2015 diesel supplement

fordowner.com ford.ca

2015 DIESEL Supplement

FC3J 19A285 AA

February 2014First Printing

Diesel SupplementPower Stroke

Litho in U.S.A.

1497644_15a_Ford_Diesel_F-250_550_Suppl_010314.indd 1 1/16/14 8:47 AM

The information contained in this publication was correct at the time of going to print. In the interest ofcontinuous development, we reserve the right to change specifications, design or equipment at any timewithout notice or obligation. No part of this publication may be reproduced, transmitted, stored in aretrieval system or translated into any language in any form by any means without our written permission.Errors and omissions excepted.© Ford Motor Company 2014

All rights reserved.Part Number: 20140103191304

IntroductionAbout This Supplement.................................3

Instrument ClusterGauges..................................................................8Warning Lamps and Indicators...................8

Starting and Stopping theEngine

Starting a Diesel Engine...............................10Switching Off the Engine..............................13Engine Idle Shutdown...................................13Engine Block Heater.......................................14

Fuel and RefuelingFuel Quality.......................................................15Selective Catalytic Reduction

System............................................................21Refueling...........................................................29Emission Control System...........................30Fuel Tank Selector Switch..........................36

BrakesGeneral Information......................................37

TowingTowing a Trailer...............................................38

Roadside EmergenciesFuel Shutoff.....................................................39Jump Starting the Vehicle...........................39

MaintenanceUnder Hood Overview..................................42Engine Oil Check............................................43Engine Coolant Check..................................45Changing the Engine Air Filter...................50

Vehicle CareCleaning the Engine......................................54Cleaning the Exhaust...................................54

Capacities and Specific-ations

Engine Specifications...................................55Motorcraft Parts.............................................55Technical Specifications..............................57

Scheduled MaintenanceGeneral Maintenance Information..........59Normal Scheduled Maintenance.............62Special Operating Conditions Scheduled

Maintenance................................................65Scheduled Maintenance Record...............71

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Super Duty (TFA) , enUSA

Table of Contents

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ABOUT THIS SUPPLEMENTThis supplement will acquaint you with thePower Stroke diesel engine. It providesrecommendations on engine care andoperating procedures. For complete vehicleinformation, also refer to your Owner’sManual included with the vehicle. It alsodescribes equipment and givesspecifications for equipment that was ineffect when this guide was approved forprinting, and should be considered apermanent part of the vehicle.Note: Your vehicle’s powertrain controlsystems can detect and store informationabout vehicle modifications that increasehorsepower and torque output such aswhether or not performance-enhancingpowertrain components commonly referredto as performance chips have been used.This information will stay in the system’smemory cannot be erased even if themodification is removed. Ford MotorCompany, Ford of Canada, Ford of Mexicoand service or repair facilities can retrievethis information when servicing your vehicle.Ford Motor Company may use thisinformation to determine if your warrantycovers any needed repairs.Note: Some aftermarket products maycause severe engine/transmission and/orexhaust system damage; refer to yourwarranty information for more information.Your new diesel engine will feel, drive andfunction somewhat differently than agasoline engine. Therefore it is veryimportant that you read and thoroughlyfamiliarize yourself and others operatingthe vehicle with this guide. A specialprocedure for turning off the diesel engineis in the Starting and Stopping the Enginechapter, See Starting a Diesel Engine(page 10). It is important to read andunderstand this material in order tomaintain the best service life for yourengine.

Ford may discontinue models or changespecifications without any notice andwithout incurring obligations.

WarningsWARNING

Throughout this guide, you will findwarnings identified by the warningsymbol. Warnings remind you to be

especially careful to reduce the risk ofpersonal injury.

Breaking-In Your VehicleYour vehicle does not need an extensivebreak-in. Try not to drive continuously atthe same speed for the first 1000 miles(1600 kilometers) of new vehicleoperation. Vary your speed to allow partsto adjust themselves to other parts.Drive your new vehicle at least 500 miles(800 kilometers) before towing a trailer.Make sure you use the specified engine oil.See Technical Specifications (page 57).Do not add friction modifier compoundsor special break-in oils during the first fewthousand miles (kilometers) of operation,since these additives may prevent pistonring seating. See Engine Oil Check (page43).

Diesel Engine InformationThe diesel engine fuel system is apressurized two-stage filtration systemand consists of:• A frame-mounted Fuel and Water

Separator primary filter with an electricfuel pump and water drain

• An engine-mounted secondary fuelfilter

• A fuel injector for each cylinder (8total)

• A high-pressure fuel pump

3


Introduction

• A high-pressure fuel rail for eachcylinder bank (2 total)

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

The fuel and water separator removesboth water and impurities from the fuel.The engine mounted filter filters finerimpurities from the diesel fuel. Theengine-mounted fuel filter and the fuel andwater separator filter should be changedat the recommended service interval orwhen indicated by the information displayLOW FUEL PRESSURE message. Refer tothe scheduled maintenance informationin this supplement for more information.The fuel and water separator should bedrained at regular intervals (recommendedat every oil change) or when indicated bythe information display and water in fuelindicator light. See Fuel Quality (page15).Proper fuel filter maintenance and promptwater draining when the water in fuel lightilluminates is essential to prevent injectionequipment damage. Ignoring the water infuel light can cause your vehicle to go intoa reduced power mode.A frame-mounted electric fuel pumplocated inside the fuel and water separatordraws fuel from the fuel tank to providepressurized fuel to the engine. The fuelpump contains a pressure relief valve foroverpressure protection in the event ofrestricted flow.The fuel injection system is controlledthrough the powertrain control module.

Engine protection modeFord diesel engines are equipped withengine protection and emission controlsystems. These systems monitor criticaltemperatures and pressures, and modifyengine operation accordingly. Thesemodified engine performancecharacteristics are normal.If these modified engine performancecharacteristics persist for an extendedperiod and either the service engine soonor powertrain malfunction,reduced power,electronic throttle control light isilluminated, have the system checked byan authorized dealer.

Service engine soon

Powertrain malfunction, reducedpower, electronic throttle control

Lubrication systemIt is important to change the engine oil atthe recommended service intervals tomaintain oil viscosity. Extending the oil andfilter change interval beyond therecommended interval can negativelyaffect engine performance, fuel economyand engine life. See Engine Oil Check(page 43).

Fast start glow plug systemThe 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 controlmodules electronically control the glowplug system. After you switch the ignitionon the glow plug control moduleimmediately energizes the glow plugs. Theglow plug control module using the enginecoolant temperature, barometric pressuresensor and environmental temperaturesensor will determine how long the glowplugs stay energized. The required time forthe glow plugs to be energized decreasesas the coolant temperature, barometricpressure and environmental temperatureincrease.

Glow Plug

Engine and secondary cooling systemThe cooling system contains a primarycooling loop to cool the engine and asecondary cooling loop to cool thetransmission, charge air, and fuel. Thecoolant serves three primary purposes: toprovide heat transfer, freeze pointprotection, and corrosion protection usingadditives.Vehicles with diesel engines typically areused to carry heavy loads and accumulatemileage rapidly. These two factors maycause the additives in the coolant to wearout in a shorter time. For more informationabout coolant additives and coolantchange intervals See Engine CoolantCheck (page 45). . Operating the enginewith insufficient coolant or coolant additivecan cause severe engine damage

Diesel Particulate Filter systemYour vehicle is equipped with a dieselparticulate filter in the exhaust system. Thediesel particulate filter reduces carbonemissions by trapping exhaust particulates(soot) before they reach the tailpipe. Youmust properly maintain your dieselparticulate filter in order for it to function

properly. Regeneration of the dieselparticulate filter occurs automaticallyduring operation above 30 mph (48 km/h)and requires no actions from the driver. Ifyou do a lot of idling or stop and go driving,pay attention to maintenance messagesthat alert you when you need to drive toclean the diesel particulate filter, orperform operator commandedregeneration. See Emission ControlSystem (page 30).

Selective catalytic reduction systemYour vehicle is equipped with a selectivecatalytic reduction system designed toreduce emission levels of nitrogen oxidesfrom the exhaust of your diesel engine. Thissystem relies on the use of Diesel ExhaustFluid (DEF) that you must replenish atcertain intervals. Failure to maintain properDEF levels or if the DEF becomescontaminated will result in vehicle speedlimitations or result in your vehicle enteringan idle-only mode. See SelectiveCatalytic Reduction System (page 21).

Speed controlIf your vehicle speed goes outside apredetermined range from the set speed,the RSM (Resume) function will not resetyour vehicle speed. You will need to resetyour vehicle speed with the SET+ or SET-button after reaching the desired speedusing the accelerator pedal.

Minor Troubleshooting GuideIf the engine won’t crank

WARNINGBattery posts, terminals and relatedaccessories contain lead and leadcompounds. 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 isturned to START the lights become dim orgo out, the battery connections may beloose or corroded, or the battery may bedischarged. If there is a clicking orstuttering sound coming from the enginecompartment when you turn the key toSTART, this may also indicate a loose orcorroded battery connection.Check the battery connections at thebattery posts, cable connection to theengine grounding point and at the starterconnection.If you suspect a discharged battery, haveit checked and corrected.• The gearshift lever must be in P (Park)

or N (Neutral) in order for the starterto operate.

• Try operating the starter switch severaltimes. This operation may cleanpotentially corroded contacts or makethe switch temporarily operable untilyou can reach the dealer.

• If all electrical connections are tightand you need assistance to start, referto Jump Starting in the RoadsideEmergencies chapter of your Owner’sManual.

If engine cranks but won’t startProlonged starter cranking (in excess of 10seconds) could cause damage to thestarter motor or the high-pressure fuelpump.

• Check the fuel gauge. You may be outof fuel. If the gauge shows that thereis fuel in the tank, the trouble may bein the electrical system or the fuelsystem. If equipped with an auxiliarytank, be sure that the tank controlswitch is set for the tank with fuel andnot on an empty tank.

• Leaving your ignition key turned to onfor over two minutes without startingmay make starting difficult becausethe glow plugs will cease activation.Reset the system by turning the ignitionkey to off and then back to on again.

Note: If the system is out of fuel and theengine will not start, do not continuecranking the engine. Continued cranking candamage the high-pressure fuel pump.

If the engine runs hotThe following could cause the engine tooverheat:• 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

WARNINGReplacement fuses and circuitbreakers must always be the samerating as the original equipment

shown. Never replace a fuse or circuitbreaker with one of a higher rating. Higherrated fuses or circuit breakers could allowcircuit overloading in the event of a circuitmalfunction, resulting in severe vehicledamage or personal injury due to fire.

Burned-out or blown fuses usually indicatean electrical short-circuit, although a fusemay occasionally burn out from vibration.Insert a second fuse. If this fuseimmediately burns out and you cannotlocate the cause, return your vehicle toyour dealer for a circuit check.Refer to the Owner’s Manual forreplacement of fuses.

Selective catalytic reduction systemspeed limit and Idle-only modesIf the vehicle’s speed is limited or in anidle-only mode, the selective catalyticreduction system may be limiting thevehicle’s functions due to low orcontaminated DEF. Check the DEF. SeeSelective Catalytic Reduction System(page 21).

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Introduction

GAUGES Cluster shown in standard measure. Metricsimilar.

E163169

Engine boost gaugeA

Engine Boost GaugeIndicates the amount of manifold airpressure in the engine

WARNING LAMPS ANDINDICATORSThe following warning lamps andindicators will alert you to a vehiclecondition that may become serious. Somelamps will light when you start your vehicleto make sure they work. If any lampsremain on after starting your vehicle, referto the respective system warning lamp forfurther information.

Note: Some warning indicators appear inthe information display and function thesame as a warning lamp but do not displaywhen you start your vehicle.

Diesel Engine Brake

E171217

Lights when you switch theengine brake on. See GeneralInformation (page 37).

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Instrument Cluster

Diesel Exhaust Fluid (DEF) (If

Equipped)

E163176

With the key in the on position,lights when the DEF iscontaminated or low. See

Selective Catalytic Reduction System(page 21).

Glow Plug Pre-HeatWith the key in the on position,lights when the glow plug heatis 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 shouldturn off. When the engine is cold, the lightshould always light for a short period.

Water In FuelDuring refueling, it is possible foryou to pumpwater-contaminated diesel fuel

into your fuel tank. Your vehicle’s fuelsystem is equipped with a fuel filter andwater separator to remove water from thefuel. The water in fuel indicator lights whenthe fuel and water separator has asignificant quantity of water in it andrequires immediate draining.If the water in fuel lights when the engineis running, stop your vehicle as soon assafely possible, shut off the engine, thendrain the fuel and water separator. SeeFuel Quality (page 15). Allowing waterto stay in the fuel system, after the waterin fuel indicator lights, could result inextensive damage or failure of the fuelinjection system.

WARNINGDo not drain the fuel and waterseparator while the engine is running.Fuel may ignite if the separator is

drained while the engine is running or thevehicle is moving.

Note: Do not drain the fuel and waterseparator while the engine is running. Air willenter into the fuel system causing the enginenot to operate properly.

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Instrument Cluster

STARTING A DIESEL ENGINERead all starting instructions carefullybefore you start your vehicle.For temperatures below 32°F (0°C), theuse of the correct grade engine oil isessential for proper operation. Refer toEngine oil specifications for moreinformation. See TechnicalSpecifications (page 57).Your vehicle may be equipped with a coldweather starting strategy that preventssevere engine damage by assisting inengine lubrication warm-up. In extremelycold ambient temperatures, this strategyactivates and prevents the acceleratorpedal from being used for 30 seconds afterstarting your vehicle. A message willappear in the information display as yourvehicle warms up. By not allowing theaccelerator pedal to be used, the engineoil is allowed to properly lubricate thebearings preventing engine damage dueto lack of proper lubrication. After the 30second warm-up period, the acceleratorpedal will be operational again and amessage will appear informing you thevehicle is ok to drive.When starting the engine in extremely coldtemperatures (-15°F [–26°C]), it isrecommended to allow the engine to idlefor several minutes before driving thevehicle.Before starting the engine check thefollowing:• 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 duringstarting.

