4.9l 6-cyl - VIN [y] Ford Econoline E150

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine is identified by the eighth character of Vehicle Identification Number (VIN). VIN is visible through windshield on left upper side of instrument panel. VIN is also located on Safety Compliance Certification Label, attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

1. Positive stop rocker arm bolts eliminate valve clearance adjustments. Valve stem-to-rocker arm clearance is measured with lifter collapsed. To obtain correct valve clearance after machine work is done,.060" (1.52 mm) undersize or oversize push rod may be used.
2. With ignition switch in "OFF" position, use remote starter switch to turn crankshaft. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. Mark timing mark on vibration damper with chalk, then make 2 additional chalk marks on vibration damper, spaced approximately 120 degrees apart. (Scheme 1)
3. Slowly collapse lifter plunger until completely bottomed, using Lifter Compressor (T70P-6513-A). While maintaining pressure on lifter, use feeler gauge to check clearance between rocker arm and valve stem tip. On all valves desired clearance is.125-.175" (3.18-4.45 mm). Allowable range is.100-.200" (2.54-5.08 mm).
4. If clearance is less than specifications, install shorter push rod. If clearance is greater than specifications, install longer push rod. Rotate crankshaft 120 degrees (in direction of normal rotation) to check next set of valves in firing order sequence. Firing order is 1-5-3-6-2-4. Repeat procedure for remaining valves.

Scheme 1

ENGINE

See ENGINE REMOVAL at end of ENGINE section.

Removal (Upper Intake)

1. Disconnect electrical leads at EGR valve position sensor, throttle position sensor, and air by-pass valve. Disconnect vacuum hoses at EGR valve, intake manifold vacuum tree, and fuel evaporative lines at throttle body.
2. Disconnect PCV hose from fitting located on side of intake manifold. Remove throttle linkage shield. Disconnect throttle linkage and cruise control cables. Disconnect accelerator cable from bracket and position cable away from engine.
3. Disconnect air inlet hoses from throttle body. Disconnect EGR tube from EGR valve and exhaust manifold. Remove EGR tube from engine. Remove thermactor (air injection) tube assembly from lower intake manifold.
4. Remove nut attaching thermactor by-pass valve bracket to lower intake manifold. On Vans, remove nut attaching transmission filler tube. Remove tube bracket from intake manifold stud.
5. On all models, remove 5 studs and 2 screws retaining upper intake manifold. Remove screw and washer attaching upper intake manifold support bracket to intake manifold. Remove upper intake manifold and throttle body as an assembly.

Installation

To install, reverse removal procedure. Use new gasket between upper and lower intake manifolds. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS table in this article.

Removal (Lower Manifolds)

1. Relieve fuel system pressure. Remove fuel tank cap and pressure relief valve cap. Install Pressure Gauge (T80L-9974-A) at pressure relief valve to depressurize fuel system.
2. Disconnect air inlet hose at crankcase filter cap. Disconnect throttle body inlet hoses. Disconnect accelerator cable. Remove accelerator return spring. Remove accelerator cable bracket from cylinder head and position cable and bracket assembly out of the way. On vehicles with automatic transmission, remove kickdown rod and return spring.
3. Disconnect fuel inlet line at fuel rail. Disconnect and label all vacuum lines. Remove crankcase vent hose from intake manifold. If equipped with power brakes, disconnect power brake vacuum line.
4. Remove the upper intake and throttle body assembly. Disconnect header pipes from exhaust manifolds. Remove manifolds from cylinder head. Discard all gaskets.

Scheme 2

1. Clean mating surfaces of cylinder head and manifolds. If only one manifold is to be replaced, transfer tube fittings and install new studs.
2. Coat manifold assembly and cylinder head mating surfaces lightly with graphite grease. Using new intake manifold gasket, install and tighten manifolds in sequence. See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table in this article. Make sure gaskets have not become dislodged. (Scheme 2)
3. Using new gaskets as required, install remaining components in reverse order of removal.

