2002 FORD F650 Owners Manual

Fuel filter replacementÐ7.3L Power Stroke engine
The fuel filter/water separator is
located on the right side of the
engine. Replace the fuel filter/water
separator as recommended in the
Scheduled Maintenance Guide, or
sooner if it becomes plugged.
Vehicles operated on fuel with more
than average impurities may require
replacement of the fuel filter more
frequently. The filter has a water
drain valve built into the bottom of
the filter housing.
Removal
1. Remove the fuel filter cap by
turning counterclockwise. The fuel
filter element will come out with the
cap.
2. Remove and discard the bevel gasket. Carefully clean the mating
surfaces.
3. Press in on the fuel filter element locking tabs to separate the element
from the cap.
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Installation
Note:The engine will not run properly if the fuel filter is not installed in
housing.
1. Apply a coating of clean diesel fuel to the new bevel gasket and install
it onto the fuel filter housing.
2. Install the new fuel filter element onto the cap. Place the new fuel
filter element and cap into the fuel filter housing. Allow fuel to soak into
the fuel filter element.
3. Tighten cap onto the fuel filter housing until cap contacts the housing.
4. Start the engine and check for fuel leaks.
After changing the fuel filter, the engine will purge the trapped air as it
runs. Engine may run roughly and smoke until the air is completely
eliminated.
Fuel filter replacementÐCummins B engine
Refer to your engine operator's manual for service intervals and
procedures.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
possible. Fuel expense, frequency of fillups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1 600 km (1 000
miles) of driving (engine break-in period). You will get a more accurate
measurement after 3 000 km±5 000 km (2 000 miles-3 000 miles).
The advertised fuel capacity of the fuel tank(s) on your vehicle is equal
to the rated refill capacity of the fuel tank(s) as listed inFuel Tank
Capacitiesin this chapter. The advertised capacity is the amount of the
Indicated Capacity and the Empty Reserve combined. Indicated Capacity
is the difference in the amount of fuel in a full tank and a tank when the
fuel gauge indicates empty. Empty Reserve is the small amount of usable
fuel remaining in the fuel tank after the fuel gauge indicates empty.
The amount of Empty Reserve varies and should not be relied
upon to increase driving range. When refueling your vehicle after
the fuel gauge indicates empty, you might not be able to refuel
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the full amount of the advertised capacity of the fuel tank due to
the empty reserve still present in the tank.
Your vehicle may be equipped with dual fuel tanks. If so, you will have a
selector control. For information on the Dual Fuel Tank Selector Control
refer to theDriving Tipssection in the7.3 Liter Power Stroke Direct
Injection Turbo Diesel Owner's Guide Supplement.
Filling the tank
For consistent results:
²Use the same fill rate setting (low Ð medium Ð high) each time
during filling.
²Allow three automatic click-offs when filling.
²Always use fuel of a known quality, preferably a national brand.
²Have the vehicle loading and distribution the same every time.
²When refueling a vehicle equipped with dual fuel tanks, if the two
tanks are not filled equally, the fuel gauge reading may fluctuate
slightly until the fuel level between the two tanks balance out and
become equal.
Your results will be most accurate if your filling method is consistent.
Note:For vehicles equipped with dual fuel tanks, engine performance
may degrade if fuel is not added to both tanks when refueling.
Calculating fuel economy
1. Fill the fuel tank(s) completely and record the initial odometer
reading (in kilometers or miles).
2. Each time you fill the tank(s), record the amount of fuel added (in
liters or gallons).
3. After at least three to five tank fill-ups, fill the fuel tank(s) and record
the current odometer reading.
4. Subtract your initial odometer reading from the current odometer
reading.
5. Follow one of the simple calculations in order to determine fuel
economy:
²Multiply liters used by 100, then divide by total kilometers traveled.
²Divide total miles traveled by total gallons used.
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Keep a record for at least one month and record the type of driving (city
or highway). This will provide an accurate estimate of the vehicle's fuel
economy under current driving conditions. Additionally, keeping records
during summer and winter will show how temperature impacts fuel
economy. In general, lower temperatures give lower fuel economy.
Driving style Ð good driving and fuel economy habits
Give consideration to the lists that follow and you may be able to change
a number of variables and improve your fuel economy.
Habits
²Smooth, moderate operation can yield up to 10% savings in fuel.
²Steady speeds without stopping will usually give the best fuel
economy.
²Anticipate stopping; slowing down may eliminate the need to stop.
²Sudden or hard accelerations may reduce fuel economy.
²Slow down gradually.
²Driving at reasonable speeds (traveling at 88 km/h [55 mph] uses 15%
less fuel than traveling at 105 km/h [65 mph]).
²Using the air conditioner or defroster may reduce fuel economy.
