2016 FORD F650 fuel pressure

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

•
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

GAUGES
Gasoline Engines
Engine oil pressure gauge.
A
Engine coolant temperature gauge.
B
Transmission fluid temperature gauge.
C
Fuel gauge.
D
Speedometer.
E
Information display.
F
Tachometer.
G
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F650750 (TBC), enUSA, First Printing Instrument ClusterE215247

Engine Oil Pressure Gauge
Indicates engine oil pressure. The needle
should stay in the normal operating range
(between L and H). If the needle falls
below the normal range, stop the vehicle,
switch off the engine and check the engine
oil level. Add oil if needed. If the oil level is
correct, have your vehicle checked by an
authorized dealer.
Engine Coolant Temperature
Gauge
WARNING
Never remove the coolant reservoir
cap while the engine is running or hot.
Indicates engine coolant temperature. At
normal operating temperature, the level
indicator is in the normal range. If the
engine coolant temperature exceeds the
normal range, stop the vehicle as soon as
safely possible, switch off the engine and
let the engine cool.
Transmission Fluid Temperature
Gauge
Indicates transmission fluid temperature.
At normal operating temperature, the level
indicator is in the normal range. If the
transmission fluid temperature exceeds
the normal range, stop the vehicle as soon
as safely possible and verify the airflow is
not restricted such as snow or debris
blocking airflow through the grille.
Special operating conditions, such as
snowplowing, towing or off-road use, can
cause higher than normal operating
temperatures. See Special Operating
Conditions Scheduled Maintenance
(page
326). Operating the transmission for extended
periods with the gauge in the higher than
normal area may cause internal
transmission damage. We recommend
altering the severity of the driving
conditions to lower the transmission
temperature into the normal range. If the
gauge continues to show high
temperatures, contact an authorized
dealer.
Fuel Gauge
Note:
The fuel gauge may vary slightly
when your vehicle is moving or on a gradient.
Switch the ignition on. The fuel gauge
indicates approximately how much fuel is
in the fuel tank. The arrow adjacent to the
fuel pump symbol indicates on which side
of your vehicle the fuel filler door is located.
The needle should move toward F when
you refuel your vehicle. If the needle points
to E after adding fuel, this indicates your
vehicle needs service soon.
After refueling, some variability in needle
position is normal:
• It may take a short time for the needle
to reach F after leaving the gas station.
This is normal and depends upon the
slope of pavement at the gas station.
• The fuel amount dispensed into the
tank is a little less or more than the
gauge indicated. This is normal and
depends upon the slope of pavement
at the gas station.
• If the gas station nozzle shuts off
before the tank is full, try a different
gas pump nozzle.
Gauge Package
(If Equipped)
If your vehicle is equipped with the optional
gauge package, it has some or all of the
following gauges:
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F650750 (TBC), enUSA, First Printing Instrument Cluster