Removal

1. Remove upper intake manifold and lower manifolds. See «MANIFOLDS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) in this article. Remove rocker arm cover. Loosen rocker arm bolts, and rotate rocker arms to one side.
2. Mark push rods and remove. Disconnect spark plug wires at spark plugs. Remove cylinder head bolts and attach lifting eyes to cylinder head. Using engine hoist and lifting sling, raise cylinder head and manifold assembly from engine.

1. Clean all gasket mating surfaces. Check block and head gasket surfaces for warpage. Position new gasket over dowel pins on cylinder block. Using lifting device, position cylinder head over block.
2. Carefully lower head assembly onto block. Ensure dowel pins engage in head. Coat threads of head bolts with engine oil and install. Tighten head bolts in sequence using 3 steps. (Scheme 3)
3. Lubricate push rod ends, rocker arm fulcrum seats and sockets with polyethylene grease and install. Reverse removal procedure to complete installation. See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table in this article.

Scheme 3

Valve Arrangement

E-I-E-I-E-I-E-I-E-I-E-I (Front-to-rear).

1. Remove rocker arm cover. Remove spark plug from cylinder to be serviced. Position piston of cylinder being serviced at TDC. Install an adapter in spark plug hole to supply compressed air to cylinder. DO NOT remove air pressure until all valve components are reinstalled.
2. Remove rocker arm bolt, fulcrum seat, rocker arm, fulcrum guide and push rod. Reinstall bolt. Using Valve Spring Compressor (T62E-6565-A), compress spring and remove retainer locks. Remove spring retainer, spring and oil seal.

Inspection

Inspect valve stem for wear and binding in valve guide. Check valve spring tension. Replace springs that fail to meet specifications. Measure spring for out-of-square. Replace spring if out-of-square more than .078" (1.98 mm).

1. Lubricate valve stem with heavy engine oil. Install new valve stem oil seal. Install spring with closed coil end downward. Install spring retainer, and compress spring to install retainer locks.
2. Apply polyethylene grease to both ends of push rod, top of valve stem, fulcrum seat and socket. Install push rod, rocker arm, fulcrum seat and bolt. Check valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y__valve-clearance-adjustment) in this article.
3. Remove air hose and adapter. Install spark plug. Reverse removal procedure to install remaining components.

VALVE SPRING INSTALLED HEIGHT

Measure assembled height of valve spring from surface of cylinder head spring pad to underside of spring retainer. If spring height is excessive, install necessary .030" (.76 mm) spacer(s) between cylinder head spring pad and valve spring to correct height.

VALVE STEM OIL SEALS

Cup-type Teflon oil seals are used on valves. Install cupped side down over valve stem. Use procedure described in VALVE SPRINGS to replace seals.

VALVE GUIDES

Measure valve stem-to-guide clearance with a dial indicator. Maximum side play should not exceed .0027" (.068 mm). Replacement valves are available in .003" (.08 mm), .015" (.38 mm) and .030" (.76 mm) oversize.

HYDRAULIC VALVE LIFTERS

Leak-down rate on all lifters is 10-50 seconds at 1/16" (1.6 mm) plunger travel, using lifter leak-down tester. Specification is for amount of time required for plunger to leak-down under 50 lb. load with testing fluid in lifter. Replace lifter assembly if range specified is exceeded.

1. Drain crankcase and cooling system. Remove radiator and shroud. Remove alternator adjusting arm bolt, and swing arm to side.
2. Remove fan, drive belts, spacer and pulleys. Remove vibration damper using Damper Remover (T58P-6316-D). Remove oil pan front bolts and front cover attaching bolts. Remove front cover and gasket.

1. Cut front oil pan gasket flush with cylinder block/pan junction. Remove gasket. Clean all gasket mating surfaces. Cut and fit new pan gasket. Gasket must fit flush with cylinder block/pan junction.
2. Coat cylinder block and front cover gasket surfaces with oil resistant sealer. Install front cover gasket. Apply silicone sealer to junction of block and pan. Lubricate front cover oil seal.
3. Position front cover in place. Start front cover and pan attaching bolts. Slide Front Cover Aligner (T61P-6019-B) over crankshaft and into seal bore.
4. Install alternator adjusting arm. Tighten the oil pan bolts first, then tighten front cover bolts. Remove the cover aligner. Install vibration damper using Damper Installer (T52L-6306-AEE). Reverse removal procedure to complete installation. See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table in this article.

