Material — Part 1 Ford Econoline E350 Super Duty

Material

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 592

Scheme 593

Scheme 594

Scheme 595

Scheme 596

Scheme 597

Scheme 598

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
4. Disconnect the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
5. Remove the bolts and position the LH fuel charge wiring harness aside.
6. Disconnect the five fuel injector electrical connectors.
7. Disconnect the five ignition coil electrical connectors.
8. Disconnect the pushpin retainers from the powertrain control module (PCM) bracket.
9. Lift the fuel charging wiring off the valve cover studs.
10. Loosen the retaining nut.
11. Remove the bolt and position the oil level indicator and tube aside.
12. Disconnect the wiring retainers from the valve cover studs.
13. 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. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

1. 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 the valve cover gasket on the cylinder head and loosely install the bolts.
4. Tighten the bolts in the sequence (Scheme 603)
5. Connect the wiring retainers on the valve cover studs.
6. Position back the oil level indicator and tube. Install the bolt.
7. Tighten the retaining nut.
8. Position the fuel charging wiring onto the valve cover studs.
9. Connect the pushpin retainers to the PCM bracket.
10. Position the LH fuel charge wiring harness and install the bolts.
11. Connect the five fuel injector electrical connectors.
12. Connect the five ignition coil electrical connectors.
13. Connect the PCV valve tube to the LH valve cover.
14. Install the engine air cleaner and engine air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380).
15. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379).
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
4. Disconnect the electrical connectors.
5. Disconnect the electrical connector position retainers, remove the nut, ground strap and mounting bracket.
6. Disconnect the oil fill tube from the RH valve cover.
7. Remove the bolt and the oil fill tube.
8. Disconnect the positive crankcase ventilation (PCV) electrical connector, tube and remove the PCV valve by rotating counterclockwise.
9. Disconnect the wiring harness retainers from the RH valve cover studs.
10. Remove the pushpin retainers and the splash shield.
11. Disconnect the A/C compressor and the crankshaft position (CKP) sensor connectors and remove the tie-strap.
12. Remove the transmission fluid filler tube nut.
13. Remove the retaining nut and position the transmission fluid indicator and tube aside.
14. Remove the stud bolts and position the RH fuel charge wiring harness aside.
15. Disconnect the five ignition coil electrical connectors.
16. Disconnect the five fuel injector electrical connectors. Lift the fuel charging wiring off the valve cover.
17. Disconnect the electronic throttle body (TB) electrical connector.
18. Position the fuel charging wiring into the passenger compartment.
19. Remove the five bolts and the RH ignition coils.
20. 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. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

1. 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 the valve cover gasket on the cylinder head and loosely install the bolts.
4. Tighten the bolts in the sequence (Scheme 617)
5. Install the five RH ignition coils and the bolts.
6. Position the fuel charging wiring harness on to the engine.
7. Connect the electronic TB electrical connector.
8. Position the RH fuel charge wiring harness and install the stud bolts.
9. Position back the transmission fluid indicator and tube. Install the retaining nut.
10. Connect the five fuel injector electrical connectors.
11. Connect the five ignition coil electrical connectors.
12. Install the transmission fluid filler tube nut.
13. Connect the A/C compressor and the CKP sensor connectors and install a tie-strap.
14. Position the splash shield and install the pushpin retainers.
15. Connect the wiring harness retainers to the RH valve cover studs.
16. Install the PCV valve by rotating clockwise and connect the PCV tube and electrical connector.
17. Connect the oil fill tube to the RH valve cover.
18. Install the oil fill tube support bracket bolt.
19. Position the mounting bracket, ground strap and install the nut. Connect the electrical connector retainers to the support bracket.
20. Connect the electrical connectors.
21. Install the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380).
22. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379).
23. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

Scheme 620

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-231358) .
4. Remove the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

Scheme 621

Scheme 622

1. Apply silicone gasket and sealant to the woodruff key slot in the crankshaft pulley.
2. Use the special tool to install the crankshaft pulley.
3. Tighten the 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.
4. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-231358) .
5. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .

MATERIAL SPECIFICATIONS

Scheme 623

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-231366-S40646428732006050800000) .
2. Using the special tool, remove the crankshaft front seal.

