7.5l v8 - VIN [g] 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.

The eighth character of the Vehicle Identification Number (VIN) identifies engine. VIN is near windshield on left upper side of instrument panel. The VIN number is also on the Safety Compliance Certification Label, attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

Scheme 28

1. Rotate crankshaft, position No. 1 piston on TDC at end of compression stroke. Make chalk mark at points "A" and "B" on crankshaft pulley at TDC. (Scheme 28) Rotate crankshaft 360 degrees for mark "B".
2. Using Lifter Bleed-Down Wrench (T71B-6513-B), apply pressure to push rod end of rocker arm. Slowly bleed down lifter until lifter plunger is completely bottomed. See VALVE CLEARANCE ADJUSTMENT table.
3. While holding lifter in this position, check clearance between rocker arm and valve stem tip using feeler gauge. Desired collapsed lifter gap clearance is.100-.150" (2.54-3.81 mm). Allowable clearance is.075-.175" (1.90-4.45).
4. If clearance is less than specified, install a.060" (1.52 mm) shorter push rod. If clearance is greater, install a.060" (1.52 mm) longer push rod.

VALVE CLEARANCE ADJUSTMENT

FUEL SYSTEM PRESSURE RELEASE

Disconnect battery cable. Remove fuel tank cap. Remove cap from pressure relief valve located on fuel supply manifold and attach EFI Pressure Gauge (T80L-9974-B). Use pressure release button on gauge to bleed off pressure and fuel into an approved container.

Another method of depressurizing system is by disconnecting inertia switch and cranking engine for a minimum of 20 seconds.

ENGINE

See 5.0L, 5.8L & 7.5L V8 under REMOVAL & INSTALLATION in ENGINE REMOVAL article.

Removal (Upper)

1. Disconnect throttle and transmission linkage from throttle body. Remove 2 bolts securing bracket to intake manifold. Remove 2 canister purge lines from fittings on throttle body.
2. Unplug all electrical connectors and disconnect upper manifold vacuum connections. Disconnect EGR and PCV systems. Remove water heater lines from throttle body.
3. Remove 4 retaining bolts and remove upper intake manifold assembly.

Installation

To install, reverse removal procedure. Ensure that new gasket is aligned.

Removal (Lower)

1. Relieve fuel system pressure. Locate and disconnect electrical connection to either the fuel pump relay, inertia switch or the in-line fuel pump. Crank engine for approximately 10 seconds. If engine starts or runs for a short time, crank engine additional 5 seconds after it stalls. Disconnect fuel lines using Spring Lock Coupling Tool (T83P-19623-C).
2. Disconnect battery(s) and drain cooling system. Disconnect coolant hoses at intake manifold and water pump. Remove PCV valve and hose. Label and disconnect all vacuum hoses.
3. Disconnect spark plug and coil wires and valve cover brackets. Remove distributor cap and spark plug wires as an assembly. Remove distributor. Disconnect accelerator linkage, transmission kickdown linkage, and speed control linkage bracket (if equipped).
4. Remove accelerator linkage attaching bolts. Position all linkages out of way. Disconnect wiring harness from main wiring. Wiring harness and lower intake manifold may be removed as an assembly.
5. Label and disconnect all other electrical wiring from intake manifold. Remove coil and bracket assembly. Remove attaching bolts and lift intake manifold and throttle body from engine as an assembly.

