2016 FORD F650 engine

Warning Lamps and Indicators................58
Audible Warnings and Indicators..............61
Information Displays
General Information......................................62
Information Messages.................................64
Climate Control
Manual Climate Control
..............................70
Hints on Controlling the Interior Climate............................................................71
Heated Exterior Mirrors
.................................72
Seats
Sitting in the Correct Position....................73
Head Restraints
...............................................73
Manual Seats
...................................................75
Power Seats
.....................................................76
Rear Seats
.........................................................78
Front Seat Armrest........................................79
Rear Seat Armrest.........................................80
Auxiliary Power Points
Auxiliary Power Points..................................81
Storage Compartments
Overhead Console
.........................................83
Starting and Stopping the Engine
General Information
.....................................84
Ignition Switch
................................................84
Starting a Gasoline Engine.........................85
Starting a Diesel Engine..............................86
Diesel Particulate Filter................................87
Switching Off the Engine............................88
Engine Idle Shutdown..................................88
Engine Block Heater
.....................................88 Fuel and Refueling
Safety Precautions
........................................90
Fuel Quality - Gasoline.................................91
Fuel Quality - Diesel......................................92
Running Out of Fuel - 6.8L.........................95
Running Out of Fuel - 6.7L Diesel............95
Selective Catalytic Reduction System...........................................................95
Refueling - 6.8L
............................................100
Refueling - 6.7L Diesel
.................................101
Fuel Consumption.......................................102
Emission Control System - 6.8L.............103
Emission Control System - 6.7L Diesel............................................................105
Fuel Tank Selector Switch..........................112
Transmission
Automatic Transmission.............................113
Power Take-Off
...............................................117
Rear Axle
General Information
.....................................118
Limited Slip Differential..............................118
Electronic Locking Differential.................118
2-Speed Rear Axle........................................119
Brakes
General Information
....................................120
Hints on Driving With Anti-Lock Brakes...........................................................120
Parking Brake
...................................................121
Full Power Brake...........................................124
Air Brakes.........................................................125
Exhaust Brake................................................126
Trailer Brakes..................................................128
Traction Control
Principle of Operation.................................132
Using Traction Control - Vehicles With: Air Brakes
.....................................................132
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Using Traction Control - Vehicles With:
Hydraulic Brakes.......................................132
Cruise Control
Principle of Operation.................................134
Using Cruise Control
....................................134
Driving Aids
Steering............................................................136
Load Carrying
Load Limit........................................................137
Air Suspension
...............................................138
Towing
Towing a Trailer.............................................140
Recommended Towing Weights.............141
Essential Towing Checks...........................142
Transporting the Vehicle............................143
Fifth Wheel Operation
................................144
Driving Hints
Breaking-In.....................................................146
General Driving Points................................146
Economical Driving
......................................147
Cold Weather Precautions
........................148
Driving Through Water...............................150
Roadside Emergencies
Roadside Assistance
....................................151
Hazard Warning Flashers...........................152
Fuel Shutoff....................................................152
Jump Starting the Vehicle
.........................153
Customer Assistance
Getting the Services You Need
...............156
In California (U.S. Only)
..............................157
The Better Business Bureau (BBB) Auto Line Program (U.S. Only)......................158 Utilizing the Mediation/Arbitration
Program (Canada Only)
........................158
Getting Assistance Outside the U.S. and Canada.........................................................159
Ordering Additional Owner's Literature.....................................................160
Reporting Safety Defects (U.S. Only).............................................................160
Reporting Safety Defects (Canada Only)..............................................................161
Fuses
Fuse Specification Chart...........................162
Changing a Fuse...........................................170
Vehicle Inspection Guide
Vehicle Inspection Information.................171
Maintenance
General Information....................................180
Opening and Closing the Hood................181
Under Hood Overview - 6.8L...................183
Under Hood Overview - 6.7L Diesel......184
Engine Oil Dipstick - 6.8L..........................185
Engine Oil Dipstick - 6.7L Diesel.............185
Engine Oil Check - 6.8L
