Engine Mechanical - 5.4l (2v) -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The 5.4L (2V) is a V-8 engine with the following features

1. Single overhead camshafts
2. Two valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder heads
5. Cast iron cylinder block
6. Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
7. Distributorless ignition system
8. Mechanical Returnless Fuel System (MRFS)

Engine Identification

Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Advantage Catalog™ or equivalent contains a complete listing of the codes and their application.

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

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ENGINE CODE INFORMATION LABEL REFERENCE CHART

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Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION - GASOLINE MODELS .

Induction System

The Sequential Multi-Port Fuel Injection (SFI) provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel injectors

1. are mounted in the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor is positioned upstream from the fuel injectors on the fuel rail.

Valve Train

The valve train operates as follows

1. Ball-tip hydraulic lash adjusters provide automatic lash adjustment.
2. Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Lubrication System

The engine lubrication system operates as follows

1. Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
2. Oil is pumped through the oil filter on the left front side of the cylinder block.
3. Oil enters the main gallery where it is distributed to the crankshaft main journals and to both cylinder heads.
4. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.
5. The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash adjusters and the primary and secondary timing chain tensioners.
6. The camshaft lobe and roller followers are lubricated by splash created through valve train operation.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically, this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure, both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .

For driveability concerns, refer to the INTRODUCTION - GASOLINE MODELS .

Material

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

Removal

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
3. Remove the Air Cleaner (ACL) assembly and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
5. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
6. Disconnect the quick connect coupling and remove the crankcase ventilation tube from the LH valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
7. Remove the Throttle Body (TB) spacer. For additional information, refer to «FUEL CHARGING & CONTROLS - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-charging-system-fuel-control-system-54l-2v-e-series) .
8. Disconnect the upper radiator hose.
9. Disconnect the heater coolant hose.
10. Disconnect the Electronic Throttle Control (ETC) wiring harness retainer.
11. Disconnect the generator wiring harness retainer from the generator support bracket stud bolt.
12. Remove the 2 bolts, the 2 stud bolts and the generator upper support bracket.
13. Remove the front transmission fluid filler tube support bracket bolt.
14. Remove the rear transmission fluid filler tube support bracket nut and position the transmission fluid filler tube aside.
15. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to- EVAP canister purge valve tube quick connect coupling from the EVAP purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
16. Remove the bolt and the EVAP canister purge valve.
17. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics-e-series) .
18. Disconnect the quick connect coupling and remove the PCV tube from the RH valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
19. Disconnect the 8 fuel injector electrical connectors.
20. Disconnect the 8 ignition coil electrical connectors.
21. Remove the 8 bolts and the 8 ignition coils.
22. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal.
23. Remove the 9 bolts, the intake manifold assembly and discard the intake manifold gaskets.

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1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
2. Install the intake manifold in the following sequence. Position the new intake manifold gaskets. Position the intake manifold. Loosely install the 9 intake manifold bolts.
3. Using a new O-ring seal, install the thermostat.
4. Loosely install the thermostat housing and the 2 bolts.
5. Tighten the 11 bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
6. Install the 8 ignition coils and the 8 bolts. Apply a light coat of dielectric compound to the inside of the coil boots prior to installation. Tighten to 6 Nm (53 lb-in).
7. Connect the 8 ignition coil electrical connectors.
8. Connect the 8 fuel injector electrical connectors.
9. Position the PCV tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
10. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics-e-series) .
11. Position the EVAP canister purge valve and install the bolt. Tighten to 10 Nm (89 lb-in).
12. Connect the electrical connector and the EVAP canister-to- EVAP canister purge valve tube quick connect coupling to the EVAP purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
13. Position the transmission fluid filler tube and install the rear retaining nut. Tighten to 28 Nm (21 lb-ft).
14. Install the transmission fluid filler tube front support bracket bolt. Tighten to 10 Nm (89 lb-in).
15. Position the generator support bracket and install the 2 bolts and the 2 stud bolts. Tighten to 10 Nm (89 lb-in).
16. Connect the generator wiring harness retainer to the generator support bracket stud bolt.
17. Connect the ETC wiring harness retainer to the generator support bracket stud bolt.
18. Connect the heater coolant hose.
19. Connect the upper radiator hose.
20. Install the TB spacer. For additional information, refer to «FUEL CHARGING & CONTROLS - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-charging-system-fuel-control-system-54l-2v-e-series) .
21. Position the crankcase ventilation tube and connect the quick connect coupling to the LH valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
22. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
23. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
24. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
25. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. Remove the Air Cleaner (ACL) assembly and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
3. Disconnect the crankcase ventilation tube quick connect coupling from the valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
4. Remove the oil level indicator and tube support bracket nut.
5. Remove the bolt and position the oil level indicator and tube aside.
6. Disconnect the 4 LH fuel injector electrical connectors, 4 LH ignition coil electrical connectors and the 4 LH wire harness retainers.
7. Disconnect the wiring harness retainer and position the engine control wiring harness aside.
8. Disconnect the electrical connector.
9. Disconnect the engine wiring harness retainer and the 2 PCM electrical connectors.
10. Remove the LH valve cover. Fully loosen the fasteners 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.

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1. Apply instant gel adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
2. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
3. Position the valve cover and gasket on the cylinder head and loosely install all of the fasteners.
4. Tighten the 13 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Connect the engine wiring harness retainer and the 2 PCM electrical connectors.
6. Connect the electrical connector.
7. Position the engine control wiring harness retainer onto the valve cover stud.
8. Connect the 4 LH ignition coils, the 4 LH fuel injector electrical connectors and the 4 wiring harness retainers.
9. Position the oil level indicator and tube and install the bolt. Tighten to 10 Nm (89 lb-in).
10. Install the oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
11. Position the crankcase ventilation tube and connect the quick connect coupling to the valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
12. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
13. Install the ACL housing and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. Remove the 4 RH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .
2. Remove the oil fill tube support bracket bolt.
3. Remove the clamp and the oil filler tube.
4. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
5. Rotate the PCV valve counterclockwise and remove the PCV valve from the valve cover. Discard the PCV valve.
6. Disconnect the 2 generator wiring harness retainers and position the wiring harness aside.
7. Disconnect the electrical connector, remove the nut and ground strap.
8. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube. Remove the fluid level indicator. Disconnect the rear heater hose hanger.
9. Remove the bolt, nut and position the transmission fluid filler tube aside.
10. Disconnect the 4 RH fuel injector electrical connectors.
11. Remove the fuel charging wiring harness from the valve cover studs and position the wiring harness and support bracket aside.
12. Remove the RH valve cover. Fully loosen the 14 fasteners 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.

