Engine Mechanical - 6.8l -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

PARTS DESCRIPTION CHART

PARTS DESCRIPTION CHART

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The 6.8L (415 CID) is a V-10 engine with the following features

1. SOHC
2. 2 valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder heads
5. Cast iron, 90-degree V-cylinder block
6. Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
7. Electronic Ignition (EI) system with 10 ignition coils
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 Catalog Advantage™ 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 10 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.

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.

Refer to ENGINE SYSTEM - GENERAL INFORMATION for basic mechanical concerns or refer to the INTRODUCTION - GASOLINE MODELS for driveability concerns.

Material

MATERIAL SPECIFICATIONS

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PARTS DESCRIPTION CHART

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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. 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) .
4. 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) .
5. Disconnect the fuel supply hose 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 generator electrical wiring harness retainer and the generator electrical connector.
7. Position the generator B+ protective boot aside and remove the generator B+ nut and terminal and position the generator harness aside.
8. Remove the 3 bolts, the stud bolt and the generator support bracket.
9. Compress and slide the hose clamp and disconnect the coolant hose.
10. Disconnect the electronic Electronic Throttle Control (ETC) electrical connector.
11. Disconnect the Throttle Position (TP) sensor electrical connector.
12. 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) .
13. Disconnect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
14. Disconnect the brake booster vacuum hose and the Evaporative Emission (EVAP) hose 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) .
15. Disconnect the electrical connector, remove the bolt and position the EVAP canister purge valve aside.
16. Remove the 4 bolts and the Throttle Body (TB) and TB spacer as an assembly. Discard the TB spacer gasket.
17. Disconnect the heater coolant hose.
18. Disconnect the 10 fuel injector electrical connectors.
19. Disconnect the 10 ignition coil electrical connectors.
20. Remove the transmission fluid indicator and tube support bracket nut.
21. Remove the transmission fluid level indicator tube support bracket nut and position the tube aside.
22. Disconnect the 2 RH engine wiring harness retainers and position the harness aside.
23. Disconnect the 3 LH engine wiring harness retainers and position the harness aside.
24. Remove the bolt and position the engine wiring harness support bracket aside.
25. Remove the 10 bolts and the 10 ignition coils.
26. Remove the 2 bolts, thermostat housing and thermostat. Discard the O-ring seal.
27. Remove the 11 bolts, the intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.

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1. Clean the mating surfaces of the cylinder head and the intake manifold with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Position new intake manifold gaskets and the intake manifold, and loosely install the 11 bolts.
3. Using a new O-ring seal, install the thermostat.
4. Position the thermostat housing and loosely install the 2 bolts.
5. Tighten the bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
6. Position the 10 ignition coils and install the 10 bolts. Apply silicone brake caliper grease and dielectric compound to the inside of the coil boots prior to installation. Tighten to 6 Nm (53 lb-in).
7. Connect the pushpin retainer to the intake manifold bracket.
8. Position the engine harness and connect the 3 LH engine wiring harness retainers.
9. Position the engine harness and connect the 2 RH engine wiring harness retainers.
10. Position back the transmission fluid level indicator tube and install the nut. Tighten to 10 Nm (89 lb-in).
11. Install the transmission fluid indicator and tube support bracket nut. Tighten to 28 Nm (21 lb-ft).
12. Connect the 10 ignition coil electrical connectors.
13. Connect the 10 fuel injector electrical connectors.
14. Connect the heater coolant hose.
15. Install a new TB spacer gasket and the TB and TB spacer as an assembly. Tighten the 4 bolts in 2 stages. Stage 1: Tighten to 9 Nm (80 lb-in). Stage 2: Tighten an additional 90 degrees.
16. Position the EVAP canister purge valve and install the bolt and the electrical connector. Tighten to 10 Nm (89 lb-in).
17. Connect the brake booster vacuum hose and the EVAP hose 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) .
18. Connect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
19. 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) .
20. Connect the TP sensor electrical connector and wiring harness retainer. Push in the red clip.
21. Connect the ETC electrical connector. Push in the red clip.
22. Install the upper radiator hose.
23. Position the generator harness and the generator B+ terminal and install the nut and protective boot. Tighten to 8 Nm (71 lb-in).
24. Connect the generator electrical wiring harness retainer and the generator electrical connector.
25. Connect the fuel hose 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) .
26. Install the 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) .
27. 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) .
28. 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) .
29. Fill 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) .

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Clutch Pulley 303-478 (94T-6312-AH) Wrench, Fan Clutch Nut 303-214 (T83T-6312-B)

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MATERIAL SPECIFICATIONS

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1. 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) .
2. 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) .
3. Using the Fan Clutch Nut Wrench and the Fan Clutch Pulley Holding Wrench, loosen the fan clutch and position the cooling fan and clutch assembly into the shroud.
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. Remove the 4 exhaust Y-pipe flange nuts.
6. Loosen the 2 transmission insulator and retainer nuts.
7. Loosen the 2 LH engine support insulator nuts.
8. Remove the 2 RH engine support insulator nuts.
9. Using a utility stand positioned on the RH rear of the cylinder block, raise the engine 25.4 mm (1 in).
10. Remove the 2 RH engine support insulator-to-crossmember bracket nuts.
11. Remove the nut and the RH engine support insulator-to-crossmember bracket.
12. Using the utility stand positioned on the RH rear of the cylinder block, lower the engine 38 mm (1.5 in).
13. Disconnect the 2 PCM electrical connectors and the wiring harness retainer.
14. Disconnect the 3 LH engine wiring harness retainers.
15. Disconnect the engine wiring harness retainer from the LH valve cover stud bolt.
16. Disconnect the Camshaft Position (CMP) sensor electrical connector.
17. Disconnect the engine wiring harness retainer from the engine front cover stud bolt.
18. Disconnect the LH 5 fuel injector electrical connectors.
19. Disconnect the LH 5 ignition coil electrical connectors and position the engine wiring harness aside.
20. Remove the oil level indicator and tube support bracket nut.
21. Remove the bolt and position the oil level indicator and tube aside.
22. Disconnect the quick connect coupling and remove the crankcase vent 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) .
23. 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. Discard the valve cover 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 the valve cover gasket on the cylinder head and loosely install the 14 bolts.
4. Tighten the 14 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Position back the oil level indicator and tube and install the bolt. Tighten to 10 Nm (89 lb-in).
6. Tighten the oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
7. Position back the engine wiring harness and connect the 3 wiring harness retainers.
8. Connect the LH 5 fuel injector electrical connectors.
9. Connect the LH 5 ignition coil electrical connectors.
10. Connect the CMP sensor electrical connector.
11. Connect the engine wiring harness retainer to the engine front cover stud bolt.
12. Connect the engine wiring harness retainer to the LH valve cover stud bolt.
13. Position the crankcase vent 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) .
14. Connect the 2 PCM electrical connectors and the wiring harness retainer.
15. Using the utility stand positioned on the RH rear of the cylinder block, raise the engine 38 mm (1.5 in).
16. Position the engine support insulator-to-crossmember bracket and install the nut finger-tight.
17. Install the 2 engine support insulator-to-crossmember bracket nuts. Tighten to 90 Nm (66 lb-ft).
18. Tighten the engine support insulator-to-crossmember bracket nut. Tighten to 90 Nm (66 lb-ft).
19. Using a utility stand positioned on the RH rear of the cylinder block, lower the engine.
20. Tighten the 2 LH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
21. Install the 2 RH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
22. Tighten the 2 transmission insulator and retainer nuts. Tighten to 90 Nm (66 lb-ft).
23. Install the 4 exhaust Y-pipe flange nuts. Tighten to 40 Nm (30 lb-ft).
24. Position the PCV valve 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) .
25. Position the cooling fan and clutch assembly and using the Fan Clutch Nut Wrench and the Fan Clutch Pulley Holding Wrench, install the cooling fan and clutch. Tighten to 133 Nm (98 lb-ft).
26. Install the ACL 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) .
27. 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) .