..............................185
Engine Oil Check - 6.7L Diesel.................186
Changing the Engine Oil and Oil Filter..............................................................188
Changing the Coalescer Filter Element.......................................................189
Oil Change Indicator Reset.......................190
Engine Coolant Check - 6.8L
...................190
Engine Coolant Check - 6.7L Diesel.......195
Automatic Transmission Fluid Check...........................................................200
Brake Fluid Check.........................................201
Power Steering Fluid Check.....................202
Washer Fluid Check....................................202
Draining the Fuel Filter Water Trap - 6.7L Diesel
...........................................................203
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Fuel Filter - 6.8L...........................................204
Changing the 12V Battery.........................204
Checking the Wiper Blades.....................206
Changing the Wiper Blades....................206
Adjusting the Headlamps........................206
Removing a Headlamp
.............................208
Changing a Bulb..........................................208
Bulb Specification Chart..........................209
Changing the Engine Air Filter - 6.8L.....210
Changing the Engine Air Filter - 6.7L Diesel
..............................................................211
Changing the Engine-Mounted and Diesel Fuel Conditioner Module Fuel
Filters - 6.7L Diesel...................................215
Electrical System Inspection....................217
Air Induction System Inspection.............217
Exhaust System Inspection......................218
Brake System Inspection...........................218
Axle Inspection
..............................................221
Steering System Inspection
.....................222
Suspension System Inspection
..............222
Frame and Tow Hook Inspection
...........223
Rear Axle Fluid Check
.................................223
Spring U-Bolt Check...................................223
Vehicle Care
General Information...................................225
Cleaning Products.......................................225
Cleaning the Exterior..................................225
Waxing.............................................................226
Cleaning the Engine....................................226
Cleaning the Windows and Wiper Blades...........................................................227
Cleaning the Interior....................................227
Cleaning the Instrument Panel and Instrument Cluster Lens
.......................228
Repairing Minor Paint Damage
..............228
Cleaning the Alloy Wheels.......................229
Vehicle Storage
.............................................229 Wheels and Tires
Tire Care
..........................................................232
Using Snow Chains
.....................................246
Changing a Road Wheel............................247
Technical Specifications
...........................249
Capacities and Specific- ations
Engine Specifications - 6.8L.....................251
Engine Specifications - 6.7L Diesel........251
Motorcraft Parts - 6.8L..............................252
Motorcraft Parts - 6.7L Diesel.................253
Vehicle Identification Number................254
Vehicle Certification Label.......................255
Transmission Code Designation............255
Capacities and Specifications - 6.8L...............................................................256
Capacities and Specifications - 6.7L Diesel............................................................261
Audio System
General Information...................................270
Audio Unit - Vehicles With: AM/FM........271
Audio Unit - Vehicles With: AM/FM/CD/ SYNC.............................................................272
Satellite Radio...............................................275
Audio Input Jack............................................277
USB Port
..........................................................277
SYNC™
General Information
...................................279
Using Voice Recognition............................281
Using SYNC™ With Your Phone............283
Using SYNC™ With Your Media Player...........................................................295
SYNC™ Troubleshooting
.........................304
Accessories
Auxiliary Switches........................................310
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F650750 (TBC), enUSA, First Printing Table of Contents

ABOUT THIS MANUAL
Thank you for choosing Ford. We
recommend that you take some time to
get to know your vehicle by reading this
manual. The more that you know about
your vehicle, the greater the safety and
pleasure you will get from driving it.
WARNING
Driving while distracted can result in
loss of vehicle control, crash and
injury. We strongly recommend that
you use extreme caution when using any
device that may take your focus off the
road. Your primary responsibility is the safe
operation of your vehicle. We recommend
against the use of any hand-held device
while driving and encourage the use of
voice-operated systems when possible.
Make sure you are aware of all applicable
local laws that may affect the use of
electronic devices while driving. Note:
Always use and operate your vehicle
in line with all applicable laws and
regulations.
Note: Pass on this manual when selling
your vehicle. It is an integral part of your
vehicle.
Note: Your vehicle ’s powertrain control
systems can detect and store information
about vehicle modifications that increase
horsepower and torque output such as
whether or not performance-enhancing
powertrain components commonly referred
to as performance chips have been used.
This information will stay in the system ’s
memory and cannot be erased even if the
modification is removed. Ford Motor
Company, Ford of Canada, Ford of Mexico
and service or repair facilities can retrieve
this information when servicing your vehicle.
