Engine - 4.6l and 5.4l Ford Cutaway E350

GENERAL SPECIFICATIONS - LUBRICANTS AND SEALANTS

GENERAL SPECIFICATIONS - LUBRICANTS AND SEALANTS

GENERAL SPECIFICATIONS - ENGINE (4.6L)

GENERAL SPECIFICATIONS - ENGINE (4.6L)

GENERAL SPECIFICATIONS - ENGINE (5.4L)

GENERAL SPECIFICATIONS - ENGINE (5.4L)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 67

Engine Component View

The concept of modularity allows engine designs to share communization between concepts and engine hardware. The four modules are the

1. intake module
2. cylinder head module (RH)
3. cylinder head module (LH)
4. lower engine module

The modular engine concept supports efficiencies during repairs by allowing the removal and installation of these modules. While not all in-vehicle repairs can take advantage of the modular concept, most out-of-vehicle repairs benefit in reduction of time and labor needed to repair the engine.

The basic engine components consist of

1. single overhead camshafts.
2. two valves per cylinder.
3. sequential multiport fuel injection (SFI).
4. aluminum cylinder heads.
5. individual ignition coils for each spark plug.
6. cast iron, 90-degree V-cylinder block.
7. on 4.6L engines, two-piece intake manifold system.
8. composite-material lower intake manifold with noise insulator.
9. large-bore throttle body.

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

For driveability concerns, see INTRODUCTION - GASOLINE article.

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1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
5. Position the engine air cleaner (ACL). Remove the four bolts. Loosen the clamp. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the engine vent tube. Loosen the clamp and remove the air cleaner outlet pipe.
8. Remove the bolt for the transmission fluid level indicator and tube.
9. Remove the bolt for the transmission fluid level indicator and tube. Position the transmission fluid indicator and tube aside.
10. Compress and slide the hose clamp and disconnect the upper radiator hose.
11. Disconnect the coolant hose.
12. Disconnect the electronic throttle body (TB) electrical connector.
13. Disconnect the throttle position (TP) sensor electrical connector.
14. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
15. Disconnect the vacuum hoses from the EGR system module valve.
16. Remove the exhaust manifold to EGR system module tube. Disconnect the upper and lower fittings. Remove the tube.
17. Disconnect the following hoses: The brake booster vacuum hose. The positive crankcase ventilation (PCV) valve hose. The coolant hoses.
18. Disconnect the vacuum harness connector.
19. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information) .
20. Disconnect the emissions vapor hose.
21. Remove the four bolts, and the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
22. Disconnect the eight coil-on-plug electrical connectors.
23. Disconnect the eight fuel injector electrical connectors.
24. Remove the eight bolts and the eight ignition coils.
25. Remove the bolts and the generator upper support bracket.
26. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
27. Remove the bolts, thermostat housing and thermostat. Discard the O-ring seal.
28. Remove the nine bolts.
29. Remove the intake manifold assembly. Lift the intake manifold. Remove the intake manifold and discard the gaskets. Inspect the intake manifold assembly for damage.

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1. Clean all the sealing surfaces.
2. Install the upper intake manifold. Position the new intake manifold gaskets. Position the upper intake manifold. Loosely install nine bolts.
3. Install the thermostat. Install the thermostat. Install a new O-ring seal.
4. Install the thermostat housing and loosely install the bolts.
5. Tighten the 11 bolts in two stages in the sequence see scheme 41 Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
6. Connect the fuel pressure sensor electrical connector and the vacuum hose.
7. Install the generator upper support bracket.
8. Install the eight ignition coils and bolts.
9. Connect the eight fuel injector electrical connectors.
10. Connect the eight coil-on-plug electrical connectors.
11. Position a new throttle body adapter gasket and throttle body adapter assembly. Install the four bolts.
12. Connect the emissions vapor hose.
13. Connect the vacuum harness connector.
14. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information).
15. Connect the following vacuum hoses: The brake booster vacuum hose. The positive crankcase ventilation (PCV) valve hose. The coolant hoses.
16. Install the exhaust manifold to EGR system module tube. Hand-tighten the upper and lower fittings. Tighten to 40 Nm (30 lb-ft).
17. Connect the vacuum hoses at the EGR system module.
18. Connect the EGR system module electrical connector.
19. Connect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information).
20. Connect the TP sensor electrical connector. Push in the red clip.
21. Connect the electronic throttle body electrical connector. Push in the red clip.
22. Connect the coolant hose.
23. Install the upper radiator hose and position the clamp.
24. Position back the transmission fluid indicator and tube. Install the retaining bolt.
25. Install the bolt for the transmission fluid tube and indicator.
26. Install the air cleaner outlet pipe and tighten the clamp. Connect the engine vent tube.
27. Connect the MAF sensor and position the ACL.
28. Install the ACL. Install the four bolts. Tighten the clamp.
29. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
30. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).
31. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling).

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1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
5. Position the engine air cleaner (ACL). Remove the four bolts. Loosen the clamp. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the engine vent tube. Loosen the clamp and remove the air cleaner outlet pipe.
8. Disconnect the electronic throttle body (TB) electrical connector.
9. Disconnect the throttle position (TP) sensor electrical connector.
10. Compress and slide the hose clamp and disconnect the upper radiator hose.
11. Disconnect the coolant hose.
12. If equipped, disconnect the coolant hoses from the TB.
13. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system. Disconnect the electrical connector. Disconnect the two hoses.
14. Remove the differential pressure feedback EGR system bracket.
15. Remove the bolts and the generator upper support bracket.
16. Remove the retaining bolt for the transmission fluid indicator and tube.
17. Remove the nut for the transmission fluid indicator and tube. Position the transmission fluid indicator and tube aside.
18. Disconnect the evaporative emissions hose.
19. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information) .
20. Disconnect the EGR vacuum regulator solenoid connections.
21. Press the tab, remove and position aside the evaporative emission canister purge valve.
22. Disconnect the EGR valve vacuum hose.
23. Disconnect the brake booster and main engine vacuum harness and position aside.
24. Remove the exhaust manifold-to-EGR valve tube. Disconnect the upper fitting. Disconnect the lower fitting and remove the tube.
25. Remove the four bolts, and the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
26. Disconnect and remove the positive crankcase ventilation (PCV) hose.
27. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
28. Disconnect the eight ignition coil electrical connectors.
29. Disconnect the eight fuel injector electrical connectors.
30. Remove the eight bolts and the eight ignition coils.
31. Remove the bolts, the thermostat housing and the thermostat. Disconnect the O-ring seal.
32. Remove the nine bolts retaining the intake manifold.
33. Remove the intake manifold. Discard the intake manifold gaskets.
34. Inspect the throttle body, the intake manifold and their sealing surfaces for damage.