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Clutch Pulley 303-478 (94T-6312-AH) Wrench, Fan Clutch Nut 303-214 (T83T-6312-B)

MATERIAL SPECIFICATIONS

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1. 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) .
2. 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) .
3. Using the Fan Clutch Nut Wrench and the Fan Clutch Pulley Holding Wrench, loosen the fan clutch and position the cooling fan and clutch assembly into the shroud.
4. Remove the 4 exhaust Y-pipe flange nuts.
5. Loosen the 2 transmission insulator and retainer nuts.
6. Remove the 2 LH engine support insulator nuts.
7. Loosen the 2 RH engine support insulator nuts.
8. Using a utility stand positioned on the LH rear of the cylinder block, raise the engine 25.4 mm (1 in).
9. Remove the 3 nuts and the LH engine support insulator-to-crossmember bracket.
10. Using the utility stand positioned on the LH rear of the cylinder block, lower the engine 38 mm (1.5 in).
11. Disconnect the generator wiring harness retainer from the engine front cover stud bolt.
12. Disconnect the 2 electrical connectors.
13. Disconnect the electrical connector position retainers, remove the nut, ground strap and mounting bracket.
14. Disconnect the oil fill tube.
15. Remove the bolt and the oil fill tube.
16. 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) .
17. Rotate the PCV valve counterclockwise and remove the PCV valve.
18. Disconnect the wiring harness retainer from the front RH valve cover stud bolt.
19. Remove the nut for the transmission fluid indicator and tube.
20. Remove the nut and position the transmission fluid indicator and tube aside.
21. Disconnect the RH 5 ignition coil electrical connectors.
22. Disconnect the RH 5 fuel injector electrical connectors.
23. Disconnect the 2 retainers and position the engine wiring harness aside.
24. Remove the 5 bolts and the 5 RH ignition coils.
25. Remove the RH 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. Discard the valve cover 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 the valve cover gasket on the cylinder head and loosely install the 14 fasteners.
4. Tighten the fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Position the 5 ignition coils and install the 5 bolts. Apply silicone brake caliper grease and dielectric compound to the inside of the coil boots prior to installation. Tighten to 6 Nm (53 lb-in).
6. Position the engine wiring harness and connect the 2 retainers.
7. Connect the 5 RH fuel injector electrical connectors.
8. Connect the 5 RH ignition coil electrical connectors.
9. Position back the transmission fluid indicator and tube and install the nut. Tighten to 28 Nm (21 lb-ft).
10. Install the transmission fluid indicator and tube support bracket nut. Tighten to 10 Nm (89 lb-in).
11. Connect the wiring harness retainer to the front RH valve cover stud bolt.
12. Rotate the PCV valve clockwise and install the PCV valve.
13. 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) .
14. Connect the oil fill tube to the RH valve cover.
15. Install the oil fill tube support bracket bolt. Tighten to 10 Nm (89 lb-in).
16. Position the mounting bracket, ground strap and install the nut. Connect the electrical connector retainers to the support bracket. Tighten the nut to 25 Nm (18 lb-ft).
17. Connect the 2 electrical connectors.
18. Connect the generator wiring harness retainer to the engine front cover stud bolt.
19. Using the utility stand positioned on the LH rear of the cylinder block, raise the engine 38 mm (1.5 in).
20. Position the LH engine support insulator-to-crossmember bracket and install the 3 nuts. Tighten to 90 Nm (66 lb-ft).
21. Using a utility stand positioned on the LH rear of the cylinder block, lower the engine.
22. Install the 2 LH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
23. Tighten the 2 RH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
24. Tighten the 2 transmission insulator and retainer nuts. Tighten to 90 Nm (66 lb-ft).
25. Install the 4 exhaust Y-pipe flange nuts. Tighten to 40 Nm (30 lb-ft).
26. Position the cooling fan and clutch assembly and using the Fan Clutch Nut Wrench and the Fan Clutch Pulley Holding Wrench, install the cooling fan and clutch. Tighten to 133 Nm (98 lb-ft).
27. Install the 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) .
28. 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) .

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 bolt and washer and discard the 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 surface 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 without exceeding 200 Nm (148 lb-ft).
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 303-335 (T88T-6701-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) 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 bolt and washer and discard the 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 new crankshaft front seal inner lip with clean engine oil.
2. Using the Crankshaft Front Oil Seal Installers 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 without exceeding 200 Nm (148 lb-ft).
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 303-335 (T88T-6701-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) 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

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

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 RH and LH valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) and «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
4. Loosen the 4 coolant pump pulley bolts.
5. Rotate the tensioner clockwise and remove the accessory drive belt.
6. Remove the 4 bolts and the coolant pump pulley.
7. Remove the 3 bolts and position the power steering pump aside.
8. Disconnect the wiring harness from the bracket.
9. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
10. Disconnect the A/C compressor electrical connector.
11. Remove the nut, disconnect the tubes and remove the bracket.
12. Remove the 3 bolts and position the A/C compressor aside.
13. Remove the drain plug and drain the engine oil.
14. Disconnect the Camshaft Position (CMP) sensor electrical connector.
15. Remove the nut and the radio frequency interference capacitor.
16. Remove the bolt and the accessory drive belt idler pulley.
17. Using the Strap Wrench, remove the bolt and washer and discard the bolt.
18. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
19. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
20. Remove the 4 front oil pan bolts.
21. Remove the 15 bolts.
22. Remove the engine front cover from the front cover to cylinder block dowel. Discard the engine front cover gasket. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

Scheme 359

Scheme 360

Scheme 361

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 engine front cover-to-cylinder block dowel and loosely install the bolts.
3. Tighten the engine front cover fasteners in the sequence shown in illustration in 2 stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 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 50 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50 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 54 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 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 bolts, then tighten the bolts in 2 stages following 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 Installers and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
7. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
8. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
9. 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 without exceeding 200 Nm (148 lb-ft).
10. Connect the CMP electrical connector.
11. Position the belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
12. Install the radio frequency interference capacitor and the nut. Tighten to 25 Nm (18 lb-ft).
13. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
14. Connect the CKP sensor electrical connector.
15. Connect the A/C compressor electrical connector.
16. Position the transmission fluid cooler tube support bracket, connect the tubes and install the nut. Tighten to 30 Nm (22 lb-ft).
17. Connect the wiring harness to the bracket.
18. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
19. Position the coolant pump pulley on the coolant pump and install the 4 bolts finger-tight.
20. Rotate the tensioner clockwise and install the accessory drive belt.
21. Tighten the 4 coolant pump bolts. Tighten to 25 Nm (18 lb-ft).
22. Install the oil drain plug.
23. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) and «VALVE COVER - RH»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
24. 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) .
25. Fill the engine with clean engine oil.