Fuel gauge.
D
Speedometer.
E
Information display.
F
Tachometer.
G
Engine Oil Pressure Gauge
Indicates engine oil pressure. The needle
should stay in the normal operating range
(between L and H). If the needle falls
below the normal range, stop the vehicle,
switch off the engine and check the engine
oil level. Add oil if needed. If the oil level is
correct, have your vehicle checked by an
authorized dealer.
Engine Coolant Temperature
Gauge WARNING
Never remove the coolant reservoir
cap while the engine is running or hot.
Indicates engine coolant temperature. At
normal operating temperature, the level
indicator is in the normal range. If the
engine coolant temperature exceeds the
normal range, stop the vehicle as soon as
safely possible, switch off the engine and
let the engine cool.
Diesel Exhaust Fluid (DEF) Gauge
Indicates the fluid level in the DEF tank.
Fuel Gauge
Note:
The fuel gauge may vary slightly
when your vehicle is moving or on a gradient.
Switch the ignition on. The fuel gauge
indicates approximately how much fuel is
in the fuel tank. The arrow adjacent to the
fuel pump symbol indicates on which side
of your vehicle the fuel filler door is located. The needle should move toward F when
you refuel your vehicle. If the needle points
to E after adding fuel, this indicates your
vehicle needs service soon.
After refueling, some variability in needle
position is normal:
•
It may take a short time for the needle
to reach F after leaving the gas station.
This is normal and depends upon the
slope of pavement at the gas station.
• The fuel amount dispensed into the
tank is a little less or more than the
gauge indicated. This is normal and
depends upon the slope of pavement
at the gas station.
• If the gas station nozzle shuts off
before the tank is full, try a different
gas pump nozzle.
Gauge Package (If Equipped)
If your vehicle is equipped with the optional
gauge package, it has some or all of the
following gauges:
• Transmission temperature gauge:
Displays the transmission fluid
temperature at the transmission sump.
• Hourmeter:
Displays the hours of
engine run time.
• Voltmeter:
Displays electrical system
voltage.
Information Display
Odometer
Located in the bottom of the information
display. Registers the accumulated
distance your vehicle has traveled.
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F650750 (TBC), enUSA, First Printing Instrument Cluster

Diesel Particulate Filter (Diesel
Engine Only)
Illuminates when the soot level in the
diesel particulate filter has reached a point
where it requires operator assistance. See
Diesel Particulate Filter (page 87).
Direction Indicator Illuminates when you switch on
the left or right direction
indicator or when you switch on
the hazard warning flashers. If the
indicators stay on or flash faster, check for
a burned out bulb.
Door Ajar Displays when the ignition is on
and any door is not completely
closed.
Electronic Locking Differential
(If
Equipped) Illuminates when using the
electronic locking differential.
Engine Oil Pressure (Gasoline
Engine Only) If it illuminates with the engine
running, or when you are driving,
this indicates a malfunction.
Stop your vehicle as soon as it is safe to
do so and switch off the engine. Check the
engine oil level.
Note: Do not resume your journey if it
illuminates despite the level being correct.
Have the system checked by an authorized
dealer immediately.
Exhaust Brake On The exhaust brake indicator light
illuminates when you switch the
exhaust brake on. Fasten Safety Belt Illuminates and a tone sounds
to remind you to fasten your
safety belt.
High Beam Illuminates when you switch on
the high beam headlamps. It
flashes when you use the
headlamp flasher.
Hydromax Illuminates to indicate normal
hydromax booster reserve
system activation when the
engine is off and the service brake pedal is
applied. This light may also illuminate
momentarily if the engine is running and
the driver turns the steering wheel fully in
one direction while braking. If the light
remains on while the engine is running, this
indicates inadequate hydraulic booster
pressure or reserve pump system failure.
Stop the vehicle as soon as possible and
seek service immediately by your
authorized dealer.
Low Fuel Level (Gasoline Engine
Only) Illuminates when the fuel level
is low or the fuel tank is nearly
empty. Refuel as soon as
possible.
Parking Brake Warning Illuminates briefly when you
switch the ignition to the on
position (with the engine off). It
also illuminates when you apply the
parking brake. If the park brake lamp does
not illuminate at these times, seek service
immediately. Vehicles equipped with the
power park parking brake option: If the park
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Action
Message
The selective catalytic reduction system detects a fault. Thevehicle ’s top speed becomes limited upon restarting. Have
the system checked by an authorized dealer.
SPEED LIMITED TO 50
MPH UPON RESTART EXHAUST FLUIDSYSTEM FAULT
The selective catalytic reduction system detects a fault. Thevehicle ’s top speed is limited. Have the system checked by
an authorized dealer.
SPEED LIMITED TO 50
MPH EXHAUST FLUID SYSTEM FAULT
The selective catalytic reduction system detects a fault. Theengine enters into an idle–only mode. Have the system checked by an authorized dealer.
ENGINE IDLED SOON
EXHAUST FLUID
SYSTEM FAULT SEE MANUAL
The selective catalytic reduction system detects a fault. The
engine eventually enters into an idle–only mode. Press OK to override the idle mode. Have the system checked by an authorized dealer.
ENGINE IDLED - SEE
OWNER’ S MANUAL
EXHAUST FLUID SYSTEM FAULT
A fuel filter change is required.
FUEL FILTER CHANGE
REQUIRED
You must have your vehicle serviced by an authorized dealer
if approximately two hours after the EXHAUST OVERLOADED DRIVE TO CLEAN message has displayed and you have not
driven your vehicle above 30 mph (48 km/h) for at least 20
minutes to clean the diesel particulate filter.
EXHAUST OVER LIMIT
SERVICE NOW
You are responsible for assuring that you operate your vehiclein a manner that allows diesel particulate filter cleaning tooccur. Ignoring the EXHAUST OVER LIMIT SERVICE NOW warning message could lead to reduced drivability and
customer expense, including damage to the diesel particulate filter. Your new vehicle warranty may not cover this damage.
The water separator has reached a predetermined capacity and needs draining.
WATER IN FUEL DRAIN
FILTER SEE MANUAL
A low fuel pressure condition has occurred due to cold, lowfuel level or fuel filters need to be changed.
LOW FUEL PRESSURE
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F650750 (TBC), enUSA, First Printing Information Displays