1. Clean all gasket surfaces. Apply 1/8" bead silicone sealer to 4 corners of cylinder block seal mounting surface. Install manifold gasket and front and rear seals. Apply 1/16" bead silicone sealer along full width of front and rear seal ends.
2. Install intake manifold within 15 minutes of applying sealer. Position intake manifold over 4 studs in cylinder heads. Check for proper alignment of gaskets and seals before tightening.
3. Install manifold attaching bolts, studs and nuts. Tighten bolts in sequence to specification. (Scheme 29) See «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#75l-v8-vin-g__torque-specifications). Install fuel lines, electrical connectors and vacuum hoses. To install remaining components, reverse removal procedure.
4. Fill cooling system with 50/50 mixture of specified coolant and water. Pause several minutes for circulation. Fill radiator to filler neck seat. Disconnect heater outlet hose at water pump to bleed off trapped air. Fill radiator until coolant begins to escape. Connect heater outlet hose.
5. Fill radiator until coolant is between the cap seal in the filler neck to 1.5" (38 mm) below cap seal. Install radiator cap. Start engine and allow it to reach operating temperature. Turn off engine and retorque bolts and nuts sequentially to 22-35 ft. lbs. (30-47 N.m) to complete installation.

Scheme 29

Removal

1. If removing right exhaust manifold, remove spark plug heat shields. Remove spark plug wires from spark plugs. Disconnect thermactor air supply manifold.
2. Disconnect external EGR tube on left exhaust manifold. Disconnect exhaust manifolds at muffler inlet pipes. On Vans, remove power steering pump support bracket. Remove oil dipstick tube from left exhaust manifold.
3. Remove attaching bolts from left and right side exhaust manifold-to-cylinder head. Remove exhaust manifolds.

1. Clean mating surfaces of cylinder head and manifold. Clean mounting flange of manifold and exhaust pipe. Apply light film of graphite grease to manifold machined surface.
2. Position spark plug wire heat shields and exhaust manifold on cylinder head. Install attaching bolts and washers, starting at 4th bolt hole from front of each manifold. Tighten to specifications, starting with center bolts working to outer bolts.

1. Drain cooling system. Remove intake manifold and throttle body as an assembly. Disconnect exhaust pipes at manifolds. Loosen alternator attaching bolts and remove bolt attaching alternator bracket to right cylinder head.
2. Loosen A/C drive belt (if equipped). Shut off compressor at service valves and remove valves and hoses from compressor. Remove A/C compressor support bracket attaching nuts from water pump. Remove and position compressor aside. Remove compressor mounting bracket from cylinder head.
3. Remove thermactor air pump and assembly. Remove bolts attaching power steering reservoir bracket to left cylinder head. Position reservoir and bracket out of the way. Remove valve covers. Remove rocker arm assemblies and push rods in sequence.
4. Remove cylinder heads and exhaust manifolds as assemblies. Discard cylinder head gaskets. Remove exhaust manifolds.

1. Clean gasket mating surfaces. Check flatness of cylinder head and block mating surfaces. If exhaust manifolds were removed, install on cylinder head.
2. Place 2 long head bolts in 2 rear lower bolt holes of left cylinder head. Place one long head bolt in rear lower bolt hole of right cylinder head. Keep bolts in position until heads are installed.
3. Position head gaskets on block. DO NOT apply sealer to head gasket surfaces. Install and tighten cylinder heads in 3 steps. (Scheme 30)and «TORQUE SPECIFICATIONS»(/ford/econoline-e150/1987-1991/remont/mechanical/#75l-v8-vin-g__torque-specifications).
4. To complete installation, reverse removal procedure. Check and adjust valve clearance as needed. See «VALVE CLEARANCE»(/ford/econoline-e150/1987-1991/remont/mechanical/#75l-v8-vin-g) under ADJUSTMENTS.

Scheme 30

HYDRAULIC VALVE LIFTERS

1. Service lifters as an assembly only. Disassemble and clean lifters before testing. Test lifters with hydraulic lifter test fluid. DO NOT interchange parts between lifters.
2. Leak-down rate on hydraulic lifters is 10-50 seconds, with 1/16" (1.6 mm) plunger travel under 50 lb. (23 kg) load. Replace lifter if it fails leak-down test, or is worn or damaged.

