2011 FORD SUPER DUTY water pump

WARNINGS
Throughout this guide, you will find warnings identified by the
symbol
. Warnings remind you to be especially careful to reduce the
risk of personal injury.
NEW VEHICLE BREAK-IN
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed to allow parts to adjust
themselves to other parts.
Drive your new vehicle at least 500 miles (800 km) before towing a
trailer. Make sure you use the specified engine oil by checking the engine
oil specification chart underEngine oilin theMaintenance and
Specificationschapter.
Do not add friction modifier compounds or special break-in oils during
the first few thousand miles (kilometers) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter of this supplement for more
information on oil usage.
DIESEL ENGINE INFORMATION
The diesel engine fuel system is a pressurized two-stage filtration system
and consists of:
•a frame-mounted diesel fuel conditioner module (DFCM) with an
electric fuel pump and water drain,
•an engine-mounted secondary fuel filter,
•a fuel injector for each cylinder (8 total),
•a high-pressure fuel pump,
•a high-pressure fuel rail for each cylinder bank (2 total) and
•numerous high-pressure pipes from the high-pressure pump to the
rails, and rails to the injectors.
The DFCM acts as a primary fuel filter/water separator which removes
both water and impurities from the fuel. The engine mounted filter filters
finer impurities from the diesel fuel. The engine-mounted fuel filter and
the DFCM filter should be changed at the recommended service interval
or when indicated by the message centerLOW FUEL PRESSURE
message. Refer to thescheduled maintenance informationin this
supplement for more information.
Introduction
3
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

The DFCM should be drained at regular intervals or when indicated by
the message center message and water in fuel indicator light. SeeFuel
filter/water separatorin theMaintenance and Specificationschapter.
The fuel injection system is controlled through the powertrain control
module (PCM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump
located inside the DFCM and provides pressurized fuel to the engine.
The fuel pump contains a pressure relief valve for overpressure
protection in the event of restricted flow.
Engine protection mode
Ford diesel engines are equipped with engine protection and emission
control systems. These systems monitor critical temperatures and
pressures, and modify engine operation accordingly. These features are
intended to modify engine performance characteristics. If these modified
engine performance characteristics persist for an extended period or the
service engine soon
or powertrain malfunction/reduced
power/electronic throttle control light
is illuminated, seek service
from your authorized dealer.
Lubrication system
It is important to change the engine oil at the recommended service
intervals to maintain oil viscosity. Extending the oil and filter change
interval beyond the recommended interval can negatively affect engine
performance, fuel economy and engine life. Refer toEngine oilin the
Maintenance and Specificationschapter.
Fast start glow plug system
The diesel engine glow system consists of:
•eight glow plugs (one per cylinder)
•the glow plug control module (GPCM)
•engine coolant temperature (ECT) sensor
•barometric pressure (BARO) sensor
•environmental temperature sensor
Introduction
4
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

Water in fuel:
During refueling, it is possible for
water-contaminated diesel fuel to be
pumped into your tank. Your
vehicle’s fuel system is equipped
with a fuel filter/water separator to remove water from the fuel. The
water in fuel light will illuminate when the DFCM has a significant
quantity of water in it.
If the light illuminates when the engine is running, stop the vehicle as
soon as safely possible, shut off the engine, then drain the DFCM. Refer
toFuel filter/water separatorin theMaintenance and Specifications
chapter of this supplement for the drain procedure. Allowing water to
stay in the system could result in extensive damage to, or failure of, the
fuel injection system.
Note:Draining the water separator with the engine running will allow air
to enter the fuel system and cause engine problems.
WARNING:Do not drain the water separator while the engine is
running. Fuel may ignite if the separator is drained while the
engine is running or the vehicle is moving.
Low/contaminated diesel exhaust fluid:
With the key in the on position, this
light will illuminate if the exhaust
fluid is contaminated and/or low.
SeeDiesel exhaust fluidin the
Maintenance and Specifications
chapter for more information.
GAUGES
Engine boost gauge:
Indicates the amount of manifold air
pressure in the engine.
Instrument Cluster
7
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

Many of the world’s automakers approved the World-wide Fuel Charter
that recommends diesel fuel specifications to provide improved
performance and emission control system protection for your vehicle.
Diesel fuel that meets the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about fuel that meets the World-wide
Fuel Charter.
Do not blend used engine oil with diesel fuel under any
circumstances.Blending used oil with the fuel will significantly increase
your vehicle’s exhaust emissions and reduce engine life due to increased
internal wear.
Diesel fuel conditioner
Additives that will improve fuel cetane numbers may be used to
verify/enhance fuel quality. Use Motorcraftor an equivalent cetane
booster & performance improver as listed in theMaintenance product
specifications and capacitiessection in this chapter. The customer
warranty may be void from using additives that do not meet or exceed
Ford specifications.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/system. Use Motorcraftor an
equivalent anti-gel & performance improver as listed in theMaintenance
product specifications and capacitiessection in this chapter. The
customer warranty may be void from using additives that do not meet or
exceed Ford specifications.
Note:These ultra-low sulfur formulations are designed to meet the
emissions standards for the 6.7L engine and is backward compatible as
well (i.e., can be used in Ford 7.3L, 6.9L, 6.4L and 6.0L diesel engines in
Ford vehicles).
Fueling tips
Truck stops have pumps and nozzles designed for larger, heavy-duty
trucks. When refueling at truck stops: if the nozzle shuts off repeatedly
when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter change or if
you run out of fuel) the engine will purge the trapped air as it runs. To
purge the air sooner: prior to engine start, prime system by turning the
key to on for 30 seconds then to off. Repeat this several times. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low cetane
Maintenance and Specifications
24
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)

rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of diesel fuel.
Care should be taken whenever diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
the solution until it is run through the engine where it will be deposited
in the fuel injectors causing expensive-to-repair damage.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from a 1
18fuel dispensing nozzle. Pumping fuel
at greater flow rates may result in premature nozzle shut-off or spitback.
Fuel filler cap
Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise until it spins off.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 of a turn until it clicks at least once.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The vehicle warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraftfuel filler cap is not used.
WARNING:The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait
until it stops before completely removing the fuel filler cap. Otherwise,
fuel may spray out and injure you or others.
WARNING:If you do not use the proper fuel filler cap,
excessive pressure or vacuum in the fuel tank may damage the
fuel system or cause the fuel cap to disengage in a collision, which may
result in possible personal injury.
Maintenance and Specifications
25
2011 Econoline(eco)
Supplement, 1st Printing
USA(fus)