engine FORD F250 SUPER DUTY 2005 Manual Online

EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
• Use only the specified fuel listed.
• Avoid running out of fuel.
• Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
• Have the items listed in your Scheduled Maintenance Guide
performed according to the specified schedule.
The scheduled maintenance items listed in the Scheduled Maintenance
Guide are essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the Service engine soon light, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
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Please consult your Warranty Guide for complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When the Check
engine/Service engine soon light illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause your Check
engine/Service engine soon light to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, the Check engine/Service engine soon light should turn off. (A
driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If the Check engine/Service engine soon light remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your Check engine/Service engine
soon light is on, refer to the description in the Warning lights and
chimes section of the Instrument Cluster chapter. Your vehicle may not
pass the I/M test with the Check engine/Service engine soon light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
• First, at least 10 minutes of driving on an expressway or highway.
• Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
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engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCON  AT F.
Check the fluid level when it is at ambient temperature, 20° – 80° F (-7°
– 25° C):
1. Check the fluid level on the dipstick. It should be between the arrows in
the FULL COLD range. Do not add fluid if the level is within this range.
2. If the fluid level is low. Add fluid to bring fluid level up to be between
the arrows in the FULL COLD range.
3. Start the engine.
4. While the engine idles, turn the steering wheel left and right several times.
5. Turn the engine off.
6. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
7. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir.
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1. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to your Scheduled Maintenance Guide for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 20 miles [30 km]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer to Identifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
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If an overfill occurs, excess fluid
should be removed by a qualified
technician.
An overfill condition of
transmission fluid may cause shift and/or engagement concerns
and/or possible damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
Automatic transmission fluid filter (if equipped)
The TorqShift automatic
transmission is equipped with a
serviceable external fluid filter
mounted on the frame rail. Refer to
the Scheduled Maintenance Guide
for service intervals.
To replace the transmission filter:
1. Shut off the engine.
2. Unscrew filter housing.
3. Replace filter with a new authorized Motorcraft filter element. Refer to
the Motorcraft part numbers chart in this chapter.
4. Reinstall housing and check transmission fluid level using procedure in
this section.
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AIR FILTER MAINTENANCE
Refer to the scheduled maintenance guide for the appropriate intervals
for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer to Motorcraft part numbers in this chapter.
Note: Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
Changing the air filter element
• 5.4L Engine
1. Release two retainer clamps.
2. Pull air filter tray assembly out
toward front of vehicle and lift air
filter element up and out of housing.
The air filter box needs to be free of any debris before installing a new
air filter.
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3. Install a new air filter element
into the tray assembly.
4. Return air filter tray to original
position by pressing firmly on the
handle until all rearward movement
stops and secure the two clamps.
• 6.8L Engine
1. Loosen the clamps that secures
the air filter cover in place.
2. Carefully separate the two halves of the air filter housing.
3. Remove the air filter element from the air filter housing.
4. Install a new air filter element.
5. Reassemble the two halves of the air filter housing, aligning the notchs
and slots. Secure the clamps, making sure not to crimp the air filter edges
between the two halves of the air filter housing. This could cause filter
damage and allow unmetered air to enter the engine if not properly seated.
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MOTORCRAFT PART NUMBERS
Component 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-1011 FG-1011
Oil filter FL-820-S FL-820-S
PCV valve 1
Battery (Standard) BXT-65-650 BXT-65-650
Battery (Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum 2
Remote Automatic
Transmission Filter 3
FT-145 FT–1451
The PCV valve is a critical emission component. It is one of the items
listed in the Scheduled Maintenance Guide and is essential to the life
and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your dealer or a qualified service
technician. Refer to the Scheduled Maintenance Guide for the
appropriate intervals for changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used. 2
For spark plug replacement, see your dealer or a qualified service
technician. Refer to the Scheduled Maintenance Guide for the
appropriate intervals for changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used. 3
Also available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
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REFILL CAPACITIES
Fluid Ford Part
Name Application Capacity
Front axle Motorcraft SAE
80W-90
Premium Rear
Axle Lubricant F-250/350
(Dana 60 axle) 6.3 pints (3.0L)
F-350/450/550
(Dana 60 axle) 6.3 pints (3.0L)
Rear axle Motorcraft SAE
75W-140
Synthetic Rear
Axle Lubricant F-250 /350
(10.50 inch
axle) 1
6.9 pints (3.3L)
Motorcraft SAE
75W-90
Synthetic Rear
Axle Lubricant F-350 (DANA
80) 1
8.5 pints (4.0L)
Motorcraft SAE
75W–140
Synthetic Rear
Axle Lubricant F-450/550
(Dana S110) 14.0 pints (6.6L)
Brake fluid (and
clutch fluid-if
equipped) Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid All Fill to line or
step (for clutch)
on reservoir
Engine coolant 2
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) 5.4L V8 engine
with A/C 26.4 quarts
(25.0L)
6.8L V10 engine 27.5 quarts
(26.0L)
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Fluid Ford Part
Name Application Capacity
Engine oil
(includes filter
change)-Gas
engines 6
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) 5.4L V8 and
6.8L V10
engines 7.0 quarts
(6.6L)
Engine oil
(includes filter
change)-Diesel
engine Refer to your 6.0L Diesel Supplement
Fuel tank N/A Mid-ship tank
(optional on
Chassis Cab) 19.0 gallons
(71.9L )
Short box 30.5 gallons
(115.5L)
Long box 38.0 gallons
(143.9L)
Aft axle 40.0 gallons
(151.4L)
Power steering
fluid Motorcraft
MERCON  AT F All Fill to FULL
COLD range on
dipstick
Transfer case
fluid Motorcraft
MERCON  AT F 4x4 vehicles 2.0 quarts
(1.9L)
Manual
transmission
fluid Motorcraft
MERCON  AT F 6-speed manual 5.8 quarts
(5.5L) 4
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