2016 FORD F650 maintenance schedule

Extended Service Plan
(ESP)
Extended Service Plan (ESP)..................312
Scheduled Maintenance
General Maintenance Information.........314
Normal Scheduled Maintenance............321
Special Operating Conditions Scheduled Maintenance.............................................326
Scheduled Maintenance Record...........335
Appendices
End User License Agreement.................345
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F650750 (TBC), enUSA, First Printing Table of Contents

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

CALIFORNIA PROPOSITION 65
WARNING
Some constituents of engine
exhaust, certain vehicle components,
certain fluids contained in vehicles
and certain products of component wear
contain or emit chemicals known to the
State of California to cause cancer and
birth defects or other reproductive harm. PERCHLORATE
Certain components in your vehicle such
as airbag modules, safety belt
pretensioners and remote control batteries
may contain perchlorate material. Special
handling may apply for service or vehicle
end of life disposal.
For more information visit:
Web Address
www.dtsc.ca.gov/hazardouswaste/ perchlorate
FORD CREDIT
(U.S. Only)
Ford Credit offers a full range of financing
and lease plans to help you acquire your
vehicle. If you have financed or leased your
vehicle through Ford Credit, thank you for
your business.
For your convenience we offer a number
of ways to contact us, as well as to help
manage your account.
Phone: 1-800-727-7000
For more information regarding Ford Credit,
as well as to access Account Manager,
please go to www.fordcredit.com. REPLACEMENT PARTS
RECOMMENDATION
Your vehicle has been built to the highest
standards using quality parts. We
recommend that you demand the use of
genuine Ford and Motorcraft parts
whenever your vehicle requires scheduled
maintenance or repair. You can clearly
identify genuine Ford and Motorcraft parts
by looking for the Ford, FoMoCo or
Motorcraft branding on the parts or their
packaging.
Scheduled Maintenance and
Mechanical Repairs
One of the best ways for you to make sure
that your vehicle provides years of service
is to have it maintained in line with our
recommendations using parts that
conform to the specifications detailed in
this Owner
’s Manual. Genuine Ford and
Motorcraft parts meet or exceed these
specifications.
Collision Repairs
We hope that you never experience a
collision, but accidents do happen. Genuine
Ford replacement collision parts meet our
stringent requirements for fit, finish,
structural integrity, corrosion protection
and dent resistance. During vehicle
development we validate these parts
deliver the intended level of protection as
a whole system. A great way to know for
sure you are getting this level of protection
is to use genuine Ford replacement
collision parts.
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F650750 (TBC), enUSA, First Printing Introduction

PROTECTING THE
ENVIRONMENT
You must play your part in protecting the
environment. Correct vehicle usage and
the authorized disposal of waste, cleaning
and lubrication materials are significant
steps toward this aim.
NOISE POLLUTION CONTROL
In order to keep to the federal exterior
noise regulations, your vehicle may be
equipped with noise emission items.
Depending on your vehicle configuration,
it may have all or some of the following
items:
Air Intake System
Inspect the air cleaner. Do not alter its
location. Do not alter inlet and outlet
piping.
Body
Inspect wheel well splash shields, cab
shields and under hood insulation for
deterioration, dislocation and orientation.
Cooling System
•
Inspect the fan for blade damage. If
you find any damage, replace with the
recommended parts. Inspect for
fan-to-shroud interference and any
damage to shroud, such as cracks and
holes.
• Do not change fan ratio or alter fan
spacer dimensions and positions.
• Inspect fan clutch for proper operation.
Make sure the fan is disengaged when
cooling of the engine is not required.
• Inspect radiator shutters (if equipped)
for proper operation. The shutters
should be open during normal
operating temperatures. Engine
Valve covers and block covers damp-out
engine mechanical noise. If they need
replacing, make sure to replace them with
the recommended parts. Check for
mechanical isolations.
Transmission Enclosure
Inspect for cracks, holes and tears. Clean
any deposits, such as oil, dirt and stones.
Exhaust System
•
Inspect for leaks at various joint
connections and loose clamps.
• Perform a visual inspection for cracks
or holes in the muffler and tail pipe.
• Always use the recommended
replacement parts.
• Do not change the tail pipe elbow or
offset tail pipe orientation from the
standard position as originally received.
• To avoid abnormal changes in vehicle
sound levels, it is necessary for the
owner to perform inspections and
necessary maintenance at specified
intervals. See Scheduled
Maintenance (page 314).
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F650750 (TBC), enUSA, First Printing Environment

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

SETUP
ON or OFF
AUTO LOCK
ON or OFF
AUTO UNLOCK
ON or OFF
COURTESY WIPE
ON or OFF
REMOTE WINDOW
ENGLISH / SPANISH / FRENCH
LANGUAGE
* Diesel engine only.
PRESS RESET FOR SYSTEM CHECK
The information display begins to cycle
through the vehicle systems and provides
a status of the item if needed.
Note: Some systems show a message only
if a condition is present.
OIL LIFE
Displays the remaining oil life. An oil
change is required whenever indicated by
the information display and according to
the recommended maintenance schedule.
Only use recommended engine oils.
To reset the oil monitoring system to 100%
after each oil change, perform the
following:
1. Press and release the SETUP button to display OIL LIFE XXX% HOLD RESET
= NEW.
2. Press and hold the RESET button for two seconds and release to reset the
oil life to 100%.
Note: To change oil life 100% value (if
equipped with this feature) to another value,
proceed to Step 3.
3. Once OIL LIFE SET TO XXX% is displayed, release and press the RESET
button to change the Oil Life Start
Value. Each release and press reduces
the value by 10%. UNITS
Displays the current units English or Metric.
LANGUAGE = ENGLISH / SPANISH /
FRENCH
Allows you to choose which language the
message center displays.
Waiting four seconds or pressing the
RESET button cycles the message center
through each of the language choices.
Press the RESET button to set the
language choice.
INFORMATION MESSAGES
Note:
Depending on your vehicle options
and instrument cluster type, not all of the
messages display or are available.
Additionally, the information display may
abbreviate or shorten certain messages.
Press the RESET button to acknowledge
and remove some messages from the
information display. The information
display automatically removes other
messages after a short time.
You need to confirm certain messages
before you can access the menus.
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F650750 (TBC), enUSA, First Printing Information Displays