1. Disconnect negative battery cable. Drain cooling system and crankcase. Remove fan and radiator shroud. Disconnect radiator hoses at engine and oil cooler lines at radiator and remove radiator.
2. Remove all drive belts and water pump pulley. Remove air pump. Remove A/C compressor support bracket from water pump (if equipped). Disconnect heater hose from water pump and loosen by-pass hose clamp at pump.
3. Remove crankshaft pulley. Using Crankshaft Damper Remover (T58P-6316-D), remove vibration damper and Woodruff key from crankshaft. Remove bolts attaching front cover to cylinder block.
4. Remove front cover and water pump as an assembly. Using a knife, cut oil pan seal flush with cylinder block face. Discard front cover gasket and pan seal.

Scheme 31

1. Coat gasket surface of oil pan with gasket sealer. Cut and position required section of new seal on oil pan. Apply silicone sealer at block-to-pan junction. Apply gasket sealer to front cover and cylinder block gasket surfaces.
2. Position front cover on cylinder block. Install Front Cover Seal Aligner (T68P-6019-A) on crankshaft. (Scheme 31) Coat threads of cover bolts with oil-resistant sealer and install bolts.
3. While pushing in on aligning tool, tighten oil pan-to-cover bolts. Remove aligning tool and tighten front cover-to-cylinder block bolts. To complete installation, reverse removal procedure.

Remove crankshaft pulley and vibration damper. Place Front Cover Remover (T70P-6B070-B) or equivalent onto front cover plate over front seal. Tighten 2 bolts forcing seal remover under seal flange. Alternately tighten 2 bolts a half of turn at a time until seal is removed from engine.

Coat new seal with polyethylene grease and install seal using Seal Installer (T70P-6B070-A). Reverse removal procedure to complete installation.

Checking Timing Chain Deflection

1. Remove engine front cover. Rotate crankshaft counterclockwise (as viewed from front of engine) to take up slack on left side of timing chain. Establish a reference point on the block and measure from this point to left side of chain. (Scheme 32)
2. Rotate crankshaft clockwise to take up slack on right side of chain. Force left side of chain outward and measure distance between reference point and chain.
3. Deflection is the difference between the 2 measurements. If deflection exceeds.50" (12.7 mm), replace timing chain and sprockets.

Turn crankshaft until timing marks are aligned. Remove camshaft sprocket bolt and washer. Slide timing chain and sprockets forward and remove as an assembly.

1. Assemble timing chain and sprockets so sprocket timing marks are aligned. (Scheme 32) Install chain and sprockets as an assembly.
2. Lubricate timing chain with engine oil. To complete installation, reverse removal procedure.

Scheme 32

1. Remove radiator, front cover, timing chain and sprockets. Remove intake manifold and throttle body as an assembly. Remove valve covers.
2. Loosen all rocker arm bolts. Rotate rocker arms to one side. Remove push rods and valve lifters, keeping them in order for installation in original locations. NOTE: If lifters are stuck in bores, use Hydraulic Lifter Puller (T70L-6500-A) to remove lifters.
3. If equipped, remove A/C condenser and carefully secure condenser to left fender well. Remove grille. Remove timing chain and gears. Remove camshaft thrust plate attaching bolts. Remove camshaft, ensuring not to damage camshaft bearings or journals.

Inspection - Camshaft End Play

1. Loosen rocker arm fulcrum bolts to relieve load on camshaft. Push camshaft rearward. Install Dial Indicator and Bracket (D78P-4201-C), so that indicator point is on camshaft sprocket attaching bolt. Zero dial indicator.
2. Pull camshaft forward and release. Check dial indicator reading to obtain end play. If end play is greater than .009" (.22 mm), replace camshaft thrust plate.

