2012 FORD SUPER DUTY cooling

The glow plug system is
electronically controlled by the PCM
and GPCM. The GPCM energizes the
glow plugs immediately after the
ignition is turned on and kept on as determined by the GPCM using the
ECT, BARO and environmental temperature sensor. The required time
for the glow plugs to be energized decreases as the coolant temperature,
barometric pressure and environmental temperature increase.
Engine and secondary cooling system
The cooling system contains an engine cooling loop to cool the engine
and a secondary cooling loop to cool the transmission, exhaust gas
recirculation (EGR), charge air and fuel. The coolant serves three
primary purposes: to provide heat transfer, freeze point protection, and
corrosion protection using additives.
Vehicles with diesel engines typically are used to carry heavy loads and
accumulate mileage rapidly. These two factors may cause the additives in
the coolant to “wear out” in a shorter time. Refer to theSpecial
operating conditionssection for more information about coolant
additives and coolant change intervals. Operating the engine with
insufficient coolant and/or coolant additive can cause severe engine
damage.
Selective catalytic reduction (SCR) system
Your vehicle is equipped with a selective catalytic reduction (SCR)
system to help reduce emission levels of oxides of nitrogen from the
exhaust of the diesel engine. This system relies on the use of diesel
exhaust fluid (DEF) which must be replenished at certain intervals.
Failure to maintain proper DEF levels or if the DEF becomes
contaminated will result in vehicle speed limitations and/or result in the
vehicle entering an idle-only mode. SeeSelective catalytic reduction
(SCR) systemin theMaintenance and Specificationschapter for more
information.
Speed control (if equipped)
If vehicle speed goes outside a predetermined range from the set speed,
the RES (Resume) function will not reset vehicle speed. Vehicle speed
will need to be reset with the SET +/- button after reaching desired
speed using accelerator pedal.
Introduction
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STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F (0°C), the use of the correct grade engine
oil is essential for proper operation. Refer toEngine oil specifications
in theMaintenance and Specificationschapter for more information.
Your vehicle may be equipped with a cold weather starting strategy that
prevents severe engine damage by assisting in engine lubrication
warm-up. In extremely cold ambient temperatures, this strategy activates
and prevents the accelerator pedal from being used for 30 seconds after
starting the vehicle. By not allowing the accelerator pedal to be used, the
engine oil is allowed to properly lubricate the bearings preventing engine
damage due to lack of proper lubrication. After the 30 second warm-up
period, the accelerator pedal will be operational again as long as the
pedal is not being pressed when the 30 second time limit expires. When
starting the engine in extremely cold temperatures (-15°F [–26°C]), it is
recommended to allow the engine to idle for several minutes before
driving the vehicle.
Ensure the gearshift lever is in P (Park) and the parking brake is fully
set before you turn the key. Do not press the accelerator during starting.
Engine-driven cooling fan (fan clutch)
Your vehicle is equipped with an engine driven cooling fan drive (also
called a fan clutch). This fan drive changes the fan speed to match the
vehicle’s changing cooling air flow requirements. Fan speed, fan noise
level and fuel consumption all will increase based on the driving
conditions that include trailer towing, hill climbing, heavy loads, high
speed and high ambient temperature, individually or in combination.
The fan drive is designed to provide the minimum fan speed (and
resulting minimum fan noise and fuel consumption) required to meet the
ever changing vehicle cooling air flow requirements. You will hear the
amount of fan noise increasing and decreasing as the engine power
requirements and vehicle driving conditions change as you drive. This is
to be expected as being normal to the operation of your vehicle. High
levels of fan noise might also be heard when your engine is first started,
and should normally decrease after driving for a short time.
Driving
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place. Remove any debris, snow and/or ice on the foam filter by brushing
the surface with soft brush. Do not use water, solvents, or a hard brush
for cleaning the foam filter.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they are in
optimum condition.
•Use the proper coolant solution at the concentration recommended to
protect the engine against damage from freezing.
•Try to keep the fuel tank full as much as possible at the end of
operation to prevent condensation in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level. Also, if necessary, make sure to follow the engine oil and
filter change schedule found under theSpecial operating conditions
section listed in thescheduled maintenance information.
•At temperatures of -10°F (-23°C) or below, it is recommended that
you use an engine block heater to improve cold engine starting.
•If operating in arctic temperatures of -20°F (-29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling, especially in cold weather,
can cause a buildup of deposits which can cause engine damage.
The following cold weather idling guidelines are recommended:
•Use Motorcraftcetane improvers or non alcohol-based cetane
improvers from a reputable manufacturer.
•Maintain the engine cooling system properly.
•Avoid shutting the engine down after an extensive idling period. Drive
the vehicle for several miles with the engine at normal operating
temperatures under a moderate load.
•Consider using an engine block heater.
•For extended idle times use an approved idle speed increase device.
Driving
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IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
F-Super Duty
1. Engine oil dipstick
2. Automatic transmission dipstick
3. Brake fluid reservoir
4. Power distribution box
5. Batteries
6. Engine cooling system coolant reservoir (primary high-temperature
cooling system)
7. Power steering fluid reservoir
8. Engine oil fill
9. Engine-mounted fuel filter assembly
10. Secondary cooling system coolant reservoir
11. Air filter assembly
12. Air filter restriction gauge
13. Windshield washer fluid reservoir
1135234
57691012118
Maintenance and Specifications
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ENGINE AND SECONDARY COOLING SYSTEM COOLANT
Checking engine coolant
The concentration, additive strength and level of coolant should be
checked at the mileage intervals listed in thescheduled maintenance
information.The coolant concentration should be maintained at 50/50
coolant and water. For best results, coolant concentration should be
tested with a refractometer such as Rotunda tool 300-ROB75240E
available from your dealer. Ford does not recommend the use of
hydrometers or coolant test strips for measuring coolant concentration.
