check engine FORD F-650/750 2022 Workshop Manual

Dispose of used engine coolant in an
appropriate manner. Follow your
community
’s regulations and standards
for recycling and disposing of automotive
fluids.
Severe Climates
If you drive in extremely cold climates:
• It may be necessary to increase the
coolant concentration above 50%.
• A coolant concentration of 60%
provides improved freeze point
protection. Coolant concentrations
above 60% decrease the overheat
protection characteristics of the
coolant and may cause engine
damage.
If you drive in extremely hot climates:
• You can decrease the coolant
concentration to 40%.
• Coolant concentrations below 40%
decrease the freeze and corrosion
protection characteristics of the
coolant and may cause engine
damage.
Vehicles driven year-round in non-extreme
climates should use prediluted engine
coolant for optimum cooling system and
engine protection.
Checking Coolant Corrosion
Inhibitor Additive Strength
At specific mileage intervals as listed in the
scheduled maintenance information
chapter, the coolant corrosion inhibitor
additive should be checked. An information
message may display in the optional
information display at this time. The
purpose of checking is to verify the correct
engine coolant concentration (freeze point
protection) and corrosion inhibitor additive
level (strength) of the coolant for
maximum engine performance and
protection. Three products are available to confirm
the life and health of the coolant, one tool,
a test kit and a coolant inhibitor additive:
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ENGINE COOLANT CHECK -
7.3L
WARNING: Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury. WARNING:
Do not put coolant in
the windshield washer reservoir. If
sprayed on the windshield, coolant could
make it difficult to see through the
windshield. WARNING:
To reduce the risk of
personal injury, make sure the engine is
cool before unscrewing the coolant
pressure relief cap. The cooling system
is under pressure. Steam and hot liquid
can come out forcefully when you loosen
the cap slightly. WARNING:
Do not add coolant
further than the MAX mark.
When the engine is cold, check the
concentration and level of the coolant at
the intervals listed in the scheduled
maintenance information. See Scheduled
Maintenance
(page 321).
Note: Make sure that the coolant level is
between the
MIN and MAX marks on the
coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the
MAX mark. Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C). Check the coolant concentration
using a refractometer. We do not
recommend the use of hydrometers or
coolant test strips for measuring coolant
concentration.
Adding Coolant
WARNING:
Do not add engine
coolant when the engine is on or the
cooling system is hot. Failure to follow
this instruction could result in personal
injury. WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury.
Note: Automotive fluids are not
interchangeable. Do not use coolant or
windshield washer fluid outside of its
specified function and vehicle location.
Note: Do not use stop leak pellets, cooling
system sealants, or non-specified additives
as they can cause damage to the engine
cooling or heating systems. Resulting
component damage may not be covered by
the vehicle Warranty.
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It is very important to use prediluted
coolant approved to the correct
specification in order to avoid plugging the
small passageways in the engine cooling
system. See Cooling System Capacity
and Specification (page 296). Do not mix
different colors or types of coolant in your
vehicle. Mixing of engine coolants or using
an incorrect coolant may harm the engine
or cooling system components and may
not be covered by the vehicle Warranty.
Note: Coolants marketed for all makes and
models may not be approved to our
specifications and may cause damage to
the cooling system. Resulting component
damage may not be covered by the vehicle
Warranty.
If the coolant level is at or below the
minimum mark, add prediluted coolant
immediately.
For vehicles with overflow coolant systems
with a non-pressurized cap on the coolant
recovery system, add coolant to the
coolant recovery reservoir when the engine
is cool. Add prediluted coolant to the
maximum level. For all vehicles which have
a coolant degas system with a pressurized
cap, or if it is necessary to remove the
coolant pressure relief cap on the radiator,
follow these steps to add engine coolant:
1. Turn the engine off and let it cool.
2. Unscrew the cap slowly. Any pressure escapes as you unscrew the cap.
3. Fill the coolant reservoir slowly with prediluted engine coolant to within the
minimum and maximum range on the
engine coolant reservoir. If you
removed the radiator cap in an
overflow system, fill the radiator until
the coolant is visible and the radiator
is almost full. If coolant is added to
bring the level within the minimum and
maximum range when the engine is not
cold, the system may remain
underfilled. 4.