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

Scheme 362

Scheme 363

MATERIAL SPECIFICATIONS

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

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

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-68l-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. Scribe a location mark on the back of the balance shaft gear and the camshaft balance shaft drive gear.
5. Remove the 6 bolts and remove the 3 balance shaft bearing caps.
6. Remove the balance shaft.
7. Install and carefully tighten the Camshaft Position Aligner on the camshafts.
8. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
9. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
10. Remove the LH and RH timing chains and the crankshaft sprockets.
11. Remove the 4 bolts and the timing chain guides.
12. Remove the 2 bolts, flat washers, camshaft sprockets and RH camshaft spacer.

Installation

Note. Timing chain procedures must be followed exactly or damage to valves and pistons will result.

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

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 copper 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 RH camshaft spacer ring, both camshaft sprockets, flat washers and tighten the bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Install the timing chain guides and the 4 bolts. Tighten to 10 Nm (89 lb-in).
6. Preposition the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Tighten the Camshaft Position Aligner to maintain camshaft prepositioning. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Position Aligner to maintain camshaft prepositioning.
7. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
8. Install the crankshaft sprocket, making sure the flange faces forward.
9. Install the lower end of the LH timing chain, aligning the timing marks.
10. Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
11. Install the RH (outer) timing chain on the crankshaft sprocket.
12. Position the timing chain on the camshaft sprocket. Make sure the 2 blue-colored (marked) links align with the camshaft sprocket timing mark.
13. Position the LH and RH timing chain tensioner arms on the dowel pins and install the timing chain tensioners and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
14. Remove the retaining clips from the RH and LH timing chain tensioners.
15. Check for correct alignment of all timing marks.
16. Remove the Camshaft Position Aligner from the camshafts.
17. Install the crankshaft sensor ring on the crankshaft.
18. Lubricate the balance shaft journals with clean engine oil.
19. Position the balance shaft on the journals.
20. Align the scribed mark on the balance shaft with the camshaft balance shaft drive gear scribe mark as shown in illustration.
21. Install the bearing caps in their original locations and tighten the 6 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
22. Install engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

Scheme 382

PARTS DESCRIPTION CHART

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

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-68l-e-series) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
3. Remove the 17 bolts, the 7 camshaft bearing caps and the LH camshaft from the cylinder head.
4. Remove the 15 bolts, the 7 camshaft bearing caps and the RH camshaft from the cylinder head.

Scheme 383

1. Lubricate the camshaft journals with clean engine oil.
2. Install the RH camshaft and the 7 camshaft bearing caps in their original locations onto the cylinder head. Loosely install the 15 bolts.
3. Install the LH camshaft and the 7 camshaft bearing caps in their original locations onto the cylinder head. Loosely install the 17 bolts.
4. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
6. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

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

Scheme 384

Scheme 385

MATERIAL SPECIFICATIONS

Scheme 386

Scheme 387

1. If servicing the RH cylinder valve train 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-68l-e-series) .
2. If servicing the LH cylinder valve train 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-68l-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 2 steps for each of the camshaft roller followers being serviced.

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 springs and install the camshaft roller follower.
3. Repeat the previous 2 steps for each camshaft roller follower being serviced.
4. If servicing the RH cylinder valve train 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-68l-e-series) .
5. If servicing the LH cylinder valve train 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-68l-e-series) .

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

MATERIAL SPECIFICATIONS

Removal and Installation

1. If servicing the RH cylinder valve train 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-68l-e-series) .
2. If servicing the LH cylinder valve train 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-68l-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 spring and remove the camshaft roller follower.
6. Remove the spark plug. For additional information, refer to «ENGINE IGNITION - 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-68l-e-series) .
7. Use compressed air in the cylinder to hold both valves in position. Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
8. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.
9. Remove the valve spring retainer and the valve spring.
10. Repeat the previous 7 steps for each valve spring being serviced.
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 388

MATERIAL SPECIFICATIONS

1. Remove the valve spring. For additional information, refer to «VALVE SPRINGS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
2. Remove and discard the valve stem seal.

1. Using the Valve Stem Oil Seal Installer and Valve Spring Compressor, 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-68l-e-series) .

MATERIAL SPECIFICATIONS

1. Remove the camshaft roller follower. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
2. Remove the hydraulic lash adjuster.

1. Install the hydraulic lash adjuster.
2. Install the camshaft roller follower. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

MATERIAL SPECIFICATIONS

Scheme 389

Scheme 390

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.
4. Remove the 10 nuts, the exhaust manifold and the exhaust manifold gasket. Discard the exhaust manifold gasket and the nuts.
5. Remove and discard the 10 exhaust manifold studs.
6. 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 391

1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
2. Install 10 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
3. Position the new gaskets, the exhaust manifold and tighten the nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
4. Position the exhaust Y-pipe flange and install the 4 nuts. 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 392

Scheme 393

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 nuts.
4. Remove the 10 exhaust manifold nuts and the exhaust manifold. Discard the exhaust manifold gaskets and the nuts.
5. Remove and discard the 10 exhaust manifold studs.
6. 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 394

1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
2. Install 10 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
3. Position the new gaskets, the exhaust manifold and tighten the nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
4. Position the exhaust Y-pipe flange and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).

Scheme 395

PARTS DESCRIPTION CHART

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

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

Scheme 396

Scheme 397

Scheme 398

MATERIAL SPECIFICATIONS

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

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 intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
4. 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) .
5. Remove the 4 retainers and the shield.
6. Remove the 2 stud bolts and position the heater outlet tube aside.
7. Remove the 2 transmission-to-engine bolts.
8. Disconnect the oil fill tube from the RH valve cover.
9. Remove the bolt and the oil fill tube.
10. Assemble the Engine Lifting Bracket and Modular Engine Lift Bar Adapter.
11. Install the Engine Lifting Bracket and Modular Engine Lift Bar Adapter assembly.
12. Install the Engine Support Bar and support the engine.
13. Drain the engine oil and remove the oil filter.
14. Remove the nut and position the transmission fluid cooler tube support bracket aside.
15. Remove the 4 engine support insulator nuts.
16. Remove the 2 bolts and the flywheel inspection plate.
17. Using the Engine Support Bar, raise the engine.
18. Remove the 18 bolts and partially lower the oil pan.
19. Remove the 3 bolts retaining the oil pump screen and pickup tube and allow it to drop into the oil pan. Also remove the tube and spacer and allow it to drop into the oil pan. Remove the oil pan. Discard the oil pan gasket.
20. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

