Material — Part 2 Ford Cutaway E350 Super Duty

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
2. Install the oil pump screen cover and pickup tube. Install and tighten the spacer. Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer. Install and tighten the bolts.
3. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations (Scheme 667)
4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations (Scheme 668)
5. Tighten the bolts in the sequence (Scheme 669) Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 90 degrees.
6. Lower the engine and remove the special tools.
7. Install the flywheel inspection plate.
8. Position the transmission fluid cooler tube support bracket and install the nut. Tighten to 12 Nm (9 lb-ft).
9. Install a new oil filter. Tighten to 16 Nm (12 lb-ft).
10. Install the engine support insulator nuts.
11. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
12. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten the studs to 40 Nm (30 lb-ft).
13. Connect the oil fill tube to the RH valve cover.
14. Install the oil fill tube support bracket bolt.
15. Install the transmission-to-engine bolts.
16. Install the shield and the retainers.
17. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000).
18. Fill the engine with clean engine oil.
19. Install the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368).
20. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368).

MATERIAL SPECIFICATIONS

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

1. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-231366-S34645306792006050800000) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Drain the engine oil.
5. Disconnect the coolant hoses.
6. Remove the oil filter.
7. Remove the threaded insert and the oil cooler. Inspect the oil cooler.
8. Disconnect the oil pressure switch electrical connector.
9. Remove the oil pressure switch.
10. Disconnect the lower radiator hose.
11. Remove the nut, the bolts, the oil filter adapter and the gasket. Discard the gasket.
12. To install, reverse the removal procedure. Install a new oil filter adapter gasket. Fill the engine with clean engine oil before filling the cooling system.

Scheme 671

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000) .
3. Remove the bolts and the oil pump.

Scheme 672

1. Clean and inspect the mating surfaces.
2. Position the oil pump and loosely install the bolts. Tighten the bolts in the sequence see scheme 212
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000).
4. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000).

Scheme 673

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-231384) .
2. Remove the bolts and the flexplate.

Scheme 674

1. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence see scheme 214
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-231384).

MATERIAL SPECIFICATION

Scheme 675

Scheme 676

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000) .
2. Use the special tools to remove the crankshaft rear oil slinger.
3. Use the special tools to remove the crankshaft rear seal.

Scheme 677

1. Using the special tools, install the crankshaft rear seal.
2. Using the special tools, install the crankshaft rear oil slinger.
3. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000) .

MATERIAL SPECIFICATION

Scheme 678

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000) .
2. Using the special tools, remove the crankshaft rear oil slinger.
3. Using the special tools, remove the crankshaft rear seal.
4. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000) .
5. Remove the bolts and the crankshaft rear seal retainer plate.

Scheme 679

1. Clean and inspect the mating surface.
2. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.
3. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
4. Tighten the bolts in the sequence see scheme 224
5. Use the special tools to install the rear seal.
6. Using the special tools, install the crankshaft rear oil slinger.
7. Install the oil pan. For additional information, refer to «OIL PAN»(ref-231366-S41608161492006050800000).
8. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-231366-S41513244252006050800000).

MATERIAL SPECIFICATIONS

Scheme 680

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
3. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Remove the retainers and the shield.
5. Remove the stud bolts and position the heater outlet tube aside.
6. Remove the two transmission-to-engine bolts.
7. Disconnect the oil fill tube from the RH valve cover.
8. Remove the bolt and the oil fill tube.
9. Assemble the special tools.
10. Install the special tools.
11. Install the special tool and support the engine.
12. Remove the RH and LH nuts retaining the front engine support insulators to the front engine support bracket.
13. Using the special tool, raise the engine.
14. Disconnect the oil pressure switch electrical connector.
15. Remove the oil pressure switch.
16. Remove the bolts and remove the engine mounts from the vehicle.

Scheme 681

1. Position the engine mounts and install the bolts.
2. Install the oil pressure switch.
3. Connect the oil pressure switch electrical connector.
4. Lower the engine and remove the special tools.
5. Install the engine support insulator nuts.
6. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
7. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten the studs to 40 Nm (30 lb-ft).
8. Connect the oil fill tube to the RH valve cover.
9. Install the oil fill tube support bracket bolt.
10. Install the transmission-to-engine bolts.
11. Install the shield and the retainers.
12. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
13. Install the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
14. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .

MATERIAL SPECIFICATIONS

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

Scheme 703

1. Remove the engine. For additional information, refer to «Engine»(ref-231366-S36221756232006050800000) .
2. Remove the bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
5. Install the special tool.
6. Install the special tool.
7. Mount the engine on a suitable work stand.
8. Remove the special tool.
9. Remove the special tool.
10. Remove the RH engine mount.
11. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
13. Disconnect the camshaft position (CMP) electrical connector.
14. Disconnect the RH radio frequency interference capacitor electrical connector.
15. Disconnect the knock sensor (KS) electrical connector, if equipped.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Disconnect the oil pressure switch electrical connector.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the nuts and the two radio interference capacitors.
20. Remove the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
21. Remove the nut attaching the oil level indicator tube to the front of the engine.
22. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
23. Position the oil level indicator tube aside.
24. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
25. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
26. Remove the bolt and the idler pulley.
27. Remove the water pump pulley. Remove the bolts. Remove the water pump pulley.
28. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
29. Using the special tool, remove the crankshaft front seal.
30. Remove the power steering pump.
31. Remove the four oil pan bolts.
32. Remove the fasteners.
33. Remove the engine front cover from the cylinder block.
34. Remove the crankshaft sensor ring from the crankshaft.
35. Remove the six bolts and remove the balance shaft bearing caps.
36. Remove the balance shaft.
37. Remove the 10 spark plugs.
38. Install the special tool between the valve spring coils to prevent valve stem seal damage.
39. Use the special tool to compress the valve springs and remove the camshaft roller followers.
40. Position the crankshaft with the keyway at the 12 o'clock position.
41. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
42. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain from the crankshaft sprocket.
43. Remove both timing chain guides. Remove the bolts. Remove the timing chain guides.
44. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
45. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
46. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .
47. Install the special tools on both ends of the cylinder head.
48. Remove the hydraulic lash adjusters.
49. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
50. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
51. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surface is normal.
52. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).

MATERIAL SPECIFICATIONS

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

Scheme 721

1. Remove the engine. For additional information, refer to «Engine»(ref-231366-S36221756232006050800000) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the special tool.
12. Remove the special tool.
13. Remove the RH and LH engine mounts.
14. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
15. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
16. Disconnect the camshaft position (CMP) sensor electrical connector.
17. Disconnect the RH radio frequency interference capacitor electrical connector.
18. Disconnect the knock sensor electrical connector, if equipped.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
20. Disconnect the oil pressure switch electrical connector.
21. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
22. Remove the nuts and the two radio interference capacitors.
23. Remove the crankcase ventilation tube from the LH valve cover.
24. Remove the nut attaching the oil level indicator tube to the front of the engine.
25. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
26. Position the oil level indicator tube aside.
27. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
28. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
29. Remove the bolt and the idler pulley.
30. Remove the water pump pulley. Remove the bolts. Remove the water pump pulley.
31. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
32. Use the special tool to remove the crankshaft front oil seal.
33. Remove the power steering pump.
34. Remove the bolts.
35. Remove the fasteners.
36. Remove the engine front cover from the cylinder block.
37. Remove the crankshaft sensor ring from the crankshaft.
38. Remove the six bolts and remove the balance shaft bearing caps.
39. Remove the balance shaft.
40. Remove the 10 spark plugs.
41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
42. Use the special tool to compress the valve springs and remove the camshaft roller followers.
43. Remove the special tool.
44. Position the crankshaft with the keyway at the 12 o'clock position.
45. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
46. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain from the crankshaft sprocket.
47. Remove both timing chain guides. Remove the bolts. Remove the timing chain guides.
48. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
49. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
50. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .
51. Install the special tools on both ends of the cylinder head.
52. Remove the hydraulic lash adjusters.
53. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
54. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surface is normal.
55. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
56. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
57. Remove the bolts.
58. Remove the water pump from the cylinder block.
59. Remove the bolts and the A/C compressor.
60. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
61. Remove the bolts, the oil pan and the oil pan gasket.
62. Remove the bolts, the oil pump screen cover and tube and the spacer.
63. Remove the oil pump. Remove the bolts. Remove the oil pump.
64. Remove the bolts and the connecting rod caps. Rotate the crankshaft so that the connecting rod is a bottom dead center. Remove and discard the bolts.
65. Remove the piston and rod assembly. Using the special tool, guide the piston and rod assembly out of the cylinder.
66. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
67. Remove and discard the 12 cross-mounted bolts.
68. Remove and discard the bolts.
69. Remove the main bearing cap dowel pins.
70. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
71. Remove the crankshaft and the crankshaft main bearings from the cylinder block.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATION

Scheme 722

Scheme 723

Scheme 724

1. Remove the clips.
2. Remove the piston pin from the piston and connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-231364) .

Scheme 725

Scheme 726

1. Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.

MATERIAL SPECIFICATIONS

Scheme 727

Scheme 728

Scheme 729