Replace the coolant reservoir cap. Turn
the cap clockwise until it contacts the
hard stop.
5. Check the coolant level in the coolant reservoir the next few times you drive
your vehicle. If necessary, add enough
prediluted engine coolant to bring the
coolant level to the proper level.
Note: If prediluted coolant is not available,
use the approved antifreeze concentrate
diluting it to 50/50 with distilled water. See
Cooling System Capacity and
Specification (page 296). Using water that
has not been deionized may contribute to
deposit formation, corrosion or plugging of
the small cooling system passageways.
If you have to add more than
1.1 qt (1 L) of
engine coolant per month, have your
vehicle checked as soon as possible.
Operating an engine with a low level of
coolant can result in engine overheating
and possible engine damage.
Note: During normal vehicle operation, the
coolant may change color from orange to
pink or light red. As long as the coolant is
clear and uncontaminated, this color change
does not indicate the coolant has degraded
nor does it require the coolant to be drained,
the system to be flushed, or the coolant to
be replaced.
Note: In case of emergency, you can add a
large amount of water without coolant in
order to reach a vehicle service location.
Water alone, without coolant, can cause
engine damage from corrosion, overheating
or freezing. When you reach a service
location, you must have the cooling system
drained, flushed and refilled using the
correct specification prediluted coolant or
antifreeze concentrate. See
Cooling
System Capacity and Specification (page
296
).
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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.
Fail-Safe Cooling
Fail-safe cooling allows you to temporarily
drive your vehicle before any incremental
component damage occurs. The fail-safe
distance depends on ambient
temperature, vehicle load and terrain.
How Fail-Safe Cooling Works
If the engine begins to overheat, the
coolant temperature gauge moves toward
the red zone:
A warning lamp illuminates and
a message may appear in the
information display.
If the engine reaches a preset
over-temperature condition, the engine
switches to alternating cylinder operation.
Each disabled cylinder acts as an air pump
and cools the engine.
When this occurs, your vehicle still
operates, however:
• Engine power is limited.
• The air conditioning system turns off.
Continued operation increases the engine
temperature, causing the engine to
completely shut down. Your steering and
braking effort increases in this situation.
When the engine temperature cools, you
can re-start the engine. Have your vehicle
checked as soon as possible to minimize
engine damage. When Fail-Safe Mode Is Activated WARNING: Fail-safe mode is for
use during emergencies only. Operate
your vehicle in fail-safe mode only as
long as necessary to bring your vehicle
to rest in a safe location and seek
immediate repairs. When in fail-safe
mode, your vehicle will have limited
power, will not be able to maintain
high-speed operation, and may
completely shut down without warning,
potentially losing engine power, power
steering assist, and power brake assist,
which may increase the possibility of a
crash resulting in serious injury. WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury.
Your vehicle has limited engine power
when in the fail-safe mode, drive your
vehicle with caution. Your vehicle does not
maintain high-speed operation and the
engine may operate poorly.
Remember that the engine is capable of
shutting down to prevent engine damage.
In this situation:
1. Pull off the road as soon as safely possible and switch the engine off.
2. If you are a member of a roadside assistance program, we recommend
that you contact your roadside
assistance service provider.
3. If this is not possible, wait a short period for the engine to cool.
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4. Check the coolant level. If the coolant
level is at or below the minimum mark,
add prediluted coolant immediately.
5. When the engine temperature cools, you can re-start the engine. Have your
vehicle checked as soon as possible to
minimize engine damage.
Note: Driving your vehicle without repair
increases the chance of engine damage.
Engine Coolant Temperature
Management (If Equipped) WARNING:
To reduce the risk of
crash and injury, be prepared that the
vehicle speed may reduce and the
vehicle may not be able to accelerate
with full power until the coolant
temperature reduces.
If you tow a trailer with your vehicle, the
engine may temporarily reach a higher
temperature during severe operating
conditions, for example ascending a long
or steep grade in high ambient
temperatures.