Scheme 407

Scheme 408

Scheme 409

1. Position the new oil pan gasket and the oil pan in the vehicle from the rear of the engine.
2. 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.
3. 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).
4. Apply the silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
5. Apply silicone gasket and sealant in the locations shown in illustration.
6. Position the oil pan gasket, the oil pan and loosely install the 18 bolts. 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. Lower the engine and remove the Engine Support Bar, Engine Lifting Bracket and Modular Engine Lift Bar.
8. Position the flexplate inspection plate and install the 2 bolts. Tighten to 34 Nm (25 lb-ft).
9. Install the engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
10. Position the transmission fluid cooler tube support bracket and install the nut. Tighten to 30 Nm (22 lb-ft).
11. Install the new oil filter. Tighten to 16 Nm (142 lb-in).
12. Install the new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with engine coolant.
13. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten to 40 Nm (30 lb-ft).
14. Connect the oil fill tube to the RH valve cover.
15. Install the oil fill tube support bracket bolt. Tighten to 10 Nm (89 lb-in).
16. Install the transmission-to-engine bolts. Tighten to 47 Nm (35 lb-ft).
17. Install the shield and the 4 retainers.
18. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
19. 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) .
20. Fill the engine with clean engine oil.
21. Install 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) .
22. 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 410

1. Release the fuel system pressure. 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) .
2. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
3. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
4. Remove the 3 bolts and the oil pump.

Scheme 411

1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
2. Install the oil pump and tighten the 3 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
4. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-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-68l-e-series) .

Scheme 412

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 electrical connector.
3. Remove the EOP switch.

1. Install the EOP switch and tighten in 2 stages. Stage 1: Tighten to 14 Nm (125 lb-in). Stage 2: Tighten an additional 180 degrees.
2. Connect the EOP switch electrical connector.

MATERIAL SPECIFICATIONS

Scheme 413

PARTS DESCRIPTION CHART

Scheme 414

PARTS DESCRIPTION CHART

Scheme 415

1. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-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 engine oil cooler.
5. Remove and discard the oil filter.
6. Remove the threaded insert and the oil cooler. Inspect and discard the oil cooler.
7. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
8. Remove the EOP switch.
9. Disconnect the lower radiator hose.
10. Remove the nut, the 4 bolts, the oil filter adapter and the gasket. Discard the gasket.
11. 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 new gasket and the oil filter adapter. Install the nut and the 4 bolts. Tighten the front 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 and tighten 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. Position a new oil cooler and install the threaded insert. Tighten to 58 Nm (43 lb-ft).
6. Install a new oil filter. Tighten to 16 Nm (142 lb-in).
7. Connect the 2 coolant hoses to the engine oil cooler.
8. Fill the crankcase with clean engine oil.
9. Install the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
10. 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 416

PARTS DESCRIPTION CHART

1. Remove the engine 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-68l-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-68l-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 417

PARTS DESCRIPTION CHART

1. 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) .
2. Drain the engine oil.
3. Disconnect the 2 coolant hoses from the engine oil cooler.
4. Remove and discard the oil filter. To install, tighten to 16 Nm (142 lb-in).
5. Remove the threaded insert and discard the oil cooler. Inspect and discard the oil cooler. To install, tighten to 58 Nm (43 lb-ft).
6. To install, reverse the removal procedure. Install a new oil cooler. Fill the crankcase with clean engine oil prior to filling the cooling system.

Scheme 418

PARTS DESCRIPTION CHART

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

Scheme 419

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

Scheme 420

1. Position the flexplate and tighten the 8 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 - 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)

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MATERIAL SPECIFICATIONS

Scheme 427

Scheme 428

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
2. Remove the engine rear cover plate.
3. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
4. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.

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 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-68l-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Engine Support Bar 303-F070 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)

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-68l-e-series) .
2. Lower the engine.
3. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
4. Remove the engine rear cover plate.
5. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
6. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
7. Remove the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.
8. Clean and inspect the mating surface.

Scheme 429

1. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.
2. Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.
4. Using the Crankshaft Rear Oil Seal Installers and Crankshaft Rear Oil Slinger Installer, install the 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-68l-e-series) .
7. Using the Engine Support Bar, raise the engine.
8. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

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

MATERIAL SPECIFICATIONS

Scheme 430

PARTS DESCRIPTION CHART

Both engine support insulators

Scheme 431

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-68l-e-series) .
3. 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) .
4. Remove the 4 retainers and the shield.
5. Remove the 2 stud bolts and position the heater outlet tube aside.
6. Remove the 2 transmission-to-engine bolts.
7. Disconnect the oil fill tube from the RH valve cover.
8. Remove the bolt and the oil fill tube.
9. Assemble the Engine Lifting Bracket and Modular Engine Lift Bar Adapter.
10. Install the Engine Lifting Bracket and Modular Engine Lift Bar Adapter.
11. Install the Engine Support Bar and support the engine.
12. Remove the 4 engine support insulator nuts.
13. Using the Engine Support Bar, raise the engine. LH engine support insulator
14. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
15. Remove the EOP switch. Both engine support insulators
16. Remove the 4 bolts and the engine support insulator being serviced.

Both engine support insulators

1. Position the engine support insulator and install the 4 bolts. Tighten to 80 Nm (59 lb-ft). LH engine support insulator
2. Install the EOP switch and tighten in 2 stages. Stage 1: Tighten to 18 Nm (159 lb-in). Stage 2: Tighten an additional 180 degrees.
3. Connect the EOP switch electrical connector. Both engine support insulators
4. Lower the engine and remove the Engine Support Bar, Engine Lifting Bracket and Modular Engine Lift Bar.
5. Install the 4 engine support insulator-to-crossmember nuts. Tighten to 90 Nm (66 lb-ft).
6. Install a new O-ring seal and the heater outlet tube. Lubricate the O-ring seal with clean engine coolant prior to installation.
7. Hand-tighten the heater outlet tube upper stud and install the lower stud. Tighten to 40 Nm (30 lb-ft).
8. Connect the oil fill tube to the RH valve cover.
9. Install the oil fill tube support bracket bolt. Tighten to 10 Nm (89 lb-in).
10. Install the transmission-to-engine bolts. Tighten to 47 Nm (35 lb-ft).
11. Install the shield and the 4 retainers.
12. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
13. 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) .
14. Install 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) .
15. 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) .