²Resting your foot on the brake pedal while driving may reduce fuel
economy.
Conditions
²Carrying unnecessary weight may reduce fuel economy.
²Fuel economy may decrease with lower temperatures during the first
12±16 km (8±10 miles) of driving.
²Flat terrain driving improves fuel economy over hilly roads.
²Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the accelerator.
²Close windows for highway driving.
FUEL CONSUMPTION IMPROVEMENT MEASURES
There are two important factors you can control to improve fuel
economy: the mechanical condition of your vehicle and how you drive it.
A properly maintained vehicle will deliver better performance than a
neglected vehicle. Always follow your maintenance schedule to keep your
vehicle in top operating condition.
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Also, your driving habits have a significant influence on use of fuel. By
following these suggestions, you can stretch your fuel use:
²Avoid changes in speed as much as possible.
²Anticipate changing traffic conditions. Sudden stops and fast
acceleration waste fuel.
²Avoid extensive idling.
²Do not drive with your foot resting on the brake pedal.
CHECKING AND ADDING POWER STEERING FLUID
Checking power steering fluid level
Check the power steering fluid level using the following procedure. Refer
to the scheduled maintenance guide for the recommended service
intervals. If adding fluid is necessary, use only MERCONtAT F.
1. Set the parking brake, shift into N
(Neutral) (automatic transmission)
or 1 (First) (manual transmission)
and turn the engine off.
2. Open the hood.
3. Clean the top of the power
steering fluid reservoir.
4. Remove the dipstick from the
reservoir and wipe the dipstick
clean.
5. Reinstall the dipstick. Remove it again and check the fluid level.
²If the fluid temperature is at
approximately 20ÉC - 49ÉC (68ÉF
- 120ÉF) (fluid cool or warm to
the touch), check the COLD side
of the dipstick. The fluid level
should be within the FULL range
²If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
ADD MAX. COLDFULL
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²If the fluid temperature is at
approximately 80ÉC - 110ÉC
(176ÉF - 230ÉF) (fluid too hot
to touch), check the HOT side of
the dipstick. The fluid level
should be within the FULL range.
²If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
A low fluid level may indicate a leak in the power steering system.
Inspect the power steering system and repair the leak. If necessary, see
your dealer or a qualified service technician.
To avoid damage to the power steering system,do notoperate the
vehicle with a low power steering fluid level.
Whenever the dipstick is installed, make sure it is properly seated and
tightened securely.
CLUTCH FLUID (IF EQUIPPED)
Check the clutch fluid level. Refer to the Scheduled Maintenance Guide
for the service interval schedules.
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, maintain the fluid level at the
step in the reservoir.
Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer
toLubricant Specificationsin this chapter.
1. Set the parking brake, shift into 1
(First) and turn the engine off.
2. Open the hood.
3. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
4. Remove cap and rubber
diaphragm from reservoir.
5. Add fluid until the level reaches
the step in the reservoir.
6. Reinstall rubber diaphragm and cap onto reservoir.
ADD MAX. HOTFULL
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Clutch (if equipped)Ðlinkage lubrication
Lubricate the clutch linkage using the following procedure. Refer to the
Scheduled Maintenance Guide for the service interval schedules.
Use a grease which meets Ford specifications. Refer toLubricant
Specificationsin this chapter.
1. Set the parking brake, shift into 1 (First) and turn the engine off.
2. Remove the inspection cover from the clutch housing.
²Transmission and clutch
removed for clarity.
3. With a grease gun, lubricate the clutch release bearing (at one
location) and the clutch release shaft (at two locations) using the grease
fittings provided.
4. Lubricate clutch release wear pads at the two locations where they
contact the clutch release bearing using a brush or similar tool.
5. Install the inspection cover onto the clutch housing.
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BRAKE FLUID
Checking and adding brake fluid
Check and refill the Hydromax
brake fluid reservoir using the
following procedure. Refer to the
scheduled maintenance guide for
the service interval.
1. Clean the reservoir caps before
removal to prevent dirt or water
from entering the reservoir.
2. Visually inspect the fluid level.
3. If necessary, add brake fluid from
a clean un-opened container until
the level reaches MAX. Do not fill
above this line.
4. Use only a DOT 3 brake fluid
certified to meet Ford specifications. Refer toLubricant specifications
in this chapter.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical attention if
irritation persists. If taken internally, drink water and induce vomiting.
Seek medical attention immediately.
If you use a brake fluid that is not DOT 3, you will cause
permanent damage to your brakes.
Do not let the reservoir for the master cylinder run dry. This
may cause the brakes to fail.
AVOID MIXING LUBRICANTS
In some cases, different brands of lubricants are not compatible with
each other and deteriorate when mixed. It is best to stick with one brand
during a maintenance interval.
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