or high sulfur diesel fuel (greater than 500 ppm) in a diesel engine designed to use only Ultra Low Sulfur Diesel fuel may result in damage to engine emission control devices and the aftertreatment system, potentially rendering the vehicle inoperable.

Vehicles with engines configured for use with high sulfur diesel fuel are only available for sale in countries where ultra low sulfur diesel fuel is generally not available or mandated by the government. Vehicles originally sold in a ultra low sulfur diesel fuel market that are subsequently exported to non- ultra low sulfur diesel fuel markets will need to be retrofitted (at the customer’s expense using Ford authorized dealer service parts) in order to be reliably operated on non- ultra low sulfur diesel fuel.

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Fuel and Refueling

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Biodiesel

WARNINGS

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Do not use home heating oil, agricultural fuel, raw fats and oils, waste cooking greases, biodiesel

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fuels greater than 20% or any diesel fuel not intended for highway use. Damage to the fuel injection system, engine and exhaust catalyst can occur if an improper fuel is used. Do not add gasoline, gasohol or alcohol to diesel fuel. This practice creates a serious fire hazard and engine performance problems.

Do not mix diesel fuel with gasoline, gasohol or alcohol. This could cause an explosion resulting in personal

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injury.

Do not add gasoline, gasohol or alcohol to diesel fuel. This practice creates a serious fire hazard resulting

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in personal injury and engine performance problems.

Do not use home heating oil or any diesel fuel not intended for highway use. Damage to the fuel injection

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system, engine, exhaust catalyst and diesel particulate filter can occur if an improper fuel is used. Red dye is used to identify fuels intended for agricultural and non-highway use.

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You may operate your vehicle on diesel fuels containing up to 20% biodiesel, also known as B20.

Biodiesel fuel is a chemically converted product from renewable fuel sources, such as vegetable oils, animal fats and waste cooking greases.

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To help achieve acceptable engine performance and durability when using biodiesel in your vehicle:

Confirm the biodiesel content of the fuel to be B20 (20% biodiesel) or less

Only use biodiesel fuel of good quality that complies with industry standards

Follow the recommended service maintenance intervals. See General Maintenance Information (page 60).

Do not store biodiesel fuel in the fuel tank for more than 1 month

Consider changing brands or reducing biodiesel content if you have cold temperature fuel gelling issues or a frequent LOW FUEL PRESSURE message appearing

Do NOT use raw oils, fats or waste cooking greases

Use of biodiesel in concentrations greater than 20% may cause damage to your vehicle, including engine and/or exhaust after-treatment hardware (exhaust catalyst and particulate filter) failures. Concentrations greater than 20% can also cause fuel filter restrictions that may result in a lack of power or damage to fuel system components, including fuel pump and fuel injector failures.

SAE 5W-40 or SAE 15W-40 oil is recommended for fuels with greater than 5% biodiesel (B5). Refer to the Special operating conditions section under the Schedule Maintenance chapter for more information about oil change intervals and other maintenance when operating on biodiesel.

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Fuel and Refueling

image126

Look for a label on the fuel pump to confirm the amount of biodiesel contained in a diesel fuel. Biodiesel content is often indicated with the letter B followed by the percent of biodiesel in the fuel. For example, B20 indicates a fuel containing 20% biodiesel. Ask the service station attendant to confirm the biodiesel content of a diesel fuel if you do not see a label on the fuel pump.

Biodiesel fuels degrade more easily than diesel fuels not containing biodiesel and should not be stored in the fuel tank for more than 1 month. If you plan to park or store your vehicle for more than 1 month, then you should empty your vehicle fuel tank of biodiesel fuel. You should fill the tank with a pure petroleum-based diesel fuel and run your vehicle for a minimum of 30 minutes.

Note: Degraded or oxidized biodiesel can damage fuel system seals and plastics and corrode steel parts.

During cold weather, if you have problems operating on biodiesel, you may need to use a diesel fuel with lower biodiesel content, try another brand, or discontinue the use of biodiesel.

Diesel Fuel Additives

It should not be necessary to add any aftermarket additives to your fuel if you use a high quality diesel fuel that conforms to ASTM industry specifications. Aftermarket additives can damage the fuel injector system or engine.

Use Motorcraft cetane booster or an equivalent cetane booster additive if you suspect fuel has low cetane. Use Motorcraft anti-gel & performance improver or an equivalent additive if there is fuel gelling.

17

image127

Do not use alcohol-based additives to improve cetane quality, to prevent fuel gelling or any other use. The use of alcohol additives may result in damage to the fuel injectors and system. See Capacities and Specifications (page 56).

Your warranty may not cover repairs needed to correct the effects of using an aftermarket product that does not meet Ford specifications in your fuel.

Note: Ultra Low Sulfur Diesel fuel is designed to meet the emissions standards for the 6.7L engine and is backward compatible as well (for example, it can be used in the 7.3L, 6.9L, 6.4L and 6.0L diesel engines in Ford vehicles).

Fuel And Water Separator

Your vehicle is equipped with a diesel fuel conditioner module located on the frame-rail under the driver-side floorboard near the transmission.

You should drain water from the

image128

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 you allow the water level to exceed this level, the water may pass through to the engine and may cause fuel injection equipment damage.

Draining the Diesel Fuel Conditioner Module (DFCM)

WARNING

image129

Your vehicle must be stopped with the engine off when draining the Diesel Fuel Conditioner Module. Fuel

image130

may ignite if the separator is drained while the engine is running or vehicle is moving.

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Fuel and Refueling

image135

Note: If you drain the diesel fuel conditioner module while the system is running air will enter into the fuel system. The engine will not operate properly if air enters the system.

Note: With fuel tank levels above 3⁄4 tank it may be necessary to loosen the bowl 3 turns before opening the drain. This will actuate an anti-siphon valve at the fuel and water separator inlet and prevent the fuel from siphoning out of the tank.

Note: A loose drain valve can allow air to enter the fuel system and cause drivetrain issues. The engine will not operate properly. Be sure that you fully tighten the drain valve.

1.Stop your vehicle and shut off the engine.

2.Locate the diesel fuel conditioner module and place an appropriate container under the drain port.

image136

E163360

3.Rotate the drain counterclockwise until the O-ring is visible. Allow the diesel fuel conditioner module to drain for approximately 25 seconds or until clean fuel is observed. Rotate the drain clockwise to tighten it. If no liquid drains, there may be a clog in the drain. Have the conditioner module serviced by an authorized dealer.

4.Make sure that you fully tighten the drain valve and then remove the container from under your vehicle.

18

image137

5.Restart the engine. If the WATER IN FUEL DRAIN FILTER or WATER IN FUEL DRAIN FILTER SEE MANUAL message and light continues to illuminate, have the fuel system checked and repaired.

Low Fuel Pressure

The engine is equipped with a low fuel pressure detection system. Here are some possible causes if a low fuel pressure message appears in the information display:

Cold start or during cold operation (below 32°F (0°C)): If the low fuel pressure message appears during a cold start or up to 10 minutes after the initial cold start, monitor the information display. If the low fuel pressure message disappears and does not re-appear after the engine has fully warmed up, waxed or gelled fuel is what most likely caused the message. Do not use alcohol based additives to correct fuel gelling. This may result in damage to the fuel injectors and systems. Use an anti-gel additive. See Capacities and Specifications (page 56).

Note: Your customer warranty may be void from using additives that do not meet or exceed Ford specifications. If the low fuel pressure message persistently appears after re-fueling during the cold start and cold operation conditions defined previously and then disappear when the engine has fully warmed up, consider different fuel sources.

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Fuel and Refueling

image141

Low fuel operation: If the low fuel pressure message appears when your vehicle is warm and during low fuel tank level operation (near empty), refuel your vehicle. If the message reappears after fueling, see below. If the message does not come back, the low fuel pressure condition was due to low fuel levels in the fuel tank.

Normal operation: If the low fuel pressure message appears during normal operation when the engine is fully warm, and fuel level is not low, you must change the fuel filters regardless of the maintenance schedule interval.

If replacement of the fuel filter does not remedy the low fuel pressure message during normal operation as defined above, take the vehicle to an authorized dealer.

Refer to Motorcraft part numbers in the Capacities and Specifications chapter for the fuel filter replacement part number. See Motorcraft Parts (page 55). This part number includes filters and seals for both the engine-mounted and frame-mounted filters.

Removal – Diesel Fuel Conditioner Module filter

The diesel fuel conditioner module filter is located in the lower portion of the housing.

1.Drain the diesel fuel conditioner module. See Draining the Fuel and Water Separator earlier in this chapter.

2.Remove the lower portion of the diesel fuel conditioner module housing (filter bowl) by turning it counterclockwise using a 32 mm socket.

image142

Changing the Engine-Mounted and Diesel Fuel Conditioner Module Fuel Filters

Your vehicle is equipped with two fuel filters. The first filter mounts on top of the engine on the driver’s side. The second filter, inside the diesel fuel conditioner module, is mounted on the frame rail under the driver’s side floorboard near the transmission. You should replace both filters 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 fuel injection system damage. Refer to the scheduled maintenance information of this supplement for more information. See

General Maintenance Information (page 60).

19

image143

E163361

Note: Depending on the amount of 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.

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Fuel and Refueling

image147

Installation – Diesel Fuel Conditioner Module filter

1.Install the new filter into the filter bowl tabs and replace the seal on the diesel fuel conditioner module header (top portion of separator). Refer to Motorcraft part numbers in the Capacities and Specifications chapter for the fuel filter kit part number. See Motorcraft Parts (page 55).