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1. Clean and inspect all sealing surfaces.
2. Position the intake manifold gaskets and the intake manifold.
3. Loosely install the nine bolts.
4. Install the thermostat. Install the thermostat. Install a new O-ring seal.
5. Loosely install the thermostat housing and bolts.
6. Tighten the bolts in two stages, in the sequence see scheme 97 Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
7. Install the eight ignition coils and bolts.
8. Connect the eight fuel injector electrical connectors.
9. Connect the eight ignition coil electrical connectors.
10. Connect the fuel pressure sensor vacuum hose and electrical connector.
11. Install the PCV hose and valve.
12. Install the new throttle body adapter gasket.
13. Install the throttle body and adapter assembly. Install the four bolts.
14. Install the exhaust manifold-to-EGR valve tube and tighten the fitting in two stages. Stage 1: Hand-tighten the fittings. Stage 2: Tighten to 50 Nm (37 lb-ft).
15. Connect the brake booster and the main engine vacuum harnesses.
16. Connect the EGR vacuum hose.
17. Install the evaporative emission canister purge valve.
18. Connect the EGR vacuum regulator solenoid connections.
19. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information).
20. Connect the evaporative emissions hose on the intake manifold.
21. Position back the transmission fluid indicator and tube. Install the retaining nut.
22. Install the transmission fluid filler tube bracket and bolt.
23. Install the generator upper support bracket.
24. Install the differential pressure feedback EGR system bracket.
25. Connect the differential pressure feedback EGR sensor. Connect the electrical connector. Connect the two hoses.
26. If equipped, connect the coolant hoses to the TB.
27. Connect the coolant hose.
28. Connect the upper radiator hose.
29. Connect the TP sensor electrical connector. Push back the red clip.
30. Connect the electronic TB electrical connector. Push back the red clip.
31. Install the air cleaner outlet pipe and tighten the clamp. Connect the engine vent tube.
32. Connect the MAF sensor and position the ACL.
33. Install the ACL. Install the four bolts. Tighten the clamp.
34. Connect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information).
35. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
36. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).
37. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling).

Material

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Remove the crankcase ventilation tube from the valve cover.
5. Remove the retaining nut for the oil level indicator and tube.
6. Remove the bolt and position back the oil level indicator and tube.
7. Remove the EGR system module tube. Disconnect the upper and lower fittings. Remove the tube.
8. Disconnect the differential pressure EGR feedback sensor hose from the EGR valve tube.
9. Remove the EGR valve tube. Disconnect the upper and lower fittings. Remove the tube.
10. Remove the retaining nut for the oil level indicator and tube.
11. Remove the bolt and position the oil level indicator and tube.
12. Disconnect the LH fuel injector electrical connectors, ignition coil electrical connectors and the wire harness retainers.
13. Disconnect the camshaft position (CMP) sensor.
14. Disconnect the LH radio interference capacitor.
15. Position the engine control wiring harness off of the valve cover.
16. Disconnect the wiring harness from the power train control module (PCM) bracket.
17. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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1. If a new gasket is being installed, 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 two places where the engine front cover meets the cylinder head.
3. Position the valve cover and gasket on the cylinder head. Loosely install the bolts.
4. Tighten the bolts in the sequence (Scheme 155)
5. Tighten the bolts in the sequence (Scheme 156)
6. Connect the wiring harness to the PCM bracket.
7. Position the engine control wiring harness onto the valve cover.
8. Connect the LH radio interference capacitor electrical connector.
9. Connect the CMP electrical connector.
10. Connect the LH ignition coil and fuel injector electrical connectors and the wiring harness retainers.
11. Install the EGR system module tube. Hand-tighten the upper and lower fittings. Tighten to 40 Nm (30 lb-ft).
12. Position back the oil level indicator and tube. Install the bolt.
13. Install the retaining nut for the oil level indicator and tube.
14. Position back the oil level indicator and tube. Install the bolt.
15. Install the retaining nut for the oil level indicator and tube.
16. Install the EGR valve tube. Hand-tighten the upper and lower fittings. Tighten to 50 Nm (37 lb-ft).
17. Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.
18. Connect the crankcase ventilation tube to the valve cover.
19. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering).
20. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Disconnect the hose and position it aside, then remove the PCV valve from the valve cover.
5. Remove the clamp and oil filler tube from the valve cover.
6. Disconnect the engine wiring harness electrical connectors.
7. Disconnect the electrical connectors from the bracket. Remove the retaining nut, ground strap and bracket.
8. Remove the fuel charging wiring harness from the valve cover studs and position aside.
9. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 158

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Scheme 161

1. If a new gasket is being installed, 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 two places where the engine front cover meets the cylinder head.
3. Position the valve cover on the cylinder head, and install the bolts loosely.
4. Tighten the bolts in the sequence see scheme 166
5. Install the PCV valve in the valve cover and connect the hose.
6. Install the fuel charging wiring on the valve cover studs.
7. Install the bracket, ground strap and retaining nut. Connect the electrical connects to the bracket.
8. Connect the engine wiring harness electrical connectors.
9. Install the oil filler tube and clamp on the valve cover.
10. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering).
11. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).

MATERIAL SPECIFICATION

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Disconnect the oil fill tube.
5. Disconnect the crankcase ventilation tube.
6. Disconnect the electronic throttle body (TB) electrical connector.
7. Disconnect the throttle position (TP) sensor electrical connector.
8. Disconnect the fuel rail pressure and temperature sensor electrical connector.
9. Disconnect the engine wiring harness connectors.
10. Disconnect the engine wiring harness connectors. Remove the retaining nut, ground strap and bracket.
11. Disconnect the radio ignition interference capacitor.
12. Remove the pushpin retainers and the splash shield.
13. Disconnect the A/C compressor connector and the crankshaft position sensor connector. Remove the tie-strap.
14. Remove the fuel charging wiring from the valve cover studs.
15. Disconnect the RH fuel injector connectors.
16. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V)»(/ford/cutaway-e350/2004-2007/remont/ignition-system/#engine-ignition-46l-2v-and-54l-2v) .
17. Position the fuel charging wiring in the passenger compartment.
18. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 170

1. If a new gasket is being installed, 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 two places where the engine front cover meets the cylinder head.
3. Position the valve cover on the cylinder head and loosely install the bolts.
4. Tighten the bolts in the sequence (Scheme 179)
5. Position the fuel charging wiring on the engine.
6. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V)»(/ford/cutaway-e350/2004-2007/remont/ignition-system/#engine-ignition-46l-2v-and-54l-2v).
7. Connect the RH fuel injector connectors.
8. Position the fuel charging wiring on the valve cover studs.
9. Connect the A/C compressor and the crankshaft position sensor electrical connectors. Install a tie-strap.
10. Position the splash shield and install the pushpin retainers.
11. Connect the radio ignition interference capacitors.
12. Install the bracket, ground strap and retaining nut. Connect the electrical connectors to the bracket.
13. Connect the engine wiring harness electrical connectors.
14. Connect the fuel rail pressure and temperature sensor electrical connector.
15. Connect the TP sensor electrical connector.
16. Connect the electronic TB electrical connector.
17. Install the crankcase ventilation tube.
18. Connect the oil fill tube.
19. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
20. Install the air cleaner outlet pipe and the engine air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering).
21. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).

Special Tool(s)

SPECIAL TOOLS Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)

Scheme 171

MATERIAL SPECIFICATION

Scheme 172

1. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
3. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
4. Remove and discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

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Scheme 174

1. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install a new crankshaft pulley bolt. Tighten the bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Lower the vehicle.
5. Install the drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
6. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

SPECIAL TOOLS Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)

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MATERIAL SPECIFICATION

Scheme 178

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Using the special tool, remove the crankshaft front seal.

Scheme 179

Scheme 180

1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal into the engine front cover.
3. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

MATERIAL SPECIFICATION

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Scheme 187

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove both of the valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) , «VALVE COVER - RH, 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «VALVE COVER - RH, 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Remove the radiator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
5. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
6. Remove the top bolts and the lower bolt and position the power steering pump aside.
7. Disconnect the crankshaft position (CKP) sensor electrical connector.
8. Remove the drain plug and drain the engine oil.
9. Remove the oil pan front bolts.
10. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
11. Disconnect the camshaft position (CMP) sensor electrical connector.
12. Remove the bolt and the belt idler pulley.
13. Remove the bolts.
14. 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 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

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 (Scheme 204)
2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.
3. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
4. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
5. Position the belt idler pulley and install the bolt.
6. Connect the CMP electrical connection.
7. Install a new crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
8. Loosely install the bolts, then tighten the bolts in two stages following the sequence (Scheme 209) Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
9. Connect the crankshaft position sensor electrical connector.
10. Position the power steering pump and install the bolts.
11. Install the drain plug.
12. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l), «VALVE COVER - RH, 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «VALVE COVER - RH, 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
13. Fill the engine with clean engine oil.
14. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling).
15. Install the radiator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling).
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).