At this time, you may notice the coolant
temperature gauge moves toward the red
zone and a message may appear in the
information display.
You may notice a reduction in vehicle
speed caused by reduced engine power in
order to manage the engine coolant
temperature. Your vehicle may enter this
mode if certain high-temperature and
high-load conditions take place. The
amount of speed reduction depends on
vehicle loading, grade and ambient
temperature. If this occurs, there is no
need to pull off the road. You can continue
to drive your vehicle. The air conditioning may turn on and off
during severe operating conditions to
protect the engine from overheating. When
the coolant temperature decreases to the
normal operating temperature, the air
conditioning turns on.
If the coolant temperature gauge moves
fully into the red zone, or if the coolant
temperature warning or service engine
soon messages appear in your information
display, do the following:
1. Pull off the road as soon as safely
possible and shift the transmission into
park (P).
2. Leave the engine running until the coolant temperature gauge needle
returns to the normal position. After
several minutes, if the temperature
does not drop, follow the remaining
steps.
3. Switch the engine off and wait for it to
cool. Check the coolant level.
4. If the coolant level is at or below the minimum mark, add prediluted coolant
immediately.
5. If the coolant level is normal, restart the engine and continue.
AUTOMATIC TRANSMISSION
FLUID CHECK
The transmission does not consume fluid.
However, check the fluid level if the
transmission is not working properly, for
example if the transmission slips, shifts
slowly or if there are signs of fluid loss.
Replace the transmission fluid and filter
on your vehicle at the specified service
interval. See
Scheduled Maintenance
(page 321).
Automatic transmission fluid expands
when warmed. To check the fluid level
consistently and accurately, do the
following:
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1.
Drive the vehicle until it reaches normal
operating temperature. This may take
up to 20 mi (30 km). Make sure that
the transmission fluid temperature
gauge on the instrument cluster is
within normal operating temperature
196– 215°F (91– 102°C)
before
checking.
2. Make sure that your vehicle is on level ground.
3. With the engine running, parking brake
engaged and your foot on the brake
pedal, move the gearshift lever through
all of the gear ranges. Allow sufficient
time for each gear to engage.
4. Make sure the parking brake is on. Make
sure the transmission is in park (P) or
neutral (N) and leave the engine
running.
5. Open the hood. See
Opening and
Closing the Hood (page 219).
6. Remove the dipstick and wipe it with a clean, lint-free cloth. See
Under
Hood Overview (page 221).
7. Replace the dipstick and remove it again to check the fluid level.
8. If the fluid level is correct, replace the dipstick and make sure it is fully seated.
Note: If the fluid level is between the
maximum and minimum marks, the fluid
level is acceptable. Do not add fluid. Transmission Fluid Level
Low Fluid Level If the fluid level is at or below the minimum
mark, add fluid immediately. See
Automatic Transmission Fluid
Capacity and Specification (page 300).
Note:
If there is no indication of fluid on the
dipstick, have your vehicle checked
immediately.
Correct Fluid Level Make sure that the fluid level is between
the maximum and minimum marks.
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1. Park your vehicle on a level surface.
2. Look at the brake fluid reservoir to see
where the brake fluid level is relative
to the MIN and the MAX marks on the
reservoir.
Note: If the brake fluid level is between the
MIN
and the MAX marks on the reservoir, it
is acceptable.
Note: If the brake fluid level is below the
MIN
mark or above the MAX mark, have
your vehicle checked as soon as possible.
Note: To avoid fluid contamination, the
reservoir cap must remain in place and fully
tight, unless you are adding fluid.
Only use fluid that meets our
specifications. See
Capacities and
Specifications (page 286).
Brake Fluid Service Interval
Brake fluid absorbs water over time which
degrades the effectiveness of the brake
fluid. Change the brake fluid at the
specified intervals to prevent degraded
braking performance. For detailed interval information, see
Scheduled Maintenance in your Owner's
Manual or your local maintenance guide.
POWER STEERING FLUID
CHECK
Check the power steering fluid. See
Scheduled Maintenance
(page 321). If
adding fluid is necessary, use only
MERCON LV ATF
Check the fluid level when it is at ambient
temperature.