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1. Apply instant gel adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
2. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
3. Position the valve cover on the cylinder head and loosely install the 14 fasteners.
4. Tighten the 14 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Position the fuel charging wiring harness and connect the retainers to the valve cover studs.
6. Connect the 4 RH fuel injector electrical connectors.
7. Position the transmission fluid filler tube and install the bolt and the nut. Tighten the nut to 28 Nm (21 lb-ft). Tighten the bolt to 10 Nm (89 lb-in).
8. Install the fluid level indicator and connect the attachments to the transmission fluid filler tube. Install the fluid level indicator. Connect the rear heater hose hanger.
9. Position the engine wiring harness support bracket, ground strap and install the nut and connect the electrical connector. Tighten to 10 Nm (89 lb-in).
10. Connect the 2 generator wiring harness retainers.
11. Position a new PCV valve in the valve cover and rotate it clockwise to lock it in place.
12. Position the PCV tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
13. Install the oil filler tube and clamp onto the valve cover.
14. Install the engine oil filler tube support bracket bolt. Tighten to 9 Nm (80 lb-in).
15. Install the 4 RH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
4. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
5. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.

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1. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
2. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.
3. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
4. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the Strap Wrench to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.
6. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
4. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
5. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
6. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.

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1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
3. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
4. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
5. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the Strap Wrench to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
6. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.
7. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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PARTS DESCRIPTION CHART

Engine Front Cover and Gaskets

Note. Refer to the fastener location installation art and table in this procedure.

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PARTS DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the radiator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) or «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
4. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
5. Remove the nut and position the LH radio interference capacitor aside.
6. Remove the nut and position the RH radio interference capacitor aside.
7. Loosen the 4 coolant pump pulley bolts.
8. Rotate the tensioner clockwise and remove the accessory drive belt.
9. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
10. Remove the bolt and the accessory drive belt idler pulley.
11. Remove the 3 bolts and position the power steering pump aside.
12. Disconnect the A/C compressor electrical connector.
13. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
14. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.
15. Disconnect the Camshaft Position (CMP) sensor electrical connector.
16. Using the Strap Wrench, remove the bolt and washer and discard the bolt.
17. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
18. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.
19. Remove the front 4 oil pan bolts.
20. Remove the 15 fasteners.
21. Remove the engine front cover from the front cover-to-cylinder block dowel. Remove and discard the engine front cover gaskets.
22. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

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1. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in illustration.
2. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
3. Tighten the 15 engine front cover fasteners in 3 stages, in the sequence shown in illustration. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft). PARTS DESCRIPTION CHART Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 8 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 11 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 12 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 13 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 14 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 15 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
4. Loosely install the 4 oil pan bolts, then tighten the bolts in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
5. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
6. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.
7. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
8. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.
9. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
10. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the Strap Wrench to hold the crankshaft pulley, tighten the bolt in 4 stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
11. Connect the CMP sensor electrical connector.
12. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut. Tighten to 28 Nm (21 lb-ft).
13. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
14. Connect the A/C compressor electrical connector.
15. Connect the CKP sensor electrical connector.
16. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
17. Position the coolant pump pulley and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
18. Rotate the tensioner clockwise and install the accessory drive belt.
19. Position the RH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
20. Position the LH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
21. Install the RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) or «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
22. Fill the engine with clean engine oil.
23. Install the radiator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Aligner, Camshaft Position 303-557 (T96T-6256-B) Alignment Set, Camshaft 303-S568 (T96T-6256-AR) Holding Tool, Crankshaft 303-448 (T93P-6303-A)

Scheme 58

Scheme 59

Scheme 60

General Equipment

PARTS DESCRIPTION CHART

Note. Since the engine is not free-wheeling, the timing procedures must be followed exactly or piston and valve damage can occur.

Scheme 61

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Scheme 65

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft with the keyway at the 12 o'clock position.
4. Install and fully tighten the Camshaft Position Aligners on both camshafts.
5. Remove the timing chain tensioning system from both timing chains. Remove the 4 bolts. Remove the 2 timing chain tensioners. Remove the 2 timing chain tensioner arms.
6. Remove the 2 timing chains and crankshaft sprocket.
7. Remove the timing chain guides. Remove the 2 bolts. Remove the LH timing chain guide. Remove the 2 bolts. Remove the RH timing chain guide.

Scheme 66

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Scheme 76

1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. If the blue links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
4. Install the timing chain guides. Position the LH timing chain guide. Install the 2 LH bolts. Tighten to 10 Nm (89 lb-in). Position the RH timing chain guide. Install the 2 RH bolts. Tighten to 10 Nm (89 lb-in).
5. Install the Camshaft Alignment Set.
6. Pre-position the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.
7. Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.
8. Install the crankshaft sprocket, making sure the flange faces forward.
9. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single blue (marked) link on the chain.
10. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 blue (marked) chain links.
11. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
12. Remove the retaining clip from the LH timing chain tensioner.
13. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) link on the timing chain.
14. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 blue (marked) chain links.
15. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
16. Remove the retaining clip from the RH timing chain tensioner.
17. Remove the Camshaft Alignment Set.
18. As a post-check, verify correct alignment of all timing marks.
19. Remove the Camshaft Position Aligner.
20. Position the crankshaft sensor ring on the crankshaft.
21. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

Scheme 77

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

MATERIAL SPECIFICATIONS

Note. At no time, when the timing chains are removed and the cylinder heads are installed, may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur.

Scheme 78

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Remove the 13 bolts, the 6 bearing caps and the camshaft.
4. Clean and inspect the camshaft bearing caps. The front bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.

Scheme 79

Scheme 80

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the 6 camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the 6 camshaft bearing caps. Install the 13 bolts loosely.
3. Tighten the 13 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
4. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
5. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)

Scheme 81

Scheme 82

MATERIAL SPECIFICATIONS

Scheme 83

Scheme 84

1. If servicing the RH cylinder valvetrain components, remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. If servicing the LH cylinder valvetrain components, remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Position the piston of the cylinder being repaired at the bottom of the stroke.
4. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve stem seal from damage.
5. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.
6. Repeat the previous 3 steps for each of the roller followers being serviced.

Installation

1. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve stem seal from damage.
2. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.
3. Repeat the previous 3 steps for each camshaft roller follower being serviced.
4. If servicing the RH cylinder valvetrain components, install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
5. If servicing the LH cylinder valvetrain components, install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)

MATERIAL SPECIFICATIONS

Removal and Installation

1. If servicing the RH cylinder valvetrain components, remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. If servicing the LH cylinder valvetrain components, remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Position the piston of the cylinder being serviced at the bottom of the stroke.
4. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve stem seal from damage.
5. Use the Valve Spring Compressor to compress the valve springs and remove the camshaft roller follower.
6. Repeat the previous steps for each of the roller followers being serviced.
7. Remove the spark plug for the cylinder being serviced. To install, tighten to 14 Nm (124 lb-in).
8. Use compressed air in the cylinder to hold both valves in position.
9. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.
10. Remove the valve spring retainer and the valve spring.
11. To install, reverse the removal procedure.

SPECIAL TOOL(S) DESCRIPTION CHART Compressor, Valve Spring 303-567 (T97P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)

Scheme 85

MATERIAL SPECIFICATIONS

Scheme 86

1. Remove the valve spring for the valve stem being serviced. For additional information, refer to «VALVE SPRINGS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove and discard the valve stem seals.

1. Using the Valve Spring Compressor and Valve Stem Oil Seal Installer, install the new valve stem seal.
2. Install the valve spring. For additional information, refer to «VALVE SPRINGS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

MATERIAL SPECIFICATIONS

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the 8 hydraulic lash adjusters.