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Clutch Pulley 303-478 (T94T-6312-AH) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Wrench, Fan Clutch Nut 303-214 (T83T-6312-B)

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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-68l-e-series) .
4. 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) .
5. 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) .
6. Disconnect the lower radiator hose from the radiator. Disconnect the hose hanger. Disconnect the hose.
7. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
8. Remove the 4 nuts and disconnect the exhaust system from the LH and RH exhaust manifolds.
9. Drain the engine oil.
10. Disconnect the oil cooler coolant hoses and position aside.
11. Remove and discard the oil filter.
12. Remove and inspect the oil cooler. Discard the oil cooler.
13. Remove the 2 bolts and the flexplate inspection cover.
14. Remove the cylinder block opening cover.
15. Remove and discard the 4 torque converter-to-flexplate nuts. Rotate the crankshaft to access all of the torque converter nuts.
16. Disconnect the shift cable from the mounting bracket and shift linkage.
17. Remove the 2 transmission-to-engine bolts and position the shifter cable aside.
18. Remove the RH lower transmission-to-engine bolt.
19. Remove the 4 engine support insulator nuts.
20. 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.
21. Remove the nut and position the transmission fluid cooler support bracket aside.
22. If equipped, remove the 3 bolts and position the A/C compressor aside.
23. 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) .
24. Disconnect the upper radiator hose and the degas bottle hose from the radiator.
25. Using the Fan Clutch Pulley Holding Wrench and Fan Clutch Nut Wrench, remove the fan blade and the fan clutch.
26. Disconnect the degas bottle hose and power steering hose retainers from the fan shroud.
27. Remove the fan shroud, fan and fan clutch. Remove the 2 bolts. Lift the fan shroud, fan and fan clutch from the vehicle.
28. Remove the 4 bolts and the radiator support brackets.
29. Remove the radiator from the vehicle.
30. If equipped, disconnect the A/C pressure cutoff switch electrical connector.
31. If equipped, remove the nut and disconnect the compressor suction tube.
32. If equipped, remove the nuts and disconnect the compressor discharge tube and the condenser-to-evaporator tube from the A/C condenser core.
33. If equipped, remove the A/C condenser core. Remove the bolts. Remove the A/C condenser brackets. Remove the A/C condenser core.
34. Set the hood latch aside. Remove the hood latch bolts. Disengage the cable routing clip.
35. Remove the 3 bolts and position the power steering reservoir aside.
36. Remove the nut and the battery feed cable at the Power Distribution Box (PDB).
37. Disengage the harness routing clips and position aside the battery feed wiring harness.
38. If equipped, disconnect the air temperature sensor electrical connector.
39. Disconnect the front impact severity sensor electrical connector.
40. Disconnect the horn electrical connector.
41. Disconnect the transmission fluid cooler hose retainers.
42. Remove the bolt and position the transmission fluid cooler aside.
43. Remove the pin-type retainers and the RH and LH air deflectors.
44. Remove the 4 bolts and the 2 upper radiator support plates.
45. Remove the 8 bolts and the upper radiator support.
46. Remove the bolt and disconnect the 2 headlamp wiring harness retainers.
47. Disconnect the 4 wiring harness retainers and position the wiring harness aside.
48. Remove the 12 bolts and the lower radiator support.
49. Disconnect the lower radiator hose from the oil filter adapter water inlet and position aside.
50. Disconnect the engine wiring harness retainer and the 2 PCM electrical connectors.
51. Disconnect the engine wiring harness electrical connectors.
52. Disconnect the generator wiring harness retainer and position the wiring harness aside.
53. Disconnect the electrical connectors, remove the nut, ground strap and mounting bracket.
54. Remove the engine oil filler tube support strap bolt.
55. 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.
56. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector and remove the transmission fluid filler tube.
57. Disconnect the RH HO2S sensor wiring harness retainer from the heater coolant outlet tube bracket.
58. Disconnect the hose from the heater outlet tube.
59. Remove the 2 heater outlet tube studs.
60. Remove the heater outlet tube. Discard the O-ring seals.
61. Disconnect the transmission wiring harness retainers from the engine wiring harness.
62. Disconnect the LH HO2S sensor electrical wiring harness retainer from the rear of the LH cylinder head.
63. Disconnect the transmission wiring harness retainer and position the transmission wiring harness aside.
64. Disconnect the LH HO2S sensor electrical connector and retainer.
65. Remove the bolt and position the ground wire aside.
66. Remove the 4 upper transmission-to-engine bolts and position the fuel tube support bracket aside.
67. Install the Engine Lifting Bracket as shown in illustration.
68. Support the transmission with a jack.
69. Remove the engine from the vehicle.

SPECIAL TOOL(S) DESCRIPTION CHART Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Lifting Bracket, Engine 303-F047 (014-00073) or equivalent Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) 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-6565-AH)

Scheme 480

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MATERIAL SPECIFICATIONS

Both cylinder heads

Scheme 483

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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-68l-e-series) .
2. Remove the 8 bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the Engine Lifting Bracket.
5. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
6. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
7. Mount the engine on a suitable work stand.
8. If equipped with cylinder block drain plugs, remove the 4 bolts and the RH engine support insulator.
9. If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
10. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
11. Disconnect the Camshaft Position (CMP) electrical connector.
12. Disconnect the Knock Sensor (KS) electrical connector, if equipped.
13. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
14. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
15. Disconnect all of the engine control sensor wiring harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
16. Remove the nut and the radio frequency interference capacitor.
17. Remove the nut attaching the oil level indicator tube to the front of the engine.
18. Remove the bolt attaching the oil level indicator tube to the LH cylinder head.
19. Position the oil level indicator tube aside.
20. 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. Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
21. 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. Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
22. Remove the bolt and the 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 3 bolts and the power steering pump.
28. Remove the 4 front oil pan bolts.
29. Remove the 15 fasteners.
30. Remove the engine front cover from the cylinder block.
31. Remove the crankshaft sensor ring from the crankshaft.
32. Remove the 6 bolts and remove the balance shaft bearing caps.
33. Remove the balance shaft.
34. Remove the 10 spark plugs. For additional information, refer to «ENGINE IGNITION - 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-68l-e-series) .
35. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
36. Use the Valve Spring Compressor to compress the valve springs, and remove all of the camshaft roller followers.
37. Position the crankshaft with the keyway at the 12 o'clock position.
38. 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.
39. Remove the 2 timing chains and the crankshaft sprocket.
40. 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
41. Remove the RH exhaust manifold. Remove and discard the 10 nuts. Remove the RH exhaust manifold. Remove and discard the exhaust manifold gaskets.
42. Remove and discard the 10 RH exhaust manifold studs.
43. 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
44. Remove the cylinder head insert.
45. Remove the LH exhaust manifold. Remove and discard the 10 nuts. Remove the LH exhaust manifold. Remove and discard the LH exhaust manifold gaskets.
46. Remove and discard the 10 LH exhaust manifold studs.
47. 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) . Both cylinder heads
48. Install the Cylinder Head Remover/Installer, on both ends of the cylinder head being serviced.
49. Remove the 10 hydraulic lash adjusters.
50. Remove the bolts and the cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
51. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block 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.
52. 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) Engine Lifting Bracket 303-F047 (014-00073) or equivalent Installer, Connecting Rod 303-442 (T93P-6136-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) 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-6565-AH) Slide Hammer 100-001 (T50T-100-A)

