ENGINE-6.8L: Removal & Installation Ford Econoline E250

Removal

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1. Relieve the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
4. Remove the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
5. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .
6. Disconnect the fuel hose spring lock coupling. For additional information, Refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) .
7. Remove the accelerator cable splash shield.
8. Compress and slide the hose clamp and disconnect the coolant hose.
9. Disconnect the coolant temperature sensor electrical connector.
10. Remove the bolt and the bracket.
11. Remove the bolts and the generator upper support bracket.
12. Discount the heater hose.
13. Disconnect the throttle position (TP) sensor. Disconnect the electrical connector. Detach the harness routing clip.
14. Disconnect the throttle body control linkage. Disconnect the accelerator pedal. Disconnect the speed control actuator cable. Disconnect the throttle control return spring.
15. Remove the bolts and position the accelerator cable bracket and cables aside.
16. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.
17. Remove the four retainers from the fuel charging wiring harness and position the wiring harness away from the fuel injection supply manifold.
18. Remove the nut from the transmission fluid indicator tube rear bracket and position the tube aside.
19. If equipped, disconnect the auxiliary heater hoses and position them aside. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
20. Disconnect the evaporative emission canister purge valve hose and the vacuum hose.
21. Remove the two evaporative emission canister purge valve bracket nuts and position the valve and bracket assembly aside.
22. Disconnect and remove the idle air control (IAC) valve fresh air hose.
23. Disconnect the IAC valve electrical connector.
24. Disconnect and remove the positive crankcase ventilation (PCV) hose.
25. Disconnect the brake booster and the main engine vacuum harness and position aside.
26. Remove the four bolts, the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
27. Disconnect the 10 fuel injector electrical connectors.
28. Disconnect the 10 ignition coil electrical connectors.
29. Remove the screws and the 10 coils.
30. Disconnect the cylinder head temperature (CHT) sensor electrical connectors.
31. Remove the bolts and the thermostat housing.
32. Remove the bolts, the intake manifold and the intake manifold gaskets.
33. Clean and inspect the mating surfaces.

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1. Install the intake manifold. Position the intake manifold gaskets and the intake manifold, and loosely install the bolts.
2. Install the thermostat housing.
3. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft).
4. Install the screws and the 10 coils. Apply dielectric grease to the inside of the coil boots.
5. Connect the cylinder head temperature (CHT) sensor electrical connectors.
6. Connect the 10 ignition coil electrical connectors.
7. Connect the 10 fuel injector electrical connectors.
8. Install the throttle body adapter gasket and the throttle body and adapter as an assembly. Tighten the bolts in two stages. Stage 1: Tighten the bolts to 9 Nm (80 lb-in). Stage 2: Tighten the bolts an additional 90 degrees (1/4 turn).
9. Install the positive crankcase ventilation (PCV) hose.
10. Connect the brake booster and the main engine vacuum harness.
11. Connect the idle air control (IAC) valve electrical connector.
12. Install the IAC valve fresh air hose.
13. Install the evaporative emission canister purge valve and bracket.
14. Connect the evaporative emission canister purge valve hose and the vacuum hose.
15. If equipped, connect the auxiliary heater hoses. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
16. Position the transmission fluid indicator tube and install the nut on the rear bracket.
17. Install the four retainers on the fuel charging wiring harness.
18. Install the transmission fluid level indicator tube and bracket retaining nut.
19. Install the accelerator cable routing bracket.
20. Connect the throttle body linkage. Connect the accelerator cable. Connect the speed control actuator cable. Connect the throttle control return spring.
21. Connect the throttle position (TP) sensor. Connect the electrical connector. Attach the harness routing clip.
22. Connect the coolant hose.
23. Install the generator upper support bracket.
24. Install the accelerator cable routing bracket.
25. Connect the coolant temperature sensor electrical connector.
26. Install the upper radiator hose.
27. Install the accelerator cable snow shield.
28. Connect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) .
29. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
30. Install the interior engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
31. Install the air cleaner assembly and tubes. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
32. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-210139) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210138-S31505530742005121300000) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Remove the six bolts and remove the balance shaft bearing caps.
4. Remove the balance shaft.
5. Position the crankshaft with the keyway at the 12 o'clock position.
6. Install and carefully tighten the special tool on the camshafts.
7. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
8. Remove the LH and RH timing chain and the crankshaft sprockets. 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 from the crankshaft sprocket.
9. Remove the timing chain guides. Remove the bolts. Remove the timing chain guides.
10. On engine with bolt-on sprockets, remove the camshaft sprocket. Remove the bolt. Remove the camshaft sprocket.

Installation

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1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
4. On engines equipped with bolt-on sprockets, install the camshaft sprocket (2). Install the bolt (1). Tighten the bolt. M10 bolt: Tighten in two stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. M12 bolt: Tighten to 120 Nm (90 lb-ft).
5. Install the timing chain guides.
6. Preposition the camshafts. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tool to maintain camshaft prepositioning.
7. Position the crankshaft with the special tool, then remove the tool.
8. Install the crankshaft sprocket, making sure the flange faces forward.
9. Install the lower end of the LH timing chain, aligning the timing marks.
10. Install the LH timing chain on the camshaft sprocket with the two chain (marked) links and the timing marks aligned.
11. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
12. Install the RH (outer) timing chain on the crankshaft sprocket.
13. Position the timing chain on the camshaft sprocket. Make sure the two copper-colored (marked) links align with the camshaft sprocket timing mark.
14. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts.
15. Remove the retaining clips from the RH and LH timing chain tensioners.
16. Check for correct alignment of all timing marks.
17. Remove the special tools from the camshafts.
18. Install the crankshaft sensor ring on the crankshaft.
19. Lubricate the balance shaft journals with clean engine oil.
20. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
21. Position the balance shaft on the journals.
22. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
23. Install the bearing caps in their original locations. Install the bolts and tighten the bolts in the sequence shown.
24. Install engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210138-S31505530742005121300000) .

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1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-210138-S02948365502005121300000) .
2. Use the special tool to compress the valve springs and remove the camshaft roller followers.
3. Removal the bolts the camshaft bearing caps and the camshaft from the cylinder block.

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1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the camshaft bearing caps in their original locations onto the cylinder head. Loosely install the 15 bolts.
3. Tighten the bolts in the sequence shown.
4. Use the special tool to compress the valve springs and install the camshaft roller followers.
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-210138-S02948365502005121300000) .

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Remove the nuts.
4. Remove the 10 nuts, the exhaust manifold, and the exhaust manifold gasket. Discard the exhaust manifold gasket.
5. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
6. To install, reverse the removal procedure. Install a new exhaust manifold gasket.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the nuts.
3. Remove the exhaust manifold nuts and the exhaust manifold. Discard the exhaust manifold gaskets.
4. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
5. To install, reverse the removal procedure.