engine FORD F750 2004 11.G Repair Manual

GENERAL SERVICING GUIDELINES AND PRECAUTIONS
As with any machine, care should be taken to avoid being injured when
performing maintenance, repairs or system checks. Improper or
incomplete service could result in the vehicle not working properly
which, in turn, may result in personal injury or damage to the vehicle or
equipment. It is the operator’s responsibility to see that the vehicle
receives proper care and maintenance. If you have any questions about
performing some service, have the service done by a qualified technician.
Servicing guidelines
When servicing your vehicle, always:
•turn off the ignition unless the particular procedure calls for the
engine to be running.
•set the parking brake or chock the wheels.
•use support stands, not a jack, whenever you must be under a raised
vehicle.
•do not smoke.
•wear safety glasses for eye protection.
•operate the engine in a well-ventilated area
•do not work on the brakes or the clutch unless the proper precautions
are taken to avoid inhaling friction material dust.
•do not wear loose-fitting clothing, hanging jewelry, watches or rings.
•avoid contact with hot metal parts. Allow the hot components to cool
before working with, or around them.
Quality service parts are available through your dealer. If dealer parts are
not used, the owner must make sure that the parts that are being used
are equivalent quality to dealer parts.
The use of inferior parts can adversely affect the quality and
reliability of your vehicle which, in turn, can result in property
damage, personal injury or death.
Note:To avoid damage to the vehicle’s electrical components, disconnect
the positive (+) and negative (-) battery cables prior to electric welding.
Attach the welder ground cable as close as possible to the part being
welded. If it is necessary to weld close to an electrical component, it is
recommended that the electronic component be temporarily removed.
Follow the periodic lubrication procedures and regular inspection
intervals as outlined. Have your dealer or service center inspect your
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Air brakes - desiccant air dryer
Inspect for moisture in the air system by opening reservoirs, drain cocks
or valves and checking for presence of water. The presence of small
amounts of water due to condensation is normal and should not be
considered as an indication that the dryer is not functioning properly.
The desiccant cartridge should be replaced or rebuilt when it has been
determined that the desiccant is contaminated and does not have
adequate water absorption capacity. The desiccant change interval may
vary; it is generally recommended that the desiccant be replaced every
12 months (yearly). If experience has shown that extended or shortened
life has resulted for a particular installation, then the yearly interval can
be increased or decreased accordingly.
Hydraulic brakes - general inspection and adjustment
A regular schedule for periodic cleaning, lubrication, adjustment and
inspection should be established based on the type of vehicle operation.
It is difficult to predetermine an exact maintenance interval (time or
mileage), since vehicles will be used in a wide variety of applications and
conditions. If you are uncertain of the proper schedule and procedures
for your vehicle, contact your dealer.
Inspect the brake lining every maintenance interval. Establish inspection
intervals that provide for lining replacement before damage to the disc
occurs. Excessive lining wear may expose the backing plate to the disc
causing scoring of the disc faces.
This inspection should be performed by a qualified technician and must
be in accordance with instructions provided by the service manual.
Note:Hydraulic brake system are power assisted. Braking capabilities
will be greatly reduced without engine assist.
Hydraulic brakes - fluid level
Fluid 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.
Note:If brake fluid requires attention to maintain a proper master
cylinder level, this is an indication of either severe operation (pad wear)
or fluid system leakage. A more frequent and thorough brake inspection
will be required.
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OPENING THE HOOD
The hood and fenders are held in position by a latch located on each
fender.
The parking brake must be fully set before opening the hood or
possible personal injury may occur.
If you must leave the engine running while checking under the
hood, do not allow any loose clothing, jewelry, hair or other
items to get near moving engine components or possible personal
injury may occur.
To open the hood:
1. Set the parking brake, shift into N (Neutral) (automatic transmission)
or 1 (First) (manual transmission) and turn the engine off.
2. Lift upward on the bottom of
each latch.
3. Pull the bottom of each latch
away from the fender.
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4. Tilt the hood forward until
stopped by the retaining cables.