Inspection - Cam Lobe Lift

1. Remove valve cover. Remove fulcrum bolt, fulcrum seat and rocker arm. Ensure push rod end is in valve lifter socket.
2. Use a Dial Indicator and Bracket (D78P-4201-C) to check lobe lift in consecutive order. Position dial indicator point (or Cup-Shaped Adapter 6565-AB) on end of push rod (in same plane as push rod movement).
3. Turn crankshaft until lifter and push rod are at lowest position. Zero dial indicator. Turn crankshaft slowly until push rod is fully raised. Compare dial indicator reading with specifications.
4. Maximum allowable lobe wear is .005" (.13 mm). If lobe lift is insufficient, replace camshaft and valve lifter(s) operating on worn lobe(s).

1. Oil camshaft journals and apply polyethylene grease to camshaft lobes. Carefully slide camshaft into position. Install and tighten thrust plate.
2. Lubricate lifters with engine oil and install. Lubricate rocker arms, fulcrum seats, valve stem tips and push rods with polyethylene grease before installing.
3. To complete installation, reverse removal procedure. Use new gaskets where required.

Remove engine from vehicle. Remove camshaft, flywheel and crankshaft. Push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Using Camshaft Bearing Remover/Installer (T65L-6250-A), remove camshaft bearings.

Using camshaft bearing installer/remover, install bearings into place. Oil holes in bearings and cylinder block must be aligned. Install front bearing .040-.060" (1.02-1.52 mm) behind front face of cylinder block. Coat new rear bore plug with sealer and install.

1. Remove cylinder heads, oil pan and oil pump. Place piston at bottom of its stroke and cover with a cloth to collect metal cuttings. Use ridge reamer to remove ridge or deposits from upper end of cylinder bore. NOTE: Never cut more than 1/32" (0.79 mm) into ring travel area when removing ridge.
2. Ensure all connecting rods and caps are marked for cylinder identification. Remove rod cap. Push piston and rod out top of cylinder. Use care not to damage crankshaft journal or cylinder wall. Install rod cap on mating rod.

1. Coat cylinder bore, piston and rings with engine oil. Position ring gaps. (Scheme 33) Install ring compressor. Do not allow ring gaps to change.
2. Position crankshaft journal at bottom of stroke. Install piston with notch in top of piston facing toward center of engine.
3. Install and tighten connecting rod cap. Check side clearance of connecting rods on each crankshaft journal. Install cylinder heads, oil pump and oil pan.

Scheme 33

FITTING PISTONS & RINGS

For information on measuring pistons and rings see ENGINE OVERHAUL PROCEDURES in the ENGINE section.

PISTON SIZE CODES

Using an arbor press and using Piston Pin Remover/Installer (T68P-6135-A), press piston pin from piston and connecting rod. (Scheme 34) Check piston pin fit. If not within specifications, remove pin and measure pin bore in piston and rod. Replace if necessary.

Scheme 34

Scheme 35

1. Apply light coat of engine oil to all parts to be assembled. Assemble piston to connecting rod with numbered side of rod toward outside of engine and notch in piston head positioned forward. (Scheme 35)
2. Start piston pin in piston and connecting rod. Using arbor press and pin remover/installer, press pin into piston and connecting rod until end of pin is 1/16-1/8" (1.6-3.2 mm) below chamfer of piston pin bore.

CONNECTING ROD BEARINGS & MAIN BEARINGS

Ensure rod caps are marked for cylinder identification. Place crankshaft journal of cylinder to be checked at bottom of stroke and remove rod cap. Measure connecting rod side clearance after the bearings and caps have been installed.

To check bearing clearances and for further information on connecting rod and main bearings see ENGINE OVERHAUL PROCEDURES in the ENGINE section.

THRUST BEARING ALIGNMENT

1. Install thrust bearing cap after all other main bearing 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 thrust bearing cap bolts while retaining forward pressure on crankshaft.

1. Remove oil pan and oil pump. Loosen all main bearing cap bolts to slightly lower crankshaft. Do not lower more than 1/32" (.7938 mm). Remove rear main bearing cap and remove lower oil seal half. Use seal remover to remove upper seal.
2. If seal remover is not available, install a small metal screw in one end of seal. Pull on screw to remove seal. Use care not to damage crankshaft seal surface. If equipped, remove oil seal retaining pin from bearing cap. Pin is not used with split-lip type seal.