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MATERIAL SPECIFICATIONS

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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-68l-e-series) under the Removal portion of this section.
2. Remove the 8 bolts and the flexplate.
3. Using the Crankshaft Rear Oil Slinger Remover and Slide Hammer, remove and discard the crankshaft oil slinger.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the crankshaft rear seal.
5. Remove the 2 rear oil pan bolts and 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 from the Engine Lifting Bracket Set.
9. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
10. Mount the engine on a suitable work stand.
11. Remove the 4 bolts and the RH engine support insulator.
12. Remove the 4 bolts and the LH engine support insulator.
13. If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container. Install the drain plugs when finished. Tighten to 24 Nm (18 lb-ft).
14. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
15. Disconnect the Camshaft Position (CMP) sensor electrical connector.
16. Disconnect the Knock Sensor (KS) electrical connector.
17. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nut and the radio frequency interference capacitor.
21. Remove the nut attaching the oil level indicator tube to the front of the engine.
22. Remove the bolt attaching the oil level indicator tube to the LH cylinder head.
23. Position the oil level indicator tube aside.
24. 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. Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
25. Remove the RH valve cover. Fully loosen the 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. Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
26. Remove the bolt and the accessory drive belt idler pulley.
27. Remove the 4 bolts and the coolant pump pulley.
28. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
29. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
30. Remove the 3 bolts and the power steering pump.
31. Remove the 4 front oil pan bolts.
32. Remove the 15 fasteners.
33. Remove the engine front cover from the cylinder block.
34. Remove the crankshaft sensor ring from the crankshaft.
35. Remove the 6 bolts and remove the balance shaft bearing caps.
36. Remove the balance shaft.
37. Remove the 10 spark plugs. For additional information, refer to «ENGINE IGNITION - 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-68l-e-series) .
38. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
39. Use the Valve Spring Compressor to compress the valve springs, and remove the all of the camshaft roller followers.
40. Position the crankshaft with the keyway at the 12 o'clock position.
41. Remove the timing chain tensioning system from both timing chains. Remove the 4 bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
42. Remove the 2 timing chains and crankshaft sprocket.
43. 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.
44. Remove the RH exhaust manifold. Remove and discard the 10 nuts. Remove the RH exhaust manifold. Remove and discard the RH exhaust manifold gaskets.
45. Remove the LH exhaust manifold. Remove and discard the 10 nuts. Remove the LH exhaust manifold. Remove and discard the LH exhaust manifold gaskets.
46. Remove and discard the 20 exhaust manifold studs.
47. 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) .
48. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
49. Remove the hydraulic lash adjusters.
50. Remove the insert from the LH cylinder head.
51. Remove the 24 bolts and the cylinder heads. Discard the cylinder head gasket. Discard the cylinder head bolts.
52. 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.
53. 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) .
54. Remove the 4 bolts, the nut, the oil filter adapter and discard the gasket.
55. Clean the oil filter adapter gasket surface at the cylinder block.
56. Remove the 4 coolant pump bolts and the coolant pump. Discard the O-ring seal.
57. 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.
58. Remove the 14 bolts, the oil pan and the oil pan gasket. Discard the oil pan gasket.
59. Remove the 3 bolts, the oil pump screen cover and tube and the spacer.
60. Remove the 3 bolts and the oil pump.
61. Remove the 20 bolts and the connecting rod caps. Rotate the crankshaft so that the connecting rod is at bottom dead center. Remove and discard the bolts.
62. Remove the piston and rod assembly. Using the Connecting Rod Installer, guide the piston and rod assembly out of the cylinder.
63. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
64. Disassemble the 10 pistons. For additional information, refer to «PISTON»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
65. Remove and discard the 12 cross-mounted bolts.
66. Remove and discard the 12 bolts.
67. Remove the 12 main bearing cap dowel pins.
68. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
69. Remove the crankshaft and the crankshaft main bearings from the cylinder block.

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

MATERIAL SPECIFICATIONS

Disassembly

Note. Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

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

Scheme 520

Scheme 521

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 remove the 2 valve spring retainer keys from each valve.
3. Remove the valve spring retainer, valve spring and discard the valve seal from each valve.
4. Remove the bolts (17 LH or 15 RH), the 7 bearing caps and the 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. Check 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 522

Scheme 523

Scheme 524

1. 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.
2. Lubricate the camshaft journals with clean engine oil.
3. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the 7 camshaft bearing caps. Install the bolts loosely (17 LH or 15 RH).
4. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Install the valves in the valve guides located in the cylinder head.
6. Using the Valve Spring Compressor and the Valve Stem Oil Seal Installer, install a new valve stem seal for each valve.
7. Install a valve spring and a valve spring retainer onto each valve.
8. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
9. Using the Valve Spring Compressor, compress the valve spring. Install 2 valve spring retainer keys for each valve.

MATERIAL SPECIFICATIONS

Scheme 525

1. Remove the piston rings from the piston. Discard the piston rings.
2. Mark the piston and connecting rod on the same side for assembly reference.
3. Remove the piston pin retainers and the piston pin.
4. Separate the piston from the connecting rod.
5. 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) .

Assembly

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.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston.

MATERIAL SPECIFICATIONS

Scheme 526

PARTS DESCRIPTION CHART

1. Remove the 4 bolts, separate the fuel rail from the 10 fuel injectors and remove the fuel rail.
2. Remove the fuel injectors from the intake manifold and discard the upper and lower fuel injector O-ring seals.
3. Separate the upper and lower intake manifolds. Remove the 10 bolts. Discard the intake manifold gaskets.
4. Inspect all external and internal surfaces of the intake manifold. Inspect for cracks or other damage. Inspect for foreign material inside of the manifold. Clean the intake manifold sealing surfaces.

Scheme 527

Scheme 528

1. Position 11 new lower intake manifold gaskets and the upper intake manifold on the lower intake manifold and loosely install the 10 bolts.
2. Tighten the 10 bolts in 2 stages, using the sequence shown in illustration. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
3. Install 2 new O-ring seals on each of the 10 fuel injectors.
4. Install the 10 fuel injectors into the intake manifold.
5. Position the fuel rail onto the fuel injectors and install the 4 bolts. To install, tighten to 10 Nm (89 lb-in).

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

Scheme 529

Scheme 530

General Equipment

PARTS DESCRIPTION CHART

MATERIAL SPECIFICATIONS

Scheme 531

PARTS DESCRIPTION CHART

Scheme 532

PARTS DESCRIPTION CHART

Scheme 533

PARTS DESCRIPTION CHART

Scheme 534

PARTS DESCRIPTION CHART

Scheme 535

Scheme 536

Scheme 537

Scheme 538

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

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Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