1. Install the hydraulic lash adjusters in their original locations.
2. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

MATERIAL SPECIFICATIONS

Scheme 87

PARTS DESCRIPTION CHART

Scheme 88

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Remove the 4 exhaust Y-pipe flange nuts (2 RH and 2 LH). Discard the flange 4 nuts.
4. Remove and discard the 8 exhaust manifold nuts.
5. Remove the RH exhaust manifold and discard the gaskets.
6. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
7. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .

Scheme 89

1. Clean the sealing surfaces with metal surface prep.
2. Install 8 new exhaust manifold-to-cylinder head studs. Tighten to 12 Nm (106 lb-in).
3. Using new exhaust manifold gaskets, position the exhaust manifold and install the 8 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
4. Position the Y-pipe flange and install the 4 new nuts (2 RH and 2 LH). Tighten to 40 Nm (30 lb-ft).
5. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .

MATERIAL SPECIFICATIONS

Scheme 90

PARTS DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
3. Remove the 4 exhaust Y-pipe flange nuts (2 RH and 2 LH). Discard the 4 flange nuts.
4. Remove the 8 nuts and the exhaust manifold. Discard the 8 exhaust manifold nuts.
5. Remove and discard the exhaust manifold gasket. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
6. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
7. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .

Scheme 91

1. Clean the sealing surfaces with metal surface prep.
2. Install 8 new exhaust manifold-to-cylinder head studs. Tighten to 12 Nm (106 lb-in).
3. Using new exhaust manifold gaskets, position the LH exhaust manifold and install the 8 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
4. Position the Y-pipe flange and install the 2 new RH and 2 new LH nuts. Tighten to 40 Nm (30 lb-ft).
5. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .

Scheme 92

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

SPECIAL TOOL(S) DESCRIPTION CHART Lift Bar Adapter, Modular Engine 303-F694 Lifting Bracket, Engine 303-F047 (014-00073) Support Bar, Engine 303-F070

Scheme 93

Scheme 94

Scheme 95

MATERIAL SPECIFICATIONS

Scheme 96

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Scheme 107

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Remove the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
4. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
5. Loosen the 2 bolts and position the generator aside.
6. Remove the retainers and the shield.
7. Disconnect the Knock Sensor (KS) electrical connector and engine wiring harness retainers.
8. Disconnect the heater coolant hose from the heater outlet tube.
9. Remove the 2 heater outlet tube studs.
10. Remove the heater outlet tube. Discard the O-ring seals.
11. Remove the 2 upper transmission-to-engine bolts.
12. Assemble the Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
13. Install the Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
14. Install the Engine Support Bar and support the engine.
15. Drain the engine oil, remove and discard the oil filter.
16. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.
17. Remove the 4 engine support insulator-to-crossmember nuts.
18. Remove the 2 bolts and the flexplate inspection plate.
19. Using the Engine Support Bar, raise the engine 260.35 mm (10.25 in) from the crankshaft pulley to the lower edge of the No. 1 crossmember.
20. Remove the 16 oil pan bolts and partially lower the oil pan.
21. Remove the 3 bolts retaining the oil pump screen and pickup tube. Position the bolts and the oil pump screen and pickup tube in the oil pan.
22. Remove the oil pan from the rear of the engine. Discard the oil pan gasket.
23. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

Scheme 108

Scheme 109

Scheme 110

Scheme 111

1. Position the oil pump screen and pickup tube and the 3 bolts into the oil pan and position the oil pan and new oil pan gasket onto the crossmember.
2. Position the oil pump screen and pickup tube and install the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
3. Apply the silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
4. Apply silicone gasket and sealant in the locations shown in illustration.
5. Position the new oil pan gasket and the oil pan and loosely install the 16 bolts.
6. Tighten the bolts in 3 stages in the sequence shown in illustration. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in). Stage 3: Tighten an additional 60 degrees.
7. Install a new oil filter.
8. Lower the engine and remove the Engine Support Bar, Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
9. Install the 4 engine support insulator-to-crossmember nuts. Tighten to 90 Nm (66 lb-ft).
10. Position the flexplate inspection cover and install the 2 bolts. Tighten to 34 Nm (25 lb-ft).
11. Position the transmission fluid cooler tubes and support bracket and install the nut. Tighten to 28 Nm (21 lb-ft).
12. Install the 2 upper transmission-to-engine bolts. Tighten to 60 Nm (44 lb-ft).
13. Install the heater outlet tube.
14. Install the 2 heater outlet tube studs. Tighten to 40 Nm (30 lb-ft).
15. Connect the coolant hose to the heater outlet tube.
16. Connect the KS electrical connector and engine wiring harness retainers.
17. Install the retainers and the shield.
18. Position the generator and install the 2 bolts. Tighten to 25 Nm (18 lb-ft).
19. Connect the generator electrical connections. Tighten the B+ terminal nut to 8 Nm (71 lb-in). Connect the S electrical connector. Connect the ASI electrical connector.
20. Install the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
21. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
22. Fill the engine with clean engine oil.
23. Start the engine and check for leaks.

MATERIAL SPECIFICATIONS

Scheme 112

1. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the crankshaft sprocket. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Remove the 3 bolts and the oil pump.

Scheme 113

1. Clean and inspect the mating surfaces and install a new O-ring seal.
2. Install the oil pump and loosely install the 3 bolts. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Install the crankshaft sprocket. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
4. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

Oil Pump Screen and Pickup Tube

1. The oil pump screen and pickup tube are removed with the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

Scheme 114

PARTS DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Disconnect the Engine Oil Pressure (EOP) switch wiring harness retainer and electrical connector.
3. Remove the EOP switch. To install, tighten in 2 stages. Stage 1: Tighten to 14 Nm (124 lb-in). Stage 2: Tighten an additional 180 degrees.
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 115

PARTS DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Remove the oil cooler. For additional information, refer to «OIL COOLER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
4. Remove the LH engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
5. Drain the engine oil.
6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
7. Remove the EOP switch.
8. Release the lower radiator hose clamp and position the lower radiator hose aside.
9. Remove the nut, 4 bolts, oil filter adapter and gasket. Discard the gasket.
10. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

1. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and 4 bolts. Tighten the 4 bolts to 25 Nm (18 lb-ft). Tighten the rear nut to 48 Nm (35 lb-ft).
2. Connect the lower radiator hose.
3. Install the EOP switch in 2 stages. Stage 1: Tighten to 14 Nm (124 lb-in). Stage 2: Tighten an additional 180 degrees.
4. Connect the EOP switch electrical connector.
5. Install the drain plug. Tighten to 23 Nm (17 lb-ft).
6. Install the LH engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
7. Install the oil cooler. For additional information, refer to «OIL COOLER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
8. Fill the engine with clean engine oil.
9. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

MATERIAL SPECIFICATIONS

Scheme 116

PARTS DESCRIPTION CHART

1. Remove the Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
3. Remove the nut, the bolt and the oil level indicator and tube. Discard the O-ring seal.
4. Inspect the oil level indicator tube for damage.

