2011 FORD SUPER DUTY light

•Store DEF out of direct sunlight and in temperatures between 23°F
(-5°C) — 68°F (20°C).
•DEF will freeze below 12°F (-11°C).
•Do not store DEF bottle in vehicle. If it leaks it could cause damage to
interior components or release an ammonia odor inside the vehicle.
•DEF is non-flammable, non-toxic, colorless and water-soluble liquid.
•Do not dilute DEF with water or any other liquid.
•An ammonia odor may be smelled when the cap is removed or during
refill. Refill DEF in a well ventilated area.
FUEL FILTER/WATER SEPARATOR
Diesel Fuel Conditioner Module (DFCM)
The vehicle is equipped with a diesel fuel conditioning module (DFCM)
located on the frame-rail under the driver-side floorboard near the
transmission
Water should be drained from the
module assembly whenever the
warning light comes on and the
message center directs you to drain
the water separator. This will occur when approximately 0.32 pints (150
ml) of water accumulates in the module. If water level is allowed to
exceed this level, the water may be passed through to the engine and
may cause fuel injection equipment damage.
Draining the DFCM
1. Stop the vehicle andshut offthe engine.
WARNING:The vehicle must be stopped with the engine off
when draining the DFCM. Fuel may ignite if the separator is
drained while the engine is running or vehicle is moving.
Note:Air will enter into the fuel system if the DFCM is drained while
the system is running. The engine will not operate properly if air enters
the system.
2. Locate the DFCM and place an appropriate container under the drain
port (see illustration).
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3. Rotate the drain counterclockwise
until the O-ring is visible. Allow the
DFCM to drain for approximately
25 seconds or until clean fuel is
observed. Rotate the drain clockwise
to tighten it.
4. Make sure that the drain valve is fully tightened, then remove the
container from under the vehicle.
Note:A loose drain valve can allow air to enter the fuel system and
cause drivetrain issues. The engine will not operate properly. be sure
that the drain valve is fully tightened.
5. Restart the engine. TheWATER IN FUEL DRAIN FILTERor
WATER IN FUEL DRAIN FILTER SEE MANUALmessage and light
should not be illuminated. If they continues to illuminate, have the fuel
system checked and repaired.
LOW FUEL PRESSURE MESSAGE
The engine is equipped with a low fuel pressure detection system. If the
message center displays:LOW FUEL PRESSUREthe following
explains why and what to do:
•Cold start or cold operation (below 32°F (0°C): If this message
appears during a cold start or during cold operation up to 10 minutes
after the initial cold start, monitor the message center. If it disappears
and does not re-appear after the engine has fully warmed up, the low
fuel pressure message is most likely caused by waxed or gelled fuel.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/systems. Use an anti-gel additive
as listed inMaintenance product specifications and capacities
section in this chapter. The customer warranty may be void from using
additives that do not meet or exceed Ford specifications.
If the low fuel pressure message persistently appears after re-fueling
during the cold start and cold operation conditions defined previously
and then disappear when the engine has fully warmed up, consider
different fuel sources.
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•Do not mix with recycled coolant unless from a Ford-approved
recycling process (seeUse of recycled engine coolantsection).
WARNING:To reduce the risk of personal injury, make sure the
engine is cool before unscrewing the coolant pressure relief cap.
The cooling system(s) are under pressure; steam and hot liquid can
come out forcefully when the cap is loosened slightly.
Add the proper mixture of coolant and distilled water to the cooling
system(s) by following these steps:
1. Before you remove the cap, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the cap. Slowly
turn cap counterclockwise until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
Engine and secondary cooling system refill procedure
The following procedure should be used when refilling the engine or
secondary cooling systems after it has been drained or become extremely
low.
1. Remove the pressure relief cap from the engine or secondary coolant
reservoir as previously outlined.
2. Slowly add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
3. Reinstall the pressure relief cap.
4. Start and run the engine at 2,000 rpm for 2 minutes.
5. Shut engine off, and remove the pressure relief cap as previously
outlined.
6. If required, add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
7. Engine cooling system: Repeat Step 3 until the coolant level has
stabilized (is no longer dropping after each step) AND the upper radiator
hose at the radiator is warm to the touch (indicating that the engine
thermostat is open and coolant is flowing through the radiator).
Secondary cooling system: Repeat Step 3 until the coolant level has
stabilized (is no longer dropping after each step) AND the lower
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1. Locate the mass air flow sensor
electrical connector on the air inlet
tube. This connector will need to be
unplugged.