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 number 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 upper main bearings into the cylinder block and lubricate them with clean engine oil.
7. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.
8. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.
9. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.
10. Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.
11. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
12. Install the 12 bolts.
13. Install the 12 dowel pins so that the flat sides face the crankshaft. Install the 12 cross-mounted bolts.
14. Tighten fasteners 1 through 12 in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
15. Tighten fasteners 13 through 24 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.
16. 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) .
17. Assemble the 10 pistons. For additional information, refer to «PISTON»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
18. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
19. Make sure the dimple in the piston faces the front of the engine.
20. Use the Connecting Rod Guides and Piston Ring Compressor to install the connecting rod with the upper connecting rod bearing in place. Lubricate the piston, connecting rod bearing and rings with clean engine oil prior to installation.
21. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Guides.
22. Install the connecting rod bearings, position the connecting rod caps and loosely install the 2 new bolts for each connecting rod. Lubricate the connecting rod bearing with clean engine oil prior to installation.
23. Tighten the connecting rod bolts in the sequence shown in illustration. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
24. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
25. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and the 4 bolts. Tighten the front bolts to 25 Nm (18 lb-ft). Tighten the rear nut to 48 Nm (35 lb-ft).
26. Position the oil pump and install the 3 bolts loosely. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
27. Position the crankshaft with the keyway at the 12 o'clock position.
28. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and loosely install the 20 cylinder head bolts.
29. Tighten the bolts in 3 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
30. Install the insert into the LH cylinder head.
31. Position the oil level indicator tube and install the nut. Tighten to 25 Nm (18 lb-ft).
32. Install the bolt attaching the oil level indicator tube to the LH cylinder head. Tighten to 10 Nm (89 lb-in).
33. Install 20 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
34. Position a new gasket, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
35. Position a new gasket, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
36. Compress the tensioner plunger, using a vise.
37. Install a retaining clip on the tensioner to hold the plunger in during installation.
38. If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
39. Install the timing chain guides and the 4 bolts. Tighten to 10 Nm (89 lb-in).
40. Preposition the LH camshaft until the timing mark is approximately at 12 o'clock and preposition the RH camshaft until the timing mark is approximately at 11 o'clock.
41. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
42. Install the crankshaft sprocket, making sure the flange faces forward.
43. Install the lower end of the LH timing chain, aligning the timing marks.
44. Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
45. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
46. Install the RH (outer) timing chain on the crankshaft sprocket.
47. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
48. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
49. Remove the retaining clips from the RH and LH timing chain tensioners.
50. Check for correct alignment of all timing marks.
51. Install the crankshaft sensor ring on the crankshaft.
52. Lubricate the balance shaft journals with clean engine oil.
53. Position the balance shaft on the journals.
54. Align the timing mark on the balance shaft with the camshaft timing mark as shown in illustration.
55. Install the balance shaft bearing caps in their original locations and tighten the 6 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
56. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
57. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
58. Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.
59. Repeat the previous 3 steps for each of the camshaft roller followers.
60. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown in illustration.
61. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.
62. Tighten the 15 engine front cover fasteners in sequence in 2 stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 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 50 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50 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 54 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 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
63. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
64. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
65. Position the valve covers.
66. Tighten the 28 fasteners in the sequence shown in illustration.
67. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
68. Install the oil pump screen and pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
69. 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).
70. 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).
71. Position the coolant pump pulley on the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
72. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
73. Using the Crankshaft Vibration Damper Installer, Crankshaft Front Oil Seal Installer and the Front Cover Oil Seal Installer, install a new crankshaft front seal.
74. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
75. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
76. 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 without exceeding 200 Nm (148 lb-ft).
77. Position the RH engine support insulator and install the 4 bolts. Tighten to 80 Nm (59 lb-ft).
78. Position the LH engine support insulator and install the 4 bolts. Tighten to 80 Nm (59 lb-ft).
79. Install the radio frequency interference capacitor and the nut. Tighten to 25 Nm (18 lb-ft).
80. Position the engine control sensor wiring harness and connect all of the harness routing clips and connector retainers.
81. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
82. Connect the CMP electrical connector.
83. Connect the RH radio frequency interference capacitor electrical connector.
84. Connect the Knock Sensor (KS) electrical connector, if equipped.
85. Connect the CKP sensor electrical connector.
86. Connect the Engine Oil Pressure (EOP) switch electrical connector.
87. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
88. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
89. Using the Engine Lifting Bracket Set, remove the engine from the work stand.
90. Inspect the 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.
91. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
92. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
93. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
94. Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
95. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft rear oil slinger.
96. 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.
97. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
98. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
99. Install a new oil pan gasket and the oil pan and loosely install the 18 bolts.
100. Tighten the 18 bolts in the sequence shown in illustration in 3 stages. 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.
101. Install the oil drain plug. Tighten to 23 Nm (17 lb-ft).
102. Lower the engine onto wooden blocks.
103. Install the Engine Lifting Bracket and raise the engine.
104. Position the flexplate and tighten the 8 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).
105. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Clutch 303-478 (T94T-6312-AH) Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Wrench, Fan Clutch Nut 303-214 (T83T-6312-B)

Scheme 570

Scheme 571

MATERIAL SPECIFICATIONS

Scheme 572

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

1. Position the engine in the vehicle.
2. Remove the floor crane and the jack supporting the transmission.
3. Position the shifter cable support bracket and install the 2 transmission-to-engine bolts. Tighten to 47 Nm (35 lb-ft).
4. Install the RH lower transmission-to-engine bolt. Tighten to 47 Nm (35 lb-ft).
5. Install the 4 engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
6. Install the shift cable to the mounting bracket and shift linkage.
7. Install 4 new torque converter nuts. Rotate the crankshaft to access all of the torque converter nuts. Tighten to 40 Nm (30 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. Position the exhaust Y-pipe and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
12. Position a new oil cooler on the oil filter adapter and install the threaded insert. Tighten to 58 Nm (43 lb-ft).
13. Install a new oil filter. Tighten to 16 Nm (142 lb-in).
14. Connect the 2 oil cooler coolant hoses.
15. Position the transmission fluid cooler tube support bracket and install the nut. Tighten to 30 Nm (22 lb-ft).
16. Using the Teflon Seal Installer Set, install a new Teflon® seal on the power steering pressure tube.
17. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump. Tighten to 20 Nm (177 lb-in).
18. Install and tighten the oil drain plug. Tighten to 23 Nm (17 lb-ft).
19. Position the fuel tube support bracket and install the 4 upper transmission-to-engine bolts. Tighten to 47 Nm (35 lb-ft).
20. Position the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
21. Connect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and retainer.
22. Position the transmission wiring harness and connect the transmission wiring harness retainer.
23. Connect the LH HO2S sensor electrical wiring harness retainer to the rear of the LH cylinder head.
24. Connect the transmission wiring harness retainers to the engine wiring harness.
25. Insert the heater outlet tube over the new seals.
26. Install the 2 heater outlet tube studs. Tighten to 40 Nm (30 lb-ft).
27. Connect the hose to the heater outlet tube.
28. Connect the RH HO2S sensor wiring harness retainer to the heater coolant outlet tube bracket.
29. Connect the RH HO2S electrical connector and install the transmission fluid filler tube.
30. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator. Connect the rear heater hose hanger. Install the fluid level indicator.
31. Install the engine oil filler tube support strap bolt. Tighten to 10 Nm (89 lb-in).
32. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket. Tighten to 25 Nm (18 lb-ft).
33. Position the generator wiring harness and connect the generator wiring harness retainer.
34. Connect the engine wiring harness electrical connectors.
35. Connect the engine wiring harness retainer and the 2 PCM electrical connectors.
36. Connect the lower radiator hose to the oil filter adapter coolant inlet.
37. Position the lower radiator support and install the 12 bolts. Tighten to 20 Nm (177 lb-in).
38. Position the wiring harness and connect the 4 wiring harness retainers.
39. Connect the 2 headlamp wiring harness retainers and position the ground wire and install the bolt. Tighten to 10 Nm (89 lb-in).
40. Position the upper radiator support and install the 8 bolts. Tighten to 20 Nm (177 lb-in).
41. Position the 2 upper radiator support plates and install the 4 bolts. Tighten to 20 Nm (177 lb-in).
42. Position the RH and LH air deflectors and install the pin-type retainers.
43. Position the transmission fluid cooler and install the bolt. Tighten to 10 Nm (89 lb-in).
44. Connect the transmission fluid cooler hose retainers.
45. Connect the horn electrical connector.
46. Connect the front impact severity sensor electrical connector.
47. If equipped, connect the air temperature sensor electrical connector.
48. Route the battery feed wiring harness to the Power Distribution Box (PDB) and insert the routing clips.
49. Install the battery feed cable to the PDB and the nuts. Tighten to 8 Nm (71 lb-in).
50. Position the power steering reservoir and install the 3 bolts. Tighten to 20 Nm (177 lb-in).
51. Position the hood latch. Install the 2 bolts. Connect the cable position retainer. Tighten to 12 Nm (106 lb-in).
52. 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).
53. 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).
54. If equipped, connect the compressor suction tube and install the nut. Tighten to 15 Nm (133 lb-in).
55. If equipped, connect the A/C pressure cutoff switch electrical connector.
56. Position the radiator in the vehicle.
57. Position the radiator support brackets and install the 4 bolts. Tighten to 20 Nm (177 lb-in).
58. 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).
59. Connect the degas bottle hose and power steering hose retainers to the fan shroud.
60. Using the Fan Clutch Holding Wrench and Fan Clutch Nut Wrench, install the fan blade and the fan clutch. Tighten to 133 Nm (98 lb-ft).
61. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
62. 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) .
63. Connect the transmission cooler tubes.
64. Connect the lower radiator hose to the radiator. Connect the hose. Connect the hose hanger.
65. 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) .
66. 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) .
67. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .
68. Fill the engine with clean engine oil.
69. Start the engine and check for leaks. Stop the engine and recheck the all fluid levels.
70. Fill the transmission with clean transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(ref-370579) .
71. 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) .
72. 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) .
73. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