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

Scheme 194

Scheme 195

MATERIAL SPECIFICATION

Removal

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft with the keyway at the 12 o'clock position.
4. Install and fully tighten the special tools on both camshafts.
5. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
6. Remove the RH and LH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket.
7. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. Remove the tensioner from the vise.
4. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
5. Install the timing chain guides.
6. Install the special tool.
7. Pre-position the camshafts. Rotate the LH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.
8. Position the crankshaft so the number one cylinder is at TDC with the special tool.
9. Remove the special tool.
10. Install the crankshaft sprocket, making sure the flange faces forward.
11. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
12. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
13. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
14. Remove the retaining clip from the LH timing chain tensioner.
15. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) link on the timing chain.
16. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
17. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
18. Remove the retaining clip from the RH timing chain tensioner.
19. Remove the special tool.
20. As a post-check, verify correct alignment of all timing marks.
21. Remove the special tool.
22. Position the crankshaft sensor ring on the crankshaft.
23. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

SPECIAL TOOLS Aligner, Camshaft 303 - 380 (T91P-6256-A) Aligner, Camshaft Pulley 303 - 413 (T92P-6256-A) Holding Tool, Crankshaft 303 - 448 (T93P-6303-A)

MATERIAL SPECIFICATION

Scheme 211

Scheme 212

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.
4. Install the special tools on the camshaft.
5. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
6. Remove the timing chains and crankshaft sprocket.
7. Remove the timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
4. Install the crankshaft sprocket, making sure the flange faces forward.
5. Install the timing chain guide. Position LH timing chain guide. Install and tighten the bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
6. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
7. Remove the special tool.
8. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
9. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
10. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
11. Remove the retaining clip from the LH timing chain tensioner.
12. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
13. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
14. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
15. Remove the retaining clip from the RH timing chain tensioner.
16. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
17. Remove special tools from the camshaft.
18. Install the crankshaft sensor ring on the crankshaft.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

SPECIAL TOOLS Compressor, Valve Spring 303 - 567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303 - 382 (T91P-6565-AH)

Scheme 220

Scheme 221

Scheme 222

Scheme 223

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Position the piston at the top of the stroke.
3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal.
4. Use the special tool to compress the valve springs.
5. Remove the valve springs. Remove the valve spring retainer keys. Remove the valve spring retainers. Remove the valve springs.

Scheme 224

Scheme 225

Scheme 226

1. Position the valve spring and the valve spring retainers.
2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
3. Use the special tool to compress the valve spring. Install the valve spring retainer keys.
4. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
5. Install the spark plug.

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

Scheme 227

1. Remove the valve springs. For additional information, refer to «VALVE SPRINGS»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the valve stem seals.

Installation

1. Use the special tools to install the valve stem seals.
2. Install the valve springs. For additional information, refer to «VALVE SPRINGS»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the valve tappets.

Scheme 228

1. Install the valve tappets in their original locations.
2. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

SPECIAL TOOLS Compressor, Valve Spring 303 - 567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303 - 382 (T91P-6565-AH)

Scheme 229

Scheme 230

1. Remove the valve cover (6582). For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) , «VALVE COVER - RH, 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «VALVE COVER - RH, 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Position the piston (6108) of the cylinder being repaired at the bottom of the stroke.
3. Install the special tool between the valve spring coils to prevent valve stem seal damage.
4. Use the special tool to compress the valve springs (6513) and remove the camshaft roller followers.

Scheme 231

Scheme 232

1. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers.
2. Remove the special tool.
3. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) , «VALVE COVER - RH, 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «VALVE COVER - RH, 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

MATERIAL SPECIFICATION

Scheme 233

Scheme 234

Scheme 235

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) . CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed, may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur.
2. Remove the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Remove the camshaft sprocket. Remove the bolt. Remove the camshaft sprocket.
4. Remove the bolts, the 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. Remove the bolts, the bearing caps and the camshaft.
7. 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.

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

1. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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 camshaft bearing caps. Install the bolts loosely.
4. Tighten the bolts in the sequence (Scheme 257)
5. Install the camshaft sprocket. Install the sprocket. Install and tighten the bolt in two stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
6. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
7. Tighten the bolts in the sequence (Scheme 260)
8. Install the timing chains. For additional information, refer to «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
9. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

Scheme 242

Scheme 243

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting).
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).
3. Remove the four exhaust Y-pipe-to-exhaust manifold nuts.
4. Remove the eight nuts and the exhaust manifold.
5. Remove and discard the exhaust manifold gasket.
6. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information).
7. To install, reverse the removal procedure. Tighten the exhaust manifold nuts in the sequence see scheme 304

Scheme 244

Scheme 245

Scheme 246

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Remove the EGR system module tube. Disconnect the upper and lower fittings. Remove the tube. Windsor engine (5.4L)
4. Disconnect the differential pressure feedback EGR sensor hoses from the EGR valve tube.
5. Disconnect the upper and lower fittings and remove the EGR valve tube.
6. Remove the nuts.
7. Remove the nuts and the exhaust manifold.
8. Remove and discard the exhaust manifold gasket.
9. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .

Scheme 247

Scheme 248

1. Position the exhaust manifold gasket.
2. Position the exhaust manifold and loosely install the nuts.
3. Tighten the nuts in the sequence (Scheme 264)
4. Install the three-way catalytic converter to exhaust manifold nuts.
5. Install the EGR valve fittings in two stages. Stage 1: Hand-tighten the fittings. Stage 2: Tighten the lower fitting to 50 Nm (37 lb-ft).
6. Connect the differential pressure feedback EGR sensor hoses to the EGR valve tube.
7. Install the EGR system module tube in two stages. Stage 1: Connect the upper and lower fittings and hand-tighten. Stage 2: Tighten to 40 Nm (30 lb-ft).
8. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).

MATERIAL SPECIFICATION

Scheme 249

Scheme 250

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Drain the engine oil.
4. Disconnect the coolant hoses.
5. Remove the oil filter.
6. Remove the threaded insert and the oil cooler.
7. Clean and inspect the oil cooler. Plug the coolant connections. Flush the oil passages with parts cleaner. If metal particles are present in the oil cooler, install a new cooler.

Scheme 251

1. Position the oil cooler on the oil filter adapter and install the threaded insert.
2. Install a new oil filter.
3. Connect the coolant hoses.
4. Install the oil drain plug.
5. Fill the engine with clean engine oil.
6. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

MATERIAL SPECIFICATION

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
4. Drain the engine oil.
5. Remove the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
6. Disconnect the coolant hoses.
7. Remove the oil filter.
8. Remove the threaded insert and the oil cooler. Clean and inspect the oil cooler.
9. Disconnect the oil pressure switch electrical connector.
10. Remove the oil pressure switch.
11. Disconnect the lower radiator hose.
12. Remove the nuts, bolts, oil filter adapter and gasket. Discard the gasket.
13. Remove the nut, bolts, oil filter adapter and gasket. Discard the gasket.
14. Clean the gasket surface at the cylinder block.