Ford Motor Company may use this
information to determine if your warranty
covers any needed repairs. Note:
Some aftermarket products may
cause severe engine/transmission and/or
exhaust system damage; refer to your
warranty information for more information.
Your new diesel engine will feel, drive and
function somewhat differently than a
gasoline engine. Therefore it is very
important that you read and thoroughly
familiarize yourself and others operating
the vehicle with this guide. There is a
special procedure for turning off the diesel
engine. See Starting a Diesel Engine
(page 86). It is important to read and
understand this material in order to
maintain the best service life for your
engine.
Ford may discontinue models or change
specifications without any notice and
without incurring obligations.
Note: Either Ford Motor Company or an
authorized Ford dealer may have originally
sold this incomplete vehicle to a vehicle
modifier who upfitted it. As a result, some
of the options and features on this vehicle
may differ from what we describe in this
manual.
This manual may qualify the location of a
component as left-hand side or right-hand
side. The side is determined when facing
forward in the seat.
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F650750 (TBC), enUSA, First Printing Introduction

Right-hand side.
A
Left-hand side.
B
Warnings WARNING
Throughout this guide, you will find
warnings identified by the warning
symbol. Warnings remind you to be
especially careful to reduce the risk of
personal injury. Diesel Engine Information
The diesel engine fuel system is a
pressurized two-stage filtration system
and consists of:
•
A frame-mounted Fuel and Water
Separator primary filter with an electric
fuel pump and water drain
• An engine-mounted secondary fuel
filter
• A fuel injector for each cylinder (8
total)
• A high-pressure fuel pump
• A high-pressure fuel rail for each
cylinder bank (2 total)
• Numerous high-pressure pipes from
the high-pressure pump to the rails,
and rails to the injectors The fuel and water separator removes
both water and impurities from the fuel.
The engine-mounted filter filters finer
impurities from the diesel fuel. The
engine-mounted fuel filter and the
frame-mounted fuel filter should be
changed at the recommended service
interval or when indicated by the
information display LOW FUEL PRESSURE
message. See Scheduled Maintenance
(page 314).
The fuel and water separator should be
drained at regular intervals (recommended
at every oil change) or when indicated by
the information display and water in fuel
indicator light. See
Fuel Quality (page
92).
Proper fuel filter maintenance and prompt
water draining when the water in fuel light
illuminates is essential to prevent injection
equipment damage. Ignoring the water in
fuel light or the information display
message WATER IN FUEL DRAIN FILTER
can cause your vehicle to go into a reduced
power mode.
A frame-mounted electric fuel pump
located inside the fuel and water separator
draws fuel from the fuel tank to provide
pressurized fuel to the engine. The fuel
pump contains a pressure relief valve for
overpressure protection in the event of
restricted flow.
The fuel injection system is controlled
through the powertrain control module.
Engine Protection Mode
Ford diesel engines are equipped with
engine protection and emission control
systems. These systems monitor critical
temperatures and pressures, and modify
engine operation accordingly. These
modified engine performance
characteristics are normal.
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F650750 (TBC), enUSA, First Printing IntroductionE154903

If these modified engine performance
characteristics persist for an extended
period and either the service engine soon
or powertrain malfunction, reduced power,
electronic throttle control light is
illuminated, have the system checked by
an authorized dealer.
Service engine soon
Powertrain malfunction, reduced
power, electronic throttle control
Diesel Lubrication System
It is important to change the engine oil at
the recommended service intervals or
when indicated by the information display
to maintain oil viscosity. Extending the oil
and filter change interval beyond the
recommended interval can negatively
affect engine performance, fuel economy
and engine life. See Engine Oil Check
(page 186).
Engine and secondary cooling system
The cooling system contains a primary
cooling loop to cool the engine and a
secondary cooling loop to cool the
transmission, charge air, and fuel. The
coolant serves three primary purposes: to
provide heat transfer, freeze point
protection, and corrosion protection using
additives.
Vehicles with diesel engines typically are
used to carry heavy loads and accumulate
mileage rapidly. These two factors may
cause the additives in the coolant to wear
out in a shorter time. You can find more
information about coolant additives and
coolant change intervals in the coolant
chapter. See
General Maintenance
Information (page 314). Operating the
engine with insufficient coolant or coolant
additive can cause severe engine damage. Selective catalytic reduction system
Your vehicle is equipped with a selective
catalytic reduction system designed to
reduce emission levels of nitrogen oxides
from the exhaust of your diesel engine. This
system relies on the use of Diesel Exhaust
Fluid (DEF) that you must replenish at
certain intervals. Failure to maintain proper
DEF levels or if the DEF becomes
contaminated will result in vehicle speed
limitations or result in your vehicle entering
an idle-only mode. See
Selective
Catalytic Reduction System (page 95).
