Power Stroke Diesel Operating and Maintenance Requirements

Power Stroke Diesel engines offer industry-leading power and performance.  In order to continue to extract this performance, ensure longevity and reduce downtime from these high-technology engines, it is very important that customers adhere to the Ford maintenance requirements.  As the customer’s primary point-of-contact, Ford Dealerships need to be well versed in these requirements and make appropriate recommendations to customers on their service visits.

What’s New

 

• 6.7L Power Stroke Diesel maintenance vs. 6.4 and 6.0
• Intelligent Oil Life Monitor System
• Diesel Exhaust Fluid (DEF) requirements and filling practices
• OAT Coolant
• Coolant test procedures

 

Background

Since the launch of the 2008 Super Duty, Ford Motor Company has made a concerted effort to ensure all Dealers are aware of critical Power Stroke® diesel engine operating characteristics and maintenance requirements. To help accomplish this, there have been a number of initiatives/ communications released.

Even with these initiatives there have been an increasing number of instances of diesel engine issues resulting from inadequate maintenance. Customers may be unaware that more frequent maintenance is required when their vehicle is utilized under severe service special operating conditions (towing, long idle/commercial delivery, off road/dusty, biodiesel).

• Engine failures have occurred due to lack of proper coolant strength and nitrite level checks.
• Turbocharger failures can occur due to a lack of proper lubrication or dusting from unfiltered intake air.
• Turbocharger & EGR valve coking deposits collect faster in colder weather, without proper maintenance.
• Low fuel pressure and/or fuel volume due to fuel filter contamination can cause hard starting and slower cranking times.
• Fuel injector internal failures can occur due to loss of fuel pressure from clogged filters, fuel line freeze up and the injector spook valve can stick when the oil is contaminated and/or the wrong oil viscosity.
• Fuel injector failure, High Pressure Fuel Pump/System failures due to contaminated fuel (water in the fuel as an example)

 

In addition, customers should be advised that non-Ford maintenance products (engine oil and oil filters, air filters, fuel filters and engine coolant) may not provide an adequate level of protection due to varying levels of aftermarket production standards and processes

 

Engine Oil Requirements

Ensure you review the engine oil SAE viscosity grade requirements contained in the Owner’s Guide Supplement. To ensure trouble-free operation and longevity, it is essential that these viscosity grade requirements are followed since they change depending on ambient temperatures and vehicle usage (i.e. towing).

Use only Motorcraft oil or equivalent oil conforming to Ford specification WSS-M2C171-E or API service categories CJ-4 or CJ-4/SM.  These oils are compatible with the emission control equipment of the vehicle to meet the more stringent emission standards.

 

Cold Starting

 

Warm-Up Idling Time – Adequate warm-up idling time is required. In cold weather, the engine should idle for a minimum of 30 seconds prior to increasing engine rpm.

Block Heaters – Block heater usage is not unique to the Power Stroke engine.  All Power Stroke Diesel engines have recommended block heaters to be used in cold temperatures.  The Power Stroke Diesel Owner’s Guide Supplement strongly recommends that an engine block heater be used at temperatures below -23°C (-10°F). 

 

Diesel Fuel Conditioners

Additives that will improve fuel cetane numbers may be used to verify and enhance fuel quality. Use Motorcraft Cetane Booster & Performance Improver part number PM 22B. For cold weather operation use Motorcraft Anti-Gel & Cetane Performance Improver part number PM 23B. Both levels of additives are fully compatible with all Power Stroke Diesel engines.

 

Note: DO NOT USE alcohol based additives. This may result in damage to the fuel injectors/system.

PM 15 is a fuel lubricity additive that was required to be added when injector(s) were replaced on a 7.3L. This lubricity additive is not required for 6.0L, 6.4L or 6.7L.

 

Maintenance Interval Reminder

A review of your customer’s driving habits is imperative to determine if they should follow a Normal Maintenance Interval Schedule or Special Operating Conditions.  See the Power Stroke 6.0L and 6.4L Diesel Owner’s Guide Supplement for details.

Customers who operate in Special Operating Conditions* need to be aware of the service requirements, and the service interval requirements (which include kilometres, time/months or hours of operation whichever occurs first)

*refer to PSM 2010-22N for revisions to 2011 Model Year

Oil Change Interval	2007 – 2008 6.0 L	2008 – 2010 6.4 L	2011 6.7 L
Normal Schedule	12,000 km or 6 months, whichever occurs first	16,000 km or 6 months, whichever occurs first	As indicated by Intelligent Oil Life Monitor system, up to 16,000 km or 1-year. (see below)
Special Operating Conditions	8,000 km, 6 months or 200 hours of engine operation, whichever occurs first	8,000 km, 6 months or 200 hours of engine operation, whichever occurs first

 

Intelligent Oil Life Monitor (6.7L only)

The IOLM system monitors several key engine sensors, then, using an algorithm determines the remaining oil life. It notifies the driver via the message center when the engine oil needs to be changed and the Diesel Owner Guide Supplement lists other required services to be performed for each interval.