Scheme 259

Scheme 260

Scheme 261

1. Position the oil filter adapter gasket and the oil filter adapter. Install the nuts and bolts.
2. Position the oil filter adapter gasket and the oil filter adapter. Install the nut and bolts.
3. Connect the lower radiator hose.
4. Install the oil pressure switch.
5. Connect the oil pressure switch electrical connector.
6. Position the oil cooler on the oil filter adapter and install the threaded insert.
7. Install a new oil filter.
8. Connect the coolant hoses.
9. Install the left engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
10. Install the drain plug.
11. Fill the engine with clean engine oil.
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
13. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

MATERIAL SPECIFICATION

Scheme 262

1. Remove the engine air cleaner (ACL) and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
2. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Remove the oil level indicator and the retaining nut.
4. Remove the oil level indicator and the retaining nut.
5. Remove the bolt and the oil level tube. Remove and discard the O-ring seal.
6. Inspect the oil level indicator tube for damage.

1. Lubricate the new O-ring seal with clean engine oil.
2. Insert the oil level indicator tube and install the bolt.
3. Install the retaining nut and insert the oil level indicator.
4. Install the retaining nut and insert the oil level indicator.
5. Install the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
6. Install the ACL outlet pipe and the ACL. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .

SPECIAL TOOLS Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Heavy Duty Engine Support 303-F070 Lift Bar Adapter, Modular Engine 303-F694

Scheme 263

Scheme 264

MATERIAL SPECIFICATION

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Remove the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
4. Loosen the 2 bolts and position the generator aside.
5. Remove the retainers and the shield.
6. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
7. Disconnect the hose from the heater outlet tube.
8. Remove the heater outlet tube studs.
9. Remove the heater outlet tube.
10. Remove the two transmission-to-engine bolts.
11. Assemble the special tools.
12. Install the special tools.
13. Install the special tool and support the engine.
14. Drain the engine oil and remove the oil filter.
15. Remove the nut and position the transmission fluid cooler tubes and support bracket aside.
16. Remove the four engine mount nuts.
17. Remove the flexplate inspection plate.
18. Using the special tool, raise the engine 10-1/4 inches from the crankshaft pulley to the lower edge of the No. 1 crossmember.
19. Remove the bolts and partially lower the oil pan.
20. Remove the bolts retaining the oil pump screen cover and pickup tube and let the bolts drop into the oil pan.
21. Remove the oil pan at the rear of the engine.
22. Clean the oil pan thoroughly and inspect the oil pan gasket.

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

1. 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.
2. Position the oil pump screen and pickup tube in the oil pan and position the oil pan into the vehicle.
3. Install the oil pump screen and pickup tube.
4. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations see scheme 367
5. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations see scheme 368
6. Tighten the bolts in three stages, in the sequence see scheme 369 Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 90 degrees.
7. Install a new oil filter.
8. Lower the engine and remove the special tools.
9. Install the four engine mount nuts.
10. Install the flexplate inspection plate.
11. Position the transmission fluid cooler tubes and support bracket and install the nut.
12. Position the transmission fluid cooler tubes and support bracket and install the nut.
13. Install the transmission-to-engine bolts.
14. Insert the heater outlet tube over the new seals.
15. Install the heater outlet tube studs.
16. Install the heater outlet tube studs.
17. Connect the hose to the heater outlet tube.
18. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
19. Install the retainers and the shield.
20. Position the generator and tighten the bolts.
21. Install the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling).
22. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
23. Fill the engine with clean engine oil.
24. Start the engine and check for leaks.

Scheme 288

1. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) in this section.
2. Remove the crankshaft sprocket. For additional information, refer to «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Remove the bolts and the oil pump.

Scheme 289

1. Clean and inspect the mating surfaces.
2. Position the oil pump, and install the bolts loosely. Tighten the bolts in the sequence see scheme 384
3. Install the crankshaft sprocket. For additional information, refer to «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
4. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

Scheme 290

Scheme 291

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-4r70w-4r75w) .
2. Remove the bolts and the flexplate.
3. Remove the bolts and the flexplate.

Scheme 292

Scheme 293

1. Position the flexplate. Loosely install the bolts, then tighten the bolts in the sequence (Scheme 306)
2. Position the flexplate. Loosely install the bolts, then tighten the bolts in the sequence (Scheme 307)
3. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-4r70w-4r75w)..

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

Scheme 294

Scheme 295

Scheme 296

MATERIAL SPECIFICATION

Scheme 297

Scheme 298

1. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Using the special tools, remove the crankshaft rear oil slinger.
3. Using the special tools, remove the crankshaft rear oil seal.

Scheme 299

1. Clean and inspect the mating surface.
2. Using the special tools, install the crankshaft rear seal.
3. Using the special tools, install the crankshaft rear oil slinger.
4. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

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

MATERIAL SPECIFICATION

Scheme 300

1. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
3. Using the special tools, remove the crankshaft rear oil seal slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the six bolts and the crankcase rear seal retainer.

Scheme 301

1. Clean and inspect the mating surface.
2. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
3. Install the rear oil seal retainer and loosely install the six bolts.
4. Tighten the bolts in the sequence see scheme 398
5. Using the special tools, install the rear seal.
6. Using the special tools, install the crankshaft rear oil slinger.
7. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
8. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

SPECIAL TOOLS Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Heavy Duty Engine Support 303-F070 Lift Bar Adapter, Modular Engine 303-F694

Scheme 302

Scheme 303

Scheme 304

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the fan shroud and the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
4. Remove the bolts and the generator.
5. Remove the retainers and the shield.
6. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
7. Disconnect the hose from the heater outlet tube.
8. Remove the heater outlet tube studs.
9. Remove the heater outlet tube.
10. Remove the two transmission-to-engine bolts.
11. Assemble the special tools.
12. Install the special tools.
13. Install the special tool and support the engine.
14. Raise the vehicle on the hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
15. For the RH front engine support insulator, remove the starter motor. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(ref-231373) .
16. Remove the nuts.
17. For the LH engine support insulator, disconnect the engine oil pressure (EOP) sensor electrical connector.
18. For the LH engine support insulator, remove the EOP sensor.
19. Lower the vehicle.
20. Using the Heavy Duty Engine Support, raise the engine.
21. Raise the vehicle.
22. Remove the bolts and remove the insulators from the vehicle.

Scheme 305

Scheme 306

1. Position the insulators and install the bolts.
2. Lower the vehicle.
3. Using the Heavy Duty Engine Support, lower the engine.
4. Raise the vehicle.
5. Install the nuts.
6. For the LH engine support insulator, install the EOP sensor.
7. For the LH engine support insulator, connect the EOP electrical connector.
8. For the RH front engine support insulator, install the starter motor. For additional information, refer to «STARTING SYSTEM - GASOLINE ENGINES»(ref-231373) .
9. Lower the vehicle.
10. Remove the special tool.
11. Remove and disassemble the special tools.
12. Install the two transmission-to-engine bolts.
13. Insert the heater outlet tube over the new seals.
14. Install the heater outlet tube studs.
15. Install the heater outlet tube studs.
16. Connect the hose to the heater outlet tube.
17. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
18. Position the shield and install the retainers.
19. Position the generator and install the bolts.
20. Connect the generator electrical connections. Install the B+ terminal and the nut. Connect the S electrical connector. Connect the ASI electrical connector.
21. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
22. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .

SPECIAL TOOLS Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Wrench, Fan Clutch Nut 303 - 240 (T84T-6312-D) Holding Wrench, Fan Pulley 303-239 (T84T-6312-C)

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

1. Recover the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information).
2. With the vehicle in NEUTRAL, position it on a hoist, For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting).
3. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).
4. Remove the front bumper. For additional information, refer to «BUMPERS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#bumpers).
5. Disconnect the lower radiator hose from the radiator. Disconnect the hose hanger. Disconnect the hose.
6. Remove the pushpin retainers and the splash shield.
7. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
8. Disconnect the exhaust system from the LH and RH exhaust manifolds.
9. Drain the engine oil.
10. Disconnect the oil cooler hoses and set aside.
11. Remove the oil filter.
12. Loosen the threaded insert and remove and discard the oil cooler.
13. Remove the starter motor solenoid terminal cover.
14. Disconnect the starter motor electrical connections.
15. Remove the starter motor. Remove the stud bolt. Remove the two bolts. Remove the starter.
16. Remove the flexplate inspection cover.
17. Remove the cylinder block opening cover.
18. Remove the four nuts retaining the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts. Discard the torque converter nuts.
19. Disconnect the shift cable and the mounting bracket. Disconnect the clip. Remove the bolts.
20. Remove the two transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
21. Remove the RH lower transmission-to-engine bolt.
22. Remove the four engine mount nuts.
23. 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.
24. Remove the nut and position the transmission fluid cooler support bracket aside.
25. Remove the valance panel. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels).
26. Disconnect the upper radiator hose and the degas hose from the radiator.
27. Remove the fan blade assembly and fan clutch. Use the special tool to hold the coolant pump pulley. Using the special tool, remove the fan blade and the fan clutch.
28. Disconnect the degas hose retainer from the fan shroud.
29. Remove the fan shroud, fan and fan clutch. Remove the bolts. Lift the fan shroud, fan and fan clutch from the vehicle.
30. Remove the bolts and the radiator support brackets.
31. Remove the radiator from the vehicle.
32. Disconnect the A/C pressure cutoff switch electrical connector.
33. Disconnect the compressor suction tube.
34. Disconnect the condenser core refrigerant tubes. Disconnect the compressor discharge tube. Disconnect the condenser-to-evaporator tube.
35. Remove the A/C condenser core. Remove the bolts. Remove the A/C condenser brackets. Remove the A/C condenser core.
36. Set the hood latch aside. Remove the hood latch bolts. Disengage the cable routing clip.
37. Remove the bolts and set the power steering reservoir aside.
38. Remove the nuts and the battery feed cable at the power distribution box.
39. Set aside the battery feed wiring harness to the power distribution box. Disengage the routing clips.
40. If equipped, disconnect the air temperature sensor electrical connector.
41. Disconnect the front impact severity sensor electrical connector.
42. Disconnect the horn electrical connector.
43. Remove the eight bolts and the upper radiator support.
44. Remove the pin-type retainers and the RH and LH air deflectors.
45. Set aside the LH side of the headlamp dash panel junction wiring harness. Remove the screw. Disengage the routing clips.
46. Set aside the RH side of the headlamp dash panel junction wiring harness. Disconnect the electrical connector. Remove the screw. Disengage the routing clips.
47. Remove the 12 bolts and the lower radiator support.
48. Disconnect the lower radiator hose from the oil filter adapter water inlet and set aside.
49. Rotate the tensioner clockwise to release belt tension and remove the drive belt.
50. Disconnect the generator electrical connections. Remove the B+ terminal nut and disconnect the terminal. Disconnect the S electrical connector. Disconnect the ASI electrical connector.
51. Remove the bolts and the generator.
52. Disconnect the engine wiring harness from the powertrain control module (PCM) bracket.
53. Disconnect the PCM electrical connectors. Position the engine wiring on the engine.
54. Disconnect the engine wiring harness electrical connectors.
55. Disconnect the electrical connectors, remove the nut, ground strap and mounting bracket.
56. Remove the engine oil filler tube support strap bolt.
57. 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.
58. Disconnect the evaporative emission canister purge valve electrical connector.
59. Remove the nut and the transmission fluid filler tube, and allow the fluid to drain into a suitable container.
60. Release the wiring retainers from the heater outlet tube bracket. Release the knock sensor electrical connector retainer. Release the engine harness routing clip retainer.
61. Disconnect the hose from the heater outlet tube.
62. Remove the heater outlet tube studs.
63. Remove the heater outlet tube.
64. Release the transmission wiring harness connector retainer from the bracket. Disconnect the transmission wiring harness and the LH and RH heated oxygen sensor (HO2S) electrical connectors.
65. Remove the four upper transmission-to-engine bolts and the fuel line, and the LH HO2S brackets.
66. Install the special tool see scheme 491
67. Support the transmission with a jack.
68. Remove the engine from the vehicle.

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

Scheme 344

Scheme 345

Scheme 346

MATERIAL SPECIFICATION

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

1. Remove the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
5. Install the special tool.
6. Install the special tool.
7. Mount the engine on a suitable work stand.
8. Remove the special tool.
9. Remove the special tool.
10. Remove the RH engine mount.
11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Disconnect the RH radio frequency interference capacitor electrical connector.
15. Disconnect the knock sensor electrical connector.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Disconnect the oil pressure switch electrical connector.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the nuts and the two radio interference capacitors.
20. Remove the crankcase ventilation tube from the LH valve cover.
21. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
22. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
23. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
24. Remove the bolt and the belt idler pulley.
25. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
26. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
27. Use the special tool to remove the crankshaft front seal.
28. Remove the power steering pump.
29. Remove the four oil pan bolts.
30. Remove the fasteners.
31. Remove the engine front cover from the cylinder block.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Remove the eight spark plugs.
34. Install the special tool between the valve spring coils to prevent valve stem seal damage.
35. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
36. Position the crankshaft with the keyway at the 12 o'clock position.
37. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
38. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
39. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides. RH cylinder head
40. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket. LH cylinder head
41. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
42. Remove the bolt and the oil level indicator tube.
43. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .
44. Install the special tools on both ends of the cylinder head.
45. Remove the hydraulic lash adjusters.
46. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
49. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).

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

MATERIAL SPECIFICATION

Scheme 366

1. Remove the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the bolts and the flexplate.
3. Lower the engine onto wooden blocks.
4. Remove the special tool.
5. Install the special tool.
6. Install the special tool.
7. Mount the engine on a suitable work stand.
8. Remove the special tool.
9. Remove the special tool.
10. Remove the RH engine mount.
11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Disconnect the RH radio frequency interference capacitor electrical connector.
15. Disconnect the knock sensor electrical connector.
16. Disconnect the crankshaft position (CKP) sensor electrical connector.
17. Disconnect the oil pressure switch electrical connector.
18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
19. Remove the nuts and the two radio interference capacitors.
20. Remove the crankcase ventilation tube from the LH valve cover.
21. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
22. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the bolt and the belt idler pulley.
24. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
25. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
26. Use the special tool to remove the crankshaft front seal.
27. Remove the power steering pump.
28. Remove the bolts.
29. Remove the fasteners.
30. Remove the engine front cover from the cylinder block.
31. Remove the crankshaft sensor ring from the crankshaft.
32. Remove the eight spark plugs.
33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
34. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
35. Position the crankshaft with the keyway at the 12 o'clock position.
36. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
37. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
38. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
39. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
40. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
41. Remove the bolt and the oil level indicator tube. All cylinder heads
42. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .
43. Install the special tools on both ends of the cylinder head.
44. Remove the hydraulic lash adjusters.
45. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
46. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
48. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).

