2009 FORD SUPER DUTY engine

Failure to use the correct air filter element may result in severe
engine damage.
•E-series air filter:
1. Disconnect the hoses from the air filter outlet tube.
2. Loosen the clamp and disconnect
the air filter outlet tube.
3. Disconnect the mass air flow
(MAF) sensor electrical connector.
(Slide out the red lock, press tab
and remove the electrical
connector.)
4. Disconnect the three latches and
remove the air filter cover
5. Remove the air filter.
6. To install, reverse the removal procedure.
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1. Release the toggle clamps and
raise the air filter housing cover. It
may be necessary to pull the
auxiliary inlet tube away from the
air filter to allow the cover to be
removed.
2. Pull the top edge of the air filter
out and away from the housing to
release the air filter seal from the
air filter housing, then remove the
air filter.Note:Do NOT use a tool
to pry the air filter from the
housing. Failure to follow this
instruction may result in damage to
the air filter housing, air filter seal
and engine.
3. When installing the air filter, first make certain the bottom of the air
filter is positioned to the inboard side of the stop feature located in the
bottom of the air filter housing, Then compress the air filter seal down
and in towards the engine so the air filter is seated into the air filter
housing.Note:If not installed properly, the air filter housing cover will
not properly seat and the toggle clamps may not latch
4. Replace the air filter housing cover, push the auxiliary tube against the
air filter and close the toggle clamps.
DIESEL EXHAUST SYSTEM: OXIDATION CATALYST/DIESEL
PARTICULATE FILTER SYSTEM (F-SUPER DUTY ONLY)
Your vehicle is equipped with a diesel particulate filter (DPF), which is
coupled to a diesel oxidation catalyst, that reduces the amount of
harmful exhaust emitted from the tailpipe. As soot gathers in the system
it begins to restrict the filter. The soot gathered inside the filter needs to
be periodically cleaned. The soot can be cleaned in two different ways;
passive regeneration and active regeneration. Both methods occur
automatically and require no actions from the driver/operator. During
either one of these regeneration methods you may notice an
increase/change in exhaust noise/tone and increased engine idle speed.
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Passive regeneration
In passive regeneration, the exhaust constituents / temperature are at an
appropriate level where some soot can be reduced or oxidized (burned)
thus cleaning the filter. This method occurs naturally as a result of
normal engine operating conditions (at varying levels due to drive
patterns).
Active regeneration
If there is not enough passive regeneration naturally occurring due to
vehicle drive patterns, the engine control system will initiate an active
regeneration. In an active regeneration, the filter is cleaned by raising
the exhaust temperature to a point where the soot is burned away. This
is accomplished through various engine actions which raise the exhaust
temperature in the oxidation catalyst/DPF system to an appropriate high
level where the soot is burned off. After the soot is burned off, the
exhaust temperature and back-pressure (restriction) fall back to normal
levels.
Filter service/maintenance
Over time a slight amount of ash will build up in the DPF which is not
removed during the regeneration process. The DPF may need to be
removed for ash cleaning at approximately 120,000 miles (193,000 km)
or greater (actual mileage can vary greatly depending upon
engine/vehicle operating conditions) and replaced with a new or
remanufactured (ash cleaned) part. The filter may need to be replaced
at approximately 250,000 miles (400,000 km) depending upon
engine/vehicle operating conditions. In both cases the engine control
system will set a service light (
) to inform you to bring the vehicle
to the dealer for service.
If there are any issues with the oxidation catalyst/DPF system a service
light (
or) will be set by the engine control system to inform
you to bring the vehicle into a dealership for service.
Resonator/Tailpipe assembly maintenance
The diesel resonator tail-pipe assembly is a uniquely functioning device
that accompanies the Oxidation Catalyst/DPF assembly. The assembly
serves multiple functions. First it serves as an acoustic device to
attenuate exhaust noise. Second it provides an exit path for the exhaust
from the vehicle. It also is designed to help control the temperature of
the exhaust during DPF regeneration events. The visible holes in each
leg of the twin tip and the holes under the shield just inboard of the
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right rear tire(s) are functional. The holes need to be kept clear of
mud/debris or foreign material to maintain proper function of the
exhaust system. Clean and remove debris or foreign material if present
as needed. Spraying with a hose during regular washing of vehicle should
help keep holes clean and clear of debris or foreign material.
Note:Additions of aftermarket devices or modifications to the exhaust
system can reduce the effectiveness of the exhaust system as well as
cause damage to the exhaust system and/or engine. These actions may
also affect the vehicle’s warranty. See the vehicle’s warranty guide for
more information.
WARNING:Failure to maintain the functional holes, in the
tailpipe section of the exhaust, clean and free of debris or
foreign material may result in the holes becoming blocked or plugged.
Do not modify or remove the tail-pipe section. Blocked or plugged
holes or removal/modification of the system could result in elevated
exhaust gas temperatures which may result in vehicle/property damage
or personal injury.
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Use special care when
working around the diesel oxidation catalytic converter and/or the
diesel particulate filter (DPF). The diesel oxidation catalytic converter
and/or the DPF heats up to a high temperature after only a short
period of engine operation and can stay hot even after the engine is
turned off. Failure to follow these instructions may result in personal
injury.