Scheme 624

Scheme 625

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»(ref-231366-S40646428732006050800000) .

MATERIAL SPECIFICATIONS

Scheme 626

Scheme 627

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Remove both of the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-231366-S05233704782006050800000) and «VALVE COVER - RH»(ref-231366-S19092288982006050800000) .
4. Remove the radiator. For additional information, refer to «ENGINE COOLING»(ref-231368) .
5. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-231368) .
6. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-231366-S17820143772006050800000) .
7. Remove the top bolts and the lower bolt and position the power steering pump aside.
8. Disconnect the wiring harness from the bracket.
9. Remove the retaining nut. Disconnect the tubes and remove the bracket.
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Remove the drain plug and drain the engine oil.
12. Remove the four front oil pan bolts.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Remove the bolt and the accessory drive belt idler pulley.
15. Remove the bolts.
16. Remove the engine front cover from the front cover-to-cylinder block dowel. Remove 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 635

Scheme 636

Scheme 637

Scheme 638

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 638)
2. Install the engine front cover with the engine front cover gasket on the engine front cover-to-cylinder block dowel and loosely install the bolts.
3. Tighten the engine front cover fasteners in sequence in two stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
4. Position the accessory drive belt idler pulley and install the bolt.
5. Connect the CMP electrical connector.
6. Loosely install the bolts, then tighten the bolts in two stages, in the sequence see scheme 125 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
7. Connect the CKP sensor electrical connector.
8. Install the bracket and connect the tubes. Install the retaining nut.
9. Connect the wiring harness to the bracket.
10. Position the power steering pump and install the bolts.
11. Install the oil drain plug.
12. Install a new crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-231366-S17820143772006050800000).
13. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-231366-S05233704782006050800000) and «VALVE COVER - RH»(ref-231366-S19092288982006050800000).
14. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(ref-231368).
15. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-231368).
16. Fill the engine with clean engine oil.
17. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356).

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 639

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-231366-S27580012382006050800000) .
2. Use the special tool to compress the valve springs and remove the camshaft roller followers.
3. Remove the bolts, the camshaft bearing caps and the camshaft from the cylinder block.

Scheme 640

Scheme 641

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 see scheme 164
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-231366-S27580012382006050800000).

Scheme 642

Scheme 643

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Remove the four exhaust Y-pipe flange 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-231364) .
6. To install, reverse the removal procedure. Install a new exhaust manifold gasket.

Scheme 644

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
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-231364) .
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 645

Scheme 646

Scheme 647

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .
2. Drain the engine oil.
3. Disconnect the coolant hoses.
4. Remove the oil filter.
5. Remove the threaded insert and the oil cooler. Inspect the oil cooler.
6. To install, reverse the removal procedure. Fill the engine with clean engine oil before filling the cooling system.

MATERIAL SPECIFICATION

Scheme 648

1. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
2. Remove the oil level indicator and the nut retaining the oil level indicator tube and bracket assembly.
3. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-231366-S34220912382006050800000) .
4. Remove the bolt and the oil level indicator tube.
5. Inspect the oil level indicator tube for damage.
6. To install, reverse the removal procedure. Install new O-ring seals and lubricate them with clean engine oil.

MATERIAL SPECIFICATIONS

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
3. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(ref-231368) .
4. Remove the retainers and the shield.
5. Remove the stud bolts and position the heater outlet tube aside.
6. Remove the two transmission-to-engine bolts.
7. Disconnect the oil fill tube from the RH valve cover.
8. Remove the bolt and the oil fill tube.
9. Assemble the special tools.
10. Install the special tools.
11. Install the special tool and support the engine.
12. Drain the engine oil and remove the oil filter.
13. Remove the nut and position the transmission fluid cooler tube support bracket aside.
14. Remove the RH and LH nuts retaining the front engine support insulators to the front engine support bracket.
15. Remove the flywheel inspection plate.
16. Using the special tool, raise the engine.
17. Remove the bolts and partially lower the oil pan.
18. Remove the bolts retaining the oil pump screen cover and pickup tube and allow it to drop into the oil pan. Also remove the tube and spacer and allow it to drop into the oil pan. Remove the oil pan.
19. Clean the mating surfaces for the oil pan and the engine with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Scheme 659

Scheme 660