To lower the hood:
1. Push the hood rearward at the top center of the hood above the grille
until closed.
2. Engage the latch on each fender.
3. Push down on the bottom of each latch until locked.
To reduce the risk of the possibility of personal injury, never
stand beneath the hood when it is being raised or lowered.
ENGINE OIL
Checking engine oil level—Cummins B and Caterpillar engines
Refer to the appropriate engine operator’s manual for information on the
engine oil.
Checking engine oil level—6.0L Power Stroke engine
Refer to the general maintenance information section for the appropriate
intervals for checking the engine oil.
Check the engine oil level consistently and accurately. The following
procedure is recommended:
1. Start the engine and let it run until it reaches normal operating
temperature (the engine coolant temperature gauge indicator will be
near the center of the normal area between H and C).
2. Park the vehicle on level ground.
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3. Set the parking brake and shift into N (Neutral) (automatic
transmission) or 1 (First) (manual transmission).
4. Turn off the engine and wait a few minutes for the oil to drain
completely into the oil pan.
5. Open the hood. Protect yourself from engine heat.
6. Locate and carefully remove the
engine oil level indicator (dipstick).
7. Wipe the indicator clean. Insert the indicator fully, then remove it
again.
•If the oil level isbetween FULL and OPERATING RANGE,the oil
level is acceptable.DO NOT ADD OIL.
•Maintain the oil level between ADD and OPERATING RANGE on the
dipstick by adding oil as required.
•The distance from ADD to OPERATING RANGE on the dipstick
represents 1.9L (2.0 quarts).
•Oil levels above OPERATING RANGE may cause engine damage. Some
oil must be removed from the engine by a qualified service technician.
8. Put the indicator back into the engine and ensure it is fully seated.
Engine oil and filter recommendations—Cummins B and Caterpillar
engines
Refer to the appropriate engine operator’s manual for information on the
engine oil.
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Engine oil and filter recommendations—6.0L Power Stroke engine
To help achieve proper engine performance and durability, it is important
that you:
•Use only engine lubricating oils and oil filters of the proper quality.
•Change the engine oil and filterno laterthan the recommended
service interval. Refer to the general maintenance information section
for the appropriate intervals for changing the engine oil and filter.
•Change your engine oil and filter more frequently if your vehicle
operation includes extended periods of idling or low-speed operation,
driving for a long time in cold temperatures or short driving distances.
Diesel engines require specially formulated oil to resist contamination.
Proper quality oils also provide maximum efficiency of the crankcase
ventilation system which reduces air pollution.
For normal or severe service, use Motorcraft oil or an equivalent oil
conforming to Ford Specification WSS-M2C171–C or API Service
categories CI-4 or CI-4/SL. If CI-4 oil is not available, CH-4 is acceptable.
Diesel engine oils with improved fuel economy properties (energy
conserving) are currently available. If you use an energy conserving oil,
be sure it meets Ford specification WSS-M2C171–D or API service
category designation CI-4/SL and is of the proper viscosity grade for the
temperature range in which you expect to operate your vehicle. Some
energy conserving oils do not meet the requirements necessary for your
diesel engine.
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* Heavy duty trailer towing with ambient temperatures above 10°C
(50°F) requires 15W-40 engine oil.
Using the chart, determine which SAE viscosity grade best suits the
temperature range in which you expect to operate your vehicle. The use
of the correct oil viscosity grade for diesel engines is important for
satisfactory engine operation.
A symbol has been developed by the American Petroleum Institute (API)
to help you select the proper engine oil. The symbol will be included on
the oil container you purchase.
The top section of the symbol shows
the API service category
designation. This should be CI-4/SL.
The center section of the API
symbol shows the SAE viscosity
grade.
The lower section of the API symbol will stateenergy conservingif the
engine oil has been proven to have fuel savings capabilities.
Use a Ford engine oil filter, part number FL-1995 or equivalent. This
filter protects your engine by filtering harmful, abrasive or sludge
particles.