EMISSION CONTROL SYSTEM(S) LAWS
Federal law prohibits vehicle manufacturers, dealers and other persons
engaged in the business of repairing, servicing, selling, leasing or trading
motor vehicles as well as fleet operations from unknowingly removing or
rendering emission control system(s) inoperative. Further, modifications
of the emission control system(s) could create liability on the part of the
individual owners under the laws of some states. In Canada,
modifications of the emission control system(s) could create liability
under applicable Federal or Provincial laws.
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Do not remove or alter the original equipment floor covering or
insulation between it and the metal floor of the vehicle. The floor
covering and insulation protect occupants of the vehicle from the engine
and exhaust system heat and noise. On vehicles with no original
equipment floor covering insulation, do not carry passengers in a manner
that permits prolonged skin contact with the metal floor. Provide
adequate insulation.
NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS
AND MAINTENANCE
On January 1, 1978, Federal regulation became effective governing the
noise emission on trucks over 10,000 lbs. (4,536 kg) GVWR (Gross
Vehicle Weight Rating). The following statements concerning prohibited
tampering acts and maintenance, and the noise warranty found in the
Warranty Guide, are applicable to complete chassis cabs over
10,000 lbs. (4,536 kg) GVWR.
Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use, or
(2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
•Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
•Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer’s specifications.
The complexity of the diesel engine makes it so the owner is discouraged
from attempting to perform maintenance other than the services
described in this supplement.
If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
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•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
WARNING:Do not use starting fluid such as ether or gasoline
in the diesel air intake system. Such fluids can cause immediate
explosive damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. The engine is
designed to run roughly as the fuel tank nears Empty. This is a warning
to the driver to add fuel as soon as possible. Longer engine cranking
time may be required once air is in the fuel system. If air enters the fuel
system (either through running the fuel tank(s) empty or during a fuel
filter change), the engine will self-purge the trapped air once it starts
running. The engine may run roughly and produce white smoke while air
is in the fuel system; this is normal and should stop after a short time.
MINOR TROUBLESHOOTING GUIDE
Air purge procedure
Turn the key on for 30 seconds, then turn off. Repeat procedure four or
five times.
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or when
the ignition is turned to START the lights become dim or go out, the
battery connections may be loose or corroded, or the battery may be
discharged. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to START, this may also
indicate a loose or corroded battery connection.
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Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds.Wash hands after handling.
•For vehicles with manual transmissions,the clutch pedalmustbe
fully depressed in order for the starter to operate.
•For vehicles with automatic transmissions,the gearshift lever
must be in P (Park) or N (Neutral) in order for the starter to operate.
•Try operating the starter switch several times. Should the switch be
corroded, this operation may clean the contacts or make the switch
temporarily operable until you can reach the dealer.
•If all electrical connections are tight and you need assistance to start,
refer toJump startingin theRoadside Emergencieschapter of your
Owner’s Guide(F-Super Duty) or refer to theJump startingsection
in theRoadside Emergencieschapter of this supplement (E-Series).
If engine cranks but won’t start
Prolonged starter cranking (in excess of 30 seconds) could cause
damage to the starter motor.
•Check the fuel gauge. You may be out of fuel. If the gauge shows that
there is fuel in the tank, the trouble may be in the electrical system or
the fuel system. If equipped with an auxiliary tank, be sure that the
tank control switch is set for the tank with fuel and not on an empty
tank.
•Leaving the ignition key turned to ON for over two minutes without
starting may make starting difficult because the glow plugs will cease
activation. Reset the system by turning the ignition key to OFF and
then back to ON again.
If the engine runs hot
The following could cause the engine to overheat:
•Lack of coolant.
•Dirty cooling system.
•Plugged radiator fins, charge air cooler, A/C condenser and/or oil
cooler.
•Driving with frozen coolant.
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•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.
If fuses burn out
Burned-out or blown fuses usually indicate an electrical short-circuit,
although a fuse may occasionally burn out from vibration. Insert a second
fuse. If this fuse immediately burns out and you cannot locate the cause,
return your vehicle to your dealer for a circuit check.
WARNING:Replacement fuses and circuit breakers must always
be the same rating as the original equipment shown. Never
replace a fuse or circuit breaker with one of a higher rating. Higher
rated fuses or circuit breakers could allow circuit overloading in the
event of a circuit malfunction, resulting in severe vehicle damage or
personal injury due to fire.
Refer to theOwner’s Guidefor replacement of fuses.
MOTORCRAFT PART NUMBERS
Item Ford Part Number
Engine oil filter FL-2016
Air filter - E-Series* FA-1804
Air filter - F-Super Duty* FA-1886
Fuel filter kit - E-Series
(2 included - engine and frame rail
mounted)FD-4606
Fuel filter kit - F-Super Duty
(2 included - engine and frame rail
mounted )FD-4609
Battery (2 Required) BXT-65-750
* Always use the authorized Motorcraft air filter listed.Failure to use
the correct air filter may result in severe engine damage.
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