Material — Part 3 Ford Econoline E350 Super Duty

Scheme 730

1. Remove the four fuel rail bolts.
2. Remove the bolts from the fuel pressure regulator (FPR). Remove the fuel rail and injectors as an assembly.
3. Remove the fuel injectors from the fuel rail.
4. Remove and discard the O-ring seals from each fuel injector.
5. Separate the upper and lower intake manifolds. Remove the bolts. Discard the intake manifold gasket.
6. Using a metal surface prep, clean and inspect the upper and lower manifold internal passengers and mating surfaces.
7. Allow the upper and lower intake manifolds to dry completely.

Scheme 731

Scheme 732

1. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.
2. Tighten the bolts in two stages, using the sequence (Scheme 745) Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
3. Install new O-ring seals on each fuel injector.
4. Install the fuel injectors into the fuel rail.
5. Position the fuel rail. Install the bolts for the FPR sensor.
6. Install the four fuel rail bolts.

MATERIAL SPECIFICATIONS

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart, determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is a "2." Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in 3 and the Bearing Select Fit Chart (Scheme 751), Oversize Bearings chart to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.
8. Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.
9. Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.
10. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the bolts.
12. Install the 10 dowel pins so that the flat sides face the crankshaft. Install the cross-mounted bolts.
13. Tighten fasteners 1 through 12 in two stages, in the sequence (Scheme 753) Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
14. Tighten fasteners 13 through 24 in two stages, in the sequence see scheme 461 Stage 1: Tighten to 30 Nm (22 lb-ft). Stage 2: Tighten an additional 90 degrees.
15. Using the special tools, install the piston and connecting rod assembly.
16. Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.
17. Install the connecting rod bearings, position the connecting rod cap and loosely install the two new bolts.
18. Tighten the connecting rod bolts in the sequence see scheme 463 Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
19. Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
20. Install the oil filter adapter.
21. Install the front engine support insulators.
22. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence see scheme 465
23. Rotate the crankshaft to position the keyway at 12 o'clock.
24. Install the head gasket over the dowel pins.
25. Install the special tool.
26. Install the special tool.
27. Install the cylinder head on the head gasket. Remove the special tool and loosely install the bolt.
28. Remove the special tool.
29. Tighten the bolts in the sequence see scheme 472 Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
30. Position the oil level indicator and install the nut attaching the oil level indicator tube to the front of the engine.
31. Install the bolt attaching the oil level indicator tube to the rear of the engine.
32. Install the left and right exhaust manifold gaskets and exhaust manifolds. Loosely install the nuts. Tighten the nuts in the sequence see scheme 475
33. Compress the tensioner plunger, using a vise.
34. Install a retaining clip on the tensioner to hold the plunger in during installation.
35. Remove the tensioner from the vise.
36. If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.
37. Install the timing chain guides.
38. Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
39. Position the crankshaft with the special tool.
40. Remove the special tool.
41. Install the crankshaft sprocket, making sure the flange faces forward.
42. Install the lower end of the LH (inner) timing chain, aligning the timing marks.
43. Position the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.
44. Position the RH (outer) timing chain on the crankshaft sprocket.
45. Position the RH timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.
46. As a post-check, verify timing mark alignment.
47. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
48. Remove the retaining clip from the LH timing chain tensioner.
49. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
50. Remove the retaining clip from the RH timing chain tensioner.
51. Lubricate the balance shaft journals with clean engine oil.
52. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.
53. Position the balance shaft on the journals.
54. Align the chalk mark on the balance shaft with the camshaft timing mark (Scheme 764)
55. Install the bearing caps in their original locations and install the bolts. Tighten the bolts in the sequence see scheme 495
56. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
57. Install the special tool between the valve spring coils to prevent valve stem seal damage.
58. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
59. Position the crankshaft sensor ring.
60. Apply a bead of silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface as specified.
61. Install a new engine front cover gasket onto the engine front cover, then position the engine front cover on the front cover to cylinder block dowel.
62. 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).
63. Install the belt idler pulley and tighten the bolt.
64. Position the oil pump screen and pickup tube. Install and tighten the spacer. Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer. Install and tighten the bolts.
65. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
66. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
67. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
68. Install the oil pan. Tighten the bolts in the sequence (Scheme 770) Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 90 degrees.
69. Install the oil drain plug.
70. Install the water pump. Lubricate the new O-ring seal, using engine coolant, and install the O-ring seal onto the coolant pump. Position the coolant pump into the cylinder block. Install the coolant pump retaining bolts.
71. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
72. Using the special tool, install the crankshaft front seal.
73. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
74. Using the special tool, install the crankshaft pulley.
75. 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.
76. Position the coolant pump pulley on the coolant pump and install the bolts.
77. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
78. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
79. Position the valve covers.
80. Tighten the bolts in the sequence (Scheme 777)
81. Install the engine control sensor wiring harness. Connect all of the harness routing clips and connector retainers.
82. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
83. Connect the camshaft position (CMP) electrical connector.
84. Connect the RH radio frequency interference capacitor electrical connector.
85. Connect the knock sensor electrical connector, if equipped.
86. Connect the crankshaft position (CKP) sensor electrical connector.
87. Connect the oil pressure switch electrical connector.
88. Attach the special tool.
89. Remove the engine from the engine stand.
90. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
91. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
92. Install the retainer plate. Tighten the bolts in two stages. Stage 1: Tighten the retainer plate bolts to 10 Nm (89 lb-in), in the sequence see scheme 525 Stage 2: Tighten the oil pan bolts to 20 Nm (15 lb-ft), then tighten an additional 90 degrees.
93. Using the special tools, install a new crankshaft rear seal.
94. Using the special tools, install the crankshaft rear oil slinger.
95. Install the flexplate in the following sequence.