2.Lube O-ring with lubricant packet in the filter kit. This will assist in making sure the filter is properly tightened.

image148

Removal – Engine-mounted fuel filter

The engine-mounted fuel filter is a plastic disposable cartridge. To remove it, do the following:

image149

E163362

3.Reinstall the lower portion of the housing by slowly turning it clockwise onto diesel fuel conditioner module 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 you do not install the diesel fuel conditioner module fuel filter in the housing or if the filter bowl is not tightened to the mechanical stop.

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.

E163363

1.Disconnect both fuel lines by squeezing the connector tabs and pulling the lines straight off.

image150

E163364

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, we recommend you place a shop rag below the filter connectors to absorb the small amount of fuel that will drain.

2.Rotate the filter fully counterclockwise until the peg is at the far end of the slot.

3.Pull the filter straight up from the bracket and discard the filter.

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Fuel and Refueling

image155

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.

21

image156

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 60). 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

image157

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).

image158

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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Fuel and Refueling

image162

WARNINGS

image163

Tampering or disabling your vehicle’s exhaust aftertreatment system will result in severe vehicle performance limitation including eventual speed limiting

image164

to 5 mph (8 km/h).

image165

Your vehicle’s information display will display a series of messages regarding the amount of DEF available. A systems check will display messages indicating the amount of DEF available (OK or under 1⁄2 full) or will produce a warning message that displays the mileage (kilometers) remaining as the fluid in the DEF tank nears empty. For more information on warning messages, see the Information Displays chapter of your Owner’s Manual.

As the DEF level nears empty,

image166

image167 the DEF warning symbol will be E163176 displayed and a series of tones will sound with the messages starting at 500 mi (805 km) remaining before DEF is

depleted. The warning symbol and messages will continue until you refill the DEF tank.

image168

Continued driving without refilling will result in the following actions as required by the California Air Resources Board (CARB) and the U.S. Environmental Protection Agency (EPA):

Within a certain number of miles (kilometers) to empty, speed will be limited upon vehicle restart. Prior to this occurring a message will appear in the information display.

Further vehicle operation without refilling your DEF tank will cause the engine to enter an idle-only condition. This will only occur upon vehicle refueling or at an extended idle. A message will indicate the required actions to resume normal operation. It is required to add a minimum of

64.2 fl oz (1.9 L) of DEF to the tank to exit the idle-only condition, but your vehicle will still be in the speed-limiting mode until you refill the tank completely.

For either vehicle speed limiting or idle-only condition, normal vehicle operation will resume when you refill the DEF tank.

Note: When filling the DEF tank from empty, there may be a short delay before detecting the increased level of fluid. The increased level detection must occur before your vehicle returns to full power.

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional information display messages shown, base information display messages similar)

Cluster Message

Distance/Exhaust Fluid

Customer

Vehicle Actions

Level or Action

Requested

Actions

Exhaust Fluid Level OK

Full exhaust fluid tank

Drive normally

None

Exhaust Fluid Under 1⁄2

Exhaust fluid tank below

Drive normally

None

Full

1⁄2 full

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Fuel and Refueling

image173

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional information display messages shown, base information display messages similar)

Exhaust Fluid Range

Approximately 500 mi

Refill exhaust

None

500 mi (805 km)

(805 km) left before

fluid

exhaust fluid tank is

empty

In 99 mi (160 km)

Approximately 99 mi

Refill exhaust

None

Speed Limited to

(160 km) left before

fluid

50 mph (80 km/h)

exhaust fluid tank is

Exhaust Fluid Empty

empty

Speed Limited to

0 mi (0 km) – exhaust

Refill exhaust

None

50 mph (80 km/h)

fluid tank is empty

fluid

Upon Restart Exhaust

Fluid Empty

Speed Limited To

Vehicle restarted with

Refill exhaust

Speed is limited

50 mph (80 km/h)

exhaust fluid tank empty

fluid

to 50 mph

Exhaust Fluid Empty

(80 km/h)

Engine Idled Soon

This occurs 200 mi

Refill exhaust

Exhaust Fluid Empty

(322 km) after the vehicle

fluid

reaches the 0 mi (0 km)

exhaust fluid range

Engine Idled-See

This occurs when the

Refill exhaust

Engine is

Owner’s Manual

exhaust fluid is empty

fluid

limited to idle

Exhaust Fluid Empty

and:

ONLY

You refuel your vehicle’s

diesel fuel tank,

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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Fuel and Refueling

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Filling the Diesel Exhaust Fluid (DEF) tank

WARNINGS

image179

Make sure that Diesel Exhaust Fluid (DEF) does not come into contact with eyes, skin or clothing. Should

image180

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,

image181

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.

image182

Note: Do not put DEF in the fuel tank. This can cause engine damage not covered by your vehicle’s warranty.

Note: Do not allow diesel fuel or oil to enter the DEF tank. The sensors in the DEF tank are very sensitive and any petroleum contamination can cause damage that your warranty will not cover. Do not use funnels or nozzles to fill the DEF tank that you have previously used with oil or diesel fuel.

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 Capacities and Specifications (page 56).

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.

image183

)

E163354

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.

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Fuel and Refueling

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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.

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.

image189

E163356

image190

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.

image191

E163355

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.

E163357

4.While filling, the fluid level in the bottle will continually drop.

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E163358

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Fuel and Refueling

image197

5.When the DEF tank is full, the fluid level in the bottle will stop dropping, indicating the fluid has stopped flowing.

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E163359

6.Once the level in the DEF bottle has stopped dropping, return the container to the vertical position slightly below the DEF filler port and let any DEF drain out of the spout. DO NOT try to continue to add DEF to the tank by shaking or repositioning the container to induce flow. This may cause spilling and overfill the tank. Overfilling the DEF tank can cause damage to the tank.

7.Once the spout has drained, remove the spout from the DEF filler port and install the blue cap on the DEF filler port.

8.Remove the spout from the diesel exhaust fluid container and install the cap back on the bottle.

9.If the container is empty, discard the empty container, or recycle if possible. If there is DEF left in the container, retain it for later use. The spout is re-useable; after use, rinse it with clean water and store the spout to keep it clean. Do not use the DEF spout with any other chemicals.

10.Wipe away any DEF that has spilled on painted surfaces with water and a damp cloth.

Diesel Exhaust Fluid (DEF) filling station nozzle fill

Filling the Diesel Exhaust Fluid (DEF) tank using a nozzle is similar to a normal fuel fill. The nozzle will shut off automatically when the tank is full. Do not continue to fill the tank as this may cause spilling and overfill can cause damage to the tank.

Note: Some filling station nozzles may prevent filling of your DEF tank due to a magnetic mechanism in the nozzle. This is not a problem with your vehicle. To refill your tank either locate another filling station or use a bottle to refill the tank.

Filling the Diesel Exhaust Fluid (DEF) tank in cold climates

Diesel Exhaust Fluid (DEF) will freeze below 12°F (-11°C); however, your vehicle is equipped with an automatic preheating system which allows the DEF system to operate below 12°F (-11°C). When your vehicle is not in operation for an extended period with temperatures at or below 12°F (-11°C), the DEF tank could freeze. If the tank is OVERFILLED and freezes, it could be damaged, therefore DO NOT OVERFILL.

To prevent overfilling of the DEF tank when filling with a bottle, Ford recommends using Motorcraft Diesel Exhaust Fluid (DEF). Additionally, if the information display indicates EXHAUST FLUID UNDER 1/2 FULL, you should only add a MAXIMUM of 2 gal (7.6 L) of DEF to the tank to prevent freeze damage due to overfilling. If the information display indicates EXHAUST FLUID LEVEL OK, do not add DEF.

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Fuel and Refueling

image203

Contaminated Diesel Exhaust Fluid (DEF) or inoperative Selective Catalytic Reduction system

Selective catalytic reduction

image204

image205 systems are sensitive to E163176 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.

27

image206

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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Fuel and Refueling

image210image211

Pick-up (3.31 axle ratio)

Driving style

Trailer towing /

Normal driving

Steady highway driving

aggressive or city

driving

Diesel Exhaust

4,100 mi (6,598 km) –

7,100 mi (11,426 km) –

9,600 mi (15,450 km)

Fluid (DEF)

7,100 mi (11,426 km)

9,600 mi (15,450 km)

– 10,000 mi

usage

(16,093 km) +

Pick-up (3.55 axle ratio)

Driving style

Trailer towing /

Normal driving

Steady highway driving

aggressive or city

driving

Diesel Exhaust

2,800 mi (4,506 km)

5,800 mi (9,334 km) –

8,100 mi (13,036 km)

Fluid (DEF)

– 5,800 mi

8,100 mi (13,036 km)

– 9,700 mi (15,611 km)

usage

(9,334 km)

Pick-up (3.73 axle ratio)

Driving style

Trailer towing /

Normal driving

Steady highway driving

aggressive or city

driving

Diesel Exhaust

2,050 mi (3,299 km)

5,050 mi (8,127 km) –

7,300 mi (11,748 km) –

Fluid (DEF)

– 5,050 mi (8,127 km)

7,300 mi (11,748 km)

8,900 mi (14,323 km)

usage

Pick-up (4.30 axle ratio)

Driving style

Trailer towing /

Normal driving

Steady highway driving

aggressive or city

driving

Diesel Exhaust

1,100 mi (1,770 km) –

4,100 mi (6,598 km) –

6,300 mi (10,139 km)

Fluid (DEF)

4,100 mi (6,598 km)

6,300 mi (10,139 km)

– 7,900 mi (12,714 km)

usage

image212

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Fuel and Refueling

image217image218

Chassis cab (non–Power Take Off)

Driving style

Trailer towing /

Normal driving

Steady highway driving

aggressive or city

driving

Diesel Exhaust

1,700 mi (2,736 km) –

4,700 mi (7,564 km) –

7,800 mi (12,553 km)

Fluid (DEF)

4,700 mi (7,564 km)

7,800 mi (12,553 km)

– 9,300 mi

usage

(14,967 km)

Chassis cab (with Power Take Off)

PTO usage

Cont. PTO usage — Min. PTO usage

Diesel Exhaust

0 mi (0 km) — 7,800 mi (12,553 km)

Fluid (DEF)

usage

image219

REFUELING

Fueling Tips

WARNING

image220

Do not use starting fluid such as ether or gasoline in the diesel air intake system. Such fluids can cause

image221

immediate explosive damage to the engine and possible personal injury.

image222

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.

