Ford F-350 Diesel Owner's Manual

owner.ford.com ford.ca

2016 DIESEL Supplement

April 2015

First Printing

Diesel Supplement

Power Stroke

Litho in U.S.A.

GC3J 19A285 AA

The 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.

Part Number: 20150323155017

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

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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Table of Contents

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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.

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

Warnings

WARNING

Throughout this guide, you will find warnings identified by the warning

symbol. Warnings remind you to be especially careful to reduce the risk of personal injury.

Breaking-In Your Vehicle

Your vehicle does not need an extensive break-in. Try not to drive continuously at the same speed for the first 1000 miles (1600 kilometers) of new vehicle operation. Vary your speed to allow parts to adjust themselves to other parts.

Drive your new vehicle at least 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

• 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.

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

Powertrain malfunction, reduced power, electronic throttle control

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

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

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

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

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

handling.

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Introduction

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.

• 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

If fuses burn out

WARNING

Replacement fuses and circuit 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.

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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Introduction

GAUGES

Cluster shown in standard measure. Metric similar.

E163169

Engine boost gaugeA

Engine Boost Gauge

Indicates the amount of manifold air pressure in the engine

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

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

E171217

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

Diesel Exhaust Fluid (DEF) (If

Equipped)

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

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.

Water In Fuel

During refueling, it is possible for 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.

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

Do not drain the fuel and water separator while the engine is running.

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

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.

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Instrument Cluster

STARTING A DIESEL ENGINE

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.

Note: Do not press the accelerator during starting.

Cold Weather Starting

WARNINGS

Do not use starting fluid, such as ether, in the air intake system (see

air filter decal). Such fluid could 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 and causes engine performance problems.

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

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

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

WARNING

To reduce the risk of vehicle damage and/or personal burn injuries do not

start your engine with the air filter removed and do not remove it while the engine is running.

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

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

Do not use starting fluid, such as ether, in the air intake system (see

air filter decal). Such fluid could cause immediate explosive damage to the engine and possible personal injury.

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

Idle Control

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).

Operation in Standing Water

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

• 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.

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.

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.

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Starting and Stopping the Engine

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 (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.

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

Biodiesel

WARNINGS

Do not use home heating oil, agricultural fuel, raw fats and oils,

waste cooking greases, biodiesel 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 injury.

Do not add gasoline, gasohol or

alcohol to diesel fuel. This practice

creates a serious fire hazard resulting 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 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.

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.

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

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.

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 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

Your vehicle must be stopped with the engine off when draining the

Diesel Fuel Conditioner Module. Fuel may ignite if the separator is drained while the engine is running or vehicle is moving.

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Fuel and Refueling

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.

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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.

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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• 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.

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).

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.

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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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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.

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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.

Removal - Engine-mounted fuel filter

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

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

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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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Installation – Engine-mounted fuel filter

1. Install the new filter into the filter bracket. Turn the filter clockwise to lock it in place.

2. Reconnect both fuel lines.

Note: Using a fuel that has more than average impurities may require you to replace the fuel filter more frequently than the service interval specifies.

Note: You will need to purge the system of air after removal or changing of the filter. See purging air from the fuel system later in this chapter.

Purging air from the fuel system

Turn the ignition key to on for 30 seconds, then turn it to off. Do this six times in a row to purge any trapped air from the fuel system.

After filter service, a no start or rough running engine may indicate that air is entering the system through the filter bowl seal or drain. Make sure the drain is tight and you tightened the filter bowl to the mechanical stop.

SELECTIVE CATALYTIC REDUCTION SYSTEM

Your vehicle is equipped with a selective catalytic reduction system to help reduce emission levels of oxides of nitrogen from the exhaust of the diesel engine. The system automatically injects Diesel Exhaust Fluid (DEF) into the exhaust system to enable proper selective catalytic reduction function.

Importance of maintaining the Diesel Exhaust Fluid (DEF) level

In order for the selective catalytic reduction system to operate properly, the DEF level must be maintained. Generally, the DEF tank should be filled during the oil change service interval. See General Maintenance Information (page 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

Diesel Exhaust Fluid (DEF) must be refilled when low or replaced when

contaminated or your vehicle speed will be speed limited to 50 mph (80 km/h). In these conditions, drive with caution and refill DEF immediately. If the DEF becomes empty or contaminated and fluid is not replaced, your vehicle will become limited to idle speed only once stopped. In these conditions, be cautious where you stop your vehicle because you may not be able to drive long distances and will not be able to maintain highway speeds until you refill or replace the DEF.

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WARNINGS

Tampering or disabling your vehicle’s exhaust aftertreatment system will

result in severe vehicle performance limitation including eventual speed limiting to 5 mph (8 km/h).

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, the DEF warning symbol will be

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.

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)

Vehicle ActionsCustomer

Requested

Actions

Distance/Exhaust Fluid

Level or Action

Cluster Message

NoneDrive normallyFull exhaust fluid tankExhaust Fluid Level OK

NoneDrive normallyExhaust fluid tank below

1⁄2 full

Exhaust Fluid Under 1⁄2

Full

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Low DEF Warnings and Actions — Instrument Cluster Messages (Optional information

display messages shown, base information display messages similar)

NoneRefill exhaust

fluid

Approximately 500 mi

(805 km) left before

exhaust fluid tank is

empty

Exhaust Fluid Range

500 mi (805 km)

NoneRefill exhaust

fluid

Approximately 99 mi

(160 km) left before exhaust fluid tank is

empty

In 99 mi (160 km)

Speed Limited to

50 mph (80 km/h)

Exhaust Fluid Empty

NoneRefill exhaust

fluid

0 mi (0 km) – exhaust

fluid tank is empty

Speed Limited to

50 mph (80 km/h)

Upon Restart Exhaust

Fluid Empty

Speed is limited

to 50 mph (80 km/h)

Refill exhaust

fluid

Vehicle restarted with

exhaust fluid tank empty

Speed Limited To

50 mph (80 km/h)

Exhaust Fluid Empty

-Refill exhaust

fluid

This occurs 200 mi

(322 km) after the vehicle

reaches the 0 mi (0 km)

exhaust fluid range

Engine Idled Soon

Exhaust Fluid Empty

Engine is

limited to idle

ONLY

Refill exhaust

fluid

This occurs when the

exhaust fluid is empty

and:

Engine Idled-See

Owner’s Manual

Exhaust Fluid Empty

You refuel your vehicle’s

diesel fuel tank,

The engine is shut off for

10 minutes,

The engine is idling with

the parking brake

engaged for 60 minutes.

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Filling the Diesel Exhaust Fluid (DEF) tank

WARNINGS

Make sure that Diesel Exhaust Fluid (DEF) does not come into contact

with eyes, skin or clothing. Should any DEF contact your eyes, flush them with plenty of water and contact a physician. Clean affected skin with soap and water. If any DEF is swallowed, drink plenty of water and contact a physician immediately

Refill DEF in a well-ventilated area.

When opening the cap on the DEF

tank or bottle containing DEF, ammonia vapors may escape. The vapors can be irritating to skin, eyes and mucous membranes. Inhaling ammonia vapors can cause burning to the eyes, throat and nose and cause coughing and watery eyes.

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

Note: 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.

)

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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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