1. Check the fluid level in the reservoir. It should be between the MIN and MAX
range. Do not add fluid if the level is
within this range.
2. If the fluid level is low, add fluid to bring
the fluid level up to between the MIN
and MAX range.
3. Switch the engine on.
4. While the engine idles, turn the steering
wheel left and right several times.
5. Switch the engine off.
6. Recheck the fluid level in the reservoir. Do not add fluid if the level is between
the MIN and MAX range.
7. If the fluid is low, add the proper type of fluid in small amounts, continuously
checking the level until it is between
the MIN and MAX range. See
Hydraulic Power Steering Fluid
Capacity and Specification
(page
304). Be sure to put the cap back on the
reservoir.
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5. Turn the air conditioning (if equipped)
on and allow the engine to idle for at
least one minute.
6. Release the parking brake. With your foot on the brake pedal and with the
air conditioning on, put the vehicle in
drive (D) and allow the engine to idle
for at least one minute.
•If you do not allow the engine to
relearn its idle trim, the idle quality
of your vehicle may be adversely
affected until the idle trim is
eventually relearned.
7. Drive the vehicle to complete the relearning process
•The vehicle may need to be driven
10 mi (16 km) or more to relearn the
idle and fuel trim strategy along
with the ethanol content for flexible
fuel vehicles.
If the battery has been disconnected or a
new battery has been installed, the clock
and radio settings must be reset once the
battery is reconnected.
Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized standards
for disposal. Call your local authorized
recycling center to find out more about
recycling automotive batteries.
Battery Management System (If
Equipped)
The battery management system (BMS)
monitors battery conditions and takes
actions to extend battery life. If excessive
battery drain is detected, the system may
temporarily disable certain electrical
features to protect the battery. Those
electrical accessories affected include the
rear defrost, heated/cooled seats, climate
control fan, heated steering wheel, audio
and navigation system. A message may be
shown in the information displays to alert the driver that battery protection actions
are active. These messages are only for
notification that an action is taking place,
and not intended to indicate an electrical
problem or that the battery requires
replacement.
Electrical accessory installation
To ensure proper operation of the BMS,
any electrical devices that are added to
the vehicle should not have their ground
connection made directly at the negative
battery post. A connection at the negative
battery post can cause inaccurate
measurements of the battery condition
and potential incorrect system operation.
Note:
Electrical or electronic accessories
added to the vehicle by the dealer or the
owner may adversely affect battery
performance and durability, and may also
affect the performance of other electrical
systems in the vehicle.
When a battery replacement is required,
the battery should only be replaced with
a Ford recommended replacement battery
which matches the electrical requirements
of the vehicle. After battery replacement,
or in some cases after charging the battery
with the external charger, the BMS requires
eight hours of vehicle sleep time (key off
with doors closed) to relearn the new
battery state of charge. Prior to relearning
the state of charge, the BMS may disable
electrical features (to protect the battery)
earlier than normal.
ADJUSTING THE HEADLAMPS
Vertical Aim Adjustment
The headlamps on your vehicle are
properly aimed at the assembly plant. If
your vehicle has been in an accident, the
alignment of your headlamps should be
checked by your authorized dealer.
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Before engine operation, remove any debris
blocking the core.
•
Turbocharger-to-charge air cooler.
• Charge air cooler-to-intake manifold
pipe.
• Mounting bracket.
• Chassis-mounted charge air cooler
core.
Inspect air intake piping:
• Check for accumulation of salt
deposits (where applicable). If present,
disassemble and clean the complete
air intake piping system. If pitting is
evident on the intake piping, use
Motorcraft Silicone Gasket and Sealant
TA-30 to seal joints against leakage.
• Check for loose hoses and clamps.
• Check for ruptured or collapsed hoses.
• Check air cleaner housing for cracks.
EXHAUST SYSTEM
INSPECTION
Note: If your vehicle is equipped with a
catalytic converter or muffler, do not blend
waste oil with diesel fuel. Operate only on
ultra-low sulfur (less than 15 parts per
million sulfur) diesel fuel with a cetane
value of 45 or higher.
