engine FORD F650 2017 13.G Service Manual

WARNINGS
your vehicle becomes limited to engine idle
only once stopped. In these conditions, be
cautious where you stop your vehicle
because you may not be able to drive long
distances or maintain highway speeds until
you refill or replace the diesel exhaust fluid. Tampering with or disabling selective
catalytic reduction system results in
severe vehicle performance
limitation including eventual speed limiting
to 5 mph (5 km/h). The information display shows a series of
messages about the amount of diesel
exhaust fluid available. A systems check
displays messages indicating the amount
of diesel exhaust fluid available or displays
a warning message indicating the
approximate distance remaining as the
fluid in the diesel exhaust fluid tank nears
empty. See
Information Messages
(page 64). As the diesel exhaust fluid level
nears empty, the warning
symbol displays and a series of
tones and messages starting at
500 mi
(800 km) remaining before diesel exhaust
fluid is depleted. The warning symbol and
messages continue until you refill the
diesel exhaust fluid tank. Continued driving without refilling results
in the following actions as required by the
California Air Resources Board (CARB) and
the U.S. Environmental Protection Agency
(EPA):
•
Within a preset distance to empty,
speed is limited upon vehicle restart.
Prior to this occurring a message
appears in the information display.
• Further vehicle operation without
refilling the diesel exhaust fluid tank
causes the engine to enter an idle-only
condition. This only occurs upon vehicle
refueling or at an extended idle. A
message indicates the required actions
to resume normal operation. It is
required to add a minimum of
1.0 gal
(3.8 L) of diesel exhaust fluid to the
tank to exit the idle-only condition, but
your vehicle is still in the speed-limiting
mode until you refill the tank
completely.
Note: For either vehicle speed limiting or
idle-only condition, normal vehicle operation
resumes when you refill the diesel exhaust
fluid tank.
Note: When filling the diesel exhaust fluid
tank from empty, there may be a short delay
before detecting the increased level of fluid.
The increased level detection must occur
before your vehicle returns to full power.
Diesel Exhaust Fluid Guidelines
and Information
• Use only diesel exhaust fluid that
carries the American Petroleum
Institute (API) certified diesel exhaust
fluid trademark or ISO 22241.
• Do not put diesel exhaust fluid in the
diesel fuel tank.
• Do not overfill the diesel exhaust fluid
tank.
• Diesel exhaust fluid is corrosive.
• Do not re-use the diesel exhaust fluid
container once it is emptied.
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•
Avoid spilling diesel exhaust fluid on
painted surfaces, carpeting or plastic
components. Immediately wipe away
any diesel exhaust fluid that has spilled
with a damp cloth and water. If it has
already crystallized, use warm water
and a sponge.
• Store diesel exhaust fluid out of direct
sunlight and in temperatures between
23°F (-5°C) and 68°F (20°C).
• Diesel exhaust fluid freezes below 12°F
(-11°C)
.
• Do not store the diesel exhaust fluid
bottle in your vehicle. If it leaks it could
cause damage to interior components
or release an ammonia odor inside your
vehicle.
• Diesel exhaust fluid is non-flammable,
non-toxic, colorless and water-soluble
liquid.
• The system has a diesel exhaust fluid
quality sensor. Dilution of diesel
exhaust fluid or use of any other liquid
in the SCR system leads to a diesel
exhaust fluid system fault, eventually
leading to the vehicle only operating in
idle-only mode.
• Do not dilute diesel exhaust fluid with
water or any other liquid.
• An ammonia odor may be smelled
when the cap is removed or during
refill. Refill diesel exhaust fluid in a well
ventilated area. Typical Diesel Exhaust Fluid Usage
When Using the Power Take Off (PTO) Continuous PTO use—Minimal PTO use
0–7,800 mi (0– 12,550 km)
Contaminated Diesel Exhaust
Fluid or Inoperative Selective
Catalytic Reduction System
Selective catalytic reduction systems are
sensitive to contamination of the diesel
exhaust fluid. Maintaining the purity of the
fluid is important to avoid system
malfunctions. If you remove or drain the
diesel exhaust fluid tank, do not use the
same fluid to refill the tank. The system
has a sensor to monitor fluid quality. A warning lamp illuminates and
a message appears in the
information display if the system
becomes contaminated or inoperative.