1. Using a new O-ring seal, position the oil level indicator and install the bolt. Tighten to 10 Nm (89 lb-in).
2. Install the front oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
3. Install the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
4. Install the ACL outlet pipe and the ACL . For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .

MATERIAL SPECIFICATIONS

Scheme 117

PARTS DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Drain the engine oil.
4. Disconnect the 2 coolant hoses from the oil cooler.
5. Remove and discard the oil filter.
6. Remove the threaded insert and discard the oil cooler.

1. Position a new oil cooler on the oil filter adapter and install the threaded insert. Tighten to 58 Nm (43 lb-ft).
2. Install a new oil filter. Tighten to 16 Nm (142 lb-in).
3. Connect the 2 coolant hoses to the oil cooler.
4. Install the oil drain plug. Tighten to 23 Nm (17 lb-ft).
5. Fill the engine with clean engine oil.
6. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

Scheme 118

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(ref-370579) or «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(ref-370580) .
2. Remove the 8 bolts and the flexplate.

Scheme 119

1. Install the flexplate and the 8 bolts. Tighten the bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 80 Nm (59 lb-ft).
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(ref-370579) or «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(ref-370580) .

SPECIAL TOOL(S) DESCRIPTION CHART Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Slide Hammer 100-001 (T50T-100-A)

Scheme 120

Scheme 121

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Scheme 125

MATERIAL SPECIFICATIONS

Scheme 126

Scheme 127

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the engine rear cover plate.
3. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove the crankshaft oil slinger. Discard the crankshaft oil slinger.
4. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove the crankshaft rear seal. Discard the crankshaft rear seal.

Scheme 128

1. Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
2. Using the Crankshaft Rear Oil Seal Installers and Crankshaft Rear Oil Slinger Installer, install a new crankshaft rear oil slinger.
3. Install the engine rear cover plate.
4. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Slide Hammer 100-001 (T50T-100-A) Support Bar, Engine 303-F070

MATERIAL SPECIFICATIONS

1. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Using the Engine Support Bar, lower the engine.
3. Install the 4 engine support insulator-to-support insulator bracket nuts. Tighten to 90 Nm (66 lb-ft).
4. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
5. Remove the engine rear cover plate.
6. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
7. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
8. Remove the 6 bolts and the crankshaft rear seal retainer plate.
9. Clean and inspect the mating surface.

Scheme 129

1. Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block.
2. Tighten the 6 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
4. Using the Crankshaft Rear Oil Seal Installers and Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.
5. Install the engine rear cover plate.
6. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
7. Remove the 4 engine support insulator-to-support insulator bracket nuts.
8. Using the Engine Support Bar, raise the engine 260.35 mm (10.25 in) from the crankshaft pulley to the lower edge of the No. 1 crossmember.
9. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

Scheme 130

PARTS DESCRIPTION CHART

All engine support insulators

Scheme 131

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Scheme 136

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. If servicing the RH engine support insulator, remove the starter motor. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-gasoline-models-e-series) .
3. Remove the 2 bolts and position the cooling fan shroud onto the cooling fan.
4. Remove the 4 exhaust Y-pipe flange nuts. Discard the flange nuts.
5. Remove the 4 engine support insulator-to-support insulator bracket nuts. RH engine support insulator
6. Using a jack positioned on the RH rear of the cylinder block, raise the engine 25.4 mm (1 in).
7. Remove the engine support insulator-to-crossmember bracket nut.
8. Remove the 2 nuts and the engine support insulator-to-crossmember bracket.
9. Remove the 3 bolts and the RH engine support insulator. LH engine support insulator
10. Using a jack positioned on the LH rear of the cylinder block, raise the engine 25.4 mm (1 in).
11. Remove the 3 nuts and the engine support insulator-to-crossmember bracket.
12. Remove the 2 bolts, the nut and the LH engine support insulator.

RH engine support insulator

1. Position the RH engine support insulator and install the 3 bolts. Tighten to 80 Nm (59 lb-ft).
2. Position the RH engine support insulator bracket and install the 2 nuts. Tighten to 90 Nm (66 lb-ft).
3. Install the engine support insulator bracket-to-crossmember nut. Tighten to 90 Nm (66 lb-ft).
4. Using the jack positioned on the RH rear of the cylinder block, lower the engine. LH engine support insulator
5. Position the LH engine support insulator and install the 2 bolts and the nut. Tighten to 80 Nm (59 lb-ft).
6. Position the LH engine support insulator bracket and install the 3 nuts. Tighten to 90 Nm (66 lb-ft).
7. Using the jack positioned on the LH rear of the cylinder block, lower the engine. All engine support insulators
8. Install the new 4 exhaust Y-pipe flange nuts. Tighten to 40 Nm (30 lb-ft).
9. Install the 4 engine support insulator-to-support insulator bracket nuts. Tighten to 90 Nm (66 lb-ft).
10. If servicing the RH engine support insulator, install the starter motor. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-gasoline-models-e-series) .
11. Position the cooling fan shroud and install the 2 bolts. Tighten to 6 Nm (53 lb-in).

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Pulley 303-239 (T84T-6312-C) Lifting Bracket, Engine 303-F047 (014-00073) Wrench, Fan Clutch Nut 303-240 (T84T-6312-D)