The level of coolant should be maintained within the COLD FILL RANGE
in the coolant reservoirs. If the level falls below, add coolant per the
instructions in theAdding coolantsection.
Your vehicle was factory-filled with a 50/50 coolant and water
concentration. If the concentration of coolant falls below 40% or above
60%, the engine parts could become damaged or not work properly.A
50/50 mixture of coolant and water provides the following:
•Improved freeze protection.
•Improved boiling protection.
•Protection against rust and other forms of corrosion.
•Enables calibrated gauges to work properly.
When the engine is cold, check the level of coolant in the reservoirs. See
Identifying components in the engine compartmentfor the location of
the engine and secondary cooling system reservoirs.
•The coolant should be within the COLD FILL RANGE in the coolant
reservoirs.
•Refer to thescheduled maintenance informationfor service interval
schedules.
•Be sure to read and understandPrecautions when servicing your
vehiclein yourOwner’s Guide.
If the coolant has not been checked at the recommended interval, the
engine or secondary coolant reservoir may become low or empty. If
either reservoir is low or empty, add coolant to the reservoir(s). Refer to
Engine and secondary cooling system refill procedurein this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant or windshield washer fluid outside of its specified function and
vehicle location.
Maintenance and Specifications
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Adding coolant
When adding coolant, make sure it is a 50/50 mixture of coolant and
distilled water. Add the mixture to the coolant reservoir(s),when the
engine is cool, until the appropriate fill level is obtained.
If you have to add more than 1.0 quart (1.0 liter) of coolant per month,
have your dealer check the cooling system. Your cooling system may
have a leak. Operating an engine with a low level of coolant can result in
engine overheating and possible engine damage.
Note:If coolant is added to bring the level within the COLD FILL
RANGE when the engine is not cold, the system will remain underfilled.
WARNING:Do not add coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
WARNING:Do not put coolant in the windshield washer fluid
container. If sprayed on the windshield, coolant could make it
difficult to see through the windshield.
•DO NOT MIX different colors or types of coolant in your
vehicle. Make sure the correct coolant is used.Refer to
Maintenance product specifications and capacitiesin this chapter
for the proper coolant type.
•The use of an improper coolant may harm engine and cooling
system components and may void the warranty.Refer to
Maintenance product specifications and capacitiesin this chapter
for the proper coolant type.
Note:Do not use stop leak pellets or cooling system sealants/additives
as they can cause damage to the engine cooling and/or heating systems.
This damage would not be covered under your vehicle’s warranty.
•A large amount of water without engine coolant may be added to the
engine cooling system only, in case of emergency, to reach a vehicle
service location. Avoid this procedure if delivery to the service location
requires heavy engine loads. In this instance, the cooling system(s)
must be drained, chemically cleaned with MotorcraftPremium
Cooling System Flush, and refilled with a 50/50 mixture of coolant and
distilled water as soon as possible. Water alone (without coolant) can
cause damage from corrosion, overheating or freezing.DO NOTuse
this method for the secondary cooling system. The secondary cooling
system operates close to ambient temperature, and is susceptible to
freezing in any subfreezing environment, in the absence of coolant.
Maintenance and Specifications
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•Do not use alcohol, methanol or brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not mix with recycled coolant. We do not recommend the
use of recycled coolant in vehicles equipped with Motorcraft
Speciality Engine Coolant, since a Ford approved recycling
process is not yet available.
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.
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. 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.
5. 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.
6. Reinstall the pressure relief cap.
7. Start and run the engine at 2,000 rpm for 2 minutes.
8. Shut engine off, and remove the pressure relief cap as previously
outlined.
9. 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.
Maintenance and Specifications
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10. Engine cooling system: Repeat Step 5 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 5 until the coolant level has
stabilized (is no longer dropping after each step) AND the lower
passenger side of the secondary radiator is warm to the touch
(indicating secondary thermostat is open and coolant is flowing
through the entire system).
11. Reinstall the pressure relief cap. Shut the engine off and let it cool.
12. Check the coolant level in the reservoir before you drive your vehicle
the next few times (with the engine cool).
13. If necessary, 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. After any coolant has been added, check the
coolant concentration. SeeEngine and secondary cooling system
coolantearlier. If the concentration is not 50/50, drain some coolant and
adjust the concentration. It may take several drains and additions to
obtain a 50/50 coolant concentration.
Whenever coolant has been added, the coolant level in the reservoir should
be checked the next few times you drive the vehicle. If needed, add a
50/50 concentration of coolant and distilled water to the proper level.
Coolant refill capacity
To find out how much fluid your vehicle’s cooling system can hold, refer
toMaintenance product specifications and capacitiesin this chapter.
Coolant additives
At specific mileage intervals of 15,000 miles (24,000 km), as listed in the
scheduled maintenance informationchapter, the coolant additive
should be checked. The optional message center, if equipped, will also
display the messageCHECK COOLANT ADDITIVEat this time. The
purpose of checking is to verify the correct concentration (freeze point
protection) and additive strength (corrosion inhibitor) levels of the
coolant for maximum engine performance and protection. Three
products are available for ensuring the life and health of the coolant: two
test kits and a coolant inhibitor additive:
•Rotunda 328-00007 (Matthew’s Water CoolCheck) – Evaluates water
quality (hardness, chloride, and pH) for 50/50 mixture of coolant and
distilled water. Use distilled water. If distilled water is unavailable,
Maintenance and Specifications
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