Cold Weather StartingWARNINGS

Do not use starting fluid, such asether, in the air intake system (seeair filter decal). Such fluid could

cause immediate explosive damage to theengine and possible personal injury

Do not add gasoline, gasohol, alcoholor Kerosene to diesel fuel. Thispractice creates a serious fire hazard

and causes engine performance problems.

It is recommended that the engine blockheater be used for starting when thetemperature is -10°F (-23°C) or colder.Refer to Engine block heater later in thischapter for more information.When operating in cold weather,Motorcraft® cetane improvers ornon-alcohol-based cetane improvers froma reputable manufacturer may be used asneeded.Do not crank the engine for more than 10seconds as starter damage may occur. Ifthe engine fails to start, turn the key toposition 3 (off) and wait 30 secondsbefore trying again.

1. Turn the key to on without turning thekey to start. Do not start the engineuntil the glow-plug indicator turns off.

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Starting and Stopping the Engine

2. When the glow plug pre-heat indicatorturns off, turn the key to start andrelease the key as soon as the enginestarts. After starting the engine, theglow plugs may remain on for a period.If you do not start the engine beforethe glow plug activation time ends, youwill need to reset the glow plugs byturning the key to off.

3. After the engine starts, allow it to idlefor about 15 seconds. This is to protectthe engine. Do not increase enginespeed until the oil pressure gaugeindicates normal pressure.

Cold Weather OperationNote: Idling in cold weather does not heatthe engine to its normal operatingtemperature. Long periods of idling,especially in cold weather, can cause abuildup of deposits which can cause enginedamage.Changing to a lighter grade engine oil alsomakes starting easier under theseconditions. Refer to Engine oilspecifications. See TechnicalSpecifications (page 57).Diesel fuel is adjusted seasonally for coldtemperatures. Diesel fuel which has notbeen properly formulated for the ambientconditions may gel which can clog the fuelfilters. One indication that the fuel filter(s)may be clogged is if the engine starts, stallsafter a short time, and then does notrestart. If you have been using biodiesel,you may need to use a fuel with lowerbiodiesel content, try another brand, ordiscontinue using biodiesel. Do not usealcohol based additives to correct fuelgelling. This may result in damage to thefuel injectors and system. Use the properanti-gel and performance improvementproduct. See Technical Specifications(page 57).

Your vehicle is equipped with a fuel andwater separator that recirculates fuel fromthe engine to help prevent fuel filterclogging. To avoid engine fuel starvationduring cold weather operation of 32°F(0°C) or below, we recommended thatthe fuel level in your tank should not dropbelow 1⁄4 full. This helps prevent air fromentering the fuel system and stalling theengine.Your vehicle is equipped with a selectivecatalyst reduction system that uses DieselExhaust Fluid (DEF) to operate properly.You need to replenish your vehicle’s DEFat certain intervals. When filling yourvehicle’s DEF tank in cold weather, youmust take special care to prevent damageto the tank. See Selective CatalyticReduction System (page 21).In cold weather below 32°F (0°C), theengine may slowly increase to a higher idlespeed if left idling in P (Park). As the enginewarms-up, the engine sound leveldecreases due to the activation ofPCM-controlled sound reduction features.If you operate your vehicle in a heavysnowstorm or blowing snow conditions,snow and ice can clog the engine airinduction. If this occurs, the engine mayexperience a significant reduction in poweroutput. At the earliest opportunity, clearall the snow and/or ice away from insidethe air filter assembly. Remove the aircleaner cover and the pleated paper filter,leaving the foam filter in and remove anysnow or ice. Make sure you install the foamfilter correctly in place. Remove any debris,snow or ice on the foam filter by brushingthe surface with soft brush. Once you havecleared all of the debris, reinstall the airfilter and assembly.Do not use water, solvents, or a hard brushfor cleaning the foam filter.

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WARNINGTo reduce the risk of vehicle damageand/or personal burn injuries do notstart your engine with the air filter

removed and do not remove it while theengine is running.

In order to operate the engine intemperatures of 32°F (0°C) or lower, readthe following instructions:• Make sure that the batteries are of

sufficient size and are fully charged.Check other electrical components tomake sure they are in optimumcondition

• Use the proper coolant solution at theconcentration recommendedprotecting the engine against damagefrom freezing

• Try to keep the fuel tank full as muchas possible at the end of operation toprevent condensation in the fuelsystem

• Make sure you use proper cold weatherengine oil and that it is at its properlevel. Also, if necessary, make sure tofollow the engine oil and filter changeschedule found under the Specialoperating conditions section listed inthe scheduled maintenanceinformation

• At temperatures of -10°F (-23°C) orbelow, it is recommended that you usean engine block heater to improve coldengine starting

• If operating in arctic temperatures of-20°F (-29°C) or lower, consult yourtruck dealer for information aboutspecial cold weather equipment andprecautions

The following cold weather idlingguidelines are recommended:• You can use Motorcraft® cetane

improvers or non-alcohol-basedcetane improvers from a reputablemanufacturer as needed.

• Maintain the engine cooling systemproperly.

• Avoid shutting the engine down afteran extensive idling period. Drive yourvehicle for several miles with theengine at normal operatingtemperatures 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 ArcticOperation -20°F (-29°C) and BelowThe following information is a guidelineonly and is no to be the only source ofpossible solutions in resolving extremecold temperature issues.

Starting Aids

WARNINGDo not use starting fluid, such asether, in the air intake system (seeair filter decal). Such fluid could

cause immediate explosive damage to theengine and possible personal injury.

The use of the factory engine block heaterassists in engine starting in extreme coldambient temperatures. Refer to Engineblock heater in the Starting and Stoppingthe Engine chapter of your Owner’sManual.

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Idle ControlYour vehicle may have a factory option fora stationary elevated idle control throughdash-mounted upfitter switches thatallows the operator to elevate the idle rpmfor extended idle periods, as well asaftermarket equipment such as PTOoperation. You must configure this featureeven if ordered from the factory. See yourauthorized dealer for required upfitting.

Operation in Snow and RainVehicle operation in heavy snowfall orextreme rain conditions may feedexcessive amounts of snow or water intothe air intake system. This could plug theair filter with snow and may cause theengine to lose power and possibly shutdown.We recommend the following actions afteroperating your vehicle up to 200 miles(320 kilometers) in snowfall or extremerain:• Snow: At the earliest opportunity, open

the hood and clear all the snow and icefrom the air filter housing inlet (do notremove the foam filter) and reset theair filter restriction gauge.

Note: Removal of the foam filter degradesyour vehicle performance during snow andhot weather conditions.• Extreme rain: The air filter dries after

about 15–30 minutes at highwayspeeds. At the earliest opportunity,open the hood and reset the air filterrestriction gauge.

Refer to Air filter and restriction gauge inthe Maintenance chapter for moreinformation. See Changing the EngineAir Filter (page 50).

Operation in Standing WaterIngestion of water into the diesel enginecan result in immediate and severedamage to the engine. If driving throughwater, slow down to avoid splashing waterinto the intake. If the engine stalls, and yoususpect ingestion of water into the engine,do not try to restart the engine. Consultyour dealer for service immediately.Your fuel tank vents to the atmosphere byvalves on top of the tank and through thefuel cap. If water reaches the top of thetank, the valves may pull water into thefuel tank. Water in the fuel can causeperformance issues and damage the fuelinjection system.

SWITCHING OFF THE ENGINETurn the ignition to the off position.To prolong engine life (especially afterextended high speed, high ambienttemperature, or high GVW/GCW operation,such as heavy loads or heavy trailers), it isrecommended that a hot engine be idledfor 3-5 minutes. This allows theturbocharged engine to cool down. Formore information on GVW/GCW, see theLoad Carrying chapter in your Owner’sManual.

ENGINE IDLE SHUTDOWNYour vehicle may be equipped with anengine idle shutdown system. This systemautomatically shuts down your enginewhen it has been idling in P (Park) or N(Neutral) for five minutes (parking brakeset) or 15 minutes (parking brake not set).When the engine idle shutdown processhas started:

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• A chime sounds and the informationdisplay will show ENGINE TURNS OFFIN 30 (seconds) and start countingdown

• You can restart the five or 15-minutetimer by changing the position of theaccelerator pedal, brake pedal or thepark brake within the final 30 seconds

• When the timer reaches zero, theengine shuts down and this messagewill appear in your information displayENGINE TURNED OFF

• One minute after the engine has shutdown, the electrical system simulateskey off, even though the ignition is stillin the on position, initiating normalaccessory delay period

• You must move the ignition to the offposition to reset the system beforerestarting your vehicle.

The engine idle shutdown idle timer doesnot 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 theEngine chapter in your Owner’s Manual.

Rapid Heat Supplemental HeatingSystemNote: Additional aftermarket electricalloads operated during engine warm up mayaffect the performance of the rapid heatsupplemental heater.

The optional rapid heat feature is anelectrically powered device that providessupplemental heat during engine warm up.During initial warm up, you should use amid to low blower speed for maximumeffectiveness. When operating inautomatic mode (when equipped) theclimate control unit determines theappropriate blower speed for existingconditions.

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FUEL QUALITYFuel Requirements - Choosing TheRight Fuel: Vehicles OperatedWhere Ultra Low Sulfur Diesel FuelIs Required (UnitedStates/Canada/Puerto Rico/U.S.Virgin Islands And Other Locales)Note: Your warranty will not cover damagecaused by using an improper type of fuel orfuel additive.Note: Do not blend used engine oil withdiesel fuel under any circumstances.Blending used oil with the fuel willsignificantly increase your vehicle’s exhaustemissions and reduce engine life due toincreased internal wear.You should use Ultra-Low Sulfur Dieselfuel (also known as ULSD) designated asnumber 1-D or 2-D with a maximum of15-ppm sulfur in your diesel vehicle. Youmay operate your vehicle on diesel fuelscontaining up to 20% biodiesel, alsoknown as B20. These fuels should meetthe ASTM D975 diesel or the ASTM D7467B6-B20 biodiesel industry specifications.Outside of North America, use fuelsmeeting EN590 or equivalent local marketstandard.

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

ppm) in your diesel engine will causecertain emission components tomalfunction which may also cause theservice engine soon light to illuminateindicating an emissions-related concern.Diesel fuel is adjusted seasonally for coldtemperature. For best results attemperatures below 20°F (-7°C), it isrecommended to use a diesel fuel whichhas been seasonally adjusted for theambient conditions.

Fuel Requirements - Choosing TheRight Fuel: Vehicles OperatedWhere Ultra Low Sulfur Diesel FuelIs Not RequiredFor the engine to operate reliably onlow-sulfur or high-sulfur diesel fuel, theengine must be a factory built high-sulfurengine (available as a dealer order optionfor select markets) or an ultra low sulfurdiesel fuel configured engine that has beenretrofitted for high-sulfur diesel fuel usingFord Motor Company dealer service parts.Failure to use retrofit components otherthan those available through yourauthorized dealer will result in coolantsystem damage, engine overheating,selective catalyst reduction system ordiesel particulate filter damage andpossible base engine damage.Use only a diesel engine configured for usewith high sulfur diesel fuel in markets withdiesel fuel that has sulfur content greaterthan 15 ppm. Using low sulfur diesel fuel(16–500 ppm) or high sulfur diesel fuel(greater than 500 ppm) in a diesel enginedesigned to use only Ultra Low SulfurDiesel fuel may result in damage to engineemission control devices and theaftertreatment system, potentiallyrendering the vehicle inoperable.Vehicles with engines configured for usewith high sulfur diesel fuel are onlyavailable for sale in countries where ultralow sulfur diesel fuel is generally notavailable or mandated by the government.Vehicles originally sold in a ultra low sulfurdiesel fuel market that are subsequentlyexported to non- ultra low sulfur diesel fuelmarkets will need to be retrofitted (at thecustomer’s expense using Ford authorizeddealer service parts) in order to be reliablyoperated on non- ultra low sulfur dieselfuel.

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Fuel and Refueling

BiodieselWARNINGS

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

fuels greater than 20% or any diesel fuelnot intended for highway use. Damage tothe fuel injection system, engine andexhaust catalyst can occur if an improperfuel is used. Do not add gasoline, gasoholor alcohol to diesel fuel. This practicecreates a serious fire hazard and engineperformance problems.

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

injury.Do not add gasoline, gasohol oralcohol to diesel fuel. This practicecreates a serious fire hazard resulting

in personal injury and engine performanceproblems.

: Do not use home heating oil or anydiesel fuel not intended for highwayuse. Damage to the fuel injection

system, engine, exhaust catalyst and dieselparticulate filter can occur if an improperfuel is used. Red dye is used to identifyfuels intended for agricultural andnon-highway use.

You may operate your vehicle on dieselfuels containing up to 20% biodiesel, alsoknown as B20.Biodiesel fuel is a chemically convertedproduct from renewable fuel sources, suchas vegetable oils, animal fats and wastecooking greases.

To help achieve acceptable engineperformance and durability when usingbiodiesel in your vehicle:• Confirm the biodiesel content of 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 GeneralMaintenance Information (page 59).

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

• Consider changing brands or reducingbiodiesel content if you have coldtemperature fuel gelling issues or afrequent LOW FUEL PRESSUREmessage appearing

• Do NOT use raw oils, fats or wastecooking greases

Use of biodiesel in concentrations greaterthan 20% may cause damage to yourvehicle, including engine and/or exhaustafter-treatment hardware (exhaustcatalyst and particulate filter) failures.Concentrations greater than 20% can alsocause fuel filter restrictions that may resultin a lack of power or damage to fuelsystem components, including fuel pumpand fuel injector failures.SAE 5W-40 or SAE 15W-40 oil isrecommended for fuels with greater than5% biodiesel (B5). Refer to the Specialoperating conditions section under theSchedule Maintenance chapter for moreinformation about oil change intervals andother maintenance when operating onbiodiesel.