Remove fan shroud and fan. Remove all drive belts. Remove crankshaft pulley from the vibration damper. Remove vibration damper. Install Front Cover Seal Remover (T70P-6B070-B). Tighten the 2 through bolts to force the seal puller under the seal flange. Alternately tighten the 4 puller bolts a half turn at a time. Remove oil seal from the front cover. Clean out seal recess in front cover.

Lubricate new seal and place seal onto the Front Cover Seal Installer (T70P-6B070-A). Place the sleeve and seal onto the end crankshaft and install seal into the front cover. To complete installation, reverse removal procedure. (Scheme 4)

Scheme 4

TIMING GEARS

Timing Gear Backlash

1. Remove engine front cover. Make 6 chalk marks on camshaft gear, about 60 degrees apart. Attach a dial indicator to engine block and set pointer on camshaft gear tooth.
2. Using dial indicator to measure amount of gear backlash, take measurements at each of 6 chalk marks on camshaft gear.
3. To obtain an accurate reading, hold gear firmly against block. Backlash should be .004-.010" (.10-.25 mm). If any reading is not within limits, replace timing gears as set.

Drain cooling system and crankcase. Remove engine front cover and oil slinger. Align camshaft and crankshaft gear timing marks. (Scheme 5) Use Gear Puller (T82T-6256-A), to remove camshaft gear and Gear Puller (T58P-6316-D), to remove crankshaft gear.

Scheme 5

1. Make sure camshaft key spacer and thrust plate are correctly installed. Align both gear keyways with respective keys, and press on gears using Gear Installer (T65L-6306-A).
2. Make sure that timing marks on camshaft and crankshaft gears are still aligned. Install front cover and related components. See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table in this article.

1. Drain cooling system and crankcase. Remove radiator and shroud. Mark lifters for installation in original locations, then remove lifters. Remove front cover.
2. Disconnect wires to distributor, and remove distributor. Turn crankshaft to align gear timing marks. Remove camshaft thrust plate bolts, gear, key, thrust plate and spacer. Remove camshaft, taking care not to damage camshaft lobes or bearings.

1. Coat camshaft lobes with polyethylene grease and coat journals with engine oil. Install key, spacer and thrust plate on camshaft. Align gear keyway with key and install gear.
2. Install the camshaft, gear and thrust plate as an assembly. With timing marks aligned, tighten thrust plate attaching bolts. Replace front cover oil seal. Using new gaskets, replace front cover. To complete installation, reverse removal procedure. See, in this article, «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table.

CAMSHAFT END PLAY

Remove engine front cover. Loosen rocker arms. Measure end play using dial indicator. Maximum end play is .009" (.228 mm). If not within limits, replace thrust plate.

CAM LOBE LIFT

1. Remove rocker arm cover, rocker arm bolt, fulcrum seat and rocker arm. Make sure push rod end is in valve lifter socket.
2. Install remote starter switch. Position a dial indicator and cup-shaped adapter on end of push rod (in same plane as push rod movement).
3. Rotate crankshaft until lifter and push rod are at lowest position. Zero dial indicator. Rotate crankshaft slowly until push rod is fully raised. Record dial indicator reading and compare with specifications.
4. Maximum allowable lift loss is .005" (.127 mm). If lift on any lobe is below specifications, replace camshaft and valve lifters. See «CAMSHAFT»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) specification table in this article.

1. Remove engine from vehicle. See ENGINE REMOVAL in this section. Remove clutch assembly and flywheel. Remove camshaft and rear camshaft bearing plug. Remove crankshaft.
2. Push pistons to top of cylinders. Using Camshaft Bearing Remover/Installer (T65L-6250-A), drive out camshaft bearings.

