Engine - 6.8L- E350 & E450: Removal & Installation Ford Econoline E350 Super Duty

Removal

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

1. Relieve the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-231389) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
3. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
4. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
5. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .
6. Remove the generator. For additional information, refer to «HEATING & VENTILATION»(ref-231395) .
7. Disconnect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-231389) .
8. Compress and slide the hose clamp and disconnect the coolant hose.
9. Disconnect the electronic throttle body (TB) electrical connector.
10. Disconnect the throttle position (TP) sensor electrical connector.
11. Disconnect the positive crankcase ventilation (PCV) hose and engine vacuum harness.
12. Disconnect the PCV coolant hoses.
13. Disconnect the brake booster and evaporative emission hose.
14. Remove the four bolts, the throttle body and adapter as an assembly. Discard the throttle body adapter gasket.
15. Disconnect the heater hose.
16. Disconnect the vacuum connector.
17. Disconnect the fuel rail pressure (FRP) sensor electrical connector.
18. Disconnect the 10 fuel injector electrical connectors.
19. Disconnect the 10 ignition coil electrical connectors.
20. Remove the retaining nut for the transmission fluid indicator and tube.
21. Remove the transmission fluid level indicator tube bracket retaining nut and position the tube aside.
22. Remove the stud bolts and position the RH fuel charge wiring harness aside.
23. Remove the bolts and position the LH fuel charge wiring harness aside.
24. Remove the screws and the 10 coils.
25. Disconnect the pushpin retainer from the intake manifold bracket.
26. Remove the bolts, thermostat housing and thermostat. Remove and discard the O-ring seal.
27. Remove the bolts, the intake manifold and the intake manifold gaskets.
28. Clean and inspect the mating surfaces. Clean the intake manifold mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

1. Install the intake manifold. Position the intake manifold gaskets and the intake manifold, and loosely install the bolts.
2. Install the thermostat housing. Install the thermostat. Install a new O-ring seal.
3. Install the thermostat housing and loosely install the bolts.
4. 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).
5. Connect the pushpin retainer to the intake manifold bracket.
6. Install the screws and the 10 coils.
7. Position back the LH fuel charge wiring harness and install the bolts.
8. Position back the RH fuel charging wiring harness and install the stud bolts.
9. Position back the transmission fluid level indicator tube and install the retaining nut.
10. Install the retaining nut on the transmission fluid indicator and tube.
11. Connect the 10 ignition coil electrical connectors.
12. Connect the 10 fuel injector electrical connectors.
13. Connect the fuel rail pressure (FRP) sensor electrical connector.
14. Connect the vacuum connector.
15. Connect the coolant hose.
16. 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).
17. Connect the brake booster and evaporative emission hose.
18. Connect the positive crankcase ventilation (PCV) coolant hose.
19. Connect the heated PCV tube and engine vacuum harness.
20. Connect the throttle position (TP) sensor electrical connector. Push in the red clip.
21. Connect the electronic throttle body (TB) electrical connector. Push in the red clip.
22. Install the upper radiator hose.
23. Connect the fuel hose spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-231389) .
24. Install the generator. For additional information, refer to «GENERATOR AND REGULATOR»(ref-231403) .
25. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
26. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
27. Install the air cleaner assembly and tubes. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-231380) .
28. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-231368) .

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-231366-S10042982142006050800000) .
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. Remove the bolts, flat washers, camshaft sprockets and right camshaft spacer.

Installation

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

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. Install the RH spacer ring, camshaft gears, flat washers and bolts. Tighten the bolts in two stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
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, marking 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 see scheme 159
23. Install the bearing caps in their original locations. Install the bolts and tighten the bolts in the sequence see scheme 160
24. Install engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-231366-S10042982142006050800000).