16


Fuel and Refueling

Look for a label on the fuel pump toconfirm the amount of biodiesel containedin a diesel fuel. Biodiesel content is oftenindicated with the letter B followed by thepercent of biodiesel in the fuel. Forexample, B20 indicates a fuel containing20% biodiesel. Ask the service stationattendant to confirm the biodiesel contentof a diesel fuel if you do not see a label onthe fuel pump.Biodiesel fuels degrade more easily thandiesel fuels not containing biodiesel andshould not be stored in the fuel tank formore than 1 month. If you plan to park orstore your vehicle for more than 1 month,then you should empty your vehicle fueltank of biodiesel fuel. You should fill thetank with a pure petroleum-based dieselfuel and run your vehicle for a minimum of30 minutes.Note: Degraded or oxidized biodiesel candamage fuel system seals and plastics andcorrode steel parts.During cold weather, if you have problemsoperating on biodiesel, you may need touse a diesel fuel with lower biodieselcontent, try another brand, or discontinuethe use of biodiesel.

Diesel Fuel AdditivesIt should not be necessary to add anyaftermarket additives to your fuel if youuse a high quality diesel fuel that conformsto ASTM industry specifications.Aftermarket additives can damage the fuelinjector system or engine.Use Motorcraft® cetane booster or anequivalent cetane booster additive if yoususpect fuel has low cetane. UseMotorcraft® anti-gel & performanceimprover or an equivalent additive if thereis fuel gelling.

Do not use alcohol-based additives toimprove cetane quality, to prevent fuelgelling or any other use. The use of alcoholadditives may result in damage to the fuelinjectors and system. See TechnicalSpecifications (page 57).Your warranty may not cover repairsneeded to correct the effects of using anaftermarket product that does not meetFord specifications in your fuel.Note: Ultra Low Sulfur Diesel fuel isdesigned to meet the emissions standardsfor the 6.7L engine and is backwardcompatible as well (for example, it can beused in the 7.3L, 6.9L, 6.4L and 6.0L dieselengines in Ford vehicles.

Fuel And Water SeparatorYour vehicle is equipped with a diesel fuelconditioner module located on theframe-rail under the driver-side floorboardnear the transmission.

You should drain water from themodule assembly whenever thewarning light comes on and the

message center directs you to drain thewater separator. This will occur whenapproximately 0.32 pints (150 ml) of wateraccumulates in the module. If you allowthe water level to exceed this level, thewater may pass through to the engine andmay cause fuel injection equipmentdamage.

Draining the Diesel Fuel ConditionerModule (DFCM)

WARNINGYour vehicle must be stopped withthe engine off when draining theDiesel Fuel Conditioner Module. Fuel

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

17


Fuel and Refueling

Note: If you drain the diesel fuel conditionermodule while the system is running air willenter into the fuel system. The engine willnot operate properly if air enters the system.Note: With fuel tank levels above 3⁄4 tankit may be necessary to loosen the bowl 3turns before opening the drain. This willactuate an anti-siphon valve at the fuel andwater separator inlet and prevent the fuelfrom siphoning out of the tank.Note: A loose drain valve can allow air toenter the fuel system and cause drivetrainissues. 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 appropriatecontainer under the drain port.

E163360

3. Rotate the drain counterclockwise untilthe O-ring is visible. Allow the dieselfuel conditioner module to drain forapproximately 25 seconds or untilclean fuel is observed. Rotate the drainclockwise to tighten it. If no liquiddrains, there may be a clog in the drain.Have the conditioner module servicedby an authorized dealer.

4. Make sure that you fully tighten thedrain valve and then remove thecontainer from under your vehicle.

5. Restart the engine. If the WATER INFUEL DRAIN FILTER or WATER IN FUELDRAIN FILTER SEE MANUAL messageand light continues to illuminate, havethe fuel system checked and repaired.

Low Fuel PressureThe engine is equipped with a low fuelpressure detection system. Here are somepossible causes if a low fuel pressuremessage appears in the informationdisplay:• Cold start or during cold operation

(below 32°F (0°C): If the low fuelpressure message appears during acold start or up to 10 minutes after theinitial cold start, monitor theinformation display. If the low fuelpressure message disappears and doesnot re-appear after the engine has fullywarmed up, waxed or gelled fuel iswhat most likely caused the message.Do not use alcohol based additives tocorrect fuel gelling. This may result indamage to the fuel injectors andsystems. Use an anti-gel additive. SeeTechnical Specifications (page 57).

Note: Your customer warranty may be voidfrom using additives that do not meet orexceed Ford specifications. If the low fuelpressure message persistently appears afterre-fueling during the cold start and coldoperation conditions defined previously andthen disappear when the engine has fullywarmed up, consider different fuel sources.

18


Fuel and Refueling

• Low fuel operation: If the low fuelpressure message appears when yourvehicle is warm and during low fueltank level operation (near empty),refuel your vehicle. If the messagereappears after fueling, see below. Ifthe message does not come back, thelow fuel pressure condition was due tolow fuel levels in the fuel tank.

• Normal operation: If the low fuelpressure message appears duringnormal operation when the engine isfully warm, and fuel level is not low,you must change the fuel filtersregardless of the maintenanceschedule interval.

• If replacement of the fuel filter doesnot remedy the low fuel pressuremessage during normal operation asdefined above, take the vehicle to anauthorized dealer.

Changing the Engine-Mounted andDiesel Fuel Conditioner Module FuelFiltersYour vehicle is equipped with two fuelfilters. The first filter mounts on top of theengine on the driver’s side. The secondfilter, inside the diesel fuel conditionermodule, is mounted on the frame rail underthe driver’s side floorboard near thetransmission. You should replace bothfilters at the same time. Regular fuel filterchanges are an important part of enginemaintenance; failing to keep with thescheduled maintenance could lead toengine performance issues and fuelinjection system damage. Refer to thescheduled maintenance information of thissupplement for more information. SeeGeneral Maintenance Information(page 59).

Refer to Motorcraft part numbers in theCapacities and Specifications chapter forthe fuel filter replacement part number.See Motorcraft Parts (page 55). This partnumber includes filters and seals for boththe engine-mounted and frame-mountedfilters.

Removal - Diesel Fuel ConditionerModule filterThe diesel fuel conditioner module filter islocated in the lower portion of the housing.1. Drain the diesel fuel conditioner

module. See Draining the Fuel andWater Separator earlier in this chapter.

2. Remove the lower portion of the dieselfuel conditioner module housing (filterbowl) by turning it counterclockwiseusing a 32 mm socket.

E163361

Note: Depending on the amount of sealswelling, removal of the filter bowl may benoisy and require some effort. Replace theseal prior to reinstalling the filter bowl toimprove assembly.3. Remove and discard the old fuel filter

element.4. Carefully clean the mating surfaces

using a lint-free rag.

19


Fuel and Refueling

Installation – Diesel Fuel ConditionerModule filter1. Install the new filter into the filter bowl

tabs and replace the seal on the dieselfuel conditioner module header (topportion of separator). Refer toMotorcraft part numbers in theCapacities and Specifications chapterfor the fuel filter kit part number. SeeMotorcraft Parts (page 55).

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

E163362

3. Reinstall the lower portion of thehousing by slowly turning it clockwiseonto diesel fuel conditioner modulehousing, allowing fuel to soak into thefuel filter element. Tighten the lowerhousing until it contacts themechanical stop.

Note: The engine will not run properly if youdo not install the diesel fuel conditionermodule fuel filter in the housing or if thefilter bowl is not tightened to themechanical stop.Note: You will need to purge the system ofair after removal or changing of the filter.See purging air from the fuel system laterin this chapter.

Removal - Engine-mounted fuel filterThe engine-mounted fuel filter is a plasticdisposable cartridge. To remove it, do thefollowing:

E163363

1. Disconnect both fuel lines by squeezingthe connector tabs and pulling the linesstraight off.

E163364

Note: Although the fuel system is not fullypressurized when the vehicle is off, someresidual pressure may remain in the fuelsystem since it can take some time for thepressure to completely bleed off. Therefore,we recommend you place a shop rag belowthe filter connectors to absorb the smallamount 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.

20


Fuel and Refueling

Installation – Engine-mounted fuelfilter1. Install the new filter into the filter

bracket. Turn the filter clockwise tolock it in place.

2. Reconnect both fuel lines.Note: Using a fuel that has more thanaverage impurities may require you toreplace the fuel filter more frequently thanthe service interval specifies.Note: You will need to purge the system ofair after removal or changing of the filter.See purging air from the fuel system laterin this chapter.

Purging air from the fuel systemTurn the ignition key to on for 30 seconds,then turn it to off. Do this six times in a rowto purge any trapped air from the fuelsystem.After filter service, a no start or roughrunning engine may indicate that air isentering the system through the filter bowlseal or drain. Make sure the drain is tightand you tightened the filter bowl to themechanical stop.

SELECTIVE CATALYTICREDUCTION SYSTEMYour vehicle is equipped with a selectivecatalytic reduction system to help reduceemission levels of oxides of nitrogen fromthe exhaust of the diesel engine. Thesystem automatically injects DieselExhaust Fluid (DEF) into the exhaustsystem to enable proper selective catalyticreduction function.

Importance of maintaining theDiesel Exhaust Fluid (DEF) levelIn order for the selective catalytic reductionsystem to operate properly, the DEF levelmust be maintained. Generally, the DEFtank should be filled during the oil changeservice interval. See GeneralMaintenance Information (page 59).However, certain conditions or drivingstyles, such as trailer towing or fast ratesof acceleration, will require the refilling ofthe DEF tank more often.The engine control unit will monitor theamount of fluid available in the DEF tank.Running a system check in the informationdisplay will indicate whether the DEF levelis ok or if it is less than 1/2 full. A messagewill display in the information display whenthe DEF level is low and needs to berefilled. When you see this message, youshould refill your tank. See the Informationdisplays chapter of your Owner’s Manualfor information display functions. Forinstructions on refilling your DEF tank, seefilling the Diesel Exhaust Fluid (DEF) tankin this supplement.

Diesel Exhaust Fluid (DEF)warning messages and vehicleoperations

WARNINGSDiesel Exhaust Fluid (DEF) must berefilled when low or replaced whencontaminated or your vehicle speed

will be speed limited to 50 mph (80 km/h).In these conditions, drive with caution andrefill DEF immediately. If the DEF becomesempty or contaminated and fluid is notreplaced, your vehicle will become limitedto idle speed only once stopped. In theseconditions, be cautious where you stopyour vehicle because you may not be ableto drive long distances and will not be ableto maintain highway speeds until you refillor replace the DEF.

21


Fuel and Refueling

WARNINGSTampering or disabling your vehicle’sexhaust aftertreatment system willresult in severe vehicle performance

limitation including eventual speed limitingto 5 mph.

Your vehicle’s information display willdisplay a series of messages regarding theamount of DEF available. A systems checkwill display messages indicating theamount of DEF available (OK or under 1⁄2full) or will produce a warning messagethat displays the mileage (kilometers)remaining as the fluid in the DEF tank nearsempty. For more information on warningmessages, see the Information Displayschapter of your Owner’s Manual.

E163176

As the DEF level nears empty,the DEF warning symbol will bedisplayed and a series of tones

will sound with the messages starting at500 miles (805 km) remaining before DEFis depleted. The warning symbol andmessages will continue until you refill theDEF tank.

Continued driving without refilling willresult in the following actions as requiredby the California Air Resources Board(CARB) and the U.S. EnvironmentalProtection Agency (EPA):• Within a certain number of miles

(kilometers) to empty, speed will belimited upon vehicle restart. Prior tothis occurring a message will appear inthe information display.

• Further vehicle operation withoutrefilling your DEF tank will cause theengine to enter an idle-only condition.This will only occur upon vehiclerefueling or at an extended idle. Amessage will indicate the requiredactions to resume normal operation. Itis required to add a minimum of 0.5gallons (1.9L) of DEF to the tank to exitthe idle-only condition, but your vehiclewill still be in the speed-limiting modeuntil you refill the tank completely.

For either vehicle speed limiting or idle-onlycondition, normal vehicle operation willresume when you refill the DEF tank.Note: When filling the DEF tank fromempty, there may be a short delay beforedetecting the increased level of fluid. Theincreased level detection must occur beforeyour vehicle returns to full power.

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

Vehicle ActionsCustomerRequested Actions

Distance/ExhaustFluid Level or Action

Cluster Message

NoneDrive normallyFull exhaust fluidtank

Exhaust Fluid LevelOK

NoneDrive normallyExhaust fluid tankbelow 1⁄2 full

Exhaust Fluid Under1⁄2 Full

22


Fuel and Refueling

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

NoneRefill exhaust fluidApproximately 500miles (805 km) leftbefore exhaust fluid

tank is empty

Exhaust Fluid Range500 miles (805 km)

NoneRefill exhaust fluidApproximately 99Miles (159 km) left

before exhaust fluidtank is empty

In 99 Miles (159 km)Speed Limited to 50

MPH (80 km/h)Exhaust Fluid Empty

NoneRefill exhaust fluid0 Miles (0 km) –exhaust fluid tank is

empty

Speed Limited to 50MPH (80 km/h)

Upon RestartExhaust Fluid Empty

Speed is limited to50 MPH. (80 km/h)

Refill exhaust fluidVehicle restartedwith exhaust fluid

tank empty

Speed Limited To 50MPH (80 km/h)

Exhaust Fluid Empty

-Refill exhaust fluidThis occurs 200Miles (322 km) afterthe vehicle reachesthe 0 mile (0 km)

exhaust fluid range

Engine Idled SoonExhaust Fluid Empty

Engine is limited toidle ONLY

Refill exhaust fluidThis occurs whenthe exhaust fluid is

empty and:

Engine Idled-SeeOwner’s Manual

Exhaust Fluid EmptyThe vehicle’s dieselfuel tank is refueled

or,the engine is shut off

for 10 minutes or,the engine is idling

with the parkingbrake engaged for

60 minutes.