Refer to PSM 2010-22N and MBG 2010-127N for further details

 

Diesel Exhaust Fluid (DEF)

DEF (also referred to as Reductant) is to be filled on every maintenance visit, or as directed through the instrument cluster message centre.  Ensure you follow the filling instructions in the vehicle Owner’s Guide.  When the DEF tank is full, the fluid level in the bottle will stop dropping, indicating the fluid has stopped flowing.  DO NOT try to continue to add DEF to the tank by shaking or repositioning the container to induce flow. This may cause spilling and overfill the tank. Overfilling the DEF tank can cause damage to the tank.

Diesel equipped Super Duty vehicles are shipped with a factory fill of DEF.  If the message centre indicates that DEF level is OK, it is neither required nor necessary to add DEF.  If Owner Guide filling instructions are not followed, it is possible to overfill the tank.

Ensure proper storage of unused DEF as the freezing point of DEF is -11C (12F).

Review proper re-filling procedures with your service staff as well as with your customers so they are familiar with this. Directions on proper filling are listed in the Diesel Supplement Guide, and on the back of the Motorcraft jug. The Motorcraft jug comes with an automatic shut off fill spout which aids in preventing overfilling of the DEF tank.

NOTE: Do Not overfill the DEF tank, or damage to the DEF tank and internal components may occur

 

Diesel Coolant Maintenance – Service Tips

TSB 09-08-05 was released to provide additional information to supplement the Workshop Manual (WSM) and Owner Guide information on the importance of cooling system maintenance for diesel engine equipped vehicles. Some customers, using their trucks under special operating conditions, indicate that operating with insufficient coolant strength (antifreeze or anticorrosion) can result in significant engine damage. Insufficient coolant strength can result when:

• Cooling system pressure and coolant is lost.
• The coolant level is topped off using the incorrect coolant.
• The coolant is mixed with hard water.
• Coolant is mixed at the incorrect concentration.
• Vehicles are operated under the special operating conditions as defined in the maintenance schedule (heavy commercial use that results in frequent or extensive idling, frequent low speed/rush hour traffic use; vehicles   operated under special conditions such as: sustained high speed driving at maximum GVWR load, towing a trailer, using a slide in camper (F-Super Duty) or car top carrier (E-Series).

 

Proper cooling system maintenance is critical for maximum engine performance and efficiency on today’s high technology diesel engines. It is essential that; the proper coolant is used, the coolant level is checked routinely, the coolant strength (antifreeze and anticorrosion property) is tested frequently and that the cooling system is flushed (with Motorcraft® Engine Cooling System Iron Cleaner) at the proper intervals.

Check the anticorrosion strength (nitrite level) of the coolant using the Rotunda 3-Way HD Antifreeze Test Strip Kit part number 328-00001, 1-800-Rotunda (768-8632) option 2 or equivalent. Perform coolant anticorrosion strength at the frequencies recommended.

Refer to the TSB or updated Workshop Manual for service procedures

For the 6.7L, check the coolant inhibitor strength with a special test kit for Specialty Orange Engine Coolant and increase additive levels if the test kit says they are low.  If incorrect coolant, containing high levels of Nitrite, is added or used in their truck it could cause issues with the heat exchangers.  Use the 3 way test kit to check for Nitrite.  Refer to the WSM for complete details.

 

Coolant Requirements

6.0L and 6.4L – Motorcraft® Premium Gold Engine Coolant CVC-7 – 3-Way HD Antifreeze Coolant Test Kit

6.7L – Motorcraft® Specialty Orange Engine Coolant CVC-3B and Motorcraft® – Specialty Orange Engine Coolant Revitalizer – VC-12 – 3-Way HD Antifreeze Coolant Test Kit                                                                

 

Fuel Filters and Maintenance Intervals

The 6.0L, 6.4L and 6.7L Power Stroke Diesel engines are equipped with 2 fuel filters.  Be aware that many aftermarket suppliers sell these filters individually and customers who do not maintain their vehicles at Ford Dealerships may not be replacing both filters and could encounter hard starting, driveability and injector damage concerns as a result.

Fuel Filter Change Interval	2007 – 2008 6.0 L	2008 – 2009 6.4 L	2011 6.7 L
Normal Schedule	24,000 km or 12 months, whichever occurs first	32,000 km or 24 months, whichever occurs first	Required when directed through the message centre located in the Instrument Cluster
Special Operating Conditions	16,000 km or 400 hours of engine operation, whichever occurs first	16,000 km or 400 hours of engine operation, whichever occurs first

 

Power Stroke Diesel vehicles are equipped with a Fuel Conditioner Module (DFCM/HFCM) that houses one of the fuel filters and separates water from the diesel fuel.  Water should be drained from the module assembly whenever the WATER IN FUEL (WIF) warning light comes on or every month, whichever occurs first.  While changing these fuel filters, it is requested that the fuel is sampled for signs of contamination and is reviewed with the customer and addressed.

 

Best Practice:  Some Dealerships have included draining the fuel separator whenever a customer brings their truck in for service.  This low effort service has high value for the customer and shows that you are looking after them and their vehicle.

Not addressing fuel contamination and or not draining the WIF, ignoring the warning, and or the use of alcohol based fuel additives will allow water and contaminates to bypass the WIF separator and fuel filters, resulting in damage to the engine.