engine FORD F750 2012 12.G Repair Manual

Preparing your vehicle
1.Use only a 12–volt supply to start your vehicle.Do not attach the
jumper cables to the glow plug relay as this could severely damage the
glow plugs, injector driver module and PCM.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect from any electrical
surges. Turn all other accessories off.
Connecting the jumper cables
1. Connect the positive (+) jumper cable to the positive (+) terminal of
the discharged battery.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
2. Connect the other end of the positive (+) cable to the positive (+)
terminal of the assisting battery.
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3. Connect the negative (-) cable to the negative (-) terminal of the
assisting battery.
4. Make the final connection of the negative (-) cable to an exposed
metal part of the stalled vehicle’s engine, away from the battery and the
carburetor/fuel injection system.Do notuse fuel lines, engine rocker
covers or the intake manifold asgroundingpoints.
WARNING:Do not connect the end of the second cable to the
negative (-) terminal of the battery to be jumped. A spark may
cause an explosion of the gases that surround the battery.
5. Ensure that the cables are clear of fan blades, belts, moving parts of
both engines, or any fuel delivery system parts.
Jump starting
1. Start the engine of the booster vehicle and run the engine at
moderately increased speed.
2. Start the engine of the disabled vehicle.
3. Once the disabled vehicle has been started, run both engines for an
additional three minutes before disconnecting the jumper cables.
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4. Remove the jumper cable from the positive (+) terminal of the
disabled vehicle’s battery.
After the disabled vehicle has been started and the jumper cables
removed, allow it to idle for several minutes so the engine computer can
relearnits idle conditions.
WRECKER TOWING INSTRUCTIONS
Before moving the disabled vehicle, check for adequate road clearance of
vehicle components. It is recommended the disabled vehicle be unloaded
prior to being towed to reduce any abnormal load to the vehicle
components resulting from the towing procedures. Before towing, be sure to
fully release the parking brake. The spring-actuated type parking brake can
be reset by recharging the air system with at least 64 psi (441 kPa) of air. If
the brake system does not retain air pressure, then the spring brakes must
be released manually. Refer toParking brakein theDrivingchapter.
Note:For towing, make sure the vehicle is securely connected to the
tow vehicle and the tow vehicle’s parking brakes are applied before
releasing the disabled vehicle’s spring brakes.
WARNING:To reduce the risk of personal injury or property
damage when manually releasing the spring brakes, be sure to
block the wheels so the vehicle cannot move once the brakes are
released.
Towing the vehicle with the front wheels suspended
When it is necessary to tow a vehicle with the front wheels suspended, extra
precautions must be taken to avoid transmission or differential damage:
•Remove the axle shafts from the axle assembly to prevent the wheels
from driving the differential and the transmission.
•The wheel hub ends must be covered to prevent loss of axle lubricant
and entrance of other contaminants. If the axle shafts are not
removed, removal of the driveshaft is required.
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In the case of 1 or 2 above, the consumer must also notify the
manufacturer of the need for the repair of the nonconformity at the
following address:
Ford Motor Company
16800 Executive Plaza Drive
Mail Drop 3NE-B
Dearborn, MI 48126
UTILIZING THE MEDIATION/ARBITRATION PROGRAM
(CANADA ONLY)
For vehicles delivered to authorized Canadian dealers. In those cases
where you continue to feel that the efforts by Ford of Canada and the
authorized dealer to resolve a factory-related vehicle service concern
have been unsatisfactory, Ford of Canada participates in an impartial
third party mediation/arbitration program administered by the Canadian
Motor Vehicle Arbitration Plan (CAMVAP).
The CAMVAP program is a straight forward and relatively speedy alternative
to resolve a disagreement when all other efforts to produce a settlement
have failed. This procedure is without cost to you and is designed to
eliminate the need for lengthy and expensive legal proceedings.
In the CAMVAP program, impartial third-party arbitrators conduct
hearings at mutually convenient times and places in an informal
environment. These impartial arbitrators review the positions of the
parties, make decisions and, when appropriate, render awards to resolve
disputes. CAMVAP decisions are fast, fair, and final as the arbitrator’s
award is binding on both you and Ford of Canada.
CAMVAP services are available in all Canadian territories and provinces.