23


Fuel and Refueling

Filling the Diesel Exhaust Fluid (DEF)tank

WARNINGSMake sure that Diesel Exhaust Fluid(DEF) does not come into contactwith eyes, skin or clothing. Should

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

Refill DEF in a well-ventilated area.When opening the cap on the DEFtank or bottle containing DEF,

ammonia vapors may escape. The vaporscan be irritating to skin, eyes and mucousmembranes. Inhaling ammonia vapors cancause burning to the eyes, throat and noseand cause coughing and watery eyes.

Note: Do not put DEF in the fuel tank. Thiscan cause engine damage not covered byyour vehicle’s warranty.Note: Immediately wipe away any DEF thathas spilled on painted surfaces with waterand a damp cloth to prevent damage to thepaint.Your vehicle is equipped with a DEF tankwith a blue-capped filler port located nextto the diesel fuel fill inlet. The tank can befilled using a nozzle at a DEF filling station(similar to fuel fill) or using a DEF bottlewith a spout. We recommend Motorcraft®DEF bottles since they are designed to bespill proof and will stop the flow of DEFwhen the tank is full. You can use otheraftermarket bottles, but they should havea seal on the spout and an internal venttube to achieve best fill performance andprevent overfilling. Overfilling your DEFtank can cause damage to the tank. Foryour DEF tank capacity. See TechnicalSpecifications (page 57).

You can purchase Diesel Exhaust Fluid(DEF) at an authorized dealer, mosthighway truck stops or you can contactroadside assistance for help in finding aretailer that sells DEF. See the CustomerAssistance chapter in the Owner’s Manualfor more information. In addition, there isa government website locator for DEF atthe following web address to find thenearest location to purchase DEF:http://www.afdc.energy.gov/afdc/locator/def.

E163354)

E163354

Use only DEF certified by the AmericanPetroleum Institute (API) such asMotorcraft® DEF or equivalent meetingFord specification WSS-M99C130-Aand/or ISO 22241. Look for API certificationtrademark shown here. Your vehicle’swarranty will not cover repairs resultingfrom the use of non-certified dieselexhaust fluid products.Maintaining the purity of DEF is importantto avoid malfunctions in the selectivecatalytic reduction system.If you remove the DEF for tank repair, youcannot use the same fluid to refill the tank.You can no longer guarantee the purity ofthe DEF.To fill the DEF tank in cold climates, seefilling the Diesel Exhaust Fluid (DEF) tankin cold climates later in this section or seean authorized dealer.

24


Fuel and Refueling

Diesel Exhaust Fluid (DEF) bottle fill withspoutThe following procedure applies toMotorcraft® Diesel Exhaust Fluid (DEF) orsimilar diesel exhaust fluid bottles; forother brands or bottle types, refer to theinstructions on the bottle label.1. Remove the cap from the DEF

container. Remove the spout from thebottle and insert the straw end into thebottle. Ensure you align the arrowabove the nut with the bottle handleand the small tube end extends intothe far corner of the bottle. Twist thespout nut on the container until it istight.

E163355

2. Open the DEF filler port on your vehicleby turning the blue capcounterclockwise. Do not put DEF inthe fuel tank. This can cause enginedamage not covered by your vehicle’swarranty.

E163356

3. Lift and hold the DEF container,without tipping, and insert the spoutinto the DEF filler port until the smallblack seal on the spout completelyseats into the filler port.

E163357

4. While filling, the fluid level in the bottlewill continually drop.

E163358

25


Fuel and Refueling

5. When the DEF tank is full, the fluid levelin the bottle will stop dropping,indicating the fluid has stoppedflowing.

E163359

6. Once the level in the DEF bottle hasstopped dropping, return the containerto the vertical position slightly belowthe DEF filler port and let any DEF drainout of the spout. DO NOT try tocontinue to add DEF to the tank byshaking or repositioning the containerto induce flow. This may cause spillingand overfill the tank. Overfilling the DEFtank can cause damage to the tank.

7. Once the spout has drained, removethe spout from the DEF filler port andinstall the blue cap on the DEF fillerport.

8. Remove the spout from the dieselexhaust fluid container and install thecap back on the bottle.

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

10. Wipe away any DEF that has spilledon painted surfaces with water anda damp cloth.

Diesel Exhaust Fluid (DEF) filling stationnozzle fillFilling the Diesel Exhaust Fluid (DEF) tankusing a nozzle is similar to a normal fuelfill. The nozzle will shut off automaticallywhen the tank is full. Do not continue to fillthe tank as this may cause spilling andoverfill can cause damage to the tank.Note: Some filling station nozzles mayprevent filling of your DEF tank due to amagnetic mechanism in the nozzle. This isnot a problem with your vehicle. To refillyour tank either locate another filling stationor use a bottle to refill the tank.

Filling the Diesel Exhaust Fluid (DEF)tank in cold climatesDiesel Exhaust Fluid (DEF) will freezebelow 12°F (-11°C); however, your vehicleis equipped with an automatic preheatingsystem which allows the DEF system tooperate below 12°F (-11°C). When yourvehicle is not in operation for an extendedperiod with temperatures at or below 12°F(-11°C), the DEF tank could freeze. If thetank is OVERFILLED and freezes, it couldbe damaged, therefore DO NOT OVERFILL.To prevent overfilling of the DEF tank whenfilling with a bottle, Ford recommendsusing Motorcraft® Diesel Exhaust Fluid(DEF). Additionally, if the informationdisplay indicates EXHAUST FLUID UNDER1/2 FULL, you should only add a MAXIMUMof 2 gallons (6.7L) of DEF to the tank toprevent freeze damage due to overfilling.If the information display indicatesEXHAUST FLUID LEVEL OK, do not addDEF.

26


Fuel and Refueling

Contaminated Diesel Exhaust Fluid(DEF) or inoperative SelectiveCatalytic Reduction system

E163176

Selective catalytic reductionsystems are sensitive tocontamination of the Diesel

Exhaust Fluid (DEF). USE ONLY API or ISO22241 CERTIFIED DIESEL EXHAUST FLUID(DEF). If the selective catalytic reductionsystem becomes contaminated orinoperative, the Diesel Exhaust Fluid (DEF)light will illuminate and exhaust fluidsystem fault messages will appear in theinformation display.

Continued driving without replacing DEFor having the selective catalytic reductionsystem repaired will result in the followingactions as required by the California AirResources Board (CARB) and U.S.Environmental Protection Agency (EPA):• Within a certain number of miles

(kilometers) to empty, speed will belimited upon restart. Prior to thisoccurring a message will appear in theinformation display.

• Further vehicle operation withoutreplacing contaminated DEF will causethe engine to enter an idle-onlycondition. This will only occur uponvehicle refueling, vehicle idling in parkfor 1 hour, or engine shutdown for 10minutes or more and will be indicatedby a message in the information displayindicating required actions to resumenormal operation.

For either vehicle speed limiting or idle-onlycondition, normal vehicle operation willresume when you repair the contaminatedsystem. To service a contaminated orinoperative system, see an authorizeddealer.

Diesel Exhaust Fluid (DEF) guidelinesand information• Use only Diesel Exhaust Fluid that

carries the trademark: AmericanPetroleum Institute (API) certified DEFor 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 thathas spilled with a damp cloth andwater. If it has already crystallized, usewarm water and a sponge.

• Store DEF out of direct sunlight and intemperatures 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 causedamage to interior components orrelease an ammonia odor inside yourvehicle.

• DEF is non-flammable, non-toxic,colorless and water-soluble liquid.

• Do not dilute DEF with water or anyother liquid.

• An ammonia odor may be smelledwhen the cap is removed or duringrefill. Refill DEF in a well ventilatedarea.

Typical Diesel Exhaust Fluid (DEF)UsageThe charts below illustrate approximateDiesel Exhaust Fluid (DEF) usage for thegiven distances traveled under variousdriving conditions and when using thepower take off. Your usage may varydepending on: driving style, trailer towing,loaded vehicle weight, weather, idle time,PTO usage.

27


Fuel and Refueling

Pick-up (3.31 axle ratio)

Steady highwaydriving

Normal drivingTrailer towing /aggressive or city

driving

Driving style

9600 miles (15450km) – 10000 miles

(16093 km) +

7100 miles (11426km) – 9600 miles

(15450 km)

4100 miles (6598km) – 7100 miles

(11426 km)

Diesel Exhaust Fluid(DEF) usage




driving

Driving style

8100 miles (13036km) – 9700 miles

(15611 km)

5800 miles (9334km) – 8100 miles

(13036 km)

2800 miles (4506km) – 5800 miles

(9334 km)





driving

Driving style

7300 miles (11748km) – 8900 miles

(14323 km)

5050 miles (8127km) – 7300 miles

(11748 km)

2050 miles (3299km) – 5050 miles

(8127 km)





driving

Driving style

6300 miles (10139km) – 7900 miles

(12714 km)

4100 miles (6598km) – 6300 miles

(10139 km)

1100 miles (1770 km)– 4100 miles (6598

km)


28


Fuel and Refueling

Chassis cab (non–Power Take Off)



driving

Driving style

7800 miles (12553km) – 9300 miles

(14967 km)

4700 miles (7564km) – 7800 miles

(12553 km)

1700 miles (2736km) – 4700 miles

(7564 km)


Chassis cab (with Power Take Off)

Cont. PTO usage — Min. PTO usagePTO usage

0 miles (0 km) — 7800 miles (12553 km)Diesel Exhaust Fluid(DEF) usage

REFUELINGFueling Tips

WARNINGDo not use starting fluid such asether or gasoline in the diesel airintake system. Such fluids can cause

immediate explosive damage to the engineand possible personal injury.

Truck stops have pumps and nozzlesdesigned for larger, heavy-duty trucks.When refueling at truck stops: if the nozzleshuts off repeatedly when refueling, wait5–10 seconds; then use a slower rate offlow (don’t depress the nozzle trigger asfar).

If air is allowed to enter the fuel system(during fuel filter change or if you run outof fuel) the engine will purge the trappedair as it runs. To purge the air sooner: priorto engine start, prime the system by turningthe key to on for 30 seconds then to off.Repeat this several times. The engine mayrun rough and produce white smoke whileair is in the system. This is normal.An engine that suddenly becomes noisy oroperates poorly after a fuel fill could beusing substandard fuel (for example, highwater content, low cetane rating orgasoline in the fuel). You should purchasediesel fuel from a reputable station thatsells a large amount of diesel fuel.Use only clean, approved containers thatwill prevent the entry of dirt or waterwhenever you store diesel fuel.Diesel fuel must not be stored in agalvanized container. The fuel will dissolvethe zinc in the galvanized container. Thezinc will then remain in the fuel. If you runthe contaminated fuel through the engine,the zinc will deposit in the fuel injectorscausing expensive-to-repair damage.

29


Fuel and Refueling

Diesel fuel dispensing nozzle fill rateYour truck is equipped with a fuel fill pipethat is able to accept fuel up to 20 gallonsper minute from an 11⁄8 fuel-dispensingnozzle. Pumping fuel at greater flow ratesmay result in premature nozzle shut-off orspit back.

Fuel filler cap

WARNINGSThe fuel system may be underpressure. If the fuel filler cap isventing vapor or if you hear a hissing

sound, wait until it stops before completelyremoving the fuel filler cap. Otherwise, fuelmay spray out and injure you or others.

If you do not use the proper fuel fillercap, excessive pressure or vacuumin the fuel tank may damage the fuel

system or cause the fuel cap to disengagein a collision, which may result in possiblepersonal injury.

Note: If you must replace the fuel filler cap,replace it with a fuel filler cap designed foryour vehicle. The vehicle warranty may bevoid for any damage to the fuel tank or fuelsystem if the correct genuine Ford orMotorcraft® fuel filler cap is not used.Your fuel tank filler cap has an indexeddesign 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.

EMISSION CONTROL SYSTEMDiesel Exhaust System: OxidationCatalyst And Diesel ParticulateFilter System (If Equipped)

Your vehicle is equipped with a dieselparticulate filter. The diesel particulatefilter is an inline filter in the exhaust systemthat reduces carbon emissions by trappingexhaust particles before they reach thetailpipe. The diesel particulate filter lookssimilar to a traditional exhaust catalyst,except larger, and is part of the exhaustsystem under the vehicle. The filter couplesto a diesel oxidation catalyst that reducesthe amount of harmful exhaust emittedfrom the tailpipe. As soot gathers in thesystem, it begins to restrict the filter. Youneed to periodically clean the soot thatgathers inside the filter. You can clean thesoot in two different ways, passiveregeneration and active regeneration. Bothmethods occur automatically and requireno actions from the driver. During eitherone of these regeneration methods, youmay notice a change in exhaust tone. Atcertain times, the information display willdisplay various messages related to thediesel particulate filter. See the InformationDisplays chapter in the Owner Guide formore information.

Passive regenerationIn passive regeneration, the exhaustsystem temperature and constituentsautomatically clean the filter, or reducethe soot level, by burning (oxidizing) thesoot. Cleaning occurs naturally because ofnormal engine operating conditions (atvarying levels, due to driving patterns).