Continued driving without replacing diesel
exhaust fluid or having the selective
catalytic reduction system repaired results
in the following actions as required by the
California Air Resources Board (CARB) and
U.S. Environmental Protection Agency
(EPA):
• Within a preset distance to empty,
speed is limited upon vehicle restart.
Prior to this occurring a message
appears in the information display.
• Further vehicle operation without
replacing contaminated diesel exhaust
fluid causes the engine to enter an
idle-only condition. This only occurs
upon vehicle refueling, vehicle idling in
park for 1 hour, or engine shutdown for
10 minutes or more and is indicated by
a message in the information display
indicating required actions to resume
normal operation.
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Note:
For vehicle speed limiting or idle-only
condition, normal vehicle operation resumes
when you repair the contaminated system.
To service a contaminated or inoperative
system, see an authorized dealer.
REFUELING - GASOLINE WARNINGS
Fuel vapor burns violently and a fuel
fire can cause severe injuries.
Read and follow all the instructions
on the pump island.
When refueling always shut the
engine off and never allow sparks or
open flames near the fuel tank filler
valve. Never smoke or use a cell phone
while refueling. Fuel vapor is extremely
hazardous under certain conditions. Avoid
inhaling excess fumes. Stay outside your vehicle and do not
leave the fuel pump unattended
when refueling your vehicle.
Keep children away from the fuel
pump; never let children pump fuel.
Wait at least 10 seconds before
removing the fuel pump nozzle to
allow any residual fuel to drain into
the fuel tank. Stop refueling after the fuel pump
nozzle automatically shuts off for the
second time. Failure to follow this
will fill the expansion space in the fuel tank
and could lead to fuel overflowing. Do not remove the fuel pump nozzle
from its fully inserted position when
refueling. Use the following guidelines to avoid
electrostatic charge build-up when filling
an ungrounded fuel container:
•
Place approved fuel container on the
ground.
• Do not fill a fuel container while it is in
the vehicle (including the cargo area).
• Keep the fuel pump nozzle in contact
with the fuel container while filling.
• Do not use a device that would hold
the fuel pump handle in the fill position.
Fuel Filler Cap WARNINGS
The fuel system may be under
pressure. If you hear a hissing sound
near the fuel filler inlet, do not refuel
until the sound stops. Otherwise, fuel may
spray out, which could cause serious
personal injury. If you do not use the correct fuel filler
cap, excessive pressure or vacuum
in the fuel tank may damage the fuel
system or cause the fuel cap to disengage
in a crash. Failure to follow this warning
could result in serious personal injury. The fuel tank has a threaded fuel filler cap.
Note:
If you must replace the fuel filler cap,
replace it with a fuel filler cap that is
designed for your vehicle. The vehicle
Warranty may be void for any damage to
the fuel tank or fuel system if the correct
genuine Ford, Motorcraft or other certified
fuel filler cap is not used.
When refueling the vehicle fuel tank do the
following.
1. When your vehicle has stopped, shift into neutral (N) or park (P).
2. Apply the parking brake and switch the
ignition off.
3. Turn the fuel filler cap counterclockwise and remove it.
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4. Refuel your vehicle as required.
5. Replace the fuel filler cap, turn it
clockwise until you feel a strong
resistance.
If the fuel cap warning lamp or a warning
message appears in the instrument cluster,
you may not have installed the fuel filler
cap correctly.
If the fuel cap warning lamp remains on,
at the next opportunity, safely pull off of
the road, remove the fuel filler cap, align
the cap properly and reinstall it. The check
fuel cap warning lamp or warning message
may not reset immediately. It may take
several driving cycles for the indicators to
turn off. A driving cycle consists of an
engine start-up (after four or more hours
with the engine off) followed by normal
city and highway driving.