29

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Fuel and Refueling

image227

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

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The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing

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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

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system or cause the fuel cap to disengage in a collision, which may result in possible personal injury.

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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.

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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 your 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’s Manual 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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Fuel and Refueling

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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 – 35 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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Fuel and Refueling

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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

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Failure to comply with the following instructions for Operator Commanded Regeneration may

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result in fire, serious injury, death and/or property damage.

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Before you start operator commanded regeneration, do the following:

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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

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Stay clear of exhaust tip during regeneration. You or others can be burned.

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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

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Commanded Regeneration if the service engine soon light is

illuminated.

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Fuel and Refueling

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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

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

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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 15 to 40 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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Fuel and Refueling

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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

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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

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Service engine soon

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Resonator and Tailpipe assembly maintenance

WARNINGS

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Failure to maintain the functional holes, in the tailpipe section of the exhaust, clean and free of debris or

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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

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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

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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.

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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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Fuel and Refueling

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Emission Control System(s) Laws

WARNING

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Do not remove or alter the original equipment floor covering or insulation between it and the metal

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floor of the vehicle. The floor covering and insulation protect occupants of the vehicle from the engine and exhaust system heat and noise. On vehicles with no original equipment floor covering insulation, do not carry passengers in a manner that permits prolonged skin contact with the metal floor. Provide adequate insulation. Failure to follow these instructions may result in fire or personal injury.

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In the U.S. federal law and certain state laws prohibit removing or rendering inoperative emission control system(s). Similar federal or provincial laws may apply in Canada. Ford recommends against any vehicle modification without determining applicable law.

Tampering with emissions

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control systems (including related sensors and the Diesel

Exhaust Fluid (DEF) injection system) can result in reduced engine power and the illumination of the service engine soon light.

Tampering with a Noise Control System

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

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Among those acts, which the U.S. Environmental Protection Agency may presume to constitute tampering are the acts listed below:

Removal of hood blanket, fender apron absorbers, fender apron barriers, underbody noise shields or acoustically absorptive material.

Tampering or rendering inoperative the engine speed governor, to allow engine speed to exceed manufacturer’s specifications.

The complexity of the diesel engine makes it so the owner is discouraged from attempting to perform maintenance other than the services described in this supplement.

If you experience difficult starting the engine, rough idling, excessive exhaust smoke, a decrease in engine performance or excess fuel consumption, perform the following checks:

A plugged or disconnected air inlet system or engine air filter element.

Water in the fuel filter and water separator.

A clogged fuel filter.

Contaminated fuel.

Air in the fuel system, due to loose connections.

An open or pinched sensor hose.

Check engine oil level.

Wrong fuel or oil viscosity for the climatic conditions.

If these checks do not help you correct the engine performance problem you are experiencing, consult an authorized dealer.

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Fuel and Refueling

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Noise Emissions Warranty, Prohibited

Tampering Acts and Maintenance

On January 1, 1978, Federal regulation became effective governing the noise emission on trucks over 10,000 lbs. (4,536 kg) GVWR (Gross Vehicle Weight Rating). The preceding statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Guide, are applicable to complete chassis cabs over 10,000 lbs. (4,536 kg) GVWR.

FUEL TANK SELECTOR

SWITCH

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E163365

If your vehicle is equipped with dual fuel tanks, you will have a selector control, located to the right of the steering wheel, which allows you to draw fuel from either tank. Your fuel gauge and the DTE (distance to empty) will display the amount of fuel in the currently selected tank.

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Brakes

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GENERAL INFORMATION

Diesel Engine Braking

WARNING

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Do not use the tow/haul or engine brake features when driving in icy or slippery conditions as the increased

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engine braking can cause the rear wheels to slide and your vehicle to swing around with the possible loss of vehicle control.

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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

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switch bank next to the audio

E171217  unit to switch the system on or

off.

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.

Warning Lamp Conditions:

Illuminates when this feature is switched on and the system is operating properly.

Flashes when the engine brake is disabled due a fault or the engine does not meet the required braking conditions.

Does not illuminate when the switch or indicator is faulty.

You can switch the system on at anytime.

The system will become active once the

braking conditions are met.

Braking Conditions:

Your vehicle is in a forward gear.

The engine speed is above approximately 1500 rpm.

Your foot is off the accelerator.

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Towing

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TOWING A TRAILER

Refer to your Owner’s Manual for full

details on towing a trailer.

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Roadside Emergencies

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FUEL SHUTOFF

WARNING

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Failure to inspect and, if necessary, repair fuel leaks after a collision may increase the risk of fire and serious

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injury. Ford Motor Company recommends that the fuel system be inspected by an authorized dealer after any collision.

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Note: When you try to restart your vehicle after a fuel shutoff, your vehicle makes sure that various systems are safe to restart.

Once your vehicle determines that the systems are safe, then your vehicle will allow you to restart.

In the event of a moderate to severe collision, your vehicle is equipped with a fuel pump shut-off feature that stops the flow of fuel to the engine. Not every impact will cause a shutoff.

After an accident, if the engine cranks but does not start, this switch may have been activated.

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The switch has a red button on top of it.

To reset the switch:

1.Turn the ignition off.

2.Check the fuel system for leaks.

3.If no leaks are apparent, reset the switch by pushing in on the reset button.

4.Turn the ignition on.

5.Wait a few seconds and return the key to off.

6.Make another check for leaks.

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This switch is located on the passenger’s side of the instrument panel. Open the front passenger door and remove the small access panel.

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Running Out Of DEF (Diesel Exhaust Fluid)

If your vehicle runs out of DEF, it will enter into a speed limited mode and can also enter into an idle-only mode. Normal vehicle operation will not resume until DEF is refilled. See Selective Catalytic Reduction System (page 21).

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.

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Roadside Emergencies

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JUMPSTARTINGTHEVEHICLE

WARNINGS

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Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow

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flames, sparks or lighted substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide correct ventilation.

Keep batteries out of reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or

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clothing. Shield your eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately.

Use only adequately sized cables with insulated clamps.

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Preparing Your Vehicle

Do not attempt to push-start your automatic transmission vehicle.

Note: Attempting to push-start a vehicle with an automatic transmission may cause transmission damage.

Note: Use only a 12-volt supply to start your vehicle.

Note: Do not disconnect the battery of the disabled vehicle as this could damage the vehicle electrical system.

Park the booster vehicle close to the hood of the disabled vehicle, making sure the two vehicles do not touch.

Connecting the Jumper Cables

WARNINGS

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Do not attach the cables to fuel lines, engine rocker covers, the intake manifold or electrical components

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as grounding points. Stay clear of moving parts. To avoid reverse polarity connections, make sure that you correctly identify the positive (+) and negative (-) terminals on both the disabled and booster vehicles before connecting the cables.

Do not attach the end of the positive cable to the studs or L-shaped eyelet located above the positive (+)

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terminal of your vehicle’s battery. High current may flow through and cause damage to the fuses.

Do not connect the end of the second cable to the negative (-) terminal of the battery to be jumped.

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A spark may cause an explosion of the gases that surround the battery.

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Note: In the illustration, the bottom vehicle represents the booster vehicle.

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Roadside Emergencies

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1

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3

4

2

Jump Starting

1.Start the engine of the booster vehicle and rev the engine moderately, or press the accelerator gently to keep your engine speed between 2000 and 3000 RPM, as shown in your tachometer.

2.Start the engine of the disabled vehicle.

3.Once the disabled vehicle has been started, run both vehicle engines for an additional three minutes before disconnecting the jumper cables.

Removing the Jumper Cables

Remove the jumper cables in the reverse order that they were connected.

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4

E142664

1.Connect the positive (+) jumper cable to the positive (+) terminal of the discharged battery.

2.Connect the other end of the positive

(+) cable to the positive (+) terminal of the booster vehicle battery.

3.Connect the negative (-) cable to the negative (-) terminal of the booster vehicle battery.

4.Make the final connection of the negative (-) cable to an exposed metal part of the stalled vehicle’s engine, away from the battery and the fuel injection system, or connect the negative (-) cable to a ground connection point if available.

1

2

3

E142665

1.Remove the negative (-) jumper cable from the disabled vehicle.

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Roadside Emergencies

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2.Remove the jumper cable on the negative (-) terminal of the booster vehicle battery.

3.Remove the jumper cable from the positive (+) terminal of the booster vehicle battery.

4.Remove the jumper cable from the positive (+) terminal of the disabled vehicle battery.

5.Allow the engine to idle for at least one minute.

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Maintenance

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UNDER HOOD OVERVIEW

F-Super Duty

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M  E  A  B  C  D

E163368

L

K

J

I

H

G

F

E

A.Engine oil dipstick

B.Automatic transmission fluid dipstick

C.Brake fluid reservoir

D.Power distribution box

E.Batteries

F.Engine cooling system coolant reservoir (primary high-temperature cooling system)

G.Power steering fluid reservoir

H.Engine oil fill

IEngine-mounted fuel filter assembly

JSecondary cooling system coolant reservoir K Air filter assembly

L Air filter restriction gauge

M Windshield washer fluid reservoir

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Maintenance

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Scheduled Maintenance

The scheduled maintenance services in the scheduled maintenance information of this supplement are required because they are considered essential to the life and performance of your vehicle. See

General Maintenance Information (page 60).

Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft® parts are designed and built for best performance in your vehicle.

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6.Maintain the oil level within the crosshatch area on the dipstick by adding oil as required. Do not overfill the oil past the maximum line as depicted by the arrow.

ENGINE OIL CHECK

Because it is normal to add some oil between oil changes, check your engine oil level each time you stop for fuel. To check the engine oil level consistently and accurately, the following procedure is recommended:

1.Have engine at normal operating temperature (at least into the NORMAL range on the engine coolant temperature gauge).

2.Park the vehicle on a level surface, then turn off the engine and open the hood.

3.Allow at least 20 minutes after engine shutdown to ensure that the oil contained in the upper parts of the engine has returned to the oil pan.

4.Protecting yourself from engine heat, pull out the dipstick, wipe it clean and reinsert fully.

5.Read oil level on both sides of dipstick and use highest level (reading) for the actual engine oil level.

Engine Oil Specifications

To help achieve acceptable engine performance and durability, it is important that only engine oils of good quality are used in your diesel engine and it is changed at the recommended interval. For normal or severe service, use Motorcraft® oil or an equivalent oil conforming to Ford specifications as listed in the Capacities and Specifications chapter. See Capacities and Specifications (page 56). It is important to use these oils because they are compatible with the emission control equipment of your vehicle to meet the more stringent emission standards.

The use of correct oil viscosities for diesel engines is important for satisfactory operation. Determine which oil viscosity best suits the temperature range you expect to encounter for the next service interval from the following SAE viscosity grade chart.

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Maintenance

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(1) For severe duty service, use SAE

5W-40 API CJ-4.

(2) For biodiesel fuel blends (B20 max), use SAE 5W-40 or SAE 15W-40 API CJ-4.

An engine block heater is recommended at temperatures below –10°F (–23°C).

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The American Petroleum Institute (API) service symbol is used to identify the proper engine oil for your engine. The API service symbol will be displayeded on the oil container you purchase. The API symbol displays the oil performance category in the top half of symbol and the viscosity grade in the center of the symbol.

Changing the Engine Oil and Oil Filter

WARNINGS

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Do not handle a hot oil filter with bare hands.

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Continuous contact with used motor oil has caused cancer in laboratory mice. Protect your skin by washing

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with soap and water.

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Your vehicle is equipped with an Intelligent Oil Life Monitor™ that calculates the proper oil change service interval. When the information display indicates: OIL CHANGE REQUIRED, change the engine oil and oil filter. See the Information Displays chapter in the Owner’s Manual for more information.

The engine oil filter protects your engine by filtering harmful, abrasive or sludge particles and particles significantly smaller than most available will-fit filters. For engine oil filter part number, See Motorcraft Parts (page 55).

To change the engine oil and oil filter:

1.Unscrew the oil filter and oil pan drain plug and wait for the oil to drain.

2.Replace the filter.

3.Reinstall the oil pan drain plug.

4.Refill the engine with new oil. For the proper capacity, See Capacities and Specifications (page 56).

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Maintenance

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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)

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 the Robinair® Coolant and Battery Refractometer 75240 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.

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 60).

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Adding Engine Coolant

WARNINGS

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Do not add engine coolant when the engine is hot. Steam and scalding liquids released from a hot cooling

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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

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coolant could make it difficult to see through the windshield.

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Maintenance

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WARNINGS

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To reduce the risk of personal injury, make sure the engine is cool before unscrewing the coolant pressure

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relief cap. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.

Do not add coolant further than the MAX mark.

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Note: Do not use stop leak pellets, cooling system sealants, or additives as they can cause damage to the engine cooling or heating systems. This damage would not be covered under your vehicle’s warranty.

Note: During normal vehicle operation, the engine coolant may change color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the system to be flushed, or the engine coolant to be replaced.

Do not mix different colors or types of coolant in your vehicle. Make sure the correct coolant is used. Mixing of engine coolants may harm your engine’s cooling system. The use of an improper coolant may harm engine and cooling system components and may void the warranty. Use engine coolant meeting the Ford specification. See Capacities and Specifications (page 55).

In case of emergency, a large amount of water without engine coolant may be added in order to reach a vehicle service location. In this instance, the cooling system must be drained, chemically cleaned with Motorcraft Premium Cooling System Flush, and refilled with engine coolant as soon as possible. Water alone (without engine coolant) can cause engine damage from corrosion, overheating or freezing.

Do not use alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze (coolant).

Alcohol and other liquids can cause engine damage from overheating or freezing.

Do not add extra inhibitors or additives to the coolant. These can be harmful and compromise the corrosion protection of the engine coolant.

Add prediluted engine coolant meeting the Ford specification (Motorcraft Orange Antifreeze/Coolant Prediluted). See Capacities and Specifications (page 56).

Note: Generic coolants marketed for all makes and models may not meet the Ford specification and may cause damage to the cooling system. This damage may void the warranty.

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Maintenance

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For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add coolant to the coolant recovery reservoir when the engine is cool. Add prediluted engine coolant (Motorcraft Orange Antifreeze/Coolant Prediluted) to the FULL COLD level. For all other vehicles which have a coolant degas system with a pressurized cap, or if it is necessary to remove the coolant pressure relief cap on the radiator of a vehicle with an overflow system, follow these steps to add engine coolant.

1.Turn the engine off and let it cool.

2.When the engine is cool, wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir (a translucent plastic bottle). Slowly turn cap counterclockwise until pressure begins to release. When you are sure that all the pressure has been released, use the cloth to turn it counterclockwise and remove the cap.

3.Fill the coolant reservoir slowly with prediluted engine coolant to within the FULL COLD level, or between the MIN and MAX marks (within the COLD FILL RANGE), as listed on the engine coolant reservoir. If you removed the radiator cap in an overflow system, fill the radiator until the coolant is visible and radiator is almost full. If coolant is added to bring the level within the COLD FILL RANGE when the engine is not cold, the system may remain under filled.

4.Replace the cap. Turn until tightly installed. Cap must be tightly installed to prevent coolant loss.

Whenever coolant has been added, the coolant level in the coolant reservoir should be checked the next few times you drive the vehicle. If necessary, add enough prediluted engine coolant to bring the coolant level to the proper level.

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If you have to add more than 1.0 quart (1.0 liter) of engine coolant per month, have your authorized dealer check the engine cooling system. Your cooling system may have a leak. Operating an engine with a low level of coolant can result in engine overheating and possible engine damage.

Engine and Secondary Cooling System Refill Procedure

The following procedure should be used when refilling the engine or secondary cooling systems after it has been drained or become extremely low.

1.Before you remove the cap, turn the engine off and let it cool.

2.When the engine is cool, wrap a thick cloth around the cap. Slowly turn cap counterclockwise until pressure begins to release.

3.Step back while the pressure releases.

4.When you are sure that all the pressure has been released, use the cloth to turn it counterclockwise and remove the cap.

5.Slowly add prediluted engine coolant to the coolant reservoir until the coolant level is within the COLD FILL RANGE as listed on the reservoir.

6.Reinstall the pressure relief cap.

7.Start and run the engine at 2000 rpm for 2 minutes.

8.Shut engine off, and remove the pressure relief cap as previously outlined.

9.If required, add prediluted engine coolant to the coolant reservoir until the coolant level is within the COLD FILL RANGE as listed on the reservoir.

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Maintenance

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10.Engine cooling system: Repeat Step 5 until the coolant level has stabilized (is no longer dropping after each step) AND the upper radiator hose at the radiator is warm to the touch (indicating that the engine thermostat is open and coolant is flowing through the radiator). Secondary cooling system: Repeat Step 5 until the coolant level has stabilized (is no longer dropping after each step) AND the lower passenger side of the secondary radiator is warm to the touch (indicating secondary thermostat is open and coolant is flowing through the entire system).

11.Reinstall the pressure relief cap. Shut the engine off and let it cool.

12.Check the coolant level in the reservoir before you drive your vehicle the next few times (with the engine cool).

13.If necessary, add prediluted engine coolant to the coolant reservoir until the coolant level is within the COLD FILL RANGE as listed on the reservoir. After any coolant has been added, check the coolant concentration. See Adding Engine Coolant earlier in the chapter for more information.

Whenever coolant has been added, the coolant level in the reservoir should be checked the next few times you drive the vehicle. If needed, add prediluted engine coolant to bring the coolant level to the proper level on the reservoir.

Recycled Engine Coolant

Ford Motor Company does not recommend the use of recycled engine coolant since a Ford-approved recycling process is not yet available.

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Used engine coolant should be disposed of in an appropriate manner. Follow your community’s regulations and standards for recycling and disposing of automotive fluids.

Severe Climates

If you drive in extremely cold climates:

It may be necessary to have a Ford authorized dealer increase the coolant concentration above 50%.

A coolant concentration of 60% will provide improved freeze point protection. Engine coolant concentrations above 60% will decrease the overheat protection characteristics of the engine coolant and may cause engine damage.

If you drive in extremely hot climates:

It may be necessary to have a Ford authorized dealer decrease the coolant concentration to 40%.

A coolant concentration of 40% will provide improved overheat protection. Engine coolant concentrations below 40% will decrease the freeze and corrosion protection characteristics of the engine coolant and may cause engine damage.