1. Using Camshaft Bearing Remover/Installer (T65L-6250-A) install new bearings. Ensure oil holes in bearings align with oil holes in cylinder block.
2. Install front bearing so distance of .020-.035" (.51-.89 mm) exists between front edge of bearing and face of cylinder block.

OIL PAN

See OIL PAN REMOVAL in this section.

1. Remove cylinder head, oil pan and oil pump. Remove ridge and deposits from upper end of cylinder bore. Never cut into ring travel area in excess of 1/32" when removing ridge. Make sure all connecting rod caps are marked for cylinder identification. Remove connecting rod cap.
2. Push connecting rod and piston out top of cylinder. Avoid damage to crankshaft journal or cylinder wall, when removing piston and rod.

1. Properly install piston rings. (Scheme 6) Oil piston, rings and cylinder wall with light engine oil. Install ring compressor on piston, making sure ring location does not change.
2. Place piston into cylinder bore, with notch on top of piston toward front of engine. Carefully guide rod over crankshaft journal, until it seats on journal. Install and tighten rod cap. Check connecting rod side play using a feeler gauge.

FITTING PISTONS

1. Inspect cylinder bore as described in ENGINE OVERHAUL PROCEDURE in this section. Taper must not exceed .010" (.25 mm). Out-of-round must not exceed .005" (.13 mm).
2. If taper or out-of-round are not within limits, or cylinder walls are deeply scored, hone or bore cylinders for installation of new pistons. See PISTON SIZE CODE chart.
3. If bore diameter is in lower third of range, Red piston should be used. In middle third of range, Blue piston should be used. For upper third of range, Yellow or .003" (stamped on dome) piston should be used.

PISTON SIZE CODE

FITTING RINGS

1. Measure piston ring clearances as described in ENGINE OVERHAUL PROCEDURES in this section.
2. Properly install rings on piston. Space end gaps of oil ring segments 1" on either side of oil ring spacer end gap. (Scheme 6)

Scheme 6

Use press and Pin Remover/Installer and Adapter (T68P-6135-A and T81P-6135-A) to remove piston pin from piston and connecting rod.

Scheme 7

1. Lightly coat parts to be assembled with engine oil. Position piston and connecting rod as shown. (Scheme 7)
2. When properly assembled, notch on piston head will face toward front of engine, and bearing tang side of connecting rod will be positioned toward camshaft (left) side of engine.
3. Start piston pin in piston and connecting rod. Using press and Pin Remover/Installer (T68P-6135-A), push piston pin through piston until pin is centered in connecting rod. Make sure piston floats freely throughout press operation.

CONNECTING ROD BEARINGS

1. Measure clearance using Plastigage method. Standard bearing may be used in combination with .001" (.025 mm) or .002" (.051 mm) undersize bearing to obtain proper bearing clearance. Try to obtain minimum specified clearance.
2. Install upper bearing in rod and pull rod down until bearing seats fully on journal. Install other bearing in rod cap. Install cap and tighten. Check rod side clearance.

Removal & Installation

1. Fit main bearings individually, leaving other bearings securely fastened. Make sure main bearing caps are marked for identification.
2. Remove main bearing cap. Support crankshaft weight by placing jack under counterweight adjacent to bearing being checked.
3. Use Plastigage method to measure bearing clearance. Standard size bearings may be used in combination with .001" (.025 mm) or .002" (.051 mm) undersize bearing.
4. If .002" (.051 mm) undersize main bearings are used on more than one journal, install them on cylinder block side of crankshaft. NOTE: To replace rear main bearing, engine must be removed from vehicle.
5. Replace each main bearing set individually. Loosen all main bearing caps until they are finger tight. This will make it easier to remove and install upper bearings. Remove bearing cap to which new bearings are to be installed.
6. Insert Upper Bearing Remover/Installer (6331-E) into crankshaft journal oil hole. Turn crankshaft in direction of normal rotation to push upper bearing out of block. NOTE: Upper and lower bearing halves are not interchangeable. Upper half is drilled and grooved to provide entry of oil.
7. Lightly oil bearing and journal surfaces. Partially install plain end of upper bearing in place. Insert Upper Bearing Remover/Installer (6331-E) into journal oil hole.
8. Turn crankshaft slowly in opposite direction of normal rotation until bearing is seated. Remove bearing remover/installer. Install and tighten main bearing cap. See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table in this article.