Scheme 137

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. If equipped, recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics-e-series) .
3. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
4. Remove the accessory drive belt.
5. Remove the starter. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-gasoline-models-e-series) .
6. Remove the front bumper. For additional information, refer to «BUMPERS»(/ford/cutaway-e350-super-duty/2008-2012/remont/exterior-body-panels/#bumper-system-e-series) .
7. Disconnect the lower radiator hose from the radiator. Disconnect the hose hanger. Disconnect the hose.
8. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
9. Remove the 4 exhaust Y-pipe flange nuts.
10. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
11. Disconnect the oil cooler coolant hoses and position aside.
12. Remove and discard the oil filter.
13. Loosen the threaded insert and remove and discard the oil cooler.
14. If equipped, disconnect the block heater electrical connector and 2 wiring harness retainers.
15. Remove the 2 bolts and the flexplate inspection cover.
16. Remove the cylinder block opening cover.
17. Remove the 4 nuts retaining the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts. Discard the torque converter nuts.
18. Disconnect the shift cable and the mounting bracket. Disconnect the clip. Remove the 2 bolts.
19. Remove the 2 transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
20. Remove the RH lower transmission-to-engine bolt.
21. Remove the 4 engine support insulator-to-crossmember nuts.
22. Disconnect the power steering reservoir hose and the power steering pressure tube at the power steering pump. Allow the fluid to drain into a drain pan.
23. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.
24. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
25. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
26. If equipped, remove the 3 bolts and position the A/C compressor aside.
27. Remove the radiator grille support. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-e-series) .
28. Disconnect the upper radiator and the degas bottle coolant hoses from the radiator.
29. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan assembly.
30. Disconnect the degas bottle hose and power steering hose retainers from the fan shroud.
31. Remove the fan shroud, fan and fan clutch. Remove the 2 bolts. Lift the fan shroud, fan and fan clutch from the vehicle.
32. Remove the 4 bolts and the radiator support brackets.
33. Remove the radiator from the vehicle.
34. If equipped, disconnect the A/C pressure cutoff switch electrical connector.
35. If equipped, remove the nut and disconnect the compressor suction tube.
36. If equipped, remove the nuts and disconnect the compressor discharge tube and the condenser-to-evaporator tube from the A/C condenser core.
37. Remove the A/C condenser core. Remove the 2 bolts. Remove the 2 A/C condenser brackets. Remove the A/C condenser core.
38. Set the hood latch aside. Remove the 2 hood latch bolts. Disengage the cable routing clip.
39. Remove the 3 bolts and position the power steering reservoir aside.
40. Remove the nut and the battery feed cable at the Power Distribution Box (PDB).
41. Disengage the harness routing clips and position aside the battery feed wiring harness.
42. If equipped, disconnect the air temperature sensor electrical connector.
43. Disconnect the front impact severity sensor electrical connector.
44. Disconnect the horn electrical connector.
45. Disconnect the transmission fluid cooler hose retainers.
46. Remove the bolt and position the transmission fluid cooler aside.
47. Remove the pin-type retainers and the RH and LH air deflectors.
48. Remove the 4 bolts and the 2 upper radiator support plates.
49. Remove the 8 bolts and the upper radiator support.
50. Remove the bolt and disconnect the 2 headlamp wiring harness retainers.
51. Disconnect the 4 wiring harness retainers and position the wiring harness aside.
52. Remove the 12 bolts and the lower radiator support.
53. Disconnect the lower radiator coolant hose and position aside.
54. Remove the 3 bolts and the power steering pump.
55. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
56. Remove the 2 bolts and the generator.
57. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
58. Disconnect the electrical connector.
59. Disconnect the engine wiring harness retainer and the 2 PCM electrical connectors.
60. Disconnect the 2 generator wiring harness retainers and position the wiring harness aside.
61. Disconnect the electrical connector, electrical connector retainer and remove the nut, ground strap and mounting bracket.
62. Remove the engine oil filler tube support strap bolt.
63. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube. Remove the fluid level indicator. Disconnect the rear heater hose hanger.
64. Disconnect the oil fill tube from the RH valve cover.
65. Disconnect the Knock Sensor (KS) electrical connector and engine wiring harness retainers.
66. Disconnect the coolant hose from the heater outlet tube.
67. Remove the 2 heater outlet tube studs.
68. Remove the heater outlet tube. Discard the O-ring seals.
69. Remove the bolt and the ground strap and disconnect the RH HO2S electrical connector and retainer.
70. Disconnect the transmission wiring harness retainers from the engine wiring harness.
71. Disconnect the LH HO2S sensor electrical wiring harness retainer from the rear of the LH cylinder head.
72. Disconnect the transmission wiring harness retainer and position the transmission wiring harness aside.
73. Disconnect the LH HO2S sensor electrical connector and retainer.
74. Remove the 4 upper transmission-to-engine bolts and position the fuel tube support bracket aside.
75. Install the Engine Lifting Bracket.
76. Support the transmission with a jack.
77. Using a floor crane, remove the engine assembly from the vehicle.

SPECIAL TOOL(S) DESCRIPTION CHART Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) or equivalent Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Scheme 180

Scheme 181

Scheme 182

MATERIAL SPECIFICATIONS

All cylinder heads

Scheme 183

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Scheme 201

1. Remove the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Lower the engine onto wooden blocks.
3. Remove the Engine Lifting Bracket.
4. Install the Engine Lifting Bracket Set.
5. Install the Engine Lifting Bracket Set.
6. Mount the engine on a suitable work stand.
7. If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support insulator.
8. If equipped, remove the cylinder block drain plugs and drain the coolant in a suitable container.
9. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
10. Disconnect the Camshaft Position (CMP) sensor electrical connector.
11. Disconnect the RH radio frequency interference capacitor electrical connector.
12. Disconnect the Knock Sensor (KS) electrical connector.
13. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.
14. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
15. Remove the 2 nuts and the 2 radio interference capacitors.
16. Remove the bolt and the oil level indicator tube. Discard the O-ring seal.
17. Remove the LH valve cover. Fully loosen the 14 fasteners 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.
18. Remove the RH valve cover. Fully loosen the 14 fasteners 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.
19. Remove the bolt and the accessory drive belt idler pulley.
20. Remove the 4 bolts and the coolant pump pulley.
21. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
22. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
23. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
24. Remove the 4 front oil pan bolts.
25. Remove the 15 fasteners.
26. Remove the engine front cover from the cylinder block.
27. Remove the crankshaft sensor ring from the crankshaft.
28. Remove the 8 spark plugs. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .
29. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
30. Use the Valve Spring Compressor to compress the valve springs and remove all of the camshaft roller followers.
31. Position the crankshaft with the keyway at the 12 o'clock position.
32. Remove the timing chain tensioning system from both timing chains. Remove the 4 bolts. Remove the 2 timing chain tensioners. Remove the timing chain tensioner arms.
33. Remove the timing chains and crankshaft sprocket.
34. Remove the timing chain guides. Remove the 2 bolts. Remove the LH timing chain guide. Remove the 2 bolts. Remove the RH timing chain guide. RH cylinder head
35. Remove the RH exhaust manifold. Remove and discard the 8 nuts. Remove the RH exhaust manifold. Remove and discard the 2 RH exhaust manifold gaskets.
36. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
37. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) . LH cylinder head
38. Remove the LH exhaust manifold. Remove and discard the 8 nuts. Remove the LH exhaust manifold. Remove and discard the 2 LH exhaust manifold gaskets.
39. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
40. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) . All cylinder heads
41. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
42. Remove the 16 hydraulic lash adjusters. All cylinder heads
43. Remove the 20 bolts and the cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
44. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence. 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 surfaces is normal.
45. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Installer, Connecting Rod 303-442 (T93P-6136-A) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) or equivalent Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Slide Hammer 100-001 (T50T-100-A)

Scheme 202

MATERIAL SPECIFICATIONS

Note. Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

Note. The flexplate, the spacer plate, the crankshaft rear seal, the crankshaft rear oil slinger and the rear seal retainer plate must be removed before mounting the engine on the engine stand.

Note. For additional information, refer to the exploded view under the ASSEMBLY procedure.