REFUELING - DIESEL
An engine that suddenly becomes noisy or
operates poorly after a fuel fill could be
using substandard fuel. We recommend
that you purchase diesel fuel from a
reputable fuel station.
Use only clean, approved containers that
will prevent the entry of dirt or water
whenever you store diesel fuel.
Do not store diesel fuel in a galvanized
container. The fuel dissolves the zinc in the
galvanized container. The zinc will then
remain in the fuel. If you run the
contaminated fuel through the engine, the
zinc damages the fuel injectors. Engine
damage caused may not be covered by
the vehicle Warranty. Fuel Filler Cap WARNINGS
The fuel system may be under
pressure. If you hear a hissing sound
near the fuel filler inlet, do not refuel
until the sound stops. Otherwise, fuel may
spray out, which could cause serious
personal injury. If you do not use the correct fuel filler
cap, excessive pressure or vacuum
in the fuel tank may damage the fuel
system or cause the fuel cap to disengage
in a crash. Failure to follow this warning
could result in serious personal injury. The fuel tank has a threaded fuel filler cap.
Note:
If you must replace the fuel filler cap,
replace it with a fuel filler cap that is
designed for your vehicle. The vehicle
Warranty may be void for any damage to
the fuel tank or fuel system if the correct
genuine Ford, Motorcraft or other certified
fuel filler cap is not used.
When refueling the vehicle fuel tank do the
following.
1. When your vehicle has stopped, shift into neutral (N) or park (P).
2. Apply the parking brake and switch the
ignition off.
3. Turn the fuel filler cap counterclockwise and remove it.
4. Refuel your vehicle as required.
5. Replace the fuel filler cap, turn it clockwise until you feel a strong
resistance.
If the fuel cap warning lamp or a warning
message appears in the instrument cluster,
you may not have installed the fuel filler
cap correctly.
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If the fuel cap warning lamp remains on,
at the next opportunity, safely pull off of
the road, remove the fuel filler cap, align
the cap properly and reinstall it. The check
fuel cap warning lamp or warning message
may not reset immediately. It may take
several driving cycles for the indicators to
turn off. A driving cycle consists of an
engine start-up (after four or more hours
with the engine off) followed by normal
city and highway driving.
Fuel Fill Rate
Your vehicle has a fuel fill pipe that is able
to accept fuel up to 20 gal (75 L) per
minute from a fuel-dispensing nozzle.
Pumping fuel at greater flow rates may
result in premature nozzle shut-off or spit
back.
Truck stops have fuel pumps and nozzles
designed for larger, heavy-duty trucks. If
you are refueling your vehicle at a truck
stop and the nozzle shuts off repeatedly,
wait 5-10 seconds, then use a slower fill
rate.
FUEL CONSUMPTION
Real world fuel consumption is governed
by many factors, for example driving style,
high speed driving, stop-start driving, air
conditioning usage, the accessories fitted,
payload and towing. •
The usable capacity of the fuel tank is
the amount of fuel that can be added
into the tank after the gauge indicates
empty.
• The advertised capacity is the total fuel
tank size. See
Capacities and
Specifications (page 252). It is the
combined usable capacity plus the
empty reserve.
• Due to the empty reserve, you may not
be able to refuel the full amount of the
advertised capacity of the fuel tank
even when the fuel gauge reads empty.
Empty reserve is the amount of fuel
remaining in the tank after the fuel gauge
indicates empty. The amount of usable
fuel in the empty reserve varies and should
not be relied upon to increase driving range.
Filling the Tank
For consistent results when filling the fuel
tank:
• Turn the ignition off before refueling
your vehicle; a temporary inaccurate
reading may result if the engine is left
on when refueling your vehicle.
• Use the same fill rate
(low-medium-high) each time the tank
is refueled.
• Allow no more than two automatic
click-offs when refueling your vehicle.
Results are most accurate when the filling
method is consistent.