MATERIAL SPECIFICATION

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

1. Position the engine in the vehicle.
2. Remove the floor crane and the jack supporting the transmission.
3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
4. Position the shifter cable support bracket and install the two transmission-to-engine bolts.
5. Install the RH lower transmission-to-engine bolt.
6. Install the shift cable to the mounting bracket and shift linkage.
7. Install four new nuts to retain the torque converter to the flexplate. Rotate the crankshaft to access all of the torque converter nuts.
8. Install the cylinder block opening cover.
9. Install the flexplate inspection cover.
10. Install the four engine mount nuts.
11. Install the starter motor. Position the starter. Install the two bolts. Install the stud bolt.
12. Connect the starter motor electrical connections.
13. Install the starter motor solenoid terminal cover.
14. Mount the exhaust system to the LH and RH exhaust manifolds.
15. Position a new oil cooler on the oil filter adapter and install the threaded insert.
16. Install a new oil filter.
17. Connect the oil cooler hoses.
18. Position the transmission fluid cooler tube support bracket and install the nut.
19. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
20. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
21. Install and tighten the oil drain plug.
22. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the four upper transmission-to-engine bolts.
23. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
24. Insert the heater outlet tube over the new seals.
25. Install the heater outlet tube studs.
26. Position the transmission fluid filler tube in the vehicle. Connect the HO2S electrical connector.
27. Connect the hose to the heater outlet tube.
28. Install the wiring retainers in the heater outlet tube bracket. Install the knock sensor electrical connector retainer. Install the engine harness routing clip retainer.
29. Connect the evaporative emission canister purge valve electrical connector.
30. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator. Connect the rear heater hose hanger. Install the fluid level indicator.
31. Install the engine oil filler tube support strap bolt.
32. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
33. Connect the engine wiring harness electrical connectors.
34. Connect the powertrain control module (PCM) electrical connectors.
35. Connect the engine wiring harness to the PCM bracket.
36. Connect the lower radiator hose to the oil filter adapter coolant inlet.
37. Position the lower radiator support and install the twelve bolts.
38. Install the RH side of the headlamp dash panel junction wiring harness. Connect the electrical connector. Install the screw. Insert the routing clips.
39. Install the LH side of the headlamp dash panel junction wiring harness. Install the screw. Insert the routing clips.
40. Position the RH and LH air deflectors and install the pin-type retainers.
41. Position the upper radiator support and install the eight bolts.
42. Connect the horn electrical connector.
43. Connect the front impact severity sensor electrical connector.
44. If equipped, connect the air temperature sensor electrical connector.
45. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
46. Install the battery feed cable to the power distribution box.
47. Install the power steering reservoir.
48. Install the hood latch. Install the hood latch. Insert the cable routing clip.
49. Install the A/C condenser core. Position the A/C condenser core in the vehicle. Position the A/C condenser brackets. Install the bolts.
50. Connect the condenser core refrigerant tubes. Connect the condenser to evaporator tube. Connect the compressor discharge tube.
51. Connect the compressor suction tube.
52. Connect the A/C pressure cutoff switch electrical connector.
53. Position the radiator in the vehicle.
54. Position the radiator support brackets and install the bolts.
55. Position the fan shroud and the fan and fan clutch in the vehicle, and install the bolts.
56. Insert the degas hose retainer in the fan shroud.
57. Install the fan blade assembly and fan clutch. Install the fan blade and the fan clutch. Using the special tool, hold the coolant pump pulley. Using the special tool, tighten the fan clutch nut.
58. Connect the upper radiator hose and the degas hose to the radiator.
59. Install the valance panel. For additional information, refer to «FRONT END BODY PANELS»(ref-231417) .
60. Connect the transmission cooler tubes.
61. Position the splash shield and install the pushpin retainers.
62. Connect the lower radiator hose to the radiator. Connect the hose. Connect the hose hanger.
63. Install the front bumper. For additional information, refer to «BUMPERS»(ref-231425) .
64. Fill the engine with clean engine oil.
65. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-231366-S37433118952006050800000) .
66. Fill all fluids to the correct levels. Fill the transmission with clean transmission fluid. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(ref-231385) . Fill the power steering system with clean fluid. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-231357) .
67. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
68. Evacuate and recharge the air conditioning system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-231392) .