Scheme 203

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1. Remove the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
2. Remove the 8 bolts and the flexplate.
3. Using the Crankshaft Rear Oil Slinger Remover and the Slide Hammer, remove the crankshaft rear oil slinger.
4. Using the Crankshaft Rear Oil Seal Remover and the Slide Hammer, remove the crankshaft rear seal.
5. Remove the 2 rear oil pan bolts, the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the Engine Lifting Bracket.
8. Install the Engine Lifting Bracket Set.
9. Install the Engine Lifting Bracket Set.
10. Mount the engine on a suitable work stand.
11. Remove the 6 bolts and the RH and LH engine support insulators.
12. If equipped, remove the cylinder block drain plugs and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
14. Disconnect the Camshaft Position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the Knock Sensor (KS) electrical connector.
17. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the 2 nuts and the 2 radio interference capacitors.
20. Remove the nut, bolt and the oil level indicator tube. Discard the O-ring seal.
21. Remove the LH and RH valve covers. Fully loosen the 28 fasteners and remove the valve covers. 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.
22. Remove the bolt and the accessory drive belt idler pulley.
23. Remove the 4 bolts and the coolant pump pulley.
24. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
25. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
26. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
27. Remove the 4 front oil pan bolts.
28. Remove the 15 fasteners.
29. Remove the engine front cover from the cylinder block.
30. Remove the crankshaft sensor ring from the crankshaft.
31. Remove the 8 spark plugs. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .
32. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
33. Use the Valve Spring Compressor to compress the valve springs and remove all of the camshaft roller followers.
34. Position the crankshaft with the keyway at the 12 o'clock position.
35. Remove the timing chain tensioning system from both timing chains. Remove the 4 bolts. Remove the 2 timing chain tensioners. Remove the 2 timing chain tensioner arms.
36. Remove the 2 timing chains and crankshaft sprocket.
37. Remove the timing chain guides. Remove the 2 bolts. Remove the LH timing chain guide. Remove the 2 bolts. Remove the RH timing chain guide.
38. Remove the RH exhaust manifold. Remove and discard the 8 nuts. Remove the RH exhaust manifold. Remove and discard the 2 RH exhaust manifold gaskets.
39. Remove the LH exhaust manifold. Remove and discard the 8 nuts. Remove the LH exhaust manifold. Remove and discard the 2 LH exhaust manifold gaskets.
40. Remove and discard the 16 exhaust manifold-to-cylinder head studs.
41. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .
42. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
43. Remove the 16 hydraulic lash adjusters.
44. Remove the 20 bolts and the cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
45. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence. 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 surfaces is normal.
46. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .
47. Remove the 5 fasteners, the oil filter adapter and discard the oil filter adapter gasket.
48. Clean the oil filter adapter gasket surface at the cylinder block.
49. Remove the 4 coolant pump bolts. Discard the O-ring seal.
50. Remove the coolant pump from the cylinder block.
51. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent following the manufacturer's instructions.
52. Remove the 14 bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
53. Remove the 3 bolts and the oil pump screen and pickup tube.
54. Remove the oil pump screen and pickup tube spacer.
55. Remove the 3 bolts and the oil pump.
56. Remove the 16 bolts and the 8 connecting rod caps. Rotate the crankshaft so that the connecting rod is at Bottom Dead Center (BDC). Remove and discard the bolts.
57. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
58. Disassemble the 8 pistons. For additional information, refer to «PISTON»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
59. Remove the fasteners. Remove and discard the 10 cross-mounted main cap bolts. Remove the 10 dowels. Remove and discard the 10 main bearing cap bolts.
60. Remove the 5 main bearing caps and the lower crankshaft main bearings.
61. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

SPECIAL TOOL(S) DESCRIPTION CHART Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)

MATERIAL SPECIFICATIONS

Note. LH shown in illustration, RH similar.

Scheme 216

PARTS DESCRIPTION CHART

Disassembly

Note. Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face.

Scheme 217

1. Install the Valve Spring Compressor Spacer tool between the valve spring coils to protect the valve stem seal from damage.
2. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.
3. Remove the valve spring retainers, valve springs and discard the valve seal.
4. Remove the 13 bolts, 6 bearing caps and camshaft.
5. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
6. Clean the cylinder head sealing surfaces. 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 surfaces is normal.
7. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .

Scheme 218

Scheme 219

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the 6 camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the 13 bolts loosely.
3. Tighten the 13 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
4. Install the valves in the valve guides located in the cylinder head.
5. Using the Valve Spring Compressor and Valve Stem Oil Seal Installer, install the new valve stem seal.
6. Install the valve springs and the valve spring retainers onto the valves.
7. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
8. Using the Valve Spring Compressor, compress the valve springs. Install the valve spring retainer keys.
9. Install the hydraulic lash adjusters in their original locations.
10. Remove the Valve Spring Compressor Spacer.

MATERIAL SPECIFICATIONS

Scheme 220

Scheme 221

Scheme 222

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»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .

Scheme 223

Scheme 224

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 225

PARTS DESCRIPTION CHART

1. Remove the 4 fuel rail bolts.
2. Separate the fuel rail from the 8 fuel injectors and remove the fuel rail.
3. Remove the 8 fuel injectors from the intake manifold. Remove and discard the fuel injector O-ring seals.
4. Remove the 6 engine coolant crossover assembly bolts.
5. Remove the engine coolant crossover assembly. Discard the gaskets.

Assembly

1. Position new engine coolant crossover assembly gaskets, the engine coolant crossover assembly and install the 6 bolts. Tighten to 10 Nm (89 lb-in).
2. Using new O-ring seals, install the fuel injectors into the intake manifold.
3. Install the fuel rail and the 4 fuel rail bolts. Tighten to 10 Nm (89 lb-in).

SPECIAL TOOL(S) DESCRIPTION CHART Alignment Pins, Cylinder Head 303-1040 (SR-015486) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) or equivalent Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Scheme 226