Vehicles driven year-round in non-extreme climates should use prediluted engine coolant for optimum cooling system and engine protection.

Checking Coolant Corrosion Inhibitor Additive Strength

At specific mileage intervals of 15000 miles (24000 km), as listed in the scheduled maintenance information chapter, the coolant corrosion inhibitor additive should be checked. The optional information display, if equipped, will also display the message CHECK COOLANT ADDITIVE at this time. The purpose of

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Maintenance

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checking is to verify the correct engine coolant concentration (freeze point protection) and corrosion inhibitor additive level (strength) of the coolant for maximum engine performance and protection.

Three products are available to confirm the life and health of the coolant, one tool, a test kit and a coolant inhibitor additive:

Robinair® Coolant and Battery Refractometer 75240 available from your dealer (Rotunda tool 023-75240)

– recommended refractometer to test coolant concentration.

Rotunda 328-R071–ELC (Antifreeze Coolant ELC Contamination Kit) – Evaluates the corrosion inhibitor additive strength. Note the first step is to verify the vehicle’s coolant concentration is in the correct range of 40 – 60%. Coolant concentrations outside this range will not provide valid test results. If the report results in a pass (i.e., the cooling system does not show excessive contamination/the corrosion inhibitor additive strength is sufficient), no action is required. If the report results as insufficient (does not pass), the corrosion inhibitor additive strength of the coolant is too low. If the ENGINE COOLING SYSTEM corrosion inhibitor additive strength is low, add 48 fluid oz. of Motorcraft Specialty Orange Engine Coolant Revitalizer. If the SECONDARY COOLING SYSTEM corrosion inhibitor additive strength is low, add 16 fluid oz. of Motorcraft Specialty Orange Engine Coolant Revitalizer.

Motorcraft Specialty Orange Engine Coolant Revitalizer – Additive to boost the corrosion inhibitor level based upon the test results of the Antifreeze Coolant ELC Contamination Kit. The Revitalizer may be added two times over the life of the coolant. If additional dosages are required, the cooling system must be flushed and refilled per the instructions in the Workshop Manual.

Make sure to follow the proper coolant and

additive specifications. See Capacities

and Specifications (page 55).

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Maintenance

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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.

Make sure to follow the proper coolant specifications. See Capacities and Specifications (page 55).

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.

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CHANGING THE ENGINE AIR FILTER

Air Filter Restriction Gauge

WARNING

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To reduce the risk of vehicle damage and/or personal burn injuries do not start your engine with the air filter

image396

removed and do not remove it while the engine is running.

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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.

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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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Maintenance

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air filter when the restriction gauge reads near the change filter line and the gauge is yellow. If you allow the restriction gauge to reach maximum restriction you can affect your engine performance and fuel economy.

Note: Do not blow out the air filter element with compressed air since the compressed air could damage the filter paper.

Note: Do not rely on filter appearance alone. A filter which appears to be dirty may actually have several thousand miles (kilometers) of life remaining.

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Air Filter Replacement

When replacing the air filter element, use a Motorcraft® air filter element. See Motorcraft Parts (page 55).

Note: Failure to use the correct air filter element may result in severe engine damage.

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E163373

After installation of the new filter element, reset the gauge by pressing the reset button on top of the gauge.

The following actions are recommend after operating the vehicle up to 200 miles (320 km) in heavy 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.

E163374

1.Locate the mass airflow sensor electrical connector on the air inlet tube. This connector will need to be unplugged. Unlock the locking clip on the connector, then squeeze and pull the connector off the air inlet tube.

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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.

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2.Release the four clamps that secure the cover to the air filter housing. Push the air filter cover forward (away from you) and up slightly to release it.

3.Remove the air filter element from the air filter housing.

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Maintenance

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4.Remove and install a new foam filter if needed according to the service interval indicated in the scheduled maintenance information in this guide. If you do not replace the foam filter, be sure the existing foam filter is in place.

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6.Replace the air filter housing cover and secure all the clamps. Be careful not to crimp the filter element edges between the air filter housing and cover. Ensure that you align the tabs on the edge properly into the slots.

7.Reconnect the mass airflow sensor electrical connector to the inlet tube. Make sure the locking tab on the connector is in the locked position.

Air Purge Procedure

Turn the key on for 30 seconds, and then turn off. Repeat the procedure six times.

5.Install a new air filter element. Be sure that the groove seal on the pleated paper filter traps both sides of the vertical partition of the air box.

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Vehicle Care

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CLEANING THE 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 Motorcraft Engine Shampoo and Degreaser on all parts that require cleaning and pressure rinse clean. In Canada, use Motorcraft Engine Shampoo.

Never wash or rinse the engine while it is hot or running; water in the running engine may cause internal damage.

Never wash or rinse any ignition coil, spark plug wire or spark plug well, or the area in and around these locations.

Cover the battery, power distribution box, and air filter assembly to prevent water damage when cleaning the engine.

CLEANING THE EXHAUST

WARNINGS

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Failure to maintain the functional holes, in the tailpipe section of the exhaust, clean and free of debris or

image419

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.

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WARNINGS

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The normal operating temperature of the exhaust system is very high. Never work around or attempt to

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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.

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The visible holes in the exhaust 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.

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Capacities and Specifications

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ENGINE SPECIFICATIONS  Dual Alternator

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Drivebelt Routing

Single Alternator

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MOTORCRAFT PARTS

Component

6.7L Diesel

Engine oil filter

FL-2051S

Foam pre-filter

FA-1909

Air filter

FA-1902

Fuel filter kit (2 included – engine and frame

FD-4615

rail mounted)

Battery

BXT-65-750

Windshield wiper blade

WW-2242

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For scheduled maintenance, we recommend Motorcraft replacement parts available at your Ford dealer or at fordparts.com. These parts meet or exceed Ford Motor Company’s specifications and are engineered for your vehicle. Use of other parts may impact vehicle performance, emissions and durability. Your warranty may be void for any damage related to use of other parts.

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Capacities and Specifications

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Capacities

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Item

Capacity

Engine oil (includes filter change)

13.1 qt (12.4 L)

Engine coolant (primary high-temperature

30.3 qt (28.7 L)

*

cooling system loop)

Engine coolant additive (primary high-

48.0 fl oz (1.42 L)

**

temperature cooling system loop)

Engine coolant (secondary cooling system)

10.8 qt (10.2 L)

*

Engine coolant additive (secondary cooling

16.0 fl oz (473 ml)

**

system)

Diesel Exhaust Fluid (DEF) – Pickup

5.0 gal (18.9 L)

Diesel Exhaust Fluid (DEF) – Chassis Cab

6.0 gal (22.7 L)

Fuel tank – Pickup regular cab long box and

26.0 gal (98.4 L)

all short box

Fuel tank – Pickup long box (except regular

37.5 gal (142 L)

cab )

Fuel tank – Chassis cab (midship)

28.0 gal (106 L)

Fuel tank – Chassis cab (aft of axle)

40.0 gal (151.4 L)

Fuel tank – Dual tanks

40.0 gal (151.4 L)

28.0 gal (106 L)

A/C refrigerant

26 oz (0.74 kg)

A/C refrigerant compressor oil

3.5 fl oz (103.5 ml)

Transmission Fluid

Refer to owners manual

Axle Fluid

Refer to owners manual

*Use the coolant type originally equipped in your vehicle. Using any other coolant may result in vehicle damage.

**Per addition if required.

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Capacities and Specifications

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Specifications

Materials

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Name

Specification

Recommended motor oil (U.S.):

WSS-M2C171-E

Motorcraft SAE 10W-30 Super Duty Diesel Motor Oil*

XO-10W30-QSD

Recommended motor oil (Canada):

WSS-M2C171-E

Motorcraft SAE 10W-30 Super Duty Diesel Motor Oil*

CXO-10W30-LSD12

Recommended motor oil (U.S.):

WSS-M2C171-E

Motorcraft SAE 15W-40 Super Duty Diesel Motor Oil*

XO-15W40-QSD

Recommended motor oil (Canada):

WSS-M2C171-E

Motorcraft SAE 15W-40 Super Duty Diesel Motor Oil*

CXO-15W40-LSD12

Recommended motor oil (U.S.):

WSS-M2C171-E

Motorcraft SAE 5W-40 Full Synthetic Diesel Motor Oil*

XO-5W40-5QSD

Recommended motor oil (U.S.):

WSS-M2C171-E

Motorcraft SAE 0W-40 Full Synthetic Diesel Motor Oil*

XO-0W40-DAS

Engine coolant primary high temperature (U.S.):

WSS-M97B44-D2

Motorcraft Orange Antifreeze/Coolant Prediluted

VC-3DIL-B

Engine coolant primary high temperature (Canada):

WSS-M97B44-D2

Motorcraft Orange Antifreeze/Coolant Prediluted

CVC-3DIL-B

Engine coolant secondary cooling system (U.S.):

WSS-M97B44-D2

Motorcraft Orange Antifreeze/Coolant Prediluted

VC-3DIL-B

Engine coolant secondary cooling system (Canada):

WSS-M97B44-D2

Motorcraft Orange Antifreeze/Coolant Prediluted

CVC-3DIL-B

Engine coolant additive primary high temperature /

secondary cooling (U.S. and Canada):

Motorcraft Specialty Orange Engine Coolant Revitalizer

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Capacities and Specifications

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Name  image449 Specification

image450 VC-12

Diesel Exhaust Fluid (DEF):  WSS-M99C130-A

Motorcraft Diesel Exhaust Fluid

PM-27-Gal / PM-27-Jug

Cetane Booster & Performance Improver (U.S.):  

Motorcraft Cetane Booster & Performance Improver PM-22-A

Cetane Booster & Performance Improver (Canada):  

Motorcraft Cetane Booster & Performance Improver PM-22-B

Anti-Gel & Performance Improver (U.S.):  

Motorcraft Anti-Gel & Performance Improver PM-23-A

Anti-Gel & Performance Improver (Canada):  

Motorcraft Anti-Gel & Performance Improver PM-23-B

A/C refrigerant (U.S.):  WSH-M17B19-A

Motorcraft R-134a Refrigerant

YN-19

A/C refrigerant (Canada):  WSH-M17B19-A

Motorcraft R-134a Refrigerant

CYN-16-R

A/C refrigerant (Mexico):  WSH-M17B19-A

Motorcraft R-134a Refrigerant

MYN-19

A/C refrigerant compressor oil:  WSH-M1C231-B

Motorcraft PAG Refrigerant Compressor Oil YN-12-D

*See the SAE VISCOSITIES GRADES chart for correct temperature usage.