•
Open the windows at least 1 in (3 cm).
• Set your climate control to outside air.
STARTING A DIESEL ENGINE WARNING
Operation of a diesel engine near
flammable vapors in the air may
cause the engine speed to increase
uncontrollably and over speed. If this
situation occurs, mechanical damage, fire,
explosion, personal injury or death could
result. Turning off the ignition key does not
slow or stop the engine due to
uncontrollable fueling of the engine
through flammable vapors being drawn
into the engine air inlet. Operation of
components, for example starter,
alternator, electric motors and static
electricity could also ignite flammable
vapors. Do not operate your vehicle in the
possible presence of flammable vapors
unless both a complete hazard analysis is
carried out and necessary additional safety
processes and/or equipment, for example
vapor testing, air intake shutoff devices
and ventilation are utilized. You are
responsible for using those processes
and/or equipment to make sure that the
diesel engine and all other components on
your vehicle can be operated safely under
the specific conditions and hazards that
may be encountered. Read all starting instructions carefully
before you start your vehicle.
Diesel Engine Fast Start Glow Plug
System
The diesel engine glow system consists of:
•
Eight glow plugs (one per cylinder)
• Glow Plug Control Module
• Engine Coolant Temperature sensor •
Barometric pressure sensor
• Environmental temperature sensor
The powertrain and glow plug control
modules electronically control the glow
plug system. After you switch the ignition
on the glow plug control module
immediately energizes the glow plugs. The
glow plug control module using the engine
coolant temperature, barometric pressure
sensor and environmental temperature
sensor will determine how long the glow
plugs stay energized. The required time for
the glow plugs to be energized decreases
as the coolant temperature, barometric
pressure and environmental temperature
increase.
Before starting the engine, check the
following:
• Make sure all occupants have fastened
their safety belts.
• Make sure the headlamps and
electrical accessories are off.
• Make sure the parking brake is on.
• Make sure the transmission is in park
(P) or neutral (N).
• Turn the ignition key to the on position.
Note: Do not press the accelerator during
starting.
Cold Weather Starting WARNINGS
Do not use starting fluid, for example
ether, in the air intake system (see
air filter decal). Such fluid could
cause immediate explosive damage to the
engine and possible personal injury. Do not add gasoline, gasohol, alcohol
or Kerosene to diesel fuel. This
practice creates a serious fire hazard
and causes engine performance problems. 86
F650750 (TBC), enUSA, First Printing Starting and Stopping the Engine