Calculating Fuel Economy
Do not measure fuel economy during the
first
900 mi (1,500 km) of driving (this is
your engine ’s break-in period); a more
accurate measurement is obtained after
1,900 mi (3,000 km)
.
Fuel expense, frequency of fill ups or fuel
gauge readings are not accurate ways to
measure fuel economy.
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1.
Fill the fuel tank completely and record
the initial odometer reading.
2. Each time you fill the fuel tank, record the amount of fuel added.
3. After at least three fill ups, fill the fuel tank and record the current odometer
reading.
4. Subtract your initial odometer reading from the current odometer reading.
5. Calculate fuel economy by dividing miles traveled by gallons used (For
Metric: Multiply liters used by 100, then
divide by kilometers traveled).
Keep a record for at least one month and
record the type of driving (city or highway).
This provides an accurate estimate of your
vehicle ’s fuel economy under current
driving conditions. Keeping records during
summer and winter will show how
temperature impacts fuel economy. In
general, your vehicle will use more fuel in
cold temperatures.
Conditions That Affect Fuel Economy
• Heavily loading your vehicle or towing
a trailer may reduce fuel economy at
any speed.
• Carrying unnecessary weight in your
vehicle may reduce fuel economy.
• Adding certain accessories to your
vehicle such as bug deflectors, rollbars
or light bars, running boards and ski
racks may reduce fuel economy.
• Using fuel blended with alcohol may
lower fuel economy.
• Fuel economy may decrease with lower
temperatures.
• You will get better fuel economy when
driving on flat terrain than when driving
on hilly terrain. •
Transmissions give their best fuel
economy when operated in the top
cruise gear and with steady pressure
on the accelerator pedal.
• Close the windows for high-speed
driving.
EMISSION CONTROL SYSTEM
- GASOLINE WARNINGS
Do not park, idle or drive your vehicle
on dry grass or other dry ground
cover. The emission system heats up
the engine compartment and exhaust
system, creating the risk of fire. Exhaust leaks may result in entry of
harmful and potentially lethal fumes
into the passenger compartment. If
you smell exhaust fumes inside your
vehicle, have your vehicle inspected
immediately. Do not drive if you smell
exhaust fumes. Your vehicle has various emission control
components and a catalytic converter that
enables it 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 scheduled
maintenance information performed
according to the specified schedule.
The scheduled maintenance items listed
in scheduled maintenance information are
essential to the life and performance of
your vehicle and to its emissions system.
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If you use anything other than Ford,
Motorcraft or Ford-authorized parts 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.
Illumination of the service engine soon
indicator, 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.
An improperly operating or damaged
exhaust system may allow exhaust to
enter the vehicle. Have a damaged or
improperly operating exhaust system
inspected and repaired immediately.
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
also lists engine displacement.
Please consult your warranty information
for complete details.
On-Board Diagnostics (OBD-II)
Your vehicle has a computer known as the
on-board diagnostics system (OBD-II) that
monitors the engine ’s emission control
system. The system protects the
environment by making sure that your
vehicle continues to meet government
emission standards. The OBD-II system
also assists a service technician in properly
servicing your vehicle. When the service engine soon
indicator illuminates, the OBD-II
system has detected a
malfunction. Temporary malfunctions may
cause the service engine soon indicator to
illuminate. Examples are:
1. Your vehicle has run out of fuel —the
engine may misfire or run poorly.
2. Poor fuel quality or water in the fuel —the engine may misfire or run
poorly.
3. The fuel fill inlet may not have closed properly. See Refueling (page 100).
4. Driving through deep water —the
electrical system may be wet.
You can correct these temporary
malfunctions by filling the fuel tank with
good quality fuel, properly closing the fuel
fill inlet or letting the electrical system dry
out. After three driving cycles without these
or any other temporary malfunctions
present, the service engine soon indicator
should stay off the next time you start the
engine. A driving cycle consists of a cold
engine startup followed by mixed city and
highway driving. No additional vehicle
service is required.