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

Scheme 367

MATERIAL SPECIFICATION

Scheme 368

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

1. Remove the engine. For additional information, refer to «ENGINE - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) and «ENGINE - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the RH and LH engine mounts.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the knock sensor (KS) electrical connector.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
18. Disconnect the oil pressure switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
22. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
24. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
25. Remove the bolt and the belt idler pulley.
26. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
27. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
28. Use the special tool to remove the crankshaft front seal.
29. Remove the power steering pump.
30. Remove the four oil pan bolts.
31. Remove the fasteners.
32. Remove the engine front cover from the cylinder block.
33. Remove the crankshaft sensor ring from the crankshaft.
34. Remove the eight spark plugs.
35. Install the special tool between the valve spring coils to prevent valve stem seal damage.
36. Use the special tool to compress the valve springs, and remove 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 bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
39. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
40. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
41. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
42. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
43. Remove the bolt and the oil level indicator tube.
44. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .
45. Install the special tools on both ends of the cylinder head.
46. Remove the hydraulic lash adjusters.
47. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
49. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
50. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
51. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
52. Clean the oil filter adapter gasket surface at the cylinder block.
53. Remove the bolts.
54. Remove the coolant pump from the cylinder block.
55. Remove the bolts and the A/C compressor.
56. 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.
57. Remove the bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
58. Remove the bolts and the oil pump screen and pickup tube.
59. Remove the oil pump screen and pickup tube spacer.
60. Remove the oil pump. Remove the bolts. Remove the oil pump.
61. Remove the bolts and the connecting rod cap. Discard the bolts.
62. Use the special tool to push the piston through the top of the cylinder block.
63. Remove the crankshaft bearing cap fasteners. Remove and discard the cross-mounted main cap bolts. Loosen the jack screws. Remove and discard the main cap bolts.
64. Remove the five main bearing caps and the lower crankshaft main bearings.
65. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

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

MATERIAL SPECIFICATION

Scheme 381

Scheme 382

Scheme 383

Scheme 384

1. Remove the engine. For additional information, refer to «ENGINE - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) and «ENGINE - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the RH and LH engine mounts.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the knock sensor electrical connector.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
18. Disconnect the oil pressure switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
22. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
24. Remove the bolt and the belt idler pulley.
25. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
26. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
27. Use the special tool to remove the crankshaft front seal.
28. Remove the power steering pump.
29. Remove the four oil pan bolts.
30. Remove the fasteners.
31. Remove the engine front cover from the cylinder block.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Remove the eight spark plugs.
34. Install the special tool between the valve spring coils to prevent valve stem seal damage.
35. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
36. Position the crankshaft with the keyway at the 12 o'clock position.
37. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
38. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
39. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
40. Remove the nuts, the RH exhaust manifold and gasket. Discard the gasket.
41. Remove the nuts, the LH exhaust manifold and gasket. Discard the gasket.
42. Remove the bolt and the oil level indicator tube.
43. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .
44. Install the special tools on both ends of the cylinder head.
45. Remove the hydraulic lash adjusters.
46. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
47. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
49. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
50. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
51. Clean the oil filter adapter gasket surface at the cylinder block.
52. Remove the bolts.
53. Remove the coolant pump from the cylinder block.
54. Remove the bolts and the A/C compressor.
55. 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.
56. Remove the bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
57. Remove the bolts and the oil pump screen and pickup tube.
58. Remove the oil pump screen and pickup tube spacer.
59. Remove the oil pump. Remove the bolts. Remove the oil pump.
60. Remove the bolts and the connecting rod cap. Discard the bolts.
61. Use the special tool to push the piston through the top of the cylinder block.
62. Remove the fasteners. Remove and discard the cross-mounted main cap bolts. Remove the dowels. Remove and discard the main bearing cap bolts.
63. Remove the five main bearing caps and the lower crankshaft main bearings.
64. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

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

MATERIAL SPECIFICATION

Disassembly

Scheme 385

Scheme 386

1. Remove the hydraulic lash adjusters.
2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
3. Using the special tool, compress the valve springs.
4. Remove the valves. Remove the valve spring retainer keys. Remove the valve spring retainers. Remove the valve springs. Remove the valves.
5. Remove the valve stem seals.
6. Remove the bolts, bearing caps and camshaft.
7. 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.
8. Remove the bolts, bearing caps and camshaft.
9. 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.
10. 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.
11. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .

Scheme 387

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
3. Tighten the bolts in the sequence see scheme 699
4. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
5. Tighten the bolts in the sequence (Scheme 423)
6. Install the valves in the valve guides located in the cylinder head.
7. Using the special tools, install the valve stem seals.
8. Install the valve springs and the valve spring retainers onto the valves.
9. Install the special tool between the valve spring coils to prevent valve stem seal damage.
10. Using the special tool, compress the valve springs. Install the valve spring retainer keys.
11. Install the hydraulic lash adjusters in their original locations.
12. Remove the special tool.

MATERIAL SPECIFICATION

Scheme 388

Scheme 389

1. Press the piston pin out from the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the connecting rod and piston. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .

Scheme 390

1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Press the piston pin into the piston and rod assembly.

MATERIAL SPECIFICATION

Scheme 391

Scheme 392

1. Remove the clips.
2. Remove the piston pin from the piston and connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) .

Scheme 393

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

MATERIAL SPECIFICATION

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

1. Remove the four bolts and the fuel injection supply manifold.
2. Remove the fuel injectors from the fuel injection supply manifold.
3. Discard the two O-ring seals from each fuel injector. Install new O-ring seals.
4. Remove the bolts.
5. Separate the upper and lower intake manifolds and discard the lower intake manifold gasket.
6. Inspect all external and internal surfaces of the upper intake manifold. Inspect for cracks or other damage. Inspect for foreign material inside of the manifold. Clean the upper intake manifold sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
7. Allow the upper and lower intake manifolds to dry completely.

Scheme 399

Scheme 400

1. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.
2. Tighten the bolts in two stages using the sequence see scheme 727 Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
3. Install the fuel injectors into the fuel injection supply manifold.
4. Install the fuel injection supply manifold and the four bolts.

Scheme 401

Scheme 402

Scheme 403

Scheme 404

1. Remove the fuel infection supply manifold.
2. Remove the fuel injectors from the fuel injection supply manifold.
3. Discard the two O-ring seals from each fuel injector. Install new O-ring seals.
4. Remove the engine noise shield.
5. Remove the water crossover tube. Inspect and install new gaskets as necessary.
6. 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 with a suitable cleaner.

Scheme 405

Scheme 406

1. Install the water crossover tube.
2. Install the engine noise shield.
3. Install the fuel injectors into the fuel injection supply manifold.
4. Install the fuel injection supply manifold.

SPECIAL TOOLS Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Crankshaft Front Oil Seal 303-635 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)