For more information, without charge or obligation, call your CAMVAP
Provincial Administrator directly at 1-800-207-0685 or visit www.camvap.ca.
GETTING ASSISTANCE OUTSIDE THE U.S AND CANADA
Before exporting your vehicle to a foreign country, contact the
appropriate foreign embassy or consulate. These officials can inform you
of local vehicle registration regulations and where to find diesel fuel.
If you cannot find diesel fuel or can only get fuel with an anti-knock
index lower than is recommended for your vehicle, contact a regional
office or owner relations/customer relationship office.
The use of low quality diesel fuel may affect your emissions control
system and may cause engine damage. Ford Motor Company/Ford of
Canada is not responsible for any damage caused by use of improper
Customer Assistance
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•Do not allow paint sealant to come in contact with any non-body
(low-gloss black) colored trim, such as grained door handles, roof
racks, bumpers, side moldings, mirror housings or the windshield cowl
area. The paint sealant will “gray” or stain the parts over time.
PAINT CHIPS
Your authorized dealer has touch-up paint to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jamb) to
your authorized dealer to ensure you get the correct color.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND WHEEL COVERS
Aluminum wheels and wheel covers are coated with a clear coat paint
finish. In order to maintain their shine:
•Clean weekly with MotorcraftWheel and Tire Cleaner, which is
available from your authorized dealer. Heavy dirt and brake dust
accumulation may require agitation with a sponge. Rinse thoroughly
with a strong stream of water.
•
Never apply any cleaning chemical to hot or warm wheel rims or covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Industrial-strength (heavy-duty) cleaners, or
cleaning chemicals, in combination with brush agitation to remove
brake dust and dirt, could wear away the clear coat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•To remove tar and grease, use MotorcraftBug and Tar Remover ,
available from your authorized dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•
Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause damage.
Note:To prevent damage to the engine control module, never
spray-wash it directly. Never spray any connector.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
Cleaning
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•Spray MotorcraftEngine Shampoo and Degreaser (ZC-20) on all
parts that require cleaning and pressure rinse clean.
•Never wash or rinse the engine while it is hot or running; water in the
running engine may cause internal damage.
PLASTIC (NON-PAINTED) EXTERIOR PARTS
Use only approved products to clean plastic parts. These products are
available from your authorized dealer.
•For routine cleaning, use MotorcraftDetail Wash (ZC-3-A).
•If tar or grease spots are present, use MotorcraftBug and Tar
Remover (ZC-42).
WINDOWS AND WIPER BLADES
The windshield, rear and side windows and the wiper blades should be
cleaned regularly. If the wipers do not wipe properly, substances on the
vehicle’s glass or the wiper blades may be the cause. These may include
hot wax treatments used by commercial car washes, water repellent
coatings, tree sap, or other organic contamination; these contaminants
may cause squeaking or chatter noise from the blades, and streaking and
smearing of the windshield. To clean these items, follow these tips:
•The windshield, rear windows and side windows may be cleaned with
a non-abrasive cleaner such as MotorcraftUltra-Clear Spray Glass
Cleaner (ZC-23), available from your authorized dealer.
•The wiper blades can be cleaned with isopropyl (rubbing) alcohol or
MotorcraftPremium Windshield Washer Concentrate (ZC-32-A) in
the U.S., or Premium Quality Windshield Washer Fluid [CXC-37-(A, B,
D, or F)] in Canada, available from your authorized dealer. This
washer fluid contains special solution in addition to alcohol which
helps to remove the hot wax deposited on the wiper blade and
windshield from automated car wash facilities. Be sure to replace
wiper blades when they appear worn or do not function properly.
•Do not use abrasives, as they may cause scratches.
•Do not use fuel, kerosene, or paint thinner to clean any parts.
If you cannot remove those streaks after cleaning with the glass cleaner or
if the wipers chatter and move in a jerky motion, clean the outer surface of
the windshield and the wiper blades using a sponge or soft cloth with a
neutral detergent or mild-abrasive cleaning solution. After cleaning, rinse
the windshield and wiper blades with clean water. The windshield is clean
if beads do not form when you rinse the windshield with water.