personal injury or sickness may result.
If you splash fuel on your skin, promptly
wash your skin thoroughly with soap
and water. Consult a physician
immediately if you experience an
adverse reaction.
Low Fuel Pressure (If Equipped)
Diesel engine vehicles have a low fuel
pressure detection system.
The following are possible causes for a low
fuel pressure warning message to appear
in the information display:
• Cold start or during cold operation
below
32°F (0°C). If the low fuel
pressure message appears during a
cold start or up to 10 minutes after the
initial cold start, monitor the
information display. If the low fuel
pressure message disappears and does
not re-appear after the engine has fully
warmed up, waxed or gelled fuel is
what most likely caused the message.
Do not use alcohol based additives to
correct fuel gelling. This may result in
damage to the fuel injectors and
systems. Use an anti-gel additive. See
Capacities and Specifications (page
256
).
Note: The vehicle Warranty may be void if
you use additives that do not meet or
exceed Ford specifications. If the low fuel
pressure message persistently appears after
re-fueling and then disappears when the
engine has fully warmed up, consider using
different fuel sources. •
Low fuel operation: If the low fuel
pressure message appears when your
vehicle is warm and during low fuel
tank level operation (near empty),
refuel your vehicle. If the message
reappears after fueling, see below. If
the message does not come back, the
low fuel pressure condition was due to
low fuel levels in the fuel tank.
• Normal operation: If the low fuel
pressure message appears during
normal operation when the engine is
fully warm, and fuel level is not low,
you must change the fuel filters
regardless of the maintenance
schedule interval.
• If replacement of the fuel filter does
not remedy the low fuel pressure
message during normal operation as
defined above, take the vehicle to an
authorized dealer.
FUEL QUALITY - GASOLINE
Choosing the Right Fuel We recommend regular unleaded gasoline
with a pump (R+M)/2 octane rating of 87.
Some fuel stations offer fuels posted as
regular unleaded gasoline with an octane
rating below 87, particularly in high altitude
areas. We do not recommend fuels with
an octane rating below 87.
Do not use any fuel other than those
recommended because they could lead to
engine damage that may not be covered
by the vehicle Warranty.
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F650750 (TBC), enUSA, First Printing Fuel and RefuelingE161513

To help achieve acceptable engine
performance and durability when using
biodiesel in your vehicle:
•
Confirm the biodiesel content of the
fuel to be B20 (20% biodiesel) or less
• Only use biodiesel fuel of good quality
that complies with industry standards
• Follow the recommended service
maintenance intervals. See
Scheduled Maintenance (page 314).
• Do not store biodiesel fuel in the fuel
tank for more than 1 month
• Consider changing brands or reducing
biodiesel content if you have cold
temperature fuel gelling issues or a
frequent LOW FUEL PRESSURE
message appearing
• Do NOT use raw oils, fats or waste
cooking greases
Use of biodiesel in concentrations greater
than 20% may cause damage to your
vehicle, including engine and/or exhaust
after-treatment hardware (exhaust
catalyst and particulate filter) failures.
Concentrations greater than 20% can also
cause fuel filter restrictions that may result
in a lack of power or damage to fuel
system components, including fuel pump
and fuel injector failures.
SAE 5W-40 or SAE 15W-40 oil is
recommended for fuels with greater than
5% biodiesel (B5). Refer to the Special
operating conditions section under the
Schedule Maintenance chapter for more
information about oil change intervals and
other maintenance when operating on
biodiesel. Look for a label on the fuel pump to
confirm the amount of biodiesel contained
in a diesel fuel. Biodiesel content is often
indicated with the letter B followed by the
percent of biodiesel in the fuel. For
example, B20 indicates a fuel containing
20% biodiesel. Ask the service station
attendant to confirm the biodiesel content
of a diesel fuel if you do not see a label on
the fuel pump.
Biodiesel fuels degrade more easily than
diesel fuels not containing biodiesel and
should not be stored in the fuel tank for
more than 1 month. If you plan to park or
store your vehicle for more than 1 month,
then you should empty your vehicle fuel
tank of biodiesel fuel. You should fill the
tank with a pure petroleum-based diesel
fuel and run your vehicle for a minimum of
30 minutes.
Note:
Degraded or oxidized biodiesel can
damage fuel system seals and plastics and
corrode steel parts.
During cold weather, if you have problems
operating on biodiesel, you may need to
use a diesel fuel with lower biodiesel
content, try another brand, or discontinue
the use of biodiesel.
Diesel Fuel Additives
It should not be necessary to add any
aftermarket additives to your fuel if you
use a high quality diesel fuel that conforms
to ASTM industry specifications.
Aftermarket additives can damage the fuel
injector system or engine.
Use Motorcraft® cetane booster or an
equivalent cetane booster additive if you
suspect fuel has low cetane. Use
Motorcraft® anti-gel & performance
improver or an equivalent additive if there
is fuel gelling.
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F650750 (TBC), enUSA, First Printing Fuel and Refueling