Scheme 407

Scheme 408

MATERIAL SPECIFICATION

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

Scheme 423

Scheme 424

Scheme 425

Scheme 426

Scheme 427

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

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 two intersect. This is the required bearing grade for the number one 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 four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
8. Install the rear main bearing cap.
9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
10. Install the vertical main bearing cap fasteners and tighten in two stages, in the sequence (Scheme 435) Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
11. Tighten the jack screws against the cylinder block in two stages, in the sequence see scheme 747 Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
12. Install the side bolts and tighten them in the sequence (Scheme 436)
13. Using the special tools, install the piston and connecting rod with the upper connecting rod bearing in place.
14. Once the connecting rod is seated on the crankshaft journal, remove the special tool.
15. Position the lower bearing and connecting rod, and install the new bolts loosely.
16. Tighten the bolts in two stages, using the sequence see scheme 751 Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence see scheme 752
18. Install the head gasket over the dowel pins.
19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
20. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
21. Tighten the RH bolts in the sequence see scheme 756 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
22. Remove the special tools from both ends of the cylinder head.
23. Install the hydraulic lash adjusters in their original locations.
24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence see scheme 759
25. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence see scheme 761
27. Using a vise, compress the tensioner plunger.
28. Install a retaining clip on the tensioner to hold the plunger in during installation.
29. Remove the tensioner from the vise.
30. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
31. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
32. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
33. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
34. Remove the special tool.
35. Install the crankshaft sprocket, making sure the flange faces forward.
36. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
37. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
38. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
39. Remove the retaining clip from the LH timing chain tensioner.
40. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
41. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
42. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
43. Remove the retaining clip from the RH timing chain tensioner.
44. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
45. Install the special tool between the valve spring coils to prevent valve stem seal damage.
46. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
47. Install the eight spark plugs. Tighten to 18 Nm (13 lb-ft).
48. Install the crankshaft sensor ring on the crankshaft.
49. 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 see scheme 781
50. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
51. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
52. Position the belt idler pulley and install the bolt.
53. Lubricate the engine front cover and the front seal inner lip with clean engine oil.
54. Using the special tools, install the crankshaft front seal into the engine front cover.
55. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
56. Using the special tool, install the crankshaft pulley.
57. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
58. Position the power steering pump and install the bolts.
59. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
60. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
61. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
62. Tighten the bolts in the sequence (Scheme 443)
63. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
64. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
65. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
66. Tighten the bolts in the sequence see scheme 798
67. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
68. Install the crankcase ventilation tube on the LH valve cover.
69. Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
71. Connect the CKP sensor electrical connector.
72. Connect the oil pressure switch electrical connector.
73. Connect the KS electrical connector.
74. Connect the RH radio frequency interference capacitor electrical connector.
75. Connect the CMP sensor electrical connector.
76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
77. Install the cylinder block drain plugs.
78. Position a new gasket and the oil filter adapter. Install the bolts and nut.
79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
80. If equipped, install the A/C compressor and the bolts.
81. Install the coolant pump. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the bolts.
82. Position the coolant pump pulley on the coolant pump and install the bolts.
83. 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.
84. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
86. Tighten the bolts in the sequence see scheme 816
87. Install the oil drain plug before installing the oil pan.
88. Install the oil pump screen and pickup tube spacer.
89. Position the oil pump screen and pickup tube and install the bolts.
90. 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.
91. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
93. Install the oil pan gasket and the oil pan and loosely install the bolts.
94. Tighten the bolts in two stages, in the sequence see scheme 823 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
95. Install the special tool.
96. Install the special tool.
97. Install the special tool and remove the engine from the work stand.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
100. Install the oil level indicator tube nut and insert the oil level indicator.
101. Using the special tools, install a new crankshaft rear seal.
102. Using the special tools, install the crankshaft rear oil slinger.
103. Install the flexplate and bolts. Tighten the bolts in the sequence (Scheme 445)
104. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

SPECIAL TOOLS Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Crankshaft Front Oil Seal 303-635 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Holding Tool, Crankshaft 303 - 448 (T93P-6303-A) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Installer, Crankshaft Rear Oil Seal 303 - 518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Seal 303 - 516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Slinger 303 - 517 (T95P-6701-CH)

MATERIAL SPECIFICATION

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

Scheme 444

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 two intersect. This is the required bearing grade for the number one 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 four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the dowel pins so the flat sides face the crankshaft.
12. Install the vertical main bearing cap fasteners and tighten in two stages, in the sequence see scheme 841 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the side bolts and tighten them in two stages, in the sequence see scheme 842 Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 90 degrees.
14. Using the special tools, install the piston and connecting rod with the upper connecting rod bearing in place.
15. Once the connecting rod is seated on the crankshaft journal, remove the special tool.
16. Position the lower bearing and connecting rod, and install the new bolts loosely.
17. Tighten the bolts in two stages, using the sequence (Scheme 451) Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence (Scheme 452)
19. Install the head gasket over the dowel pins.
20. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
21. Tighten the LH bolts in the sequence see scheme 849 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
22. Tighten the RH bolts in the sequence see scheme 850 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
23. Remove the special tools from both ends of the cylinder head.
24. Install the hydraulic lash adjusters in their original locations.
25. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence see scheme 853
26. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence see scheme 855
28. Using a vise, compress the tensioner plunger.
29. Install a retaining clip on the tensioner to hold the plunger in during installation.
30. Remove the tensioner from the vise.
31. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
32. Install the timing chain guides.
33. Pre-position the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
34. Position the crankshaft so the number one cylinder is at TDC with the special tool.
35. Remove the special tool.
36. Install the crankshaft sprocket, making sure the flange faces forward.
37. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
38. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
39. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
40. Remove the retaining clip from the LH timing chain tensioner.
41. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
42. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
44. Remove the retaining clip from the RH timing chain tensioner.
45. As a post-check, verify correct alignment of all timing marks.
46. Install the special tool between the valve spring coils to prevent valve stem seal damage.
47. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
48. Install the eight spark plugs. Tighten to 18 Nm (13 lb-ft).
49. Install the crankshaft sensor ring on the crankshaft.
50. 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 (Scheme 462)
51. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
52. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
53. Position the belt idler pulley and install the bolt.
54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
55. Using the special tools, install the crankshaft front seal into the engine front cover.
56. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
57. Using the special tool, install the crankshaft pulley.
58. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
59. Position the power steering pump and install the bolts.
60. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
61. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
62. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
63. Tighten the bolts in the sequence see scheme 888
64. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
65. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
66. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
67. Tighten the bolts in the sequence see scheme 892
68. Install the crankcase ventilation tube on the LH valve cover.
69. Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
71. Connect the CKP sensor electrical connector.
72. Connect the oil pressure switch electrical connector.
73. Connect the KS electrical connector.
74. Connect the RH radio frequency interference capacitor electrical connector.
75. Connect the CMP sensor electrical connector.
76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
77. Install the cylinder block drain plugs.
78. Position a new gasket and the oil filter adapter. Install the bolts and nut.
79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
80. If equipped, install the A/C compressor and the bolts.
81. Install the coolant pump. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the bolts.
82. Position the coolant pump pulley on the coolant pump and install the bolts.
83. 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.
84. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
86. Tighten the bolts in the sequence see scheme 909
87. Install the oil drain plug before installing the oil pan.
88. Install the oil pump screen and pickup tube spacer.
89. Position the oil pump screen and pickup tube and install the bolts.
90. 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.
91. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
93. Install the oil pan gasket and the oil pan and loosely install the bolts.
94. Tighten the bolts in two stages, in the sequence see scheme 916 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
95. Install the special tool.
96. Install the special tool.
97. Install the special tool and remove the engine from the work stand.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
100. Install the oil level indicator tube nut and insert the oil level indicator.
101. Using the special tools, install a new crankshaft rear seal.
102. Using the special tools, install the crankshaft rear oil slinger.
103. Install the flexplate and bolts. Tighten the bolts in the sequence see scheme 924
104. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