If your diesel engine is equipped with a
catalytic converter, it is important to review
the maintenance schedule to make sure
proper functioning of the catalytic
converter. Also, take precautions not to
damage the catalytic converter when
servicing your engine or storing your
vehicle. BRAKE SYSTEM INSPECTION WARNING: Always wear a
respirator approved by the National
Institute of Occupational Studies of
Health (NIOSH) or Mine Safety and
Appliance (MSA) during all brake service
procedures. Wear the respirator from
removal of the wheels through assembly.
Never use compressed air or dry brushing
to clean brake parts or assemblies.
Clean brake parts and assemblies in
open air. During assembly, carefully
place all parts on the floor to avoid
getting dust in the air. Use an industrial
vacuum cleaner with a HEPA filter
system to clean dust from the brake
drums, backing plates and other brake
parts. After using the vacuum, remove
any remaining dust with a rag soaked in
water and wrung until nearly dry.
Never use compressed air or dry
sweeping to clean the work area. Use an
industrial vacuum cleaner with a HEPA
filter system and rags soaked in water
and wrung until nearly dry. Dispose of
used rags with care to avoid getting dust
in the air. Use an approved respirator
when emptying vacuum cleaners and
handling used rags.
Worker clean-up: Wash your hands
before eating, drinking or smoking.
Vacuum your work clothes after use and
then launder them separately, without
shaking them, to prevent fiber dust
getting into the air.
Your vehicle is equipped with
non-asbestos brake linings. However,
exposure to excessive amounts of brake
material (whether asbestos or
non-asbestos, fiberglass, mineral wool,
aramid or carbon) may be a serious health
hazard.
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inspection and keep to instructions
provided by the service manual.
Hydraulic brake systems are
power-assisted. There is a great
reduction in braking capabilities
without engine assist.
• Proper fluid level. The level should be
at the bottom edge of the ring on each
reservoir fill port. Do not fill the master
cylinder to the top of the reservoir. If
fluid level requires attention to
maintain a proper master cylinder level,
this is an indication of either severe
operation (pad wear) or fluid leakage.
A more frequent and thorough brake
inspection is required.
• Brake lines, hoses and fittings. Repair
or replace brake line tubes, hoses or
fittings as required. Inspect these
components every 4,000 mi
(6,000 km) for the following.
• Lines for kinks, dents, corrosion or
rupture.
• Hoses for abrasions, kinks, soft
spots or rupture, collapse, cracks,
twists or loose frame supports.
When replacing a hose, be sure
there is adequate clearance to the
hose to avoid an abrasion to the
new hose.
• All connections for leaks.
Driveline Parking Brake WARNING: Use wheel chocks and
exercise caution when inspecting under
the vehicle. A vehicle roll-away could
result in property damage, personal injury
or death.
A qualified technician should adjust the
parking brake and keep to the instructions
in the service manual. AXLE INSPECTION
Front Axle
Maintaining the front axle alignment to
specifications is very important. A qualified
technician should check and maintain the
alignment.
Regular inspections should include:
•
Toe-in inspection and adjustment (if
necessary), particularly with radial
tires.
• Checking for proper tightness of axle
mounting U-bolt nuts, attaching or
mounting bolts and nuts.
• Checking the axle for damage, binding,
worn parts and adequate lubrication.
• Checking the kingpins for excessive
wear. Also, perform this check during
other scheduled maintenance, for
example as tire rotation or service,
wheel bearing service and alignment.
See the workshop manual for proper
procedures.
Toe-in
It is essential to maintain correct toe-in
and tire pressure for optimum tire wear.
Inspecting steer axle tires in the first
3,000– 10,000 mi (5,000– 16,000 km)
generally shows if tires are wearing
normally.
Rapid outside shoulder wear on both tires
indicates too much toe-in.
Rapid inside shoulder wear on both tires
indicates too much toe-out.
In P&D-type service, there can be a
left-to-right steer tire tread life differential
up to 40% depending on routes and other
variables.
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