30


Fuel and Refueling

Diesel particulate filter maintenanceYou must properly maintain your dieselparticulate filter in order for it to functionproperly. Do not disregard the EXHAUSTOVERLOADED DRIVE TO CLEAN andEXHAUST AT LIMIT DRIVE TO CLEANNOW maintenance messages otherwisesystem damage could result that yourwarranty may not cover.Failure to perform active or OperatorCommanded Regeneration wheninstructed could result in a clogged dieselparticulate filter. If your diesel particulatefilter fills beyond the regenerationthreshold, your vehicle will disable theability for active and OperatorCommanded Regeneration. This couldresult in irreversible damage to the filterrequiring replacement that your warrantymay not cover. If your vehicle is notequipped with Operator CommandedRegeneration, check with your dealer foravailability.Once the diesel particulate filter is full ofexhaust particles, the engine controlmodule will command the exhaust systemto clean the filter through a process calledactive regeneration. Active regenerationrequires the engine computer to raise theexhaust temperature to eliminate theparticles. During cleaning, the particlesconvert to harmless gasses. Once cleanedthe diesel particulate filter will then beready to continue trapping exhaustparticles.The regeneration process operates moreefficiently when you safely operate yourvehicle at least 30 mph (48 km/h) with asteady pedal for approximately 20 minutesto complete the process. The frequencyand duration of regeneration will fluctuateby how you drive your vehicle, outside airtemperature, and altitude. For most driving,regeneration frequency will vary from 100

- 500 miles (161 - 805 km) betweenoccurrences and each occurrence will lastfrom 9 - 20 minutes. You can usuallyreduce the duration of regeneration if youmaintain a constant speed above 30 mph(48 km/h).When the engine control module detectsthat the diesel particulate filter is nearlyfull of particulates and you are notoperating your in a manner to alloweffective automatic cleaning, theinformation display will display EXHOVERLOADED DRIVE TO CLEAN forbase information display and ExhaustOverloaded Drive to Clean for theoptional information display. Thesemessages appear as a reminder for you todrive in order to clean the diesel particulatefilter. If you operate your vehicle in amanner to allow effective automaticcleaning, the information display willdisplay a cleaning exhaust filter message,which is the normal regeneration process.See the Information Displays chapter ofthe Owner Guide for more information.You can also choose OperatorCommanded Regeneration to clean theexhaust system at this point. See How tostart Operator Commanded Regenerationlater in this chapter.If you are not able to drive in a manner thatallows effective automatic cleaning (activeregeneration) or you choose to performregeneration of the diesel particulate filter(cleaning) while at idle (stationary), thenOperator Commanded Regenerationwould need to be performed. See OperatorCommanded Regeneration later in thischapter.

31


Fuel and Refueling

Operator Commanded Regeneration(If Equipped)If your vehicle is operated with significantstationary operation, low speed drivecycles less than 25 mph, short drive cycles,a drive time is less than 10 - 15 minutes orthe vehicle does not fully warm up, passiveand active regeneration may notsufficiently clean the diesel particulatefilter system. Operator CommandedRegeneration allows you to manually startregeneration of the diesel particulate filterat idle (while stationary) to clean the filter.If you are not sure whether your vehicle isequipped with this feature, contact anauthorized dealer.

When to perform Operator CommandedRegenerationUse the Operator CommandedRegeneration feature when the EXHOVERLOADED DRIVE TO CLEANmessage appears in the informationdisplay and:• the operator is not able to drive in

manner that allows effectiveautomatic cleaning (activeregeneration),

• or the operator instead wishes tomanually start regeneration (cleaning)of the diesel particulate filter while thevehicle is idle (stationary).

Operator Commanded Regenerationprecautions and safe exhaust position

WARNINGFailure to comply with the followinginstructions for OperatorCommanded Regeneration may

result in fire, serious injury, death and/orproperty damage.

Before you start operator commandedregeneration, do the following:

• Place your vehicle in P (Park) with theparking brake set on stable, levelground

• You must park your vehicle outside ofany structure

• Your vehicle must be 10 – 15 feet (3 –5 meters) away from any obstructionsand must be away from materials thatcan easily combust or melt (forexample, paper, leaves, petroleumproducts, fuels, plastics and other dryorganic material)

• Make sure there is a minimum of 1/8tank of fuel

• Make sure all fluids are at proper levelsMake sure that the louvers (holes) locatedat the tip of the exhaust are also clear ofany obstructions as they are used tointroduce fresh air into the tailpipe to coolthe exhaust gas as it leaves. See Cleaningthe Exhaust (page 54).

How to start Operator CommandedRegeneration

WARNINGStay clear of exhaust tip duringregeneration. You or others can beburned.

Note: You cannot use the OperatorCommanded Regeneration until the dieselparticulate filter load percentage hasreached 100% (Full). The diesel particulatefilter load percentage will fluctuate up anddown when driving your vehicle due to activeand passive regenerations.Note: During the use of OperatorCommanded Regeneration, you mayobserve a light amount of white smoke. Thisis normal.

You cannot use the OperatorCommanded Regeneration if theservice engine soon light is

illuminated.

32


Fuel and Refueling

Information display procedureStart with your vehicle engine fully warmedand then press the Info button on thesteering wheel until the information displayreads one of the following choices:• EXHST XX% FULL CLEAN? Y/N• EXHAUST FULL CLEAN? Y/NAnswer yes to this prompt and then followthe prompts regarding exhaust position asneeded to initiate Operator CommandedRegeneration. Be sure to understand eachprompt. If you are not sure what is beingasked by each prompt, contact anauthorized dealer. The display will confirmthe operation has started and when it hasfinished.If the diesel particulate filter is near or atsaturation, a message requestingpermission to initiate filter cleaning willdisplay EXH AT LIMIT CLEAN? Y/N.Answer yes to this prompt and then followthe prompts regarding exhaust position asneeded to initiate Operator CommandedRegeneration. Be sure to understand eachprompt. If you are not sure what is beingasked by each prompt, contact anauthorized dealer. The display will confirmthe operation has started and when it hasfinished. You can also drive to clean thefilter. See Active regeneration earlier in thischapter.

When the system is at the pointof oversaturation, the serviceengine soon light will illuminate

and the following message EXH OVERLIMIT SERVICE NOW will appear . Youwill not be able to allow cleaning. Youmust have your vehicle serviced by anauthorized dealer.

Once operator commanded regenerationstarts, the engine’s rpm will rise toapproximately 2,000 - 2,400 rpm and thecooling fan will increase speed; you willhear a change in audible sound due to thefan and engine speed increase.It is not necessary to open the hood on theengine compartment. Once OperatorCommanded Regeneration is complete,the engine rpm and fan will return tonormal idling. The exhaust system willremain very hot for several minutes evenafter regeneration is complete. Do notreposition the vehicle over materials thatcould burn until the exhaust system hashad sufficient time to cool. Depending onthe amount of soot collected by the dieselparticulate filter, ambient temperature,and altitude, Operator CommandedRegeneration may last from 10 to 25minutes.

How to interrupt or cancel OperatorCommanded RegenerationIf you need to cancel the OperatorCommanded Regeneration, pressing thebrake, accelerator, or shutting off thevehicle will stop the procedure. Dependingon the amount of time you allowed theOperator Commanded Regeneration tooperate, soot may not have had sufficienttime to be eliminated, but the exhaustsystem and exhaust gas may still be hot.If you shut your vehicle off during OperatorCommanded Regeneration, you will noticeturbo flutter. This is a normal consequencecaused by shutting off a diesel engineduring boosted operation and is considerednormal.

Filter service and maintenanceOver time, a slight amount of ash will buildup in the diesel particulate filter, which isnot removed during the regenerationprocess. The filter may need to be removedfor ash cleaning at approximately 120,000miles (193,000 km) or greater (actual

33


Fuel and Refueling

mileage can vary greatly depending uponengine/vehicle operating conditions) andreplaced with a new or remanufactured(ash cleaned) part. The filter may need tobe replaced at approximately 250,000miles (400,000 km) depending uponvehicle operating conditions.

In both cases, the engine controlsystem will set a service light toinform you to bring the vehicle

to the dealer for service.

If there are any issues with the dieselparticulate filter system a service light willbe set by the engine control system toinform you to bring your vehicle into anauthorized dealer for service.

Powertrain fault indicator or

Service engine soon

Resonator and Tailpipe assemblymaintenance

WARNINGSFailure to maintain the functionalholes, in the tailpipe section of theexhaust, clean and free of debris or

foreign material may result in the holesbecoming blocked or plugged. Do notmodify or remove the tail-pipe section.Blocked or plugged holes orremoval/modification of the system couldresult in elevated exhaust gastemperatures which may result invehicle/property damage or personalinjury.

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

repair any part of the exhaust system untilit has cooled. Use special care whenworking around the diesel oxidationcatalytic converter and/or the diesel

WARNINGSparticulate filter (DPF). The dieseloxidation catalytic converter and/or theDPF heats up to a high temperature afteronly a short period of engine operation andcan stay hot even after the engine is turnedoff. Failure to follow these instructions mayresult in personal injury.

Note: Additions of aftermarket devices ormodifications to the exhaust system canreduce the effectiveness of the exhaustsystem as well as cause damage to theexhaust system or engine. These actionsmay also affect your vehicle’s warranty. Seethe Warranty Guide for more information.The diesel resonator tail-pipe assembly isa uniquely functioning device thataccompanies the diesel particulate filterassembly. The tail-pipe assembly servesmultiple functions. First, it serves as anacoustic device to attenuate exhaust noise.Second, it provides an exit path for theexhaust from your vehicle. It also helpscontrol the temperature of the exhaustduring diesel particulate filter regenerationevents. The visible holes in each leg of thetwin tip and the holes under the shield justinboard of the right rear tire(s) arefunctional. You need to keep the holesclear of mud, debris or foreign material tomaintain proper function of the exhaustsystem. Clean and remove debris or foreignmaterial if present as needed. Sprayingwith a hose during regular washing of yourvehicle should help keep holes clean andclear of debris or foreign material.

34


Fuel and Refueling

Emission Control System(s) Laws

WARNINGDo not remove or alter the originalequipment floor covering orinsulation between it and the metal

floor of the vehicle. The floor covering andinsulation protect occupants of the vehiclefrom the engine and exhaust system heatand noise. On vehicles with no originalequipment floor covering insulation, do notcarry passengers in a manner that permitsprolonged skin contact with the metalfloor. Provide adequate insulation. Failureto follow these instructions may result infire or personal injury.

In the U.S. federal law and certain statelaws prohibit removing or renderinginoperative emission control system(s).Similar federal or provincial laws mayapply in Canada. Ford recommendsagainst any vehicle modification withoutdetermining applicable law.

Tampering with emissionscontrol systems (includingrelated sensors and the Diesel

Exhaust Fluid (DEF) injection system) canresult in reduced engine power and theillumination of the service engine soonlight.

Tampering with a Noise ControlSystemFederal law prohibits the following acts orthe causing thereof: (1) The removal orrendering inoperative by any person otherthan for purposes of maintenance, repairor replacement of any device or elementof design incorporated into any new vehiclefor the purpose of noise control prior to itssale or delivery to the ultimate purchaseror while it is in use, or (2) the use of thevehicle after such device or element ofdesign has been removed or renderedinoperative by any person.

Among those acts, which the U.S.Environmental Protection Agency maypresume to constitute tampering are theacts listed below:• Removal of hood blanket, fender apron

absorbers, fender apron barriers,underbody noise shields or acousticallyabsorptive material.

• Tampering or rendering inoperative theengine speed governor, to allow enginespeed to exceed manufacturer’sspecifications.

The complexity of the diesel engine makesit so the owner is discouraged fromattempting to perform maintenance otherthan the services described in thissupplement.If you experience difficult starting theengine, rough idling, excessive exhaustsmoke, a decrease in engine performanceor excess fuel consumption, perform thefollowing 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 climactic

conditionsIf these checks do not help you correct theengine performance problem you areexperiencing, consult an authorized dealer.

35


Fuel and Refueling

Noise Emissions Warranty, ProhibitedTampering Acts and MaintenanceOn January 1, 1978, Federal regulationbecame effective governing the noiseemission on trucks over 10,000 lbs. (4,536kg) GVWR (Gross Vehicle Weight Rating).The preceding statements concerningprohibited tampering acts andmaintenance, and the noise warrantyfound in the Warranty Guide, areapplicable to complete chassis cabs over10,000 lbs. (4,536 kg) GVWR.

FUEL TANK SELECTORSWITCH

E163365

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

36


Fuel and Refueling

GENERAL INFORMATIONDiesel Engine BrakingThis feature increases engine braking athigher engine speeds to provide bettergrade descent control with less brake andtransmission wear and tear.

E171217

Press the button located on theswitch bank next to the audiounit to switch the system on or

off.

A light will illuminate in the instrumentcluster when this feature is switched on.You can use this feature with tow/haul toprovide further increased engine braking.For more information on tow/haul, seeAutomatic Transmission operation in yourOwner's Manual.

37


Brakes

TOWING A TRAILERRefer to your Owner’s Manual for fulldetails on towing a trailer.

38


Towing

FUEL SHUTOFFIn the event of a moderate to severecollision, this vehicle is equipped with afuel pump shut-off feature that stops theflow of fuel to the engine. Not every impactwill cause a shut-off.After an accident, if the engine cranks butdoes not start, this switch may have beenactivated.

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This switch is located on the passenger’sside of the instrument panel. Open thefront passenger door and remove the smallaccess panel

E163367

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 theswitch by pushing in on the resetbutton.

4. Turn the ignition on.5. Wait a few seconds and return the key

to off.6. Make another check for leaks.

Running Out Of DEF (DieselExhaust Fluid)If your vehicle runs out of DEF, it will enterinto a speed limited mode and can alsoenter into an idle-only mode. Normalvehicle operation will not resume until DEFis refilled. See Selective CatalyticReduction System (page 21).Contact roadside assistance for help infinding a retailer that sells DEF. See theCustomer Assistance chapter in theOwner’s Manual for more information.

JUMP STARTING THE VEHICLE

WARNINGSThe gases around the battery canexplode if exposed to flames, sparks,or lit cigarettes. An explosion could

result in personal injury or vehicle damage.Batteries contain sulfuric acid whichcan burn skin, eyes and clothing, ifcontacted.Use only an adequate-sized cablewith insulated clamps.

Preparing Your VehicleNote: Do not attempt to push-start yourautomatic transmission vehicle. Automatictransmissions do not have push-startcapability. Attempting to push-start avehicle with an automatic transmission maycause transmission damage.