Scheme 36

1. Carefully clean oil seal grooves in bearing cap and block. Dip split-lip seal halves in engine oil. Carefully install upper seal into groove in cylinder block, with undercut side of seal toward front of engine. NOTE: Avoid damage to outside diameter of seal when installing in groove. Do not allow oil to get onto area where sealer will be applied.
2. Rotate seal on crankshaft journal until about 3/8" (9.525 mm) of seal protrudes below parting surface. (Scheme 36)
3. Tighten all main bearing cap bolts except rear main. Install lower seal in rear main bearing cap with undercut side of seal toward FRONT of engine.
4. Allow seal to protrude about 3/8" above parting surface to mate with upper seal when cap is installed. Apply 1/16" bead of silicone sealer to both sides of cylinder block-to-cap mating surface and to both sides of bearing cap. (Scheme 37)
5. Install and tighten rear main bearing cap before sealer sets up (about 15 minutes). To complete installation, reverse removal procedure.

Scheme 37

Valve Arrangement

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

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

ROCKER ARM ASSEMBLY

1. Inspect all rocker arm components for excessive wear or damage, and replace as necessary. Before installing rocker arm assembly, lubricate top of valve stem, fulcrum seat and socket area of rocker arm with polyethylene grease.
2. Insert fulcrum seat base in its slot on cylinder head before tightening fulcrum bolt.

1. Remove valve cover and spark plug from cylinder to be serviced. Rotate crankshaft until piston is at TDC at end of compression stroke. Remove rocker arms and push rods from valves to be serviced.
2. Install an air hose with adapter into spark plug hole and turn on air supply. DO NOT remove air pressure until valves are supported. Install rocker arm fulcrum bolt. Using Spring Compressor (T70P-6049-A), compress valve spring and remove retainer locks. Remove retainer, spring and oil seal.

Note. For further information on valve spring and hydraulic lifter diagnosis, see ENGINE OVERHAUL PROCEDURES article.

1. Hold valve closed and apply air pressure again. Install new valve stem oil seals. Place spring in position over valve and position spring retainer in place. Compress valve spring and install retainer locks.
2. Apply polyethylene grease to push rod ends, valve stem tip, fulcrum seats and sockets. Install push rods and rocker arms. Turn off air pressure. Remove air hose and adapter. To complete installation, reverse removal procedure.

VALVE SPRING INSTALLED HEIGHT

VALVE STEM OIL SEALS

Umbrella-type oil seals are used on all valves. Lubricate valve stem with engine oil and install new seal with cup side down over valve guide. Use a 5/8" deep-well socket and light mallet to seat seal on valve stem.

VALVE GUIDES

When reaming guides, always use reamers in proper sequence. Always reface valve seats and valves after valve guides are reamed. Replacement valves are available with standard, .015" (.38 mm), and .030" (.76 mm) oversize stems.

OIL PAN

1. Remove engine cover and disconnect battery. Drain cooling system. Disconnect and remove air cleaner assembly. Disconnect throttle and transmission linkage at throttle body. Disconnect fuel lines at fuel rail. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline-e150/1987-1991/remont/mechanical/#75l-v8-vin-g__fuel-system-pressure-release) .
2. Disconnect upper and lower radiator hoses. Disconnect transmission cooler lines (if equipped) at radiator. Disconnect engine cooler lines at oil filter adapter. Remove fan assembly and shroud. Remove radiator. Remove power steering pump bolts and secure out of way. Remove front engine mount through bolts.
3. Remove dipstick tube securing nuts and remove dipstick and tube. Rotate or remove A/C lines at rear of compressor to clear dash. Remove upper intake and throttle body assembly.
4. Raise vehicle. Drain engine oil and remove oil filter. Disconnect and remove muffler inlet pipe assembly. Disconnect shift linkage and kickdown linkage from transmission. Remove transmission dipstick assembly (if equipped). Remove drive shaft and coupling shaft assembly.
5. Place a transmission jack, with wooden support, under oil pan. Engine and transmission assembly will pivot around rear engine mount. Engine and transmission assembly must remain centered in engine compartment in order for it to be raised 4" (120 mm), measured at front engine mounts. Use wooden blocks to support engine assembly in this position.
6. Remove oil pan attaching bolts and lower oil pan. Remove 2 oil pump bolts and pick-up tube nut. Lower oil pump assembly into pan. Remove pan. To install, reverse removal procedure.