SPECIAL TOOL(S) DESCRIPTION CHART Alignment Pins, Cylinder Head 303-1040 (SR-015486) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Engine Lifting Bracket 303-F047 (014-00073) or equivalent Holding Tool, Crankshaft 303-448 (T93P-6303-A) 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) Set, Engine Lifting Bracket 303-DS086 (D93P-6001-A) Strap Wrench 303-D055 (D85L-6000-A)

PARTS DESCRIPTION CHART

MATERIAL SPECIFICATIONS

Both cylinder heads

Scheme 580

Scheme 581

Scheme 582

Scheme 583

1. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely. LH cylinder head
2. Tighten the 12 cylinder head 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. RH cylinder head
3. Tighten the 12 cylinder head 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. Both cylinder heads
4. Install the 20 hydraulic lash adjusters in their original locations. RH cylinder head
5. Install 10 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
6. Position a new gasket, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft). LH cylinder head
7. Install the insert into the LH cylinder head.
8. Install 10 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
9. Position a new gasket, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft). Both cylinder heads
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.
13. Install the timing chain guides and the 4 bolts. Tighten to 10 Nm (89 lb-in).
14. Preposition the LH camshaft until the timing mark is approximately at 12 o'clock and preposition the RH camshaft until the timing mark is approximately at 11 o'clock.
15. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
16. Install the crankshaft sprocket, making sure the flange faces forward.
17. Install the lower end of the LH timing chain, aligning the timing marks.
18. Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
19. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
20. Install the RH (outer) timing chain on the crankshaft sprocket.
21. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
22. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
23. Remove the retaining clips from the RH and LH timing chain tensioners.
24. Check for correct alignment of all timing marks.
25. Install the crankshaft sensor ring on the crankshaft.
26. Lubricate the balance shaft journals with clean engine oil.
27. Position the balance shaft on the journals.
28. Align the timing mark on the balance shaft with the camshaft timing mark as shown in illustration.
29. Install the balance shaft bearing caps in their original locations and tighten the 6 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
30. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
31. Use the Valve Spring Compressor to compress the valve springs, and install each of the camshaft roller followers.
32. Install the 10 spark plugs. For additional information, refer to «ENGINE IGNITION - 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/ignition-system/#engine-ignition-system-68l-e-series) .
33. 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.
34. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.
35. Tighten the 15 engine front cover fasteners in sequence in 2 stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 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 50 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50 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 54 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 54 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
36. 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.
37. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
38. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
39. Position the valve covers.
40. Tighten the 14 fasteners for each valve cover in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
41. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
42. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
43. Using the Crankshaft Vibration Damper Installer, Crankshaft Front Oil Seal Installer and the Front Cover Oil Seal Installer, install a new crankshaft front seal.
44. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
45. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
46. 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 without exceeding 200 Nm (148 lb-ft).
47. Position the coolant pump pulley on the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
48. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
49. Position the oil level indicator tube.
50. Install the bolt attaching the oil level indicator tube to the LH cylinder head. Tighten to 10 Nm (89 lb-in).
51. Install the oil level indicator and tube support bracket nut. Tighten to 25 Nm (18 lb-ft).
52. Install the radio frequency interference capacitor and the nut. Tighten to 25 Nm (18 lb-ft).
53. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
54. Connect the CKP sensor electrical connector.
55. Connect the Engine Oil Pressure (EOP) switch electrical connector.
56. Connect the Knock Sensor (KS) electrical connector, if equipped.
57. Connect the CMP electrical connector.
58. Connect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
59. If equipped, install the cylinder block drain plugs. Tighten to 24 Nm (18 lb-ft).
60. If equipped with cylinder block drain plugs, position the RH engine support insulator and install the 3 bolts. Tighten to 80 Nm (59 lb-ft).
61. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
62. Install the Engine Lifting Bracket from the Engine Lifting Bracket Set.
63. Using the Engine Lifting Bracket Set, remove the engine from the work stand.
64. Lower the engine onto wooden blocks.
65. Install the Engine Lifting Bracket and raise the engine.
66. Position the flexplate and tighten the 8 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).
67. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) .

See also:
• INTRODUCTION - GASOLINE MODELS
• ENGINE SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• INTERIOR TRIM AND ORNAMENTATION
• ENGINE COOLING
• INTAKE AIR DISTRIBUTION & FILTERING
• FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL
• JACKING & LIFTING
• ENGINE IGNITION - 6.8L
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• STARTING SYSTEM - GASOLINE ENGINES
• BUMPERS
• FRONT END BODY PANELS
• STEERING SYSTEM
• VALVE COVER - LH