Unlock the locking clip on the
connector, then squeeze and pull
the connector off of the air inlet
tube.
2. Release the four clamps that
secure the cover to the air filter
housing. Push the air filter cover
forward (away from you) and up
slightly to release it.
3. Remove the air filter element from the air filter housing.
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When the engine control module detects that the DPF is nearly full of
particulates and that the vehicle is not being operated in a manner to
allow effective automatic cleaning, the message center will display
several messages guiding the vehicle operator to drive to clean the DPF.
If the vehicle is operated in a manner to allow effective automatic
cleaning, the message center will display CLEANING EXHAUST FILTER,
which is the normal regeneration process. SeeMessage centerin the
Instrument Clusterchapter of theOwner Guidefor more information.
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
orwill 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
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 theWarranty Guidefor more information.
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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. 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 the procedure six
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.
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.
•The gearshift lever must be in P (Park) or N (Neutral) in order for
the starter to operate.
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Factory-trained technicians
Ford service technicians participate in extensive factory-sponsored training
to help them become the experts on the operation of your vehicle. Many
participate in Ford-sponsored training to become certified. Ask your dealer
about the training and certification their technicians have received.
Genuine Ford and Motorcraftreplacement parts
Ford dealerships stock Ford and Motorcraftbranded replacement parts.
These parts meet or exceed Ford Motor Company’s specifications, and
we stand behind them. Maintenance parts installed at your Ford
dealership carry a nationwide, 12 months, 12,000 mile (20,000 km) parts
and labor limited warranty. Your dealer can give you details.
Value shopping for your vehicle’s maintenance needs
Your dealership recognizes the competitive landscape of maintenance and
light repair automotive services. With factory-trained technicians, and
one-stop service from routine maintenance like oil changes and tire
rotations to repairs like brake service, check out the value your Ford
dealers can offer.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner checks and services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed by
the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in theOwner’s Guide.
Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
Maximum oil change interval
❑Normal schedule: As indicated by the instrument cluster message center❑Special Operating Conditions: Consult specific operating condition for maintenance recommendation.
Maximum fuel filter change interval
❑Normal schedule: 22,500 miles (36,000 km) or as indicated by the instrument cluster message center, whichever occurs
first.
❑Special Operating Conditions: 15,000 miles (24,000 km) or 600 hours of engine operation, see appropriate schedule.
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Coolant change interval
❑6 years or 105,000 miles (168,000 km) - change coolant (whichever comes first) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
❑After initial change - change coolant every 3 years or 45,000 miles (72,000 km) or as indicated from the coolant tests
for concentration (freeze-point) or additive strength (corrosion inhibitor).
❑Use coolant specified in theOwner’s Guideunder theMaintenance and Specificationschapter
❑For special operating conditions, seeSpecial Operating Conditionsat the end of this section
Check every month
❑Check function of all interior and exterior lights❑Check tires for wear and adjust air pressure (including spare tire)
❑Check that holes in the tail-pipe of the exhaust system are clear of debris-the holes/slots are functional
❑Check engine oil level
❑Check windshield washer fluid level
❑Check and drain fuel filter/water separator
❑Check air filter restriction gauge
Check every six months
❑Check lap/shoulder belts and seat latches for wear and function❑Check that externally-mounted spare tire is tight (seeOwner’s Guide)
❑Check power steering fluid level
❑Check washer spray, wiper operation and clean all wiper blades (replace as necessary)
❑Check parking brake for proper operation
❑Check and lubricate all hinges, latches and outside locks
❑Check and lubricate door rubber weatherstrips
❑Check and clean body and door drain holes
❑Check safety warning lamps (brake, ABS, air bag, safety belt) for operation
❑Check engine and secondary cooling system concentration (freeze-point protection), additive strength (corrosion inhibitor),
coolant level and hoses
❑Check battery connections and clean if necessary
Retightening lug nuts
❑On vehicles equipped with single rear wheels, retighten the lug nuts to the specified torque at 500 miles (800 km) after
any wheel disturbance (tire rotation, changing a flat tire, wheel removal, etc.).
❑On vehicles equipped with dual rear wheels, retighten the wheel lug nuts to the specified torque at 100 miles (160 km),
and again at 500 miles (800 km) of new vehicle operation and after any wheel disturbance (tire rotation, changing a flat
tire, wheel removal, etc.).
❑Refer toWheel Lug Nut Torque Specificationin yourOwner’s Guidefor the proper lug nut torque specification.
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