2012 FORD SUPER DUTY engine

Your vehicle’s message center will display a series of messages regarding
the amount of DEF available. A systems check will display messages
indicating the amount of DEF available (OK or under
12full) or will
produce a warning message that displays the mileage (kilometers)
remaining as the fluid in the DEF tank nears empty. For more
information on warning messages, see theMessage centersection in the
Instrument Clusterchapter of yourOwner’s Guide.
As the DEF level nears empty, the
DEF warning symbol will be
displayed and chimes will sound
with the messages starting at
500 miles (805 km) remaining
before DEF is depleted. The
warning symbol and messages will
continue until the DEF tank is
refilled.
Continued driving without refilling will result in the following actions as
required by the California Air Resources Board (CARB) and /or U.S.
Environmental Protection Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon vehicle restart. Prior to this occurring a message will
appear in the message center.
•Further vehicle operation without refilling your DEF tank will cause
the engine to enter an idle-only condition. This will only occur upon
vehicle refueling or extended idle and will be indicated by a message
in the message center indicating required actions to resume normal
operation. It is required to add a minimum of 0.5 gallons (1.9L) of
DEF to the tank to exit the idle-only condition, but the vehicle will
still be in the speed limiting mode until the tank is refilled completely.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the DEF tank is refilled.
Note:When filling the DEF tank from empty, there may be a short delay
before detecting the increased level of DEF. This must occur before full
power is returned.
Maintenance and Specifications
27
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

Low DEF Warnings and Actions — Instrument Cluster Messages
(Optional message center messages shown, base message center messages similar)
Cluster MessageDistance/Exhaust Fluid
Level or ActionCustomer
Requested
ActionsVehicle Actions
Exhaust Fluid Level OK Full exhaust fluid tank Drive normally None
Exhaust Fluid Under
12FullExhaust fluid tank below
12fullDrive normally None
Exhaust Fluid Range
500 miles (805 km)Approximately 500 miles
(805 km) left before
exhaust fluid tank is emptyRefill exhaust fluid None
In 99 Miles (159 km) Speed
Limited to 50 MPH
(80 km/h) Exhaust Fluid
EmptyApproximately 99 Miles
(159 km) left before
exhaust fluid tank is emptyRefill exhaust fluid None
Speed Limited to 50 MPH
(80 km/h) Upon Restart
Exhaust Fluid Empty0 Miles (0 km) – exhaust
fluid tank is emptyRefill exhaust fluid None
Speed Limited To 50 MPH
(80 km/h) Exhaust Fluid
EmptyVehicle restarted with
exhaust fluid tank emptyRefill exhaust fluidSpeed is limited
to 50 MPH.
(80 km/h)
Engine Idled Soon Exhaust
Fluid EmptyThis occurs 200 Miles
(322 km) after the vehicle
reaches the 0 mile (0 km)
exhaust fluid rangeRefill exhaust fluid —
Maintenance and Specifications
28
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional message
center messages shown, base message center messages similar)
Cluster MessageDistance/Exhaust Fluid
Level or ActionCustomer
Requested
ActionsVehicle Actions
Engine Idled-See Owner’s
Manual Exhaust Fluid EmptyThis occurs when the
exhaust fluid is empty and:
•The vehicle’s diesel fuel
tank is refueled or,
•the engine is shut off for
10 minutes or,
•the engine is idling with
the parking brake engaged
for 60 minutes.Refill exhaust fluidEngine is limited
to idle ONLY
Maintenance and Specifications
29
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

Filling the DEF tank
Your vehicle is equipped with a DEF tank with a blue-capped filler port
located next to the diesel fuel fill inlet. The tank can be filled using a
nozzle at a DEF filling station (similar to fuel fill) or using a DEF bottle
with a spout. MotorcraftDEF bottles are recommended as they are
designed to be spill proof and will stop the flow of DEF when the tank is
full. Other aftermarket bottles can be used, but they should have a seal
on the spout and an internal vent tube to achieve best fill performance
and prevent overfilling. Overfilling your DEF tank can cause damage to
the tank. For DEF capacity, seeMaintenance product specifications
and capacitiesin this chapter.
Note:Do not put DEF in the fuel tank. This can cause engine damage
not covered by your vehicle’s warranty.
Note:Immediately wipe away any DEF that has spilled on painted
surfaces with water and a damp cloth to prevent damage to the paint.
You can purchase DEF at your authorized dealer, most highway truck stops
or you can contact roadside assistance for help in finding a retailer that
sells DEF. See theCustomer Assistancechapter in theOwner’s Guidefor
more information. In addition, there is a government website locator for
DEF at the following web address that can be used to find the nearest
location to purchase DEF: http://www.afdc.energy.gov/afdc/locator/def.
Use only DEF certified by the
American Petroleum Institute (API)
such as MotorcraftDEF or
equivalent meeting Ford specification
WSS-M99C130-A and/or ISO 22241.
Look for API certification trademark
shown here. Repairs resulting from
the use of non-certified DEF
products may not be covered by your vehicle’s warranty.
Maintaining the purity of DEF is important to avoid malfunctions in the
SCR system.
If DEF is removed from the tank for repair work, etc., the same DEF
must not be used to refill the tank as its purity is no longer guaranteed.
WARNING:Make sure that DEF does not come into contact
with eyes, skin or clothing. Should DEF contact your eyes, flush
them with plenty of water and contact a physician. Clean affected skin
with soap and water. If DEF is swallowed, drink plenty of water and
contact a physician immediately.
Maintenance and Specifications
30
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