39


Roadside Emergencies

Note: Use only a 12-volt supply to start yourvehicle.Note: Do not disconnect the battery of thedisabled vehicle as this could damage thevehicle's electrical system.Park the booster vehicle close to the hoodof the disabled vehicle, making sure thetwo vehicles do not touch. Turn allaccessories off.

Connecting the Jumper CablesWARNING

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

as grounding points. Stay clear of movingparts. To avoid reverse polarityconnections, make sure that you correctlyidentify the positive (+) and negative (-)terminals on both the disabled and boostervehicles before connecting the cables.

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

4

2

1

3

E142664

1. Connect the positive (+) jumper cableto the positive (+) terminal of thedischarged battery.

2. Connect the other end of the positive(+) cable to the positive (+) terminalof the assisting battery.

3. Connect the negative (-) cable to thenegative (-) terminal of the assistingbattery.

4. Make the final connection of thenegative (-) cable to an exposed metalpart of the stalled vehicle's engine, orconnect the negative (-) cable to aground connection point if available.

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

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

40



Jump Starting1. Start the engine of the booster vehicle

and rev the engine moderately, or pressthe accelerator gently to keep yourengine speed between 2000 and 3000rpms, 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 anadditional three minutes beforedisconnecting the jumper cables.

Removing the Jumper CablesRemove the jumper cables in the reverseorder that they were connected.

4

1

3

2

E142665

1. Remove the jumper cable from theground metal surface or connectingpoint, if available.

2. Remove the jumper cable on thenegative (-) terminal of the boostervehicle's battery.

3. Remove the jumper cable from thepositive (+) terminal of the boostervehicle's battery.

4. Remove the jumper cable from thepositive (+) terminal of the disabledvehicle's battery.

After the disabled vehicle has been startedand the jumper cables removed, allow itto idle for several minutes so the batterycan recharge.

41



UNDER HOOD OVERVIEWF-Super Duty

E163368

M E B C

EGJKL F

DA

HI

Engine oil dipstickA.Automatic transmission fluid dipstickB.Brake fluid reservoirC.Power distribution boxD.BatteriesE.Engine cooling system coolant reservoir (primary high-temperature coolingsystem)

F.

Power steering fluid reservoirG.Engine oil fillH.Engine-mounted fuel filter assemblyISecondary cooling system coolant reservoirJAir filter assemblyKAir filter restriction gaugeLWindshield washer fluid reservoirM

42


Maintenance

Scheduled MaintenanceThe scheduled maintenance services inthe scheduled maintenance informationof this supplement are required becausethey are considered essential to the lifeand performance of your vehicle. SeeGeneral Maintenance Information(page 59).Use only recommended fuel, lubricants,fluids and service parts conforming to Fordspecifications. Motorcraft® parts aredesigned and built for best performancein your vehicle.

ENGINE OIL CHECKBecause it is normal to add some oilbetween oil changes, check your engine oillevel each time you stop for fuel. To checkthe engine oil level consistently andaccurately, the following procedure isrecommended:1. Have engine at normal operating

temperature (at least into the NORMALrange on the engine coolanttemperature gauge).

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

3. Allow at least 20 minutes after engineshutdown to ensure that the oilcontained in the upper parts of theengine has returned to the oil pan.

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

5. Read oil level on both sides of dipstickand use highest level (reading) for theactual engine oil level.

E163369

6. Maintain the oil level within thecrosshatch area on the dipstick byadding oil as required. Do not overfillthe oil past the maximum line asdepicted by the arrow.

Engine Oil SpecificationsTo help achieve acceptable engineperformance and durability, it is importantthat only engine oils of good quality areused in your diesel engine and it is changedat the recommended interval. For normalor severe service, use Motorcraft® oil or anequivalent oil conforming to Fordspecifications as listed in the Capacitiesand Specifications chapter. SeeTechnical Specifications (page 57). Itis important to use these oils because theyare compatible with the emission controlequipment of your vehicle to meet themore stringent emission standards.The use of correct oil viscosities for dieselengines is important for satisfactoryoperation. Determine which oil viscositybest suits the temperature range youexpect to encounter for the next serviceinterval from the following SAE viscositygrade chart.

43


Maintenance

E163370

• (1) For severe duty service, use SAE5W-40 API CJ-4.

• (2) For biodiesel fuel blends (B20max), use SAE 5W-40 or SAE 15W-40API CJ-4.

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

E163371

The American Petroleum Institute (API)service symbol is used to identify theproper engine oil for your engine. The APIservice symbol will be displayeded on theoil container you purchase. The API symboldisplays the oil performance category inthe top half of symbol and the viscositygrade in the center of the symbol.

Changing the Engine Oil and OilFilter

WARNINGSDo not handle a hot oil filter withbare hands.Continuous contact with used motoroil has caused cancer in laboratorymice. Protect your skin by washing

with soap and water.

Your vehicle is equipped with an IntelligentOil Life Monitor™ that calculates theproper oil change service interval. Whenthe information display indicates: OILCHANGE REQUIRED, change the engineoil and oil filter. See the InformationDisplays chapter in the Owner's Manualfor more information.The engine oil filter protects your engineby filtering harmful, abrasive or sludgeparticles and particles significantly smallerthan most available will-fit filters. Forengine oil filter part number, SeeMotorcraft 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 TechnicalSpecifications (page 57).

44


Maintenance

5. Reset the Intelligent Oil Life Monitor™.See the Information Displays chapterin the Owner's Manual for moreinformation.

Engine lubrication for severe serviceoperationThe following conditions define severeoperation for which engine operation withSAE 5W-40 API CJ-4 is recommended. Oiland oil filter change intervals will bedetermined by the Intelligent Oil LifeMonitor™ 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 25mph (40 km/h)

• Operating in severe dust conditions• Operating the vehicle off road• Towing a trailer over 1,000 miles (1,600

km)• Sustained, high-speed driving at Gross

Vehicle Weight Rating (maximumloaded weight for vehicle operation)

• Use of fuels with sulfur content otherthan ultra-low sulfur diesel (ULSD)

• Use of high-sulfur diesel fuel

ENGINE COOLANT CHECKChecking the Engine CoolantWhen the engine is cold, check theconcentration and level of engine coolantat the intervals listed in the scheduledmaintenance chapter. See ScheduledMaintenance (page 59).

Note: Make sure that the level is betweenthe MIN and MAX marks on the coolantreservoirs.Note: Coolant expands when it is hot. Thelevel may extend beyond the MAX markNote: If the level is at the MIN mark, belowthe MIN mark, or empty, add coolantimmediately. See Adding Engine Coolantin this chapter.Note: The coolant concentration should bemaintained within 48% to 50%, whichequates to a freeze point between -30 °F(-34 °C) and -34 °F (-37 °C).Note: For best results, the coolantconcentration should be tested with arefractometer such as Rotunda tool300-ROB75240 available from your dealer.Ford does not recommend the use ofhydrometers or coolant test strips formeasuring coolant concentrations.Note: Automotive fluids are notinterchangeable. Do not use engine coolantor antifreeze or windshield washer fluidoutside of its specified function and vehiclelocation.

Adding Engine CoolantWARNINGS

Do not add engine coolant when theengine is hot. Steam and scaldingliquids released from a hot cooling

system can burn you badly. Also, you canbe burned if you spill coolant on hot engineparts.

Do not put engine coolant in thewindshield washer fluid container. Ifsprayed on the windshield, engine

coolant could make it difficult to seethrough the windshield.

45


Maintenance

WARNINGSTo reduce the risk of personal injury,make sure the engine is cool beforeunscrewing the coolant pressure

relief cap. The cooling system is underpressure; steam and hot liquid can comeout forcefully when the cap is loosenedslightly.

Do not add coolant further than theMAX mark.

Note: Do not use stop leak pellets, coolingsystem sealants, or additives as they cancause damage to the engine cooling orheating systems. This damage would notbe covered under your vehicle’s warranty.Note: During normal vehicle operation, theengine coolant may change color fromorange to pink or light red. As long as theengine coolant is clear and uncontaminated,this color change does not indicate theengine coolant has degraded nor does itrequire the engine coolant to be drained, thesystem to be flushed, or the engine coolantto be replaced.

• Do not mix different colors or types ofcoolant in your vehicle. Make sure thecorrect coolant is used. Mixing ofengine coolants may harm yourengine’s cooling system. The use of animproper coolant may harm engine andcooling system components and mayvoid the warranty. Use engine coolantmeeting the Ford specification. SeeCapacities and Specifications (page55).

• In case of emergency, a large amountof water without engine coolant maybe added in order to reach a vehicleservice location. In this instance, thecooling system must be drained,chemically cleaned with MotorcraftPremium Cooling System Flush, andrefilled with prediluted engine coolantas soon as possible. Water alone(without engine coolant) can causeengine damage from corrosion,overheating or freezing.

• Do not use alcohol, methanol, brine orany engine coolants mixed with alcoholor methanol antifreeze (coolant).Alcohol and other liquids can causeengine damage from overheating orfreezing.

• Do not add extra inhibitors or additivesto the coolant. These can be harmfuland compromise the corrosionprotection of the engine coolant.

Add prediluted engine coolant meeting theFord specification (Motorcraft OrangeAntifreeze/Coolant Prediluted). SeeTechnical Specifications (page 57).Note: Generic coolants marketed for allmakes and models may not meet the Fordspecification and may cause damage to thecooling system. This damage may void thewarranty.

46


Maintenance

For vehicles with overflow coolant systemswith a non-pressurized cap on the coolantrecovery system, add coolant to thecoolant recovery reservoir when the engineis cool. Add prediluted engine coolant(Motorcraft Orange Antifreeze/CoolantPrediluted) to the FULL COLD level. For allother vehicles which have a coolant degassystem with a pressurized cap, or if it isnecessary to remove the coolant pressurerelief cap on the radiator of a vehicle withan overflow system, follow these steps toadd 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 reliefcap on the coolant reservoir (atranslucent plastic bottle). Slowly turncap counterclockwise until pressurebegins to release. When you are surethat all the pressure has been released,use the cloth to turn itcounterclockwise and remove the cap.

3. Fill the coolant reservoir slowly withprediluted engine coolant to within theFULL COLD level, or between the MINand MAX marks (within the COLD FILLRANGE), as listed on the enginecoolant reservoir. If you removed theradiator cap in an overflow system, fillthe radiator until the coolant is visibleand radiator is almost full. If coolant isadded to bring the level within theCOLD FILL RANGE when the engine isnot cold, the system may remain underfilled.

4. Replace the cap. Turn until tightlyinstalled. Cap must be tightly installedto prevent coolant loss.

Whenever coolant has been added, thecoolant level in the coolant reservoirshould be checked the next few times youdrive the vehicle. If necessary, add enoughprediluted engine coolant to bring thecoolant level to the proper level.

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

Engine and Secondary CoolingSystem Refill ProcedureThe following procedure should be usedwhen refilling the engine or secondarycooling systems after it has been drainedor 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 capcounterclockwise until pressure beginsto release.

3. Step back while the pressure releases.4. When you are sure that all the pressure

has been released, use the cloth to turnit counterclockwise and remove thecap.

5. Slowly add prediluted engine coolantto the coolant reservoir until thecoolant level is within the COLD FILLRANGE 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 previouslyoutlined.

9. If required, add prediluted enginecoolant to the coolant reservoir untilthe coolant level is within the COLDFILL RANGE as listed on the reservoir.

47


Maintenance

10. Engine cooling system: RepeatStep 5 until the coolant level hasstabilized (is no longer dropping aftereach step) AND the upper radiatorhose at the radiator is warm to thetouch (indicating that the enginethermostat is open and coolant isflowing through the radiator).Secondary cooling system: RepeatStep 5 until the coolant level hasstabilized (is no longer dropping aftereach step) AND the lower passengerside of the secondary radiator iswarm to the touch (indicatingsecondary thermostat is open andcoolant is flowing through the entiresystem).

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

12. Check the coolant level in thereservoir before you drive your vehiclethe next few times (with the enginecool).

13. If necessary, add prediluted enginecoolant to the coolant reservoir untilthe coolant level is within the COLDFILL RANGE as listed on the reservoir.After any coolant has been added,check the coolant concentration. SeeAdding Engine Coolant earlier inthe chapter for more information.

Whenever coolant has been added, thecoolant level in the reservoir should bechecked the next few times you drive thevehicle. If needed, add prediluted enginecoolant to bring the coolant level to theproper level on the reservoir.

Recycled Engine CoolantFord Motor Company does not recommendthe use of recycled engine coolant since aFord-approved recycling process is not yetavailable.

Used engine coolant should be disposedof in an appropriate manner. Follow yourcommunity’s regulations and standardsfor recycling and disposing of automotivefluids.

Severe ClimatesIf you drive in extremely cold climates:• It may be necessary to have a Ford

authorized dealer increase the coolantconcentration above 50%.

• A coolant concentration of 60% willprovide improved freeze pointprotection. Engine coolantconcentrations above 60% willdecrease the overheat protectioncharacteristics of the engine coolantand may cause engine damage.

If you drive in extremely hot climates:• It may be necessary to have a Ford

authorized dealer decrease the coolantconcentration to 40%.

• A coolant concentration of 40% willprovide improved overheat protection.Engine coolant concentrations below40% will decrease the corrosion/freezeprotection characteristics of the enginecoolant and may cause enginedamage.

Vehicles driven year-round in non-extremeclimates should use prediluted enginecoolant for optimum cooling system andengine protection.

Checking Coolant CorrosionInhibitor Additive StrengthAt specific mileage intervals of 15000miles (24000 km), as listed in thescheduled maintenance informationchapter, the coolant corrosion inhibitoradditive should be checked. The optionalinformation display, if equipped, will alsodisplay the message CHECK COOLANTADDITIVE at this time. The purpose ofchecking is to verify the correct engine

48


Maintenance

coolant concentration (freeze pointprotection) and corrosion inhibitor additivelevel (strength) of the coolant formaximum engine performance andprotection. Three products are availableto confirm the life and health of thecoolant: one tool, a test kit and a coolantinhibitor additive:

• Rotunda tool 300–ROB75240available from your dealer –recommended refractometer to testcoolant concentration.