If you use oil and fluids that do not meet the defined specification and viscosity grade, this may lead to:

Component damage which is not covered by the vehicle warranty.

Longer engine cranking periods.

Increased emission levels.

Reduced engine performance.

Reduced fuel economy.

Degraded brake performance.

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Capacities and Specifications

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Engine Oil Specifications

The use of correct oil viscosities for diesel engines is important for satisfactory operation. Determine which oil viscosity best suits the temperature range you expect to encounter for the next service interval from the following SAE viscosity grade chart.

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The American Petroleum Institute (API) service symbol is used to identify the proper engine oil for your engine. The API service symbol will be displayed on the oil container you purchase. The API symbol displays the oil performance category in the top half of symbol and the viscosity grade in the center of the symbol.

(1) For severe duty service, use SAE

5W-40 API CJ-4.

(2) For biodiesel fuel blends (B20 max), use SAE 5W-40 or SAE 15W-40 API CJ-4.

An engine block heater is recommended

at temperatures below –10°F (–23°C).

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Scheduled Maintenance

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GENERAL MAINTENANCE INFORMATION

Why Maintain Your Vehicle?

Carefully following the maintenance schedule helps protect against major repair expenses resulting from neglect or inadequate maintenance and may help to increase the value of your vehicle when you sell or trade it. Keep all receipts for completed maintenance with your vehicle.

We have established regular maintenance intervals for your vehicle based upon rigorous testing. It is important that you have your vehicle serviced at the proper times. These intervals serve two purposes; one is to maintain the reliability of your vehicle and the second is to keep your cost of owning your vehicle down.

It is your responsibility to have all scheduled maintenance performed and to make sure that the materials used meet the specifications identified in the owner’s manual.

Failure to perform scheduled maintenance invalidates warranty coverage on parts affected by the lack of maintenance.

Why Maintain Your Vehicle at Your Dealership?

Factory-trained Technicians

Service technicians participate in extensive factory-sponsored certification training to help them become experts on the operation of your vehicle. Ask your dealership about the training and certification their technicians have received.

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Genuine Ford and Motorcraft Replacement Parts

Dealerships stock Ford, Motorcraft and Ford-authorized branded re-manufactured replacement parts. These parts meet or exceed our specifications. Parts installed at your dealership carry a nationwide

24-month or unlimited mile (kilometer) parts and labor limited warranty.

If you do not use Ford authorized parts they may not meet our specifications and depending on the part, it could affect emissions compliance.

Convenience

Many dealerships have extended evening and Saturday hours to make your service visit more convenient and they offer one stop shopping. They can perform any services that are required on your vehicle, from general maintenance to collision repairs.

Note: Not all dealers have extended hours or body shops. Please contact your dealer for details.

Protecting Your Investment

Maintenance is an investment that pays dividends in the form of improved reliability, durability and resale value. To maintain the proper performance of your vehicle and its emission control systems, make sure you have scheduled maintenance performed at the designated intervals.

Your vehicle is very sophisticated and built with multiple, complex, performance systems. Every manufacturer develops these systems using different specifications and performance features. That is why it is important to rely upon your dealership to properly diagnose and repair your vehicle.

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Scheduled Maintenance

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Ford Motor Company has recommended maintenance intervals for various parts and component systems based upon engineering testing. Ford Motor Company relies upon this testing to determine the most appropriate mileage for replacement of oils and fluids to protect your vehicle at the lowest overall cost to you and recommends against maintenance schedules that deviate from the scheduled maintenance information.

We strongly recommend the use of only genuine Ford, Motorcraft or Ford-authorized re-manufactured replacement parts engineered for your vehicle.

Additives and Chemicals

This owner’s manual and the Ford Workshop Manual list the recommended additives and chemicals for your vehicle. We do not recommend using chemicals or additives not approved by us as part of your vehicle’s normal maintenance. Please consult your warranty information.

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Oils, Fluids and Flushing

In many cases, fluid discoloration is a normal operating characteristic and, by itself, does not necessarily indicate a concern or that the fluid needs to be changed. However, a qualified expert, such as the factory-trained technicians at your dealership, should inspect discolored fluids that also show signs of overheating or foreign material contamination immediately.

Make sure to change your vehicle’s oils and fluids at the specified intervals or in conjunction with a repair. Flushing is a viable way to change fluid for many vehicle sub-systems during scheduled maintenance. It is critical that systems are flushed only with new fluid that is the same as that required to fill and operate the system or using a Ford-approved flushing chemical.

Owner Checks and Services

Make sure you perform the following basic maintenance checks and inspections every month or at six-month intervals.

Check every month

Air filter restriction gauge.

image469 Fuel and water separator. Drain if necessary (or if indicated by the information display). image470

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Tires (including spare) for wear and proper pressure.

Holes and slots in the tail pipe to make sure they are functional and clear of debris.

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Scheduled Maintenance

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Tightening lug nuts

Vehicles with single rear

wheels

Vehicles with dual rear

wheels

Tighten the lug nuts to the specified torque at 500 miles (800 km) after any wheel disturbance (such as tire rota-tion, changing a flat tire or wheel removal).

Tighten the wheel lug nuts to the specified torque at 100 miles (160 km), and again at 500 miles (800 km) of new vehicle operation and after any wheel disturbance (such as tire rotation, changing a flat tire or wheel removal).

Note: For the proper lug nut torque specification, see Technical specifications in the Wheels and Tires chapter of your owner’s manual.

Multi-point Inspection

In order to keep your vehicle running right,

it is important to have the systems on your

vehicle checked regularly. This can help

identify potential issues and prevent major

problems. We recommend having the

following multi-point inspection performed

at every scheduled maintenance interval

to help make sure your vehicle keeps

running great.

image478

Multi-point inspection

Accessory drive belt(s)

Horn operation

Battery performance

Radiator, cooler, heater and A/C hoses

Engine air filter

Suspension component for leaks or

damage

Exhaust system

Steering and linkage

Exterior lamps and hazard warning system

Tires (including spare) for wear and proper

operation

pressure

**

*

; fill if necessary

Windshield for cracks, chips or pits

Fluid levels

For oil and fluid leaks

Washer spray and wiper operation

*Brake, coolant recovery reservoir, automatic transmission, power steering and window washer.

**If your vehicle is equipped with a temporary mobility kit, check the tire sealant expiration Use By date on the canister. Replace as needed.

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Scheduled Maintenance

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Be sure to ask your dealership service advisor or technician about the multi-point vehicle inspection. It is a comprehensive way to perform a thorough inspection of your vehicle. Your checklist gives you immediate feedback on the overall condition of your vehicle.

NORMAL SCHEDULED MAINTENANCE

Intelligent Oil-Life Monitor

Your vehicle is equipped with an Intelligent Oil-Life Monitor that determines when you should change the engine oil based on how your vehicle is used. By using several important factors in its calculations, the monitor helps reduce the cost of owning your vehicle and reduces environmental waste at the same time.

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This means you do not have to remember to change the oil on a mileage-based schedule. Your vehicle lets you know when an oil change is due by displaying ENGINE OIL CHANGE DUE or OIL CHANGE REQUIRED in the information display.

The following table provides examples of vehicle use and its impact on oil change intervals. It is a guideline only. Actual oil change intervals depend on several factors and generally decrease with severity of use.

When to expect the OIL CHANGE REQUIRED message

Miles (km)

7500-10000

(12000-16000)

5000-7499

(8000-11999)

3000-4999

(4000-7999)

Vehicle use and example

Normal

Normal commuting with highway driving

No, or moderate, load or towing

Flat to moderately hilly roads

No extended idling

Severe

Moderate to heavy load or towing

Mountainous or off-road conditions

Extended idling (200-300 hours)

Extended hot or cold operation

Extreme

Maximum load or towing

Extreme hot or cold operation

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Scheduled Maintenance

image489image490

When to expect the OIL CHANGE REQUIRED message

Miles (km) image491 Vehicle use and example

image492 Use of high sulfur diesel fuel

Note: Use the appropriate special operating condition for maintenance information when using high sulfur diesel fuels, operating your vehicle off-road or in dusty conditions (such as unpaved roads).

Note: For every hour that your vehicle idles, it has accumulated the equivalent of approximately 25 miles (40 kilometers) of driving.

Normal Maintenance Intervals

image493

At every oil change interval as indicated by the information display1

image494 Change the engine oil and filter.2

image495 Fuel and water separator. Drain if necessary (or if indicated by the information display). image496

image497

image498 Refill the diesel exhaust fluid tank.

image499 Rotate the tires3, inspect the tires for wear and measure tread depth.

image500 Perform a multi-point inspection (recommended).

image501 Inspect the air filter restriction gauge. Replace the filter if necessary.

image502 Inspect the automatic transmission fluid level. Consult your dealer for requirements.

image503 Inspect the brake pads, shoes, rotors, drums, brake linings, hoses and parking brake.

image504 Inspect the engine and secondary coolant level and hoses.

image505 Inspect the exhaust system and heat shields.