MATERIAL SPECIFICATIONS

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

1. Install the head gaskets over the dowel pins.
2. Install the special tool.
3. Remove the special tool and loosely install cylinder head bolts.
4. Tighten the cylinder head bolts in three stages in the sequence see scheme 590 Stage 1: Tighten the bolts to 40 Nm (30 lb-ft). Stage 2: Tighten the bolts an additional 90 degrees. Stage 3: Tighten the bolts an additional 90 degrees.
5. Tighten the cylinder head bolts in three stages in the sequence see scheme 591 Stage 1: Tighten the bolts to 40 Nm (30 lb-ft). Stage 2: Tighten the bolts an additional 90 degrees. Stage 3: Tighten the bolts an additional 90 degrees.
6. Remove the lifting handles from both ends of the cylinder head.
7. Install the hydraulic lash adjusters in their original locations.
8. Using new gaskets, install the RH exhaust manifolds. Tighten the nuts in the sequence see scheme 594
9. Using new gaskets, install the LH exhaust manifold. Tighten the nuts in the sequence see scheme 595
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger during installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides.
15. Preposition the camshafts. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
16. Position the crankshaft so the number one cylinder is at TDC with the special tool.
17. Remove the crankshaft holding tool.
18. Install the crankshaft sprocket, making sure the flange faces forward.
19. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
20. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
21. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
22. Remove the retaining clip from the LH timing chain tensioner.
23. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
24. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
26. Remove the retaining clip from the RH timing chain tensioner.
27. As a post-check, verify correct alignment of all timing marks.
28. Install the special tool between the valve spring coils to prevent valve stem seal damage.
29. Install the camshaft roller followers. Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
30. Install the 10 spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
31. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
32. Position the balance shaft on the journals.
33. It may be necessary to use an inspection mirror to see the marks. Align the chalk mark on the balance shaft with the camshaft timing mark see scheme 616
34. Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence see scheme 617
35. Install the crankshaft sensor ring on the crankshaft.
36. 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 see scheme 619
37. Install a new front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners.
38. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
39. Loosely install the bolts, then tighten in two stages, in the sequence see scheme 622 Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
40. Position the belt idler pulley and install the bolt.
41. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
42. Using the special tools, install the crankshaft front seal.
43. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
44. Use the special tool to install the crankshaft pulley.
45. Tighten the new crankshaft 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.
46. Position the coolant pump pulley on the coolant pump and install the bolts.
47. Position the power steering pump and install the bolts.
48. Apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
49. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
50. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
51. Tighten the bolts in the sequence see scheme 634
52. Apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
53. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
54. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
55. Tighten the bolts in the sequence see scheme 638
56. Position the oil level indicator tube.
57. Install the bolt attaching the oil level indicator tube to the rear of the engine.
58. Install the nut attaching the oil level indicator tube to the front of the engine.
59. Connect the crankcase vent tube to the valve cover.
60. Install the radio frequency interference capacitors.
61. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
62. Connect the crankshaft position (CKP) sensor electrical connector.
63. Connect the oil pressure switch electrical connector.
64. Connect the knock sensor electrical connector, if equipped.
65. Connect the RH radio frequency interference capacitor electrical connector.
66. Connect the camshaft position (CMP) sensor electrical connector.
67. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
68. Install the cylinder block drain plugs.
69. Install the RH engine mount. Tighten the bolts to 63 Nm (46 lb-ft).
70. Install the special tool.
71. Install the special tool.
72. Install the special tool and remove the engine from the work stand.
73. Lower the engine onto wooden blocks.
74. Remove the special tool.
75. Remove the special tool.
76. Install the special tool and raise the engine.
77. Position the flexplate and loosely install the bolts. Tighten the bolts in the sequence see scheme 657
78. Install the engine. For additional information refer to «Engine»(ref-231366-S03436327682006050800000).