SAE VISCOSITY GRADES
EXPECTED TEMPERATURE RANGE
F˚ -20 -10 0 10 20 30 40
40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 C˚50 60 70 80 90 100
*15W-40 Preferred
10W-30
5W-30
0W-30Preferred
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ENGINE COOLING SYSTEM
Inspect cooling system daily
Note:The de-aeration tank requires air space for expansion volume. The
proper fill level is identified on the reservoir; do not overfill the reservoir.
To reduce the risk of personal injury or death, use only the
following procedure to remove the pressure-type cap from the
radiator or expansion tank.
1. Always allow the engine to cool first.
2. Wrap a thick, heavy cloth around the cap.
3. Loosen the cap slowly, then pause a moment. This will reduce the risk
of possible scalding by hot water or steam.
4. Continue to unscrew the cap and remove only after pressure in the
radiator is fully released.
Note:If the coolant should get extremely low and the engine very hot,
let the engine cool for approximately 15 minutes before adding coolant.
After the engine has cooled, start the engine and add coolant slowly.
Adding coolant to a hot engine may crack the cylinder head or
crankcase. Never use only water to fill the cooling system.
Adding engine coolant - 6.0L Power Stroke
When adding coolant, make sure it is a 50/50 mixture of engine coolant
and distilled water. Add the mixture to the coolant reservoir,when the
engine is cool, until the appropriate fill level is obtained.
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 the proper mixture of coolant and
water to the“cold full”level. For all other 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 of a vehicle with an overflow
system, follow these steps to add engine coolant.
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 the cap is loosened slightly.
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Do not add engine 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.
Do not put engine coolant in the windshield washer fluid
container. If sprayed on the windshield, engine coolant could
make it difficult to see through the windshield.
1. Before you begin, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the coolant
pressure relief cap on the coolant reservoir (an opaque plastic bottle).
Slowly turn cap counterclockwise (left) 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. Fill the coolant reservoir slowly with the proper coolant mixture (see
above), to within the“cold fill range”or the“cold full”level on the
reservoir. If you removed the radiator cap in an overflow system, fill the
radiator until the coolant is visible and radiator is almost full.
6. Replace the cap. Turn until tightly installed. (Cap must be tightly
installed to prevent coolant loss.)
After any coolant has been added, check the coolant concentration (refer
toCoolant condition inspectionlater in this section). If the
concentration is not 50/50 (protection to–34°F/–36°C), 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 coolant
reservoir should be checked the next few times you drive the vehicle. If
necessary, add enough 50/50 concentration of engine coolant and
distilled water to bring the liquid level to the proper level.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant per
month, have your dealer check the engine 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.
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Extended life engine coolant
The cooling system in your vehicle is filled with yellow-colored
Motorcraft Premium Gold Engine Coolant meeting Ford Specification
WSS-M97B51–A1.
•Add Motorcraft Premium Gold Engine Coolant
(yellow-colored), VC-7–A (VC-7–B in Oregon).
Note:Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, may
darken the color of Motorcraft Premium Gold Engine Coolant from
yellow to golden tan.
•
Do not add/mix extended life coolants such as Motorcraft
Speciality Orange Engine Coolant, VC-2 (U.S.) or CXC-209
(Canada), meeting Ford specification WSS-M97B44–D, with the
factory-fill coolant, Motorcraft Premium Gold Coolant meeting
Ford Specification WSS-M97B51–A.Mixing Motorcraft Speciality
Orange Engine Coolant or any equivalent extended life engine coolant
with this factory-fill coolant can result in degraded corrosion protection.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
•
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 add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
•Do not mix with recycled coolant unless from a Ford-approved
recycling process (seeUse of Recycled Engine Coolantsection).
Coolant condition inspection
Engine cooling systems should be checked twice a year to assure proper
glycol/water concentrations. a 50/50 mixture is recommended and
provides freeze protection in weather conditions as low as–36°C (-34°F)
as well as optimum corrosion protection. For vehicle operating in
extremely cold climate, a concentration of 60% ethylene glycol will
provide freeze protection in weather conditions as low as–51°C (-59°F).
Concentrations greater than 60% glycol are not recommended.
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