Scheme 227

PARTS DESCRIPTION CHART

MATERIAL SPECIFICATIONS

Scheme 228

PARTS DESCRIPTION CHART

Scheme 229

PARTS DESCRIPTION CHART

Scheme 230

PARTS DESCRIPTION CHART

Scheme 231

PARTS DESCRIPTION CHART

Scheme 232

PARTS DESCRIPTION CHART

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2". Repeat this process for the remaining 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the 10 dowel pins so the flat sides face the crankshaft.
12. Tighten the 10 vertical main bearing cap fasteners in the sequence shown in illustration, in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the 10 side bolts and tighten them in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 90 degrees.
14. Check the crankshaft end play. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .
15. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
16. Assemble the 8 pistons. For additional information, refer to «PISTON»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
17. Make sure the ring gaps (oil spacer-A, oil ring-B and compression ring-C) are correctly spaced around the circumference of the piston.
18. Make sure the dimple in the piston faces the front of the engine.
19. Use the Connecting Rod Installers and the Piston Ring Compressor to install the connecting rod with the upper connecting rod bearing in place. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil.
20. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.
21. Position the lower bearing and connecting rod, and install the new bolts loosely.
22. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) .
23. Tighten the 16 connecting rod bearing cap bolts in 2 stages, using the sequence shown in illustration. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
24. Install the oil pump and loosely install the 3 bolts. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
25. Install the pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
26. Position the oil pump screen and pickup tube and install the 3 bolts. Tighten to 25 Nm (18 lb-ft). Tighten to 10 Nm (89 lb-in).
27. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 new cylinder head bolts loosely.
28. Tighten the 20 bolts in 3 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
29. Install the 16 hydraulic lash adjusters in their original locations.
30. Install 16 new exhaust maniflold-to-cylinder head studs. Tighten to 12 Nm (106 lb-in).
31. Position the 2 new gaskets and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
32. Position the 2 new gaskets and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
33. Compress the tensioner plunger, using a vise.
34. Install a retaining clip on the tensioner to hold the plunger in during installation.
35. If the blue links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
36. Install the timing chain guides. Position the LH timing chain guide. Install the 2 LH bolts. Tighten to 10 Nm (89 lb-in). Position the RH timing chain guide. Install the 2 RH bolts. Tighten to 10 Nm (89 lb-in).
37. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
38. Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.
39. Install the crankshaft sprocket, making sure the flange faces forward.
40. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single blue (marked) link on the chain.
41. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 blue (marked) chain links.
42. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
43. Remove the retaining clip from the LH timing chain tensioner.
44. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) link on the timing chain.
45. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 blue (marked) chain links.
46. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
47. Remove the retaining clip from the RH timing chain tensioner.
48. As a post-check, verify correct alignment of all timing marks.
49. Position the crankshaft sensor ring on the crankshaft.
50. Install the Valve Spring Compressor Spacer tool between the valve spring coils to prevent valve stem seal damage.
51. Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.
52. Repeat the previous 3 steps for each camshaft roller follower.
53. Install the 8 spark plugs. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .
54. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown in illustration.
55. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
56. Tighten the 15 engine front cover fasteners in 3 stages, in the sequence shown in illustration. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft). PARTS DESCRIPTION CHART Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 8 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 11 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 12 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 13 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 14 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 15 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
57. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
58. Using the Crankshaft Front Oil Seal Installer, the Front Cover Oil Seal Installer and the Crankshaft Vibration Damper Installer, install the crankshaft front seal into the engine front cover.
59. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
60. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
61. Tighten the new crankshaft pulley bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
62. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
63. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
64. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
65. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.
66. Tighten the 13 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
67. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
68. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
69. Position the RH valve cover and gasket on the cylinder head and install the fasteners loosely.
70. Tighten the 14 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
71. Install the coolant pump. Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
72. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
73. Using a new O-ring seal, install the oil level indicator tube and the bolt. Tighten to 10 Nm (89 lb-in).
74. Install the oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
75. Install the radio frequency interference capacitors and the nuts. Tighten to 25 Nm (18 lb-ft).
76. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
77. Connect the Engine Oil Pressure (EOP) switch electrical connector and harness retainer.
78. Connect the KS electrical connector.
79. Connect the RH radio frequency interference capacitor electrical connector.
80. Connect the CMP sensor electrical connector.
81. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
82. If equipped, install the cylinder block drain plugs. Tighten to 20 Nm (177 lb-in).
83. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and 4 bolts. Tighten the 4 front bolts to 25 Nm (18 lb-ft). Tighten the rear nut to 48 Nm (35 lb-ft).
84. Position the RH and LH engine support insulators and install the 6 bolts. Tighten to 80 Nm (59 lb-ft).
85. Position the coolant pump pulley on the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
86. Install the Engine Lifting Bracket Set.
87. Install the Engine Lifting Bracket Set.
88. Install the Engine Lifting Bracket Set and remove the engine from the work stand.
89. Lower the engine onto wooden blocks.
90. Install the Engine Lifting Bracket and raise the engine.
91. Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
92. Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block.
93. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
94. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
95. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
96. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
97. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
98. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
99. Tighten the 16 bolts in 3 stages, in the sequence shown in illustration. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in). Stage 3: Tighten an additional 60 degrees.
100. Using the 2 Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
101. Using the 2 Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install the crankshaft rear oil slinger.
102. Install the flexplate and the 8 bolts. Tighten the bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 80 Nm (59 lb-ft).
103. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Alignment Pins, Cylinder Head 303-1040 (SR-015486) Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) or equivalent Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

PARTS DESCRIPTION CHART

MATERIAL SPECIFICATIONS

All cylinder heads

Scheme 260

Scheme 261

Scheme 262

Scheme 263

1. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.
2. Tighten the 20 bolts in 3 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
3. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head being serviced.
4. Install the 16 hydraulic lash adjusters in their original locations. RH cylinder head
5. Install 8 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
6. Position the 2 new gaskets and the exhaust manifold. Tighten the 8 nuts in the sequence shown in illlustration. Tighten to 25 Nm (18 lb-ft). LH cylinder head
7. Install 8 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
8. Position the 2 new gaskets and the LH exhaust manifold and tighten the 8 nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft). All cylinder heads
9. Using a vise, compress the tensioner plunger.
10. Install a retaining clip on the tensioner to hold the plunger in during installation.
11. Remove the tensioner from the vise.
12. If the blue links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
13. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the 2 LH bolts. Tighten to 10 Nm (89 lb-in). Position the RH timing chain guide. Install and tighten the 2 RH bolts. Tighten to 10 Nm (89 lb-in).
14. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
15. Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding Tool.
16. Install the crankshaft sprocket, making sure the flange faces forward.
17. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single blue (marked) link on the chain.
18. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 blue (marked) chain links.
19. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
20. Remove the retaining clip from the LH timing chain tensioner.
21. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single blue (marked) chain link.
22. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 blue (marked) chain links.
23. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
24. Remove the retaining clip from the RH timing chain tensioner.
25. As a post-check, verify correct alignment of all timing marks.
26. Install the crankshaft sensor ring on the crankshaft.
27. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
28. Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.
29. Repeat the previous 3 steps for each camshaft roller follower.
30. Install the 8 spark plugs. For additional information, refer to «ENGINE IGNITION - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-54l-2v-e-series) .
31. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in illustration.
32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
33. Tighten the 15 engine front cover fasteners in 3 stages, in the sequence shown in illustration. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft). PARTS DESCRIPTION CHART Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30 8 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 11 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 12 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 13 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 14 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27 15 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
34. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
35. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
36. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
37. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
38. Position the LH valve cover and gasket on the cylinder head and install the 13 fasteners loosely.
39. Tighten the 13 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
40. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
41. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
42. Position the RH valve cover and gasket on the cylinder head and install the 14 fasteners loosely.
43. Tighten the 14 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
44. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
45. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
46. Using the Front Cover Oil Seal Installer, Crankshaft Front Oil Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
47. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
48. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
49. Tighten the new crankshaft pulley bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
50. Position the coolant pump pulley on the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
51. Install the radio frequency interference capacitors and the nuts. Tighten to 25 Nm (18 lb-ft).
52. Using a new O-ring seal, install the oil level indicator tube and the bolt. Tighten to 10 Nm (89 lb-in).
53. Install the oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
54. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
55. Connect the Engine Oil Pressure (EOP) switch electrical connector and harness retainer.
56. Connect the KS electrical connector.
57. Connect the RH radio frequency interference capacitor electrical connector.
58. Connect the CMP sensor electrical connector.
59. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
60. If equipped, install the cylinder block drain plugs. Tighten to 20 Nm (177 lb-in).
61. If equipped with cylinder block drain plugs, position the RH engine support insulator and install the 3 bolts. Tighten to 90 Nm (66 lb-ft).
62. Install the Engine Lifting Bracket Set.
63. Install the Engine Lifting Bracket Set.
64. Install the Engine Lifting Bracket Set and remove the engine from the work stand.
65. Lower the engine onto wooden blocks.
66. Install the Engine Lifting Bracket and raise the engine.
67. Install the flexplate and the 8 bolts. Tighten the bolts in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten to 80 Nm (59 lb-ft).
68. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Pulley 303-239 (T84T-6312-C) Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Wrench, Fan Clutch Nut 303-240 (T84T-6312-D)