• Rotunda 328-R071–ELC (AntifreezeCoolant ELC Contamination Kit) –Evaluates the corrosion inhibitoradditive strength. Note the first step isto verify the vehicle’s coolantconcentration is in the correct range of40 – 60%. Coolant concentrationsoutside this range will not provide validtest results. If the report results in apass (i.e., the cooling system does notshow excessive contamination/thecorrosion inhibitor additive strength issufficient), no action is required. If thereport results as insufficient (does notpass), the corrosion inhibitor additivestrength of the coolant is too low. If theENGINE COOLING SYSTEM corrosioninhibitor additive strength is low, add48 fluid oz. of Motorcraft SpecialtyOrange Engine Coolant Revitalizer. Ifthe SECONDARY COOLING SYSTEMcorrosion inhibitor additive strength islow, add 16 fluid oz. of MotorcraftSpecialty Orange Engine CoolantRevitalizer.

• Motorcraft Specialty Orange EngineCoolant Revitalizer – Additive toboost the corrosion inhibitor levelbased upon the test results of theAntifreeze Coolant ELC ContaminationKit. The Revitalizer may be added twotimes over the life of the coolant. Ifadditional dosages are required, thecooling system must be flushed andrefilled per the instructions in theWorkshop Manual.

See Capacities and Specifications(page 55). for the proper coolant andadditive specifications.

49


Maintenance

Coolant ChangeAt specific mileage intervals, as listed inthe scheduled maintenance information,the coolant should be changed. Theoptional information display, if equipped,will also display the message COOLANTCHANGE REQUIRED at this time.See Capacities and Specifications(page 55). for the proper coolant.

Engine-driven Cooling Fan (FanClutch)Your vehicle is equipped with an enginedriven cooling fan drive (also called a fanclutch). This fan drive changes the fanspeed to match the vehicle’s changingcooling air flow requirements. Fan speed,fan noise level and fuel consumption allwill increase based on the drivingconditions that include trailer towing, hillclimbing, heavy loads, high speed and highambient temperature, individually or incombination.The fan drive is designed to provide theminimum fan speed (and resultingminimum fan noise and fuel consumption)required to meet the ever changing vehiclecooling air flow requirements. You will hearthe amount of fan noise increasing anddecreasing as the engine powerrequirements and vehicle driving conditionschange as you drive. This is to be expectedas being normal to the operation of yourvehicle. High levels of fan noise might alsobe heard when your engine is first started,and should normally decrease after drivingfor a short time.

CHANGING THE ENGINE AIRFILTERAir Filter Restriction Gauge

WARNINGTo reduce the risk of vehicle damageand/or personal burn injuries do notstart your engine with the air filter

removed and do not remove it while theengine is running.

Note: Operating your vehicle in heavysnowfall or extreme rain conditions mayallow excessive amounts of snow or waterinto the air intake system. This could plugor soak the air filter that could cause theengine to lose power or shut down.

E163372

The restriction gauge, located on the upperhousing of the air filter assembly, measuresthe vacuum inside the air filter. The morethe air filter is restricted (dirty, clogged),the higher the vacuum reading.Check the air filter restriction gaugewhenever you open the hood to performgeneral engine maintenance or at leastevery 7,500 miles (12,000 km). If youoperate your vehicle in extremely dustyconditions, check and reset the gauge atleast every 500 miles (800 km), or twoweeks, whichever comes first. Change the

50


Maintenance

air filter when the restriction gauge readsnear the change filter line and the gaugeis yellow. If you allow the restriction gaugeto reach maximum restriction you canaffect your engine performance and fueleconomy.Note: Do not blow out the air filter elementwith compressed air since the compressedair could damage the filter paper.Note: Do not rely on filter appearancealone. A filter which appears to be dirty mayactually have several thousand miles(kilometers) of life remaining.

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After installation of the new filter element,reset the gauge by pressing the resetbutton on top of the gauge.The following actions are recommend afteroperating the vehicle up to 200 miles (320km) in heavy snowfall or extreme rain:• Snow: At the earliest opportunity, open

the hood and clear all the snow and icefrom the air filter housing inlet (do NOTremove the foam filter) and reset theair filter restriction gauge.

• Extreme rain: The air filter will dry afterabout 15–30 minutes at highwayspeeds. At the earliest opportunity,open the hood and reset the air filterrestriction gauge.

Air Filter ReplacementWhen replacing the air filter element, usea Motorcraft® air filter element. SeeMotorcraft Parts (page 55).Note: Failure to use the correct air filterelement may result in severe enginedamage.

51


Maintenance

E163374

1. Locate the mass airflow sensorelectrical connector on the air inlettube. This connector will need to beunplugged. Unlock the locking clip onthe connector, then squeeze and pullthe connector off the air inlet tube.

E163375

2. Release the four clamps that securethe cover to the air filter housing. Pushthe air filter cover forward (away fromyou) and up slightly to release it.

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

E163376

52


Maintenance

4. Remove and install a new foam filterif needed according to the serviceinterval indicated in the scheduledmaintenance information in this guide.If you do not replace the foam filter, besure the existing foam filter is in place.

E163377

5. Install a new air filter element. Be surethat the groove seal on the pleatedpaper filter traps both sides of thevertical partition of the air box.

E163378

6. Replace the air filter housing cover andsecure all the clamps. Be careful notto crimp the filter element edgesbetween the air filter housing andcover. Ensure that you align the tabson the edge properly into the slots.

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

Air Purge ProcedureTurn the key on for 30 seconds, and thenturn off. Repeat the procedure six times.

53


Maintenance

CLEANING THE ENGINEEngines are more efficient when they areclean because grease and dirt buildup keepthe engine warmer than normal.When washing:• Take care when using a power washer

to clean the engine. The high-pressurefluid could penetrate the sealed partsand cause damage.

• Do not spray a hot engine with coldwater to avoid cracking the engineblock or other engine components.

• Spray Motorcraft Engine Shampoo andDegreaser on all parts that requirecleaning and pressure rinse clean. InCanada, use Motorcraft EngineShampoo.

• Never wash or rinse the engine while itis hot or running; water in the runningengine may cause internal damage.

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

• Cover the battery, power distributionbox, and air filter assembly to preventwater damage when cleaning theengine.

CLEANING THE EXHAUST

WARNINGSFailure to maintain the functionalholes, in the tailpipe section of theexhaust, clean and free of debris or

foreign material may result in the holesbecoming blocked or plugged. Do notmodify or remove the tail-pipe section.Blocked or plugged holes orremoval/modification of the system couldresult in elevated exhaust gastemperatures which may result invehicle/property damage or personalinjury.

WARNINGSThe normal operating temperatureof the exhaust system is very high.Never work around or attempt to

repair any part of the exhaust system untilit has cooled. Use special care whenworking around the diesel oxidationcatalytic converter and/or the dieselparticulate filter (DPF). The dieseloxidation catalytic converter and/or theDPF heats up to a high temperature afteronly a short period of engine operation andcan stay hot even after the engine is turnedoff. Failure to follow these instructions mayresult in personal injury.

E163380

The visible holes in the exhaust tip and theholes under the shield just inboard of theright rear tire(s) are functional. The holesneed to be kept clear of mud/debris orforeign material to maintain properfunction of the exhaust system. Clean andremove debris or foreign material if presentas needed. Spraying with a hose duringregular washing of vehicle should helpkeep holes clean and clear of debris orforeign material.

54


Vehicle Care

ENGINE SPECIFICATIONSDrivebelt RoutingSingle Alternator

E163381

Dual Alternator

E163382

MOTORCRAFT PARTS

Ford Part NumberComponent

FL-2051Engine oil filter

FA-1909Foam pre-filter

FA-1902Air filter 1

55


Capacities and Specifications

Ford Part NumberComponent

FD-4615Fuel filter kit (2included -engine andframe railmounted )

BXT-65-750Battery (2Required)

1 Failure to use the correct air filter element may result in severe engine damage. Thecustomer warranty may be void for any damage to the engine if the correct air filterelement is not used.

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TECHNICAL SPECIFICATIONS

Ford part number /Ford specification

Ford part name orequivalent

CapacityItem

VC-3DIL-B (US)CVC-3DIL-B

(Canada) / WSS-M97B44-D2

Motorcraft OrangeAntifreeze/Coolant

Prediluted

30.3 quarts(28.7L)

Engine coolant (primaryhigh-temperature

cooling system loop)1

VC-12 / —Motorcraft SpecialtyOrange Engine

Coolant Revitalizer

48.0 fl. oz. (1.4L)per addition if

required

Engine coolant additive(primary high-temper-ature cooling system

loop)

16 fl. oz. (473mL) per addition

if required

Engine coolant additive(secondary cooling

system)

VC-3DIL-B (US)CVC-3DIL-B

(Canada) / WSS-M97B44-D2

Motorcraft OrangeAntifreeze/Coolant

Prediluted

10.8 quarts(10.2L)

Engine coolant(secondary cooling

system) 1

XO-10W30–QSD(US); CXO-10W30-LSD12 (Canada) /

WSS-M2C171–E

Motorcraft Motor OilSAE 10W-30 SuperDuty Diesel Motor Oil

13.0 quarts(12.4L)

Engine oil (includesfilter change)

XO-15W40-QSD(US); CXO-15W40-LSD12 (Canada) /

WSS-M2C171-E

Motorcraft Motor OilSAE 15W-40 Super

Duty Diesel Motor Oil

XO-5W40-5QSD(US only) / WSS-

M2C171-E

Motorcraft Motor OilSAE 5W-40 FullSynthetic Diesel

Motor Oil

XO-0W40-DAS (USonly) / WSS-M2C171-

E

Motorcraft Motor OilSAE 0W-40 FullSynthetic Diesel

Motor Oil

PM-27-GAL/PM-27-JUG / WSS-M99C130-A

Motorcraft DieselExhaust Fluid (DEF)

5 gallons (18.9L)Diesel Exhaust Fluid(DEF) — Pick-up

6 gallons (22.7L)Diesel Exhaust Fluid(DEF) — Chassis Cab

57



Ford part number /Ford specification

Ford part name orequivalent

CapacityItem

PM-22-A (US) PM-22-B (Canada) / —

Motorcraft CetaneBooster & Perform-

ance Improver

—Cetane Booster &Performance Improver

PM-23-A (US) PM-23-B (Canada) / —

Motorcraft Anti-Gel& Performance

Improver

—Anti-Gel & PerformanceImprover

Refer to Owner’s ManualAutomatic transmissionfluid

——26 gallons(98.4L)

Fuel tank — Pick upregular cab long box

and all short box

——37.5 gallons(142.0L)

Fuel tank — Pick Uplong box (except regular

cab)


Fuel tank — Chassis cab(midship)


Fuel tank — Chassis cab(aft of axle)

——40 gallon(151.4L) and 28gallon (106.0L)

Fuel tank — Dual tanks

1Use the coolant type originally equipped in your vehicle. Using any other coolant mayresult in vehicle damage.

58



GENERAL MAINTENANCEINFORMATIONWhy Maintain Your Vehicle?Carefully following the maintenanceschedule helps protect against major repairexpenses resulting from neglect orinadequate maintenance and may help toincrease the value of your vehicle whenyou sell or trade it. Keep all receipts forcompleted maintenance with your vehicle.We have established regular maintenanceintervals for your vehicle based uponrigorous testing. It is important that youhave your vehicle serviced at the propertimes. These intervals serve two purposes;one is to maintain the reliability of yourvehicle and the second is to keep your costof owning your vehicle down.It is your responsibility to have allscheduled maintenance performed and tomake sure that the materials used meetthe specifications identified in the owner'smanual.Failure to perform scheduled maintenanceinvalidates warranty coverage on partsaffected by the lack of maintenance.

Why Maintain Your Vehicle at YourDealership?Factory-trained TechniciansService technicians participate in extensivefactory-sponsored certification training tohelp them become experts on theoperation of your vehicle. Ask yourdealership about the training andcertification their technicians havereceived.

Genuine Ford and MotorcraftReplacement PartsDealerships stock Ford, Motorcraft andFord-authorized branded re-manufacturedreplacement parts. These parts meet orexceed our specifications. Parts installedat your dealership carry a nationwide24-month or unlimited mile (kilometer)parts and labor limited warranty.If you do not use Ford authorized parts theymay not meet our specifications anddepending on the part, it could affectemissions compliance.

ConvenienceMany dealerships have extended eveningand Saturday hours to make your servicevisit more convenient and they offer onestop shopping. They can perform anyservices that are required on your vehicle,from general maintenance to collisionrepairs.Note: Not all dealers have extended hoursor body shops. Please contact your dealerfor details.

Protecting Your InvestmentMaintenance is an investment that paysdividends in the form of improvedreliability, durability and resale value. Tomaintain the proper performance of yourvehicle and its emission control systems,make sure you have scheduledmaintenance performed at the designatedintervals.Your vehicle is very sophisticated and builtwith multiple, complex, performancesystems. Every manufacturer developsthese systems using differentspecifications and performance features.That is why it is important to rely upon yourdealership to properly diagnose and repairyour vehicle.

59


Scheduled Maintenance

Ford Motor Company has recommendedmaintenance intervals for various partsand component systems based uponengineering testing. Ford Motor Companyrelies upon this testing to determine themost appropriate mileage for replacementof oils and fluids to protect your vehicle atthe lowest overall cost to you andrecommends against maintenanceschedules that deviate from the scheduledmaintenance information.We strongly recommend the use of onlygenuine Ford, Motorcraft orFord-authorized re-manufacturedreplacement parts engineered for yourvehicle.

Additives and ChemicalsThis owner's manual and the FordWorkshop Manual list the recommendedadditives and chemicals for your vehicle.We do not recommend using chemicals oradditives not approved by us as part ofyour vehicle’s normal maintenance. Pleaseconsult your warranty information.