If the service engine soon indicator remains
on, have your vehicle serviced at the first
available opportunity. Although some
malfunctions detected by the OBD-II may
not have symptoms that are apparent,
continued driving with the service engine
soon indicator on can result in increased
emissions, lower fuel economy, reduced
engine and transmission smoothness and
lead to more costly repairs.
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Readiness for Inspection and
Maintenance (I/M) Testing
Some state and provincial and local
governments may have
Inspection/Maintenance (I/M) programs
to inspect the emission control equipment
on your vehicle. Failure to pass this
inspection could prevent you from getting
a vehicle registration.
If the service engine soon
indicator is on or the bulb does
not work, your vehicle may need
service. See On-Board Diagnostics.
Your vehicle may not pass the I/M test if
the service engine soon indicator is on or
not working properly (bulb is burned out),
or if the OBD-II system has determined
that some of the emission control systems
have not been properly checked. In this
case, the vehicle is not ready for I/M
testing.
If the vehicle ’s engine or transmission has
just been serviced, or the battery has
recently run down or been replaced, the
OBD-II system may indicate that the
vehicle is not ready for I/M testing. To
determine if the vehicle is ready for I/M
testing, turn the ignition key to the on
position for 15 seconds without cranking
the engine. If the service engine soon
indicator blinks eight times, it means that
the vehicle is not ready for I/M testing; if
the service engine soon indicator stays on
solid, it means that your vehicle is ready
for I/M testing.
The OBD-II system checks the emission
control system during normal driving. A
complete check may take several days.
If the vehicle is not ready for I/M testing,
you can perform the following driving cycle
consisting of mixed city and highway
driving: 1. 15 minutes of steady driving on an
expressway or highway followed by 20
minutes of stop-and-go driving with at
least four 30-second idle periods.
2. Allow your vehicle to sit for at least eight hours with the ignition off. Then,
start the vehicle and complete the
above driving cycle. The vehicle must
warm up to its normal operating
temperature. Once started, do not turn
off the vehicle until the above driving
cycle is complete.
If the vehicle is still not ready for I/M
testing, you need to repeat the above
driving cycle.
EMISSION CONTROL SYSTEM
- DIESEL
Oxidation Catalytic Converter and
Diesel Particulate Filter System (If
Equipped) WARNING
The normal operating temperature
of the exhaust system is very high.
Never work around or attempt to
repair any part of the exhaust system until
it has cooled. Use special care when
working around the diesel oxidation
catalytic converter or the diesel particulate
filter. The diesel oxidation catalytic
converter and the diesel particulate filter
heat up to very high temperatures after
only a short period of engine operation and
remain hot after you switch the engine off. Your vehicle has a diesel particulate filter.
The diesel particulate filter is an inline filter
in the exhaust system that reduces carbon
emissions by trapping exhaust particles
before they reach the tailpipe. The diesel
particulate filter looks similar to a
traditional exhaust catalyst and is part of
the exhaust system under your vehicle. The
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filter couples to a diesel oxidation catalyst
that reduces the amount of harmful
exhaust emitted from the tailpipe. As soot
gathers in the system, it begins to restrict
the filter. The system must periodically
clean the soot that gathers inside the filter.
This is carried out in two ways, passive
regeneration and active regeneration. Both
methods occur automatically and require
no actions from the driver. During either
one of these regeneration methods,
although you may notice a change in
exhaust tone. At certain times, the
information display shows various
messages related to the diesel particulate
filter. See Information Messages (page
64).
Diesel Particulate Filter Maintenance
You must properly maintain your vehicle's
diesel particulate filter in order for it to
function properly.
Do not disregard maintenance messages
that appear in the information display.
Failure to follow the instructions of an
information message may degrade vehicle
performance and could lead to engine
damage that may not be covered by the
vehicle Warranty.
Failure to perform active or operator
commanded regeneration when instructed
could result in a clogged diesel particulate
filter. If the diesel particulate filter fills
beyond the regeneration threshold, your
vehicle disables the ability for active and
operator commanded regeneration. This
could result in irreversible damage to the
diesel particulate filter requiring
replacement that may not be covered by
the vehicle Warranty. Passive Regeneration
In passive regeneration, the exhaust
system temperature and constituents
automatically clean the filter by oxidizing
the soot. Cleaning automatically occurs
during normal vehicle operating conditions
due to driving patterns.