Minor Troubleshooting Guide
If the engine won ’t crank WARNING
Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash hands after
handling. Turn on the headlights. If the lights are dim,
do not go on at all or when the ignition is
turned to the start position, the lights
become dim or go out, the battery
connections may be loose or corroded, or
the battery may be discharged. If there is
a clicking or stuttering sound coming from
the engine compartment when you turn
the key to the start position, this may also
indicate a loose or corroded battery
connection.
Check the battery connections at the
battery posts, cable connection to the
engine grounding point and at the starter
connection.
If you suspect a discharged battery, have
it checked and corrected.
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F650750 (TBC), enUSA, First Printing Introduction

•
The gearshift lever must be in P (Park)
or N (Neutral) in order for the starter
to operate.
• Try operating the starter switch several
times. This operation may clean
potentially corroded contacts or make
the switch temporarily operable until
you can reach the dealer.
• If all electrical connections are tight
and you need assistance to start, See
Jump Starting the Vehicle (page 153).
If engine cranks but won ’t start
Prolonged starter cranking (in excess of 10
seconds) could cause damage to the
starter motor or the high-pressure fuel
pump.
• Check the fuel gauge. You may be out
of fuel. If the gauge shows that there
is fuel in the tank, the trouble may be
in the electrical system or the fuel
system. If equipped with an auxiliary
tank, be sure that the tank control
switch is set for the tank with fuel and
not on an empty tank.
• Leaving your ignition key turned to on
for over two minutes without starting
may make starting difficult because
the glow plugs will cease activation.
Reset the system by turning the ignition
key to off and then back to on again.
Note: If the system is out of fuel and the
engine will not start, do not continue
cranking the engine. Continued cranking can
damage the high-pressure fuel pump.
If the engine runs hot
The following could cause the engine to
overheat:
• Lack of coolant
• Dirty cooling system.
• Plugged radiator fins, A/C condenser
and/or oil cooler
• Malfunctioning fan drive •
Driving with frozen coolant
• Sticking thermostat
• Overloading or pulling heavy trailers
during hot weather
• Grill or radiator air blockage
• Slipping or missing drive belt
• Plugged or very dirty air filter
If fuses burn out WARNING
Replacement fuses and circuit
breakers must always be the same
rating as the original equipment
shown. Never replace a fuse or circuit
breaker with one of a higher rating. Higher
rated fuses or circuit breakers could allow
circuit overloading in the event of a circuit
malfunction, resulting in severe vehicle
damage or personal injury due to fire. Burned-out or blown fuses usually indicate
an electrical short-circuit, although a fuse
may occasionally burn out from vibration.
Insert a second fuse. If this fuse
immediately burns out and you cannot
locate the cause, return your vehicle to
your dealer for a circuit check. See
Changing a Fuse
(page 170).
Selective catalytic reduction system
speed limit and Idle-only modes
If the vehicle ’s speed is limited or in an
idle-only mode, the selective catalytic
reduction system may be limiting the
vehicle ’s functions due to low or
contaminated DEF. Check the DEF. See
Selective Catalytic Reduction System
(page
95).
SYMBOLS GLOSSARY
These are some of the symbols you may
see on your vehicle.
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F650750 (TBC), enUSA, First Printing Introduction

Safety alert
See Owner's Manual
Air conditioning system
Anti-lock braking system
Avoid smoking, flames or sparks
Battery
Battery acid
Brake fluid - non petroleum
based
Brake system
Cabin air filter
Check fuel cap
Child safety door lock or unlock
Child seat lower anchor
Child seat tether anchor
Cruise control Do not open when hot
Engine air filter
Engine coolant
Engine coolant temperature
Engine oil
Explosive gas
Fan warning
Fasten seatbelt
Front airbag
Front fog lamps
Fuel pump reset
Fuse compartment
Hazard warning flashers
Heated rear window
Heated windshield
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