Tune-Up - Diesel Ford Econoline E150

ENGINE IDENTIFICATION

Engine is identified by eight character of Vehicle Identification Number (VIN). The VIN is stamped on a metal tag, attatched to upper left side of instrument panel and is visible through windshield.

VIN ENGINE CODE

TUNE-UP NOTES

Note. Always refer to Emission Control Label in engine compartment before attempting tune-up. If manual and label differ, always use emission label specifications.

Ensure all diesel injection lines and fittings are thoroughly cleaned before removing. Cap all lines, injector nozzles, and fittings when removed. Dirt in system may damage injection pump or engine. All models are equipped with a fuel conditioner/water separator. Check periodically for presence of water and drain contaminated fuel when "WATER-IN-FUEL" warning light comes on.

ENGINE COMPRESSION

1. Prior to checking compression, ensure batteries are fully charged. DO NOT add oil to cylinders. Adding oil may cause hydrostatic lock and extensive engine damage.
2. Start and warm engine to normal operating temperature. Turn ignition off. Remove air cleaner and/or intake opening cover. Disconnect injection pump cut-off solenoid.
3. Remove all glow plugs and insert a compression gauge in No. 1 cylinder glow plug hole. With ignition off, crank engine through at least 5 compression strokes. Note number of strokes required to obtain highest reading. Repeat check on each cylinder, cranking engine same number of compression strokes.

Note. Maximum compression variation between cylinders is 25%.

COMPRESSION SPECIFICATIONS

VALVE ARRANGEMENT

1. Right Bank - E-I-E-I-E-I-E-I (Front-to-rear).
2. Left Bank - I-E-I-E-I-E-I-E (Front-to-rear).

VALVE CLEARANCE

Engine is equipped with hydraulic lifters. Valves are adjusted to zero lash.

GLOW PLUGS

Each cylinder has a glow plug in the cylinder head. The tip of the glow plug projects into pre-combustion chamber to preheat cylinder and to aid in cold engine starting.

Full system voltage is supplied to glow plugs when ignition is turned on. Depending on coolant temperature, glow plug voltage is maintained at a reduced voltage for a short period of time after engine start.

7.3L Diesel Firing Order. Scheme 3

Injection Pump Static Timing

1. Remove fast idle bracket and solenoid from injection pump. Loosen 3 nuts attaching fuel injection pump to pump mounting adapter with Injection Pump Wrench (T86T-9000-C).
2. Install Injection Pump Rotator (T83T-9000-C) on front of pump. Rotate pump to align injection pump mounting flange timing mark with pump mounting adapter timing mark. (Scheme 4)
3. Remove rotator and tighten mounting nuts. Visually check timing to ensure marks are still aligned after tightening nuts. Install fast idle bracket and solenoid.

Scheme 4

Scheme 5

1. Start and warm engine to normal operating temperature. Coolant temperature MUST be 192-212°F (89-100°C) to obtain correct dynamic timing. Stop engine and connect Dynamic Timing Meter (078-00200). Install magnetic pick-up into timing probe hole until pick-up almost touches vibration damper. (Scheme 5)
2. Install Timing Meter Adapter (078-00201) clamp to line pressure sensor on No. 1 injector nozzle ("F" Series) or No. 4 injector nozzle ("E" Series) and connect to timing meter.
3. Connect dynamic timing meter to battery and dial in MINUS 20 degrees offset on meter. Disconnect cold start advance solenoid connector from solenoid terminal. (Scheme 6)
4. Raise and support rear wheels. Place transmission in Neutral and start engine. Using Throttle Controller (D83T-9000-E), set engine speed at 2000 RPM with no accessory load. Read injection timing on meter.
5. Injection timing should be 8.5 degrees BTDC at 2000 RPM. Apply 12 volts to cold start advance solenoid terminal. NOTE: After voltage is applied to cold start advance solenoid, engine speed may increase. Adjust throttle control to 2000 RPM.
6. Check timing at 2000 RPM. Timing should be advanced one degree before timing specification. If timing advance is less than one degree, replace fuel injection pump top cover.
7. If injection timing is not within 2 degrees of value, injection pump timing must be adjusted. Turn engine off. Note timing mark alignment. Remove fast idle bracket and solenoid from injection pump. Use an Injection Pump Wrench (T86T-9000C) to loosen pump retaining nuts. Keep nuts snug.
8. Using Injection Pump Rotator (T83T-9000-C), rotate pump clockwise to retard timing or counterclockwise to advance timing (as viewed from front of engine). Tap rotator with rubber mallet as needed to rotate pump.
9. Moving timing mark.030" (.75 mm) is equal to 2 degrees of timing. Retighten nuts. Start engine and recheck timing. Repeat step 7) as needed to obtain correct timing. Remove timing meter and other test equipment.

HOT (SLOW) IDLE RPM

1. Start and run engine until it reaches normal operating temperature. Place transmission in Neutral (M/T) or Drive (A/T). Ensure idle speed adjusting screw is against stop. If not, adjust accelerator linkage.
2. Using Photoelectric Tachometer (099-00001), set curb idle speed to specification indicated on Emission Control Label. Use idle speed screw on side of pump for adjustment. (Scheme 6)
3. With transmission in Neutral (M/T) or Park (A/T), increase engine speed momentarily. Shift back into specified gear and recheck idle speed. Readjust if necessary.

COLD (FAST) IDLE RPM

1. Start and run engine until it reaches normal operating temperature. Place transmission in Neutral (M/T) or Park (A/T). Disconnect wiring harness from fast idle solenoid.
2. Apply 12 volts to solenoid to activate it. Increase engine speed momentarily to set solenoid plunger. Fast idle speed should be 800-850 RPM. Adjust fast idle speed if necessary by turning solenoid plunger. (Scheme 6)

Scheme 6

COLD (FAST) IDLE RPM

VACUUM PUMP

All models are equipped with a belt-driven vacuum pump. The pump produces vacuum for operation of power brake and speed control systems. A brake/low-vacuum warning light on instrument panel illuminates if system vacuum is not adequate to operate brake booster or other vacuum systems. The warning light remains on after engine start-up until vacuum builds up in system.