Active Regeneration
Once the diesel particulate filter is full of
exhaust particles, the engine control
module commands the exhaust system to
clean the filter through active regeneration.
Active regeneration requires the engine
computer to raise the exhaust temperature
to eliminate the particles. During cleaning,
the particles convert to harmless gasses.
Once cleaned the diesel particulate filter
continues trapping exhaust particles.
The regeneration process operates more
efficiently when you drive your vehicle at
a constant speed above30 mph (48 km/h)
and at a steady engine speed for
approximately 20 minutes. The frequency
and duration of regeneration fluctuates by
how you drive your vehicle, outside air
temperature and altitude. For most driving,
regeneration frequency varies from
100–500 mi (160–805 km)
between
occurrences and each occurrence lasts
9– 35 minutes. You can usually reduce the
duration of regeneration if you maintain a
constant speed above 30 mph (48 km/h).
When the engine control module detects
that the diesel particulate filter is nearly
full of particulates and you are not
operating your vehicle in a manner to allow
effective automatic regeneration,
messages appear in the information
display as a reminder for you to drive your
vehicle in order to clean the diesel
particulate filter. If you drive your vehicle
in a manner to allow effective automatic
regeneration, the information display
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Note:
You cannot use the operator
commanded regeneration until the diesel
particulate filter load percentage has
reached 100%. The diesel particulate filter
load percentage fluctuates up and down
when driving your vehicle due to active and
passive regenerations.
Note: During the use of operator
commanded regeneration, you may observe
a light amount of white smoke. This is
normal. You may not be able to use
operator commanded
regeneration if the service engine
soon warning lamp appears in the
information display
Information Display Procedure
Start with your vehicle engine and when it
has reached the normal operating
temperature, press the information display
control button on the steering wheel. See
Information Display Control (page 45).
If a message advising that the exhaust
filter is full appears in the information
display, press the OK button to set the
display to Y. Answer yes to this prompt
and then follow the next prompts
regarding exhaust position required to
initiate operator commanded regeneration.
Be sure to understand each prompt. If you
are not sure what is being asked by each
prompt, contact an authorized dealer. The
display confirms the operation has started
and when it has finished.
If the diesel particulate filter is near or at
saturation, a message requesting
permission to initiate filter cleaning
appears in the information display. See
Information Messages
(page 64).
Answer yes to this prompt and then follow
the next prompts regarding exhaust
position required to initiate operator
commanded regeneration. Be sure to understand each prompt. If you are not
sure what is being asked by each prompt,
contact an authorized dealer. The display
confirms the operation has started and
when it has finished. You can also drive to
clean the filter. When the system is at the point
of oversaturation, the service
engine warning lamp illuminates
and a message appears in the information
display. You cannot initiate filter cleaning.
You must have your vehicle checked as
soon as possible.
Once operator commanded regeneration
starts, engine speed increases to
approximately 2000– 2500 rpm and the
cooling fan speed increases. You will hear
a change in audible sound due to engine
speed and cooling fan speed increases.
It is not necessary to open the hood on the
engine compartment. Once operator
commanded regeneration completes, the
engine speed returns to normal idling. The
exhaust system remains very hot for
several minutes even after regeneration is
complete. Do not reposition the vehicle
over materials that could burn until the
exhaust system has had sufficient time to
cool. Depending on the amount of soot
collected by the diesel particulate filter,
ambient temperature and altitude,
operator commanded regeneration lasts
approximately 30 minutes.
Operator Commanded Regeneration
with Automatic Regeneration Control
(If Equipped)
If your vehicle is operated with significant
stationary operation, low speed drive
cycles less than 25 mph (40 km/h), short
drive cycles, drive time less than 15 minutes
or the vehicle does not fully warm up,
passive and active regeneration may not
sufficiently clean the diesel particulate
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