Inspect the front axle and U-joints. Lubricate any grease fittings. (Four-wheel drive vehicles)

Inspect the steering linkage, ball joints, suspension, tie-rod ends, driveshaft and U-joints.

Lubricate any grease fittings.

1Do not exceed one year or 10000 miles (16000 kilometers) between service intervals.
2Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.

3Vehicles with dual rear wheels should rotate the front wheels when specified; rear wheels only if unusual wear is noted.

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Scheduled Maintenance

image510

Other maintenance items1

Every 15000 miles (24000 km)

Every 22500 miles (36000 km)

Every 30000 miles (48000 km)

Every 45000 miles (72000 km)

Inspect the engine and secondary cooling system concentration (freeze-point protection), additive (corro-

sion inhibitor) strength, coolant level and hoses.2

Replace the engine-mounted and frame-mounted fuel filters.3

Replace the climate-controlled (heated and cooled) seat filter.4

Replace the air inlet foam filter.

Every 60000 miles (96000 km)

At 90000 miles (144000 km)

At 100000 miles (160000 km)

Every 105000 miles (168000 km)

Every 150000 miles (240000 km)

image511

Replace the front wheel bearing grease and grease seal if using non-sealed bearings. (Two-wheel drive vehicles)

Inspect the accessory drive belt(s).5

Change the rear axle fluid (Dana axles. See Special

operating conditions).6

Change the crankcase ventilation filter assembly.

Change the engine coolant and secondary coolant.7

Change the automatic transmission fluid and filter. Consult an authorized dealer for requirements.

image512 Change the front axle fluid. (Four-wheel drive vehicles)

Change transfer case fluid. (Four-wheel drive vehicles)

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Scheduled Maintenance

image516image517

Other maintenance items1

Replace the accessory drive belt(s) if not replaced within the last 100000 miles (160000 km).

Replace the front wheel bearings and seals if using non-sealed bearings. (Two-wheel drive vehicles).

1You can perform these maintenance items within 3000 miles (4800 kilometers) of the last oil change. Do not exceed the designated distance for the interval.

2Every 15000 miles (24000 kilometers), 600 engine hours or as indicated by the information display.

3Every 22500 miles (36000 kilometers) or as indicated by the information display.

4If your vehicle has this feature.

5Perform follow-up inspections every 15000 miles (24000 kilometers) after the initial inspection. Replace the belt(s) at 150000 miles (240000 kilometers).

6Change the fluid again at 150000 miles (240000 kilometers).

7Initial change is at six years or 105000 miles (168000 kilometers), then every three years or 45000 miles (72000 kilometers).

SPECIAL OPERATING

CONDITIONS SCHEDULED

MAINTENANCE

If you operate your vehicle primarily in any

of the following conditions, you need to

perform extra maintenance as indicated.

If you operate your vehicle occasionally

under any of these conditions, it is not

necessary to perform the extra

maintenance. For specific

recommendations, see your dealership

service advisor or technician.

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Scheduled Maintenance

image522image523

Towing a trailer or using a car-top carrier

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

image524 See the axle maintenance items under Exceptions.

Every 15000 miles (24000 Inspect the coolant concentration (freeze-point protec-km) or 600 engine hours tion) and additive (corrosion inhibitor) strength. Add

engine coolant additive if necessary.

Every 15000 miles (24000  Replace the engine-mounted and frame-mounted fuel

km), 6 months, 600 engine filters.

hours, or as indicated by the

information display

Every 30000 miles (48000 Replace the wheel bearing grease and grease seals if using

km)  non-sealed bearings. (Two-wheel drive vehicles)

Every 60000 miles (96000 Change the transfer case fluid. (Four-wheel drive vehicles)

km)

Every 60000 miles (96000 Flush and refill the engine coolant. Do not add engine km) or 2400 engine hours coolant additive.

Note: When adding coolant additive, do not exceed the specified maximum of 48 fluid ounces (1.4 liters). Operating the engine with excessive coolant additive may cause overheating which could lead to severe, permanent engine damage.

Note: After the initial coolant flush and fill at 60000 miles (96000 kilometers) or 2400 engine hours, flush and fill every 45000 miles (72000 kilometers) or 1800 engine hours thereafter.

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Scheduled Maintenance

image529image530

Frequent or extended idling (over 10 minutes per hour of normal driving) or frequent low-speed operation if your vehicle is used for stationary operation

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Every 15000 miles (24000 km) or 600 engine hours

Replace the engine-mounted and frame-mounted fuel filters.

Inspect the coolant concentration (freeze-point protec-tion) and additive (corrosion inhibitor) strength. Add engine coolant additive if necessary.

Every 60000 miles (96000 Flush and refill the engine coolant. Do not add engine km) or 2400 engine hours coolant additive.

Note: When adding coolant additive, do not exceed the specified maximum of 48 fluid ounces (1.4 liters). Operating the engine with excessive coolant additive may cause overheating which could lead to severe, permanent engine damage.

Note: After the initial coolant flush and fill at 60000 miles (96000 kilometers) or 2400 engine hours, flush and fill every 45000 miles (72000 kilometers) or 1800 engine hours thereafter.

image531

Frequent low-speed operation, consistent heavy traffic under 25 mph (40 km/h) or long rush-hour traffic

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Every 15000 miles (24000 km) or 600 engine hours

Replace the engine-mounted and frame-mounted fuel filters.

Inspect the coolant concentration (freeze-point protec-tion) and additive (corrosion inhibitor) strength. Add engine coolant additive if necessary.

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Scheduled Maintenance

image536image537

Frequent low-speed operation, consistent heavy traffic under 25 mph (40 km/h) or long rush-hour traffic

Every 60000 miles (96000 Change the transfer case fluid. (Four-wheel drive vehicles)

km)

Every 60000 miles (96000 Flush and refill the engine coolant. Do not add engine km) or 2400 engine hours coolant additive.

Note: When adding coolant additive, do not exceed the specified maximum of 48 fluid ounces (1.4 liters). Operating the engine with excessive coolant additive may cause overheating which could lead to severe, permanent engine damage.

Note: After the initial coolant flush and fill at 60000 miles (96000 kilometers) or 2400 engine hours, flush and fill every 45000 miles (72000 kilometers) or 1800 engine hours thereafter.

image538

Sustained high-speed driving at gross vehicle weight rating (maximum loaded weight for vehicle operation)

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Every 15000 miles (24000 km) or 600 engine hours

Replace the engine-mounted and frame-mounted fuel filters.

Inspect the coolant concentration (freeze-point protec-tion) and additive (corrosion inhibitor) strength. Add engine coolant additive if necessary.

Every 30000 miles (48000 Replace the wheel bearing grease and grease seals if using

km)  non-sealed bearings. (Two-wheel drive vehicles)

Every 50000 miles (80000 Change the rear axle fluid (Dana rear axles only – some F-

km)  350s; all F-450s and F-550s).

image539 Change the transfer case fluid. (Four-wheel drive vehicles) image540

Every 60000 miles (96000 Flush and refill the engine coolant. Do not add engine

km) or 2400 engine hours  coolant additive.

Note: When adding coolant additive, do not exceed the specified maximum of 48 fluid ounces (1.4 liters). Operating the engine with excessive coolant additive may cause overheating which could lead to severe, permanent engine damage.

Note: After the initial coolant flush and fill at 60000 miles (96000 kilometers) or 2400 engine hours, flush and fill every 45000 miles (72000 kilometers) or 1800 engine hours thereafter.

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Replace the wheel bearing grease and grease seals if using non-sealed bearings. (Two-wheel drive vehicles)

image543image544

Scheduled Maintenance

image545image546

image547 Operating in sustained ambient temperatures below -10°F (-23°C) or above 100°F (38°C) image548

image549

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

Every 15000 miles (24000  Replace the engine-mounted and frame-mounted fuel

km), six months, 600 engine filters.

hours, or as indicated by the

information display

Every 30000 miles (48000 Replace the wheel bearing grease and grease seals if using

km)  non-sealed bearings. (Two-wheel drive vehicles)

Every 60000 miles (96000 Change the transfer case fluid. (Four-wheel drive vehicles)

km)

image550

Operating in dusty or sandy conditions (such as unpaved or dusty roads)

Every 7500 miles (12000 km)

Every 7500 miles (12000 km), six months or 300 engine hours

Rotate the tires*, inspect the tires for wear and measure tread depth.

image551 Inspect the brake system pads and rotors.

Inspect the air filter restriction gauge. Replace the filter if necessary.

Inspect the steering and suspension ball joints and tie rods.

Lubricate any grease fittings.

image552 Change the engine oil and filter.** image553 Inspect and lubricate the U-joints.

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Replace the engine-mounted and frame-mounted fuel filters.

Every 30000 miles (48000 Replace the air inlet foam filter.

km)

*Vehicles with dual rear wheels should rotate the front wheels when specified; rear wheels only if unusual wear is noted.

**Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.

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Change the transfer case fluid. (Four-wheel drive vehicles)

Inspect the front axle fluid. (Four-wheel drive vehicles)

*Vehicles with dual rear wheels should rotate the front wheels when specified; rear wheels only if unusual wear is noted.

**Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

Change the rear axle fluid (Dana rear axles only – some F-350s; all F-450s and F-550s).

Every 50000 miles (80000 km)

Every 30000 miles (48000 Replace the air inlet foam filter.

km)

Replace the wheel bearing grease and grease seals if using non-sealed bearings. (Two-wheel drive vehicles).