VACUUM REGULATOR VALVE

The vacuum regulator valve provides vacuum signals to control automatic transmission shift points. Vacuum setting of valve should be checked periodically, using the following procedure. Engine MUST NOT be running during this procedure.

1. Disconnect 2-port vacuum connector from vacuum regulator valve, located on left side of injection pump. (Scheme 7) Remove throttle cable from pump throttle lever, located on right side of pump.
2. Remove throttle return spring and reposition. Place end of spring over throttle lever ball stud and other end over throttle cable support bracket. Attach a hand-held vacuum pump to upper port of vacuum regulator valve.
3. Attach vacuum gauge to lower port (labeled "TRANS") of regulator valve. Apply and maintain 20 in. Hg to vacuum regulator valve. It will be necessary to increase vacuum as regulator valve bleeds off.
4. Cycle throttle lever 5 times from idle to wide open throttle with vacuum applied. Insert Gauging Block (T83T-7B200-AH) between pump boss and wide open throttle stop. (Scheme 8)
5. Repositioned spring should hold throttle lever stop against block. Vacuum gauge attached to regulator valve should indicate 6-8 in. Hg. If not, adjust regulator valve.
6. To adjust valve, loosen vacuum regulator valve screws and rotate valve until vacuum gauge reads 7 in. Hg. Tighten screws. If valve cannot be adjusted to specification, replace regulator valve and repeat adjustment procedure.
7. Remove gauging block. Reconnect throttle return spring in original position and connect throttle cable. Apply 20 in. Hg to vacuum regulator valve. While maintaining vacuum, cycle throttle lever 5 times from idle to wide open throttle.
8. Vacuum gauge must indicate at least 13 in. Hg with throttle at idle. If reading is less than 13 in. Hg, replace vacuum regulator valve and repeat adjustment procedure. If reading is correct, remove vacuum pump and gauging block. Attach vacuum connector.

Scheme 7

Scheme 8

FUEL CONDITIONER/WATER SEPARATOR

Water separator should be drained every 5000 miles or when warning light glows. Diesel fuel can damage asphalt and painted surfaces. Always place a drain pan under conditioner to collect fuel. To drain conditioner, use the following procedure.

1. Stop vehicle and turn engine off. Open drain valve located under fuel filter water separator. Allow fuel to drain for about 15 seconds or until water is completely drained. Tighten and ensure drain valve is fully closed or seated.
2. Restart engine and check warning light. If warning light continues to glow, fuel system needs to be checked or repaired. The only serviceable item on the separator is the water level sensor.

FUEL PUMP

A mechanical fuel pump is bolted to right front of cylinder block. The pump is mechanically operated by the camshaft. The pump cannot be disassembled for repair and must be replaced if not within specification. A damaged or worn fuel pump will not deliver any fuel to the injection pump or will not deliver enough fuel for sustained engine speed.

INSPECTION

If pump is noisy, ensure mounting bolts are tightened to 19-27 ft. lbs. (25-36 N.m) and mounting clips are not loose or missing. Inspect rubber hoses for kinks or cracks.

VOLUME TEST

1. Slowly (fuel line is pressurized) disconnect fuel line at fuel filter. Place fuel hose in a one pint minimum container.
2. Crank engine for 10 seconds and measure fuel flow. See «FUEL PUMP SPECIFICATIONS TABLE»(/ford/econoline-e150/1987-1991/remont/adjustments/#tune-up-diesel) . If fuel flow is below specification, remove fuel inlet line from fuel pump. Attach a fuel hose to pump and insert into a remote fuel supply.
3. Re-test fuel pressure and supply. If pump meets specification, service fuel separator. Check for kinked or leaking fuel hoses.
4. If fuel flow is still below specification, replace fuel pump. Ensure replacement pump actuating arm is seated correctly on camshaft.

PRESSURE TEST

1. Disconnect fuel line to injection pump. Connect Vacuum and Pressure Tester (059-00008) to injection pump end of fuel line.
2. Crank engine for 10 seconds and check fuel pressure. If fuel pressure is not as specified or is too high or too low, replace fuel pump. Reconnect fuel line and check for leaks.

FUEL PUMP SPECIFICATIONS

FUEL SELECTOR VALVE

Vehicles equipped with dual tanks have a 6-port fuel tank selector valve. The valve is powered by a small electric motor. Tank valves are opened and closed simultaneously and the motor is controlled by internal switching. The switching system also controls fuel level gauge function. A change in fuel level gauge reading will indicate that the valve position has been changed.

EMISSION CONTROL

For information on emission control systems, see EMISSION CONTROL SYSTEMS section.

FUEL INJECTION

INJECTOR OPENING PRESSURE (1)

BATTERY

BATTERY SPECIFICATIONS

BELT ADJUSTMENT

Using a standard tension gauge, measure belt tension midway between pulleys, on shortest portion of belt. Any belt that has been used for more than 10 minutes is considered a used belt.

BELT ADJUSTMENT

SERVICE INTERVALS

REPLACEMENT INTERVALS

CAPACITIES

ENGINE OIL CAPACITIES

DIFFERENTIAL CAPACITIES

TRANSFER CASE CAPACITIES

TRANSMISSION CAPACITIES

COOLING SYSTEM CAPACITIES

SYSTEM REFRIGERANT CAPACITIES

See also:
• FUEL PUMP SPECIFICATIONS TABLE