Scheme 264

MATERIAL SPECIFICATIONS

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

1. Position the engine in the vehicle.
2. Remove the floor crane, the Engine Lifting Bracket and the jack supporting the transmission.
3. Position the shifter cable support bracket and install the 2 transmission-to-engine bolts. Tighten to 60 Nm (44 lb-ft).
4. Install the RH lower transmission-to-engine bolt. Tighten to 60 Nm (44 lb-ft).
5. Install the 4 engine support insulator-to-support insulator bracket nuts. Tighten to 90 Nm (66 lb-ft).
6. Position the shift cable mounting bracket, install the 2 bolts and connect the shift cable. Tighten to 25 Nm (18 lb-ft).
7. Install 4 new torque converter nuts. Rotate the crankshaft to access all of the torque converter nuts. Tighten to 35 Nm (26 lb-ft).
8. Install the cylinder block opening cover.
9. Position the flexplate inspection cover and install the 2 bolts. Tighten to 34 Nm (25 lb-ft).
10. If equipped, install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
11. Connect the A/C compressor electrical connector and the wiring harness retainer.
12. Connect the Crankshaft Position (CKP) sensor electrical connector.
13. Position the exhaust Y-pipe and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
14. Position a new oil cooler on the oil filter adapter and install the threaded insert. Tighten to 58 Nm (43 lb-ft).
15. Install a new oil filter. Tighten to 16 Nm (142 lb-in).
16. Connect the 2 oil cooler coolant hoses.
17. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
18. Using the Teflon Seal Installer Set, install a new Teflon® seal on the power steering pressure tube.
19. Connect the Power Steering Pressure (PSP) tube and the power steering reservoir hose to the power steering pump. Tighten to 20 Nm (177 lb-in).
20. Connect the lower radiator coolant hose to the oil filter adapter coolant inlet.
21. Position the fuel tube support bracket and install the 4 upper transmission-to-engine bolts. Tighten to 60 Nm (44 lb-ft).
22. Position the ground strap, install the bolt and connect the RH HO2S electrical connector and retainer. Tighten to 10 Nm (89 lb-in).
23. Connect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and retainer.
24. Position the transmission wiring harness and connect the transmission wiring harness retainer.
25. Connect the LH HO2S sensor electrical wiring harness retainer to the rear of the LH cylinder head.
26. Connect the transmission wiring harness retainers to the engine wiring harness.
27. Insert the heater outlet tube over the new seals.
28. Install the 2 heater outlet tube studs. Tighten to 40 Nm (30 lb-ft).
29. Connect the coolant hose to the heater outlet tube.
30. Connect the KS electrical connector and engine wiring harness retainers.
31. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut. Tighten to 28 Nm (21 lb-ft).
32. Connect the oil fill tube to the RH valve cover.
33. Install the engine oil filler tube support strap bolt. Tighten to 9 Nm (80 lb-in).
34. Position the engine wiring harness support bracket, install the ground strap and nut, and connect the electrical connector to the bracket. Tighten to 10 Nm (89 lb-in).
35. Position the generator wiring harness and connect the 2 generator wiring harness retainers.
36. Connect the engine wiring harness retainer and the 2 PCM electrical connectors.
37. Connect the electrical connector.
38. Position the crankcase ventilation tube and connect the quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/fuel-system/#fuel-system-general-information-gasoline-models-diesel-models-e-series) .
39. Position the generator and install the bolts. Tighten to 25 Nm (18 lb-ft).
40. Connect the generator electrical connections. Tighten the B+ terminal nut to 8 Nm (71 lb-in). Connect the S electrical connector. Connect the ASI electrical connector.
41. Position the lower radiator support and install the 12 bolts. Tighten to 20 Nm (177 lb-in).
42. Position the wiring harness and connect the 4 wiring harness retainers.
43. Connect the 2 headlamp wiring harness retainers and position the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
44. Position the upper radiator support and install the 8 bolts. Tighten to 20 Nm (177 lb-in).
45. Position the 2 upper radiator support plates and install the 4 bolts. Tighten to 20 Nm (177 lb-in).
46. Position the RH and LH air deflectors and install the pin-type retainers.
47. Position the transmission fluid cooler and install the bolt. Tighten to 10 Nm (89 lb-in).
48. Connect the transmission fluid cooler hose retainers.
49. Connect the horn electrical connector.
50. Connect the front impact severity sensor electrical connector.
51. If equipped, connect the air temperature sensor electrical connector.
52. Route the battery feed wiring harness to the Power Distribution Box (PDB) and insert the routing clips.
53. Install the battery feed cable to the PDB and the nuts. Tighten to 8 Nm (71 lb-in).
54. Position the power steering reservoir and install the 3 bolts. Tighten to 20 Nm (177 lb-in).
55. Position the hood latch. Install the 2 bolts. Connect the cable position retainer. Tighten to 12 Nm (106 lb-in).
56. If equipped, position the A/C condenser core in the vehicle. Install the 2 bolts. Install A/C condenser bracket. Position the A/C condenser core. Tighten to 12 Nm (106 lb-in).
57. If equipped, connect the compressor discharge tube and the condenser-to-evaporator tube to the A/C condenser core and install the nuts. Tighten to 15 Nm (133 lb-in).
58. If equipped, connect the compressor suction tube and install the nut. Tighten to 15 Nm (133 lb-in).
59. If equipped, connect the A/C pressure cutoff switch electrical connector.
60. Position the radiator in the vehicle.
61. Position the radiator support brackets and install the 4 bolts. Tighten to 20 Nm (177 lb-in).
62. Position the fan shroud and the fan and fan clutch in the vehicle, and install the 2 bolts. Tighten to 6 Nm (53 lb-in).
63. Connect the degas bottle hose and power steering hose retainers to the fan shroud.
64. Using the Fan Pulley Holding Wrench and Fan Clutch Nut Wrench, install the fan blade and the fan clutch. Calculate the correct torque wrench setting for the following torque. Refer to the illustration. Tighten to 133 Nm (98 lb-ft).
65. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
66. Install the radiator grille support. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-e-series) .
67. Connect the transmission cooler tubes.
68. Connect the lower radiator hose to the radiator. Connect the hose. Connect the hose hanger.
69. Install the front bumper. For additional information, refer to «BUMPERS»(/ford/cutaway-e350-super-duty/2008-2012/remont/exterior-body-panels/#bumper-system-e-series) .
70. Install the starter. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-gasoline-models-e-series) .
71. Fill the engine with clean engine oil.
72. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) .
73. Check the transmission fluid level and fill as necessary.
74. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-power-steering/#steering-system-e-series) .
75. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
76. If equipped, evacuate and recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics-e-series) .

See also:
• INTRODUCTION - GASOLINE MODELS
• ENGINE SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• INTERIOR TRIM AND ORNAMENTATION
• INTAKE AIR DISTRIBUTION & FILTERING
• ENGINE COOLING
• FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL
• FUEL CHARGING & CONTROLS - 5.4L (2V)
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• ENGINE IGNITION - 5.4L (2V)
• JACKING & LIFTING
• STARTING SYSTEM - GASOLINE ENGINES
• BUMPERS
• FRONT END BODY PANELS
• STEERING SYSTEM
• VALVE COVER - LH