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

Scheme 445

MATERIAL SPECIFICATION

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

1. Position the engine in the vehicle.
2. Remove the floor crane and the jack supporting the transmission.
3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
4. Position the shifter cable support bracket and install the two transmission-to-engine bolts.
5. Install the RH lower transmission-to-engine bolt.
6. Install the mounting bracket and connect the shift cable. Install the bolts. Connect the clip.
7. Install four new nuts to retain the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts.
8. Install the cylinder block opening cover.
9. Install the flexplate inspection cover.
10. Install the four engine mount nuts.
11. Install the starter motor. Position the starter. Install the two bolts. Install the stud bolt.
12. Connect the starter motor electrical connections.
13. Install the starter motor solenoid terminal cover.
14. Mount the exhaust system to the LH and RH exhaust manifolds.
15. Position a new oil cooler on the oil filter adapter and install the threaded insert.
16. Install a new oil filter.
17. Connect the oil cooler hoses.
18. Position the transmission fluid cooler tube support bracket and install the nut.
19. Position the fluid cooler tube support bracket and install the nut.
20. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
21. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
22. Install and tighten the oil drain plug.
23. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the four upper transmission-to-engine bolts.
24. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
25. Insert the heater outlet tube over the new seals.
26. Install the heater outlet tube studs.
27. Install the transmission fluid filler tube.
28. Install the heater outlet tube studs.
29. Install the transmission fluid filler tube.
30. Connect the hose to the heater outlet tube.
31. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
32. Connect the evaporative emission canister purge valve electrical connector.
33. 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.
34. Install the engine oil filler tube support strap bolt.
35. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
36. Connect the engine wiring harness electrical connectors.
37. Connect the powertrain control module (PCM) electrical connectors.
38. Connect the engine wiring harness to the PCM bracket.
39. Position the generator and install the bolts.
40. Connect the generator electrical connections. Install the B+ terminal and disconnect the terminal. Connect the S electrical connector. Connect the ASI electrical connector.
41. Rotate the tensioner clockwise and install the drive belt. Refer to decal on the upper radiator air deflector for belt routing.
42. Connect the lower radiator hose to the oil filter adapter coolant inlet.
43. Position the lower radiator support and install the twelve bolts.
44. Install the RH side of the headlamp dash panel junction wiring harness. Connect the electrical connector. Install the screw. Insert the routing clips.
45. Install the LH side of the headlamp dash panel junction wiring harness. Install the screw. Insert the routing clips.
46. Position the RH and LH air deflectors and install the pin-type retainers.
47. Position the upper radiator support and install the eight bolts.
48. Connect the horn electrical connector.
49. Connect the front impact severity sensor electrical connector.
50. If equipped, connect the air temperature sensor electrical connector.
51. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
52. Install the battery feed cable to the power distribution box.
53. Install the power steering reservoir.
54. Install the hood latch. Install the hood latch. Insert the cable routing clip.
55. Install the A/C condenser core. Position the A/C condenser core in the vehicle. Position the A/C condenser brackets. Install the bolts.
56. Connect the condenser core refrigerant tubes. Connect the condenser to evaporator tube. Connect the compressor discharge tube.
57. Connect the compressor suction tube.
58. Connect the A/C pressure cutoff switch electrical connector.
59. Position the radiator in the vehicle.
60. Position the radiator support brackets and install the bolts.
61. Position the fan shroud and the fan and fan clutch in the vehicle, and install the bolts.
62. Insert the degas hose retainer in the fan shroud.
63. Install the fan blade assembly and fan clutch. Install the fan blade and the fan clutch. Using the special tool, hold the coolant pump pulley. Using the special tool, tighten the fan clutch nut.
64. Connect the upper radiator hose and the degas hose to the radiator.
65. Install the valance panel. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
66. Connect the transmission cooler tubes.
67. Position the splash shield and install the pushpin retainers.
68. Connect the lower radiator hose to the radiator. Connect the hose. Connect the hose hanger.
69. Install the front bumper. For additional information, refer to «BUMPERS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#bumpers) .
70. Fill the engine with clean engine oil.
71. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD - 4.6L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) or «INTAKE MANIFOLD - 5.4L»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l) .
72. Fill all fluids to the correct levels. Fill the transmission with clean transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-4r70w-4r75w) . Fill the power steering system with clean fluid. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) .
73. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
74. Evacuate and recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/general-servicing-all-makes/#hvac-system-climate-control-system-general-information) .

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

MATERIAL SPECIFICATION

Scheme 464

Scheme 465

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
4. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
5. Remove the special tools from both ends of the cylinder head.
6. Install the hydraulic lash adjusters in their original locations.
7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence see scheme 995
8. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence see scheme 997
10. Using a vise, compress the tensioner plunger.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
15. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
16. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
17. Remove the special tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
20. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
30. Install the eight spark plugs. Tighten to 18 Nm (13 lb-ft).
31. Install the crankshaft sensor ring on the crankshaft.
32. 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 see scheme 1017
33. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
34. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
35. Loosely install the bolts, then tighten the bolts in two stages, in the sequence see scheme 1020 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
36. Position the belt idler pulley and install the bolt.
37. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
38. Use the special tools to install the crankshaft front seal into the engine front cover.
39. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
40. Using the special tool, install the crankshaft pulley.
41. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
42. Position the coolant pump pulley on the coolant pump and install the bolts.
43. Position the power steering pump and install the bolts.
44. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
45. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
47. Tighten the bolts in the sequence see scheme 1032
48. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
50. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence see scheme 1036
52. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
53. Install the crankcase ventilation tube on the LH valve cover.
54. Install the radio frequency interference capacitors.
55. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
56. Connect the CKP sensor electrical connector.
57. Connect the oil pressure switch electrical connector.
58. Connect the KS electrical connector.
59. Connect the RH radio frequency interference capacitor electrical connector.
60. Connect the CMP sensor electrical connector.
61. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
62. Install the cylinder block drain plugs.
63. Install the RH engine mount. Tighten to 63 Nm (46 lb-ft).
64. Install the special tool.
65. Install the special tool.
66. Install the special tool and remove the engine from the work stand.
67. Lower the engine onto wooden blocks.
68. Install the special tool and raise the engine.
69. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence see scheme 1051
70. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

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

MATERIAL SPECIFICATION

Scheme 466

Scheme 467

1. Install the head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the LH bolts in the sequence see scheme 1054 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
4. Tighten the RH bolts in the sequence see scheme 1055 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
5. Remove the special tools from both ends of the cylinder head.
6. Install the hydraulic lash adjusters in their original locations.
7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence see scheme 1058
8. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence see scheme 1060
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides.
15. Pre-position the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
16. Position the crankshaft so the number one cylinder is at TDC with the special tool.
17. Remove the special tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
20. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
24. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post-check, verify correct alignment of all timing marks.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
30. Install the eight spark plugs. Tighten to 18 Nm (13 lb-ft).
31. Install the crankshaft sensor ring on the crankshaft.
32. 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 see scheme 1080
33. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
34. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
35. Loosely install the bolts, then tighten the bolts in two stages, in the sequence see scheme 1083 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
36. Position the belt idler pulley and install the bolt.
37. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
38. Use the special tools to install the crankshaft front seal into the engine front cover.
39. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
40. Use the special tool to install the crankshaft pulley.
41. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
42. Position the coolant pump pulley on the coolant pump and install the bolts.
43. Position the power steering pump and install the bolts.
44. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
45. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
46. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
47. Tighten the bolts in the sequence see scheme 1095
48. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
50. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence see scheme 1099
52. Install the crankcase ventilation tube on the LH valve cover.
53. Install the radio frequency interference capacitors.
54. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
55. Connect the CKP sensor electrical connector.
56. Connect the oil pressure switch electrical connector.
57. Connect the KS electrical connector.
58. Connect the RH radio frequency interference capacitor electrical connector.
59. Connect the CMP sensor electrical connector.
60. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
61. Install the cylinder block drain plugs.
62. Install the RH engine mount. Tighten to 63 Nm (46 lb-ft).
63. Install the special tool.
64. Install the special tool.
65. Install the special tool and remove the engine from the work stand.
66. Lower the engine onto wooden blocks.
67. Install the special tool and raise the engine.
68. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence see scheme 1113
69. Install the engine. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-46l-and-54l).

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• INTRODUCTION - GASOLINE
• INTERIOR TRIM AND ORNAMENTATION
• FUEL SYSTEM-GENERAL INFORMATION
• BATTERY, MOUNTING AND CABLES
• ENGINE COOLING
• CLIMATE CONTROL SYSTEM-GENERAL INFORMATION
• INTAKE AIR DISTRIBUTION & FILTERING
• ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V)
• ACCESSORY DRIVE
• JACKING & LIFTING
• AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W
• BUMPERS
• FRONT END BODY PANELS
• STEERING SYSTEM-GENERAL INFORMATION
• CRANKSHAFT PULLEY