THRUST BEARING ALIGNMENT

1. Install thrust bearing cap after all other main caps have been tightened. Install thrust bearing cap bolts finger tight.
2. Pry crankshaft forward against thrust surface of upper half of bearing. Hold crankshaft forward and pry thrust bearing cap to rear. Tighten cap bolts, while holding forward pressure on crankshaft. (Scheme 8)

Scheme 8

REAR MAIN BEARING OIL SEAL

Note. Seal may be replaced without removing crankshaft from engine.

1. Remove starter and transmission. Remove pressure plate and clutch disc (if equipped). Remove flywheel and engine rear cover plate. Using an awl, punch hole in oil seal metal surface between lip and block.
2. Screw threaded end of Jet Plug Puller (T77L-9533-B) into hole and remove seal. Use care not to damage crankshaft oil seal surface. Clean oil seal recess in block and main bearing cap.

1. Inspect and clean crankshaft surface. Lightly coat crankshaft and new oil seal with engine oil. Start seal in place with lip facing inward. Use Seal Installer (T65P-6701-A) to drive in seal.
2. Keep installer straight in respect to centerline of crankshaft. Seal is properly installed when installer contacts cylinder block. Coat threads of flywheel bolts with oil resistant sealer. Reverse removal procedure to complete installation. See, in this article, «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#49l-6-cyl-vin-y) table .

1. Drain cooling system. Remove alternator drive belt. On A/C equipped vehicles, remove air compressor drive belt.
2. Remove fan, spacer and pulley. Disconnect heater hose, lower radiator hose, and radiator supply line at water pump. Remove water pump.

1. Clean all gasket mating surfaces. Transfer fittings to new pump. Coat new gasket on both sides with gasket sealer and position gasket on water pump.
2. Install water pump and tighten attaching bolts. Reverse removal procedure to install remaining components.

Note. For further information on cooling systems see WATER PUMP at end of REMOVAL & INSTALLATION section.

Note. See ENGINE OVERHAUL PROCEDURES section for detailed information on performing basic engine overhaul and checking procedures.

ENGINE OILING

Oil supply from pan is forced through lubrication system by rotor oil pump. Oil flows through full-flow oil filter, which routes oil into main oil gallery.

Oil gallery supplies oil to all internal engine bearings and lifters. Oil from lifters is forced through push rods to lubricate upper valve train area. Timing gears and chain are lubricated by splash method.

Crankcase Capacity

Crankcase capacity is 5 qts. (4.75L). Add 1 qt. (.95L) when replacing oil filter.

Oil Filter

Full-flow filter has an integral by-pass valve. Anti-drain back feature prevents reverse flow of oil when engine is shut down. Replace filter at first oil change, then every second oil change thereafter.

Normal Oil Pressure

Normal oil pressure is 40-60 psi (2.8-4.2 kg/cm 2 ) at 2000 RPM.

Oil Pressure Regulator Valve

Oil pressure regulator valve is located in pump body. Valve is nonadjustable.

Remove oil pan. Remove nut securing oil pump inlet tube bracket to engine, and remove oil pump attaching bolts. Remove oil pump assembly.

Note. Oil pump is serviced as an assembly only. See OIL PUMP SPECIFICATIONS table. Replace assembly if not within specifications.

OIL PUMP SPECIFICATIONS

Prime oil pump by filling inlet opening with oil and rotating pump shaft until oil emerges from outlet opening. Install and tighten oil pump to cylinder block.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVE/VALVE SPRING SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

VALVE FILTERS SPECIFICATIONS

VALVE FILTER SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• TORQUE SPECIFICATIONS
• VALVE CLEARANCE ADJUSTMENT