Oils, Fluids and FlushingIn many cases, fluid discoloration is anormal operating characteristic and, byitself, does not necessarily indicate aconcern or that the fluid needs to bechanged. However, a qualified expert, suchas the factory-trained technicians at yourdealership, should inspect discolored fluidsthat also show signs of overheating orforeign material contaminationimmediately.Make sure to change your vehicle’s oils andfluids at the specified intervals or inconjunction with a repair. Flushing is aviable way to change fluid for many vehiclesub-systems during scheduledmaintenance. It is critical that systems areflushed only with new fluid that is the sameas that required to fill and operate thesystem or using a Ford-approved flushingchemical.

Owner Checks and ServicesMake sure you perform the following basicmaintenance checks and inspections everymonth or at six-month intervals.

Check every month

Air filter restriction gauge.

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

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.

60



Tightening lug nuts

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).

Vehicles with single rearwheels

Tighten the wheel lug nuts to the specified torque at 100miles (160 km), and again at 500 miles (800 km) of newvehicle operation and after any wheel disturbance (such

as tire rotation, changing a flat tire or wheel removal).

Vehicles with dual rearwheels

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

Multi-point InspectionIn order to keep your vehicle running right,it is important to have the systems on yourvehicle checked regularly. This can helpidentify potential issues and prevent majorproblems. We recommend having thefollowing multi-point inspection performedat every scheduled maintenance intervalto help make sure your vehicle keepsrunning great.

Multi-point inspection

Horn operationAccessory drive belt(s)

Radiator, cooler, heater and A/C hosesBattery performance

Suspension component for leaks ordamage

Engine air filter

Steering and linkageExhaust system

Tires (including spare) for wear and properpressure**

Exterior lamps and hazard warning systemoperation

Windshield for cracks, chips or pitsFluid levels*; fill if necessary

Washer spray and wiper operationFor oil and fluid leaks* Brake, coolant recovery reservoir, automatic transmission, power steering and windowwasher.**If your vehicle is equipped with a temporary mobility kit, check the tire sealant expirationUse By date on the canister. Replace as needed.

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Be sure to ask your dealership serviceadvisor or technician about the multi-pointvehicle inspection. It is a comprehensiveway to perform a thorough inspection ofyour vehicle. Your checklist gives youimmediate feedback on the overallcondition of your vehicle.

NORMAL SCHEDULEDMAINTENANCEIntelligent Oil-Life MonitorYour vehicle is equipped with an IntelligentOil-Life Monitor that determines when youshould change the engine oil based on howyour vehicle is used. By using severalimportant factors in its calculations, themonitor helps reduce the cost of owningyour vehicle and reduces environmentalwaste at the same time.

This means you do not have to rememberto change the oil on a mileage-basedschedule. Your vehicle lets you know whenan oil change is due by displaying ENGINEOIL CHANGE DUE or OIL CHANGEREQUIRED in the information display.The following table provides examples ofvehicle use and its impact on oil changeintervals. It is a guideline only. Actual oilchange intervals depend on several factorsand generally decrease with severity ofuse.

When to expect the OIL CHANGE REQUIRED message

Vehicle use and exampleMiles (km)

Normal

7500-10000(12000-16000)

Normal commuting with highway drivingNo, or moderate, load or towingFlat to moderately hilly roadsNo extended idling

Severe

5000-7499(8000-11999)

Moderate to heavy load or towingMountainous or off-road conditionsExtended idlingExtended hot or cold operation

Extreme3000-4999

(4000-7999) Maximum load or towingExtreme hot or cold operationUse of high sulfur diesel fuel

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

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Normal Maintenance Intervals

At every oil change interval as indicated by the information display1

Change the engine oil and filter.2

Refill the diesel exhaust fluid tank.

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

Perform a multi-point inspection (recommended).

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

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

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

Inspect the engine and secondary coolant level and hoses.

Inspect the exhaust system and heat shields.

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

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

1 Do not exceed one year or 10000 miles (16000 kilometers) between service intervals.2 Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.3 Vehicles with dual rear wheels should rotate the front wheels when specified; rear wheelsonly if unusual wear is noted.

Other maintenance items1

Inspect the engine and secondary cooling systemconcentration (freeze-point protection), additive (corro-sion inhibitor) strength, coolant level and hoses.2

Every 15000 miles (24000km)

Replace the engine-mounted and frame-mounted fuelfilters.3


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


Replace the air inlet foam filter.Every 45000 miles (72000km)

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Other maintenance items1

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


Inspect the accessory drive belt(s).5At 90000 miles (144000km)

Change the rear axle fluid (Dana axles. See Specialoperating conditions).6

At 100000 miles (160000km)

Change the engine coolant and secondary coolant.7Every 105000 miles(168000 km)

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

Every 150000 miles(240000 km)

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

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

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

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

1 You can perform these maintenance items within 3000 miles (4800 kilometers) of thelast oil change. Do not exceed the designated distance for the interval.2 Every 15000 miles (24000 kilometers), 600 engine hours or as indicated by theinformation 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 initialinspection. 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 yearsor 45000 miles (72000 kilometers).

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SPECIAL OPERATINGCONDITIONS SCHEDULEDMAINTENANCEIf you operate your vehicle primarily in anyof the following conditions, you need to

perform extra maintenance as indicated.If you operate your vehicle occasionallyunder any of these conditions, it is notnecessary to perform the extramaintenance. For specificrecommendations, see your dealershipservice advisor or technician.

Towing a trailer or using a car-top carrier

Change the engine oil and filter as indicated by theinformation display, and perform the services listed in thescheduled maintenance chart.

As required

See the axle maintenance items under Exceptions.

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

Every 15000 miles (24000km) or 600 engine hours

Replace the engine-mounted and frame-mounted fuelfilters.

Every 15000 miles (24000km), 6 months, 600 enginehours, or as indicated by theinformation display

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


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

Flush and refill the engine coolant. Do not add enginecoolant additive.


Note: When adding coolant additive, do not exceed the specified maximum of 48 fluidounces (1.4 liters). Operating the engine with excessive coolant additive may causeoverheating which could lead to severe, permanent engine damage.Note: After the initial coolant flush and fill at 60000 miles (96000 kilometers) or 2400engine hours, flush and fill every 45000 miles (72000 kilometers) or 1800 engine hoursthereafter.

65



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


Every 15000 miles (24000km), six months, 600 enginehours, or as indicated by theinformation display






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


As required





66



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





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


As required







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


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




67



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


As required






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

Rotate the tires*, inspect the tires for wear and measuretread depth.


Inspect the brake system pads and rotors.

Inspect the air filter restriction gauge. Replace the filter ifnecessary.

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

Change the engine oil and filter.**Every 7500 miles (12000km), six months or 300engine hours Inspect and lubricate the U-joints.





*Vehicles with dual rear wheels should rotate the front wheels when specified; rear wheelsonly if unusual wear is noted.**Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.

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Off-road operation

Inspect functional holes in each leg of the twin exhausttips and the holes under the shield just inboard of the rightrear tire to make sure they are clean and clear of debris orforeign materials. Refer to the Vehicle Care chapter of yourowner’s manual for more information.

As required

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

Rotate the tires*, inspect the tires for wear and measuretread depth.

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

Inspect the brake system pads and rotors.

Inspect the air filter restriction gauge. Replace the filter ifnecessary.

Change the engine oil and filter.**Every 7500 miles (12000km) or 300 engine hours




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

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


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 wheelsonly if unusual wear is noted.**Reset the Intelligent Oil-Life Monitor after engine oil and filter changes.

69



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


As required



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

Change engine oil and filter.Every 2500 miles (4000km) or three months (ifusing high sulfur fuel withmore than 500 ppm sulfur)

Change engine oil and filter.Every 5000 miles (8000km) or six months (if usinghigh sulfur fuel with fewerthan 500 ppm sulfur)

ExceptionsThere are several exceptions to the NormalSchedule:Normal vehicle axle maintenance: Rearaxles and power take-off units withsynthetic fluid and light-duty trucksequipped with Ford-design axles arelubricated for life; do not check or changefluid unless a leak is suspected, service isrequired or the assembly has beensubmerged in water. During long periodsof trailer towing with outside temperaturesabove 70°F (21°C) and at wide-openthrottle for long periods above 45 mph (72km/h), change non-synthetic rear axle fluidevery 3000 miles (4800 kilometers) orthree months, whichever comes first. Thisinterval can be waived if the axle is filled

with 75W140 synthetic gear fluid meetingFord specification WSL-M2C192-A, partnumber F1TZ-19580-B, or equivalent. Addfriction modifier XL-3 (EST-M2C118-A) orequivalent for complete refill ofTraction-Lok rear axles.F-450 and F-550 axle maintenance:Change rear axle fluid every 100000 miles(160000 kilometers) under normal drivingconditions on all commercial applications.When operating your vehicle at or nearmaximum Gross Vehicle Weights, changethe rear axle fluid every 50000 miles(80000 kilometers). In addition, followthis 50000-mile (80000 kilometer)schedule when operating your vehicleunder the special operating conditions,where noted.

70



Diesel Particulate Filter: The filter mayneed to be removed for ash cleaning atapproximately 120000 miles (192000kilometers) or greater (actual mileage canvary greatly depending upon engine andvehicle operating conditions) and replacedwith a new or remanufactured (ashcleaned) part. The filter may need to bereplaced at approximately 250000 miles(400000 kilometers) depending upon

engine and vehicle operating conditions.In both cases, the engine control systemsets a service light (wrench icon) to informyou to bring your vehicle to the dealer forservice. If there are any issues with theoxidation catalyst or particulate filtersystem, a service light (wrench or engineicon) sets by the engine control system toinform you to bring your vehicle into adealer for service.

SCHEDULED MAINTENANCE RECORD

E146852

Repair Order #:

Distance:

Engine hours (optional):

Multi-point inspection (recommended):Signature:

Dealer stamp

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78


AAbout This Supplement.................................3

Breaking-In Your Vehicle......................................3Diesel Engine Information...................................3Minor Troubleshooting Guide.............................5Warnings....................................................................3

ABSSee: Brakes..............................................................37

BBrakes..................................................................37

General Information............................................37

CCapacities and Specifications..................55

Technical Specifications....................................57Changing the Engine Air Filter...................50

Air Filter Replacement.........................................51Air Filter Restriction Gauge...............................50

Cleaning the Engine......................................54Cleaning the Exhaust...................................54Coolant Check

See: Engine Coolant Check..............................45

EEmission Control System...........................30

Diesel Exhaust System: Oxidation CatalystAnd Diesel Particulate Filter System................................................................................30

Engine Block Heater.......................................14Rapid Heat Supplemental Heating

System.................................................................14Engine Coolant Check..................................45

Adding Engine Coolant......................................45Checking Coolant Corrosion Inhibitor

Additive Strength ...........................................48Checking the Engine Coolant..........................45Coolant Change...................................................50Engine and Secondary Cooling System

Refill Procedure................................................47Engine-driven Cooling Fan (Fan

Clutch)................................................................50Recycled Engine Coolant..................................48Severe Climates...................................................48

Engine Idle Shutdown...................................13Engine Oil Check.............................................43

Changing the Engine Oil and Oil Filter.........44Engine Oil Specifications..................................43

Engine Specifications...................................55Drivebelt Routing..................................................55

FFuel and Refueling..........................................15Fuel Quality.......................................................15

Biodiesel...................................................................16Diesel Fuel Additives ...........................................17Fuel And Water Separator .................................17Fuel Requirements - Choosing The Right

Fuel: Vehicles Operated Where Ultra LowSulfur Diesel Fuel Is Not Required ............15

Fuel Requirements - Choosing The RightFuel: Vehicles Operated Where Ultra LowSulfur Diesel Fuel Is Required (UnitedStates/Canada/Puerto Rico/U.S. VirginIslands And Other Locales) .........................15

Fuel Shutoff.....................................................39Running Out Of DEF (Diesel Exhaust

Fluid)....................................................................39Fuel Tank Selector Switch..........................36

GGauges..................................................................8

Engine Boost Gauge..............................................8General Maintenance Information..........59

Multi-point Inspection.........................................61Owner Checks and Services............................60Protecting Your Investment.............................59Why Maintain Your Vehicle?............................59Why Maintain Your Vehicle at Your

Dealership?.......................................................59

IInstrument Cluster...........................................8Introduction........................................................3

79


Index

JJump Starting the Vehicle...........................39

Connecting the Jumper Cables......................40Jump Starting.........................................................41Preparing Your Vehicle.......................................39Removing the Jumper Cables...........................41

MMaintenance....................................................42Motorcraft Parts.............................................55

NNormal Scheduled Maintenance.............62

Intelligent Oil-Life Monitor................................62Normal Maintenance Intervals.......................63

OOil Check

See: Engine Oil Check.........................................43

RRefueling...........................................................29

Fueling Tips............................................................29Roadside Emergencies................................39

SScheduled Maintenance Record...............71Scheduled Maintenance.............................59Selective Catalytic Reduction

System..............................................................21Diesel Exhaust Fluid (DEF) warning

messages and vehicle operations..............21Importance of maintaining the Diesel

Exhaust Fluid (DEF) level..............................21Special Operating Conditions Scheduled

Maintenance.................................................65Exceptions..............................................................70

Starting a Diesel Engine...............................10Cold Weather Operation......................................11Cold Weather Starting........................................10

Starting and Stopping the Engine............10Switching Off the Engine..............................13

TTechnical Specifications

See: Capacities and Specifications...............55Towing a Trailer...............................................38Towing................................................................38

UUnder Hood Overview..................................42

F-Super Duty..........................................................42Scheduled Maintenance...................................43

VVehicle Care.....................................................54

WWarning Lamps and Indicators...................8

Diesel Engine Brake...............................................8Diesel Exhaust Fluid (DEF).................................9Glow Plug Pre-Heat...............................................9Water In Fuel............................................................9

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Index

2015 diesel supplement

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