To prevent overfilling of the DEF tank when filling with a bottle, Ford
recommends using MotorcraftDEF. Additionally, if the message center
indicatesEXHAUST FLUID UNDER 1/2 FULL, you should only add a
MAXIMUM of 2 gallons (6.7L) of DEF to the tank to prevent freeze
damage due to overfilling. If the message center indicatesEXHAUST
FLUID LEVEL OK, do not add DEF.
Contaminated DEF or inoperative SCR system
SCR systems are sensitive to
contamination of the DEF. USE
ONLY API or ISO 22241 CERTIFIED
DIESEL EXHAUST FLUID. If the
SCR becomes contaminated or
inoperative, the DEF light will
illuminate and exhaust fluid system
fault messages will appear in the
message center.
Continued driving without replacing DEF or having the SCR system
repaired will result in the following actions as required by the California
Air Resources Board (CARB) and /or U.S. Environmental Protection
Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon restart. Prior to this occurring a message will appear in
the message center.
•Further vehicle operation without replacing contaminated DEF will
cause the engine to enter an idle-only condition. This will only occur
upon vehicle refueling, vehicle idling in park for 1 hour, or engine
shutdown for 10 minutes or more and will be indicated by a message
in the message center indicating required actions to resume normal
operation.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the contaminated system is repaired.To
service a contaminated or inoperative system, see your
authorized dealer.
DEF guidelines and information
•Use only DEF that carries the trademark: American Petroleum
Institute (API) certified DEF or ISO 22241.
•Do not put DEF in the diesel fuel tank.
•Do not overfill the DEF tank.
•Do not re-use the DEF container or nozzle once it is emptied.
Maintenance and Specifications
34
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

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).
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. If no liquid drains, the
drain may be clogged. Have the
DFCM serviced by your authorized
dealer.
Maintenance and Specifications
37
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

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.
•Low fuel operation: If the message appears when the vehicle is warm
and during low fuel tank level operation, i.e. the tank level is at or
very near empty, refuel the vehicle and operate the vehicle. If the
message reappears after fueling, see below. If the message does not
come back, the low fuel pressure condition was due to low fuel levels
in the fuel tank.
•
Normal operation: If the message appears during normal operation when
the vehicle / engine is fully warm, and fuel level is not low, the fuel
filters must be changed regardless of the maintenance schedule interval.
•If replacement of the fuel filter does not remedy the low fuel pressure
message during normal operation as defined above, take the vehicle to
your authorized dealer.
Maintenance and Specifications
38
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

CHANGING THE ENGINE-MOUNTED AND DFCM FUEL FILTERS
Your vehicle is equipped with two fuel filters; one is mounted on top of
the driver’s side of the engine and the second filter, inside the DFCM, is
mounted on the frame rail under the driver-side floorboard near the
transmission. Both filters should be replaced at the same time. Regular
fuel filter changes are an important part of engine maintenance; failing to
keep with the scheduled maintenance could lead to engine performance
issues and/or fuel injection system damage. Refer to thescheduled
maintenance informationof this supplement for more information.
Refer toMotorcraft part numberslater in this chapter for the fuel filter
replacement part number. This part number includes filters and seals for
both the engine-mounted and frame-mounted filters.
Removal - DFCM filter
The DFCM filter is located in the lower portion of the DFCM housing.
1. Drain the DFCM. SeeFuel filter/water separatorearlier in this
chapter.
To install the new DFCM filter, seeInstallation – DFCM filterlater in
this section.
2. Remove the lower portion of the
DFCM housing (filter bowl) by
turning it counterclockwise using a
32 mm socket.
Note:Depending on the amount
seal swelling, removal of the filter
bowl may be noisy and require some
effort. Replace the seal prior to
reinstalling the filter/bowl to
improve assembly.
3. Remove and discard the old fuel filter element.
4. Carefully clean the mating surfaces using a lint-free rag.
Maintenance and Specifications
39
2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)