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Change the engine oil and filter.**

Replace the engine-mounted and frame-mounted fuel filters.

Every 7500 miles (12000 km) or 300 engine hours

Rotate the tires*, inspect the tires for wear and measure tread depth.

Inspect the brake system pads and rotors.

Inspect the air filter restriction gauge. Replace the filter if necessary.

Every 7500 miles (12000 km), six months or 300 engine hours

Inspect the steering and suspension ball joints and tie rods. Lubricate any grease fittings.

As required

Scheduled Maintenance

Off-road operation

Inspect functional holes in each leg of the twin exhaust tips and the holes under the shield just inboard of the right rear tire to make sure they are clean and clear of debris or foreign materials. Refer to the Vehicle Care chapter of your owner’s manual for more information.

image556image557image558image559image560

image561image562

Scheduled Maintenance

image563image564

Using biodiesel, up to and including 20% biodiesel (B20)

As required  Change the engine oil and filter as indicated by the

information display, and perform the services listed in the scheduled maintenance chart.

Every 15000 miles (24000 km), six months, 600 engine hours, or as indicated by the information display

Replace the engine-mounted and frame-mounted fuel filters.

image565

Using fuel other than ultra-low sulfur diesel fuel – vehicles operated where ultra-low sulfur diesel fuel is not required or available

Every 2500 miles (4000 km) or three months (if using high sulfur fuel with more than 500 ppm sulfur)

Every 5000 miles (8000 km) or six months (if using high sulfur fuel with fewer than 500 ppm sulfur)

Change engine oil and filter.

Change engine oil and filter.

Exceptions

There are several exceptions to the Normal Schedule:

Normal vehicle axle maintenance: Rear axles and power take-off units with synthetic fluid and light-duty trucks equipped with Ford-design axles are lubricated for life; do not check or change fluid unless a leak is suspected, service is required or the assembly has been submerged in water. During long periods of trailer towing with outside temperatures above 70°F (21°C) and at wide-open throttle for long periods above 45 mph (72 km/h), change non-synthetic rear axle fluid every 3000 miles (4800 kilometers) or three months, whichever comes first. This interval can be waived if the axle is filled

with 75W140 synthetic gear fluid meeting Ford specification WSL-M2C192-A, part number F1TZ-19580-B, or equivalent. Add friction modifier XL-3 (EST-M2C118-A) or equivalent for complete refill of Traction-Lok rear axles.

F-450 and F-550 axle maintenance: Change rear axle fluid every 100000 miles (160000 kilometers) under normal driving conditions on all commercial applications. When operating your vehicle at or near maximum Gross Vehicle Weights, change the rear axle fluid every 50000 miles (80000 kilometers). In addition, follow this 50000-mile (80000 kilometer) schedule when operating your vehicle under the special operating conditions, where noted.

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Scheduled Maintenance

image570

Diesel Particulate Filter: The filter may need to be removed for ash cleaning at approximately 120000 miles (192000 kilometers) or greater (actual mileage can vary greatly depending upon engine and vehicle operating conditions) and replaced with a new or remanufactured (ash cleaned) part. The filter may need to be replaced at approximately 250000 miles (400000 kilometers) depending upon

engine and vehicle operating conditions. In both cases, the engine control system sets a service light (wrench icon) to inform you to bring your vehicle to the dealer for service. If there are any issues with the oxidation catalyst or particulate filter system, a service light (wrench or engine icon) sets by the engine control system to inform you to bring your vehicle into a dealer for service.

SCHEDULED MAINTENANCE RECORD

image571

Dealer stamp

Repair Order #:

image572 Distance:

image573 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image574

Dealer stamp

Repair Order #:

image575 Distance:

image576 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

73

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image579image580

Scheduled Maintenance

image581image582

Dealer stamp

Repair Order #:

image583 Distance:

image584 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image585

Dealer stamp

Repair Order #:

image586 Distance:

image587 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

74

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image590image591

Scheduled Maintenance

image592image593

Dealer stamp

Repair Order #:

image594 Distance:

image595 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image596

Dealer stamp

Repair Order #:

image597 Distance:

image598 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

75

image599image600

Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image601image602

Scheduled Maintenance

image603image604

Dealer stamp

Repair Order #:

image605 Distance:

image606 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image607

Dealer stamp

Repair Order #:

image608 Distance:

image609 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

76

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image612image613

Scheduled Maintenance

image614image615

Dealer stamp

Repair Order #:

image616 Distance:

image617 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image618

Dealer stamp

Repair Order #:

image619 Distance:

image620 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

77

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image623image624

Scheduled Maintenance

image625image626

Dealer stamp

Repair Order #:

image627 Distance:

image628 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image629

Dealer stamp

Repair Order #:

image630 Distance:

image631 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

78

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image634image635

Scheduled Maintenance

image636image637

Dealer stamp

Repair Order #:

image638 Distance:

image639 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image640

Dealer stamp

Repair Order #:

image641 Distance:

image642 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

79

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image645image646

Scheduled Maintenance

image647image648

Dealer stamp

Repair Order #:

image649 Distance:

image650 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image651

Dealer stamp

Repair Order #:

image652 Distance:

image653 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

80

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image656image657

Scheduled Maintenance

image658image659

Dealer stamp

Repair Order #:

image660 Distance:

image661 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image662

Dealer stamp

Repair Order #:

image663 Distance:

image664 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

81

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Super Duty (TFA) Canada/United States of America, enUSA, First Printing

image667image668

Scheduled Maintenance

image669image670

Dealer stamp

Repair Order #:

image671 Distance:

image672 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

image673

Dealer stamp

Repair Order #:

image674 Distance:

image675 Engine hours (optional):

Multi-point inspection (recommended):

Signature:

E146852

82

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image678image679

Index

image680

A

About This Supplement  3

Breaking-In Your Vehicle  3

Diesel Engine Information  3

Minor Troubleshooting Guide  5

Warnings  3

ABS

See: Brakes  37

B

Brakes  37

General Information  37

C

Capacities and Specifications  56

Engine Oil Specifications  59

Specifications  57

Changing the Engine Air Filter  51

Air Filter Replacement  52

Air Filter Restriction Gauge  51

Cleaning the Engine  54

Cleaning the Exhaust  54

Coolant Check

See: Engine Coolant Check  46

E

Emission Control System  30

Diesel Exhaust System: Oxidation Catalyst

And Diesel Particulate Filter System

30

Engine Block Heater  14

Rapid Heat Supplemental Heating

System  14

Engine Coolant Check  46

Adding Engine Coolant  46

Checking Coolant Corrosion Inhibitor

Additive Strength  49

Checking the Engine Coolant  46

Coolant Change  51

Engine and Secondary Cooling System

Refill Procedure  48

Engine-driven Cooling Fan (Fan

Clutch)  51

Recycled Engine Coolant  49

Severe Climates  49

Engine Idle Shutdown  13

Engine Oil Check  44

Changing the Engine Oil and Oil Filter  45

Engine Oil Specifications  44

Engine Specifications  55

Drivebelt Routing  55

F

Fuel and Refueling  15

Fuel Quality  15

Biodiesel  16

Diesel Fuel Additives  17

Fuel And Water Separator  17

Fuel Requirements – Choosing The Right

Fuel: Vehicles Operated Where Ultra Low

Sulfur Diesel Fuel Is Not Required  15

Fuel Requirements – Choosing The Right

Fuel: Vehicles Operated Where Ultra Low

Sulfur Diesel Fuel Is Required (United

States/Canada/Puerto Rico/U.S. Virgin

Islands And Other Locales)  15

Fuel Shutoff  39

Running Out Of DEF (Diesel Exhaust

Fluid)  39

Fuel Tank Selector Switch  36

G

Gauges  8

Engine Boost Gauge  8

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Index

image685

General Maintenance Information  60

Multi-point Inspection  62

Owner Checks and Services  61

Protecting Your Investment  60

Why Maintain Your Vehicle?  60

Why Maintain Your Vehicle at Your

Dealership?  60

I

Instrument Cluster  8

Introduction  3

J

Jump Starting the Vehicle  40

Connecting the Jumper Cables  40

Jump Starting  41

Preparing Your Vehicle  40

Removing the Jumper Cables  41

M

Maintenance  43

Motorcraft Parts  55

N

Normal Scheduled Maintenance  63

Intelligent Oil-Life Monitor  63

Normal Maintenance Intervals  64

Selective Catalytic Reduction

System  21

Diesel Exhaust Fluid (DEF) warning

messages and vehicle operations  21

Importance of maintaining the Diesel

Exhaust Fluid (DEF) level  21

Special Operating Conditions Scheduled

Maintenance  66

Exceptions  72

Starting a Diesel Engine  10

Cold Weather Operation  11

Cold Weather Starting  10

Starting and Stopping the Engine  10

Switching Off the Engine  13

T

Technical Specifications

See: Capacities and Specifications  55

Towing a Trailer  38

Towing  38

U

Under Hood Overview  43

F-Super Duty  43

Scheduled Maintenance  44

V

Vehicle Care  54

O

W

Oil Check

Warning Lamps and Indicators……………….

8

See: Engine Oil Check………………………………….

44

Diesel Engine Brake………………………………………..

9

R

Diesel Exhaust Fluid (DEF)……………………………

9

Glow Plug Pre-Heat………………………………………..

9

Refueling…………………………………………………..

29

Water In Fuel……………………………………………………

9

Fueling Tips……………………………………………………

29

Roadside Emergencies…………………………..

39

S

Scheduled Maintenance Record…………..

73

Scheduled Maintenance………………………..

60

84

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