Raise engine at least 4" from engine mounts. Loosen oil pan attaching bolts and lower pan. Remove oil pump and oil inlet tube and lay assembly in pan. Remove pan with pump assembly.

Disassembly

Remove oil inlet tube from pump. Remove pump cover. Remove inner rotor, shaft and outer rotor from oil pump. Drill small hole in oil pressure relief valve cap. Insert self-threading sheet metal screw into cap and pull cap from chamber. Remove spring and plunger.

Inspection

1. Clean all parts thoroughly. Check pump housing, outer rotor, inner rotor, shaft and pump cover for damage, scoring or excessive wear. Remove rotor assembly from pump housing. Using feeler gauge, measure inner-to-outer rotor tip clearance.
2. Install rotor assembly in pump housing. Place a straightedge over rotor assembly and housing. Insert feeler gauge between straightedge and housing to measure rotor end play. Using a feeler gauge, measure clearance between outer rotor and pump housing.
3. Measure shaft outside diameter and housing bearing inside diameter. Difference between readings is shaft-to-housing bearing clearance.
4. Relief valve spring pressure is 20.6-22.6 lbs. (9-10 kg) at 2.49" (63.5 mm). Inspect relief valve spring for worn or collapsed condition. Check relief valve plunger for scores and free operation in bore. Check clearance between relief valve plunger and bore.

OIL PUMP SPECIFICATIONS

Assembly

Clean and oil all parts thoroughly. Install relief valve plunger, spring and cap. Stake cap into position. To complete assembly, reverse disassembly procedure.

Prime oil pump. To install oil pump, reverse removal procedure. Use new gaskets.

1. Drain cooling system. Remove fan shroud and fan. Loosen power steering pump attaching bolts. Remove upper A/C compressor bracket. Remove A/C idler pulley and bracket assembly (if equipped).
2. Remove all drive belts. Remove air pump, alternator and bracket, and power steering pump. Disconnect all hoses from water pump, and loosen by-pass hose clamp at pump. Remove remaining attaching bolts and water pump. Remove separator plate from water pump and discard gaskets.

To install, reverse removal procedure. Use new gaskets coated on both sides with water-resistant sealer.

Note. For further information on cooling systems, see ENGINE COOLING SYSTEMS in the ENGINE section.

Note. See ENGINE OVERHAUL PROCEDURES article in the ENGINE section for basic procedures not covered in this article.

ENGINE OILING SYSTEM

Distributor driven oil pump provides full-pressure lubrication to all camshaft and crankshaft bearings. Engine feeds oil through hydraulic valve lifters and hollow push rods to rocker arms and upper valve train area. Timing chain and sprockets are lubricated by drainage from No. 1 camshaft bearing.

Note. On all engines discharge A/C and remove A/C lines to remove oil pan (if necessary).

Crankcase Capacity

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

Oil Filter

Change filter at first oil change and at every other oil change thereafter.

Normal Oil Pressure

Normal oil pressure at operating temperature should be 40-65 psi (2.8-4.6 kg/cm 2 ) at 2000 RPM.

Oil Pressure Regulator Valve

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

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

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
• 5.0L, 5.8L & 7.5L V8
• TORQUE SPECIFICATIONS
• VALVE CLEARANCE
• FUEL SYSTEM PRESSURE RELEASE