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FORD CAR CARE PRODUCTS
Your vehicle’s authorized dealer has many quality products available to
clean your vehicle and protect its finishes. These quality products have
been specifically engineered to fulfill your automotive needs; they are
custom designed to complement the style and appearance of your
vehicle. Each product is made from high quality materials that meet or
exceed rigid specifications. For best results, use the following products
or products of equivalent quality:
MotorcraftBug and Tar Remover (ZC-42))
MotorcraftCustom Bright Metal Cleaner (ZC-15)
MotorcraftDetail Wash (ZC-3-A)
MotorcraftDusting Cloth (ZC-24)
MotorcraftEngine Shampoo and Degreaser (U.S. only) (ZC-20)
MotorcraftEngine Shampoo (Canada only) (CXC-66-A)
MotorcraftMulti-Purpose Cleaner (Canada only) (CXC-101)
MotorcraftPremium Glass Cleaner (Canada only) (CXC-100)
MotorcraftPremium Quality Windshield Washer Fluid (Canada only)
(CXC-37-[A, B, D or F])
MotorcraftPremium Windshield Washer Concentrate (U.S. only)
(ZC-32-A)
MotorcraftProfessional Strength Carpet & Upholstery Cleaner (ZC-54)
MotorcraftSpot and Stain Remover (U.S. only) (ZC-14)
MotorcraftUltra-Clear Spray Glass Cleaner (ZC-23)
MotorcraftVinyl Cleaner (Canada only) (CXC-93)
MotorcraftWheel and Tire Cleaner (ZC-37-A)
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GENERAL SERVICING GUIDELINES AND PRECAUTIONS
Always use care when performing vehicle maintenance, repairs or system
checks. Improper or incomplete service could result in the vehicle not
working properly which 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 service, have the service done by a qualified
technician.
Servicing guidelines
When servicing your vehicle, always:
•wear safety glasses for eye protection.
•do not wear loose-fitting clothing, hanging jewelry, watches or rings.
•do not smoke.
•set the parking brake or chock the wheels.
•use support stands, not a jack, when working under a raised vehicle.
•turn off the ignition unless a procedure requires the engine to be
running.
•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.
•avoid contact with hot metal parts. Allow the components to cool
before working with, or around, them.
Quality service parts are available through your dealer. If dealer parts are
not used, make sure the replacement parts are of equivalent quality.
WARNING: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 prior to
electric welding:
•disconnect both battery cables.
•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 component be temporarily removed.
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Air dryer:Climactic conditions affect performance of desiccant or
after-cooler type air dryers. Maintenance schedules must be established
for each specific operation.
The use of an air dryer on a vehicle does not eliminate the need to
periodically drain the air reservoirs.
Desiccant air dryer:Inspect for moisture in the air system by opening
reservoirs, draincocks 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
Inspection and adjustment:Establish a regular schedule for periodic
cleaning, lubrication and adjustment inspection based on vehicle use.
Exact maintenance intervals are difficult to predetermine since vehicles
are used in a wide variety of applications and conditions; if you are
uncertain of the proper schedule 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. Hydraulic brake systems are
power-assisted. Braking capabilities are greatly reduced without engine
assist.
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. 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.
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Brake lines, hoses and fittings:Inspect these components every
4,000 miles (6,000 km):
•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.
•Repair or replace brake line tubes, hoses or fittings as required.
Driveline parking brake
Parking brake adjustment should only be performed by a qualified
technician, and in accordance with the instructions in the service
manual.
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.
Catalytic converter (diesel engine)
If your diesel engine is equipped with a catalytic converter, it is
important to review the maintenance schedule to ensure proper
functioning of the catalytic converter. Also, take precautions not to
damage the catalytic converter when servicing your engine or storing
your vehicle.
Note:If your vehicle is equipped with a catalytic converter/muffler,do
notblend 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.
Diesel exhaust fluid (DEF), Diesel particulate filter (DPF) and Select
catalyst reduction (SCR) system
Refer to your engine operator’s manual for information regarding DEF,
DPF and SCR system service.
Air induction system
Once each year, perform a complete inspection of the air induction
system. In areas where road salt is used, the inspection consists of
disassembling the joints of each aluminum component and inspecting for
salt build-up, presence of chlorine that can cause aluminum particles to
flake off and enter the engine combustion chambers.
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