4.9l 6-cyl - VIN [y] Ford Econoline E350

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

Engine is identified by eighth character of Vehicle Identification Number (VIN). VIN is visible through windshield on left side of instrument panel. VIN is also located on Safety Compliance Certification Label attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

In most cases, valve clearance adjustment is not required. Positive-stop rocker arm bolts and hydraulic valve lifters automatically adjust stem-to-rocker arm clearance. However, repeated valve and/or valve seat refacing will change stem-to-rocker arm clearance.

When this occurs, stem-to-rocker arm clearance will be insufficient. If clearance is excessive, it will cause valve train noise; if clearance is insufficient, it will prevent valve from seating. To compensate for excessive changes in stem-to-rocker arm clearance, a longer or shorter push rod must be installed. Push rods are available in .060" (1.52 mm) longer or shorter than original.

1. Install an auxiliary starter switch, so engine can be cranked with ignition off. Make 2 chalk marks on crankshaft damper. Space marks 120 degrees apart. Including the timing mark, damper should be divided into 3 equal parts. Remove valve cover.
2. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. Ensure intake and exhaust rocker arms of No. 1 cylinder are tightened to specifications. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Slowly collapse lifter plunger using Tappet Bleed Down Wrench (T70P-6513-A) until completely bottomed.
3. While maintaining pressure on lifter, use feeler gauge to check clearance between rocker arm and valve stem tip. On all valves, desired clearance is .125-.175" (3.18-4.45 mm), and allowable range is .100-.200" (2.54-5.08 mm).
4. If clearance is less than specification, install shorter push rod. If clearance is greater than specification, install longer push rod. Rotate crankshaft 120 degrees (in direction of normal rotation) to check next set of valves in firing order sequence. Firing order is 1-5-3-6-2-4. Repeat procedure for remaining valves.

REMOVAL & INSTALLATION

Note. Discharge A/C system using approved refrigerant recovery/recycling equipment.

FUEL PRESSURE RELEASE

Disconnect negative battery cable. Remove fuel tank filler cap to release tank pressure. Attach a fuel pressure gauge to pressure relief valve on fuel rail. Release fuel pressure.

COOLING SYSTEM BLEEDING

1. To bleed trapped air from cooling system, disconnect heater hose from water pump. Using 50/50 mixture of coolant and water, fill radiator until coolant flows from heater hose fitting at water pump. Reconnect heater hose.
2. Fill radiator until coolant is 1.5" (38 mm) below radiator cap seal. Install radiator cap. Run engine until warm. Turn off engine. CAREFULLY remove radiator cap and check level. Fill as required.

ENGINE

Note. Engine removal and installation procedures are for engine without transmission attached.

Removal (Bronco & Pickup)

1. Disconnect battery cables. Drain cooling system and crankcase. Scribe hood hinge position and remove hood. Remove throttle body inlet tubes. Remove heater hoses and air cleaner assembly. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__fuel-pressure-release). NOTE: Fan clutch/water pump hub has right-hand thread.
2. Using Disconnect Tool (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 1) Remove radiator shroud and radiator. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D), remove fan and clutch assembly.
3. Remove water pump pulley. Disconnect accelerator cable at throttle body and remove return spring. Remove power brake vacuum hose at intake manifold. Disconnect kickdown cable at throttle body (A/T). Separate exhaust pipe from manifold.
4. Remove wiring harness from coil and all sending units. Disconnect all Electronic Engine Control (EEC) sensor connectors. Remove alternator mounting bolts and set alternator aside with wires attached. Remove power steering pump from mounting brackets and set aside with lines attached.
5. On A/C-equipped models, discharge system and disconnect pressure lines. On all models, raise and support vehicle. Remove starter and A/T filler tube bracket (if equipped). Remove upper right bolt from engine rear plate.
6. Remove all bellhousing lower retaining bolts and disconnect clutch retracting spring (if equipped). On A/T models, remove converter housing access cover and remove flex plate-to-converter nuts. Secure converter assembly in housing.
7. Remove transmission cooler lines from clip at engine. Remove converter housing lower retaining bolts. On all models, remove insulator support bracket nut from each front engine support. Lower vehicle and support transmission with floor jack.
8. Remove remaining bellhousing-to-engine bolts. Attach engine hoist to engine. Raise engine slightly to separate from transmission. Remove engine from vehicle.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Fill or top off all fluid levels. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING .

Scheme 1

Removal (Van)

1. Remove engine cover and air cleaner assembly. Drain cooling system. Disconnect battery. Remove front bumper, grille and lower gravel deflector. Disconnect coolant hoses and transmission oil lines from radiator (if equipped).
2. Remove radiator and shroud. Disconnect brake booster and heater hoses at intake manifold. Disconnect alternator and set aside. Remove power steering pump drive belt, pump and bracket from engine.
3. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__fuel-pressure-release). Using Disconnect Tool (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 1)
4. Disconnect distributor, Electronic Engine Control (EEC) sensors and sending unit wires from engine. Disconnect accelerator cable and remove bracket from engine. Disconnect A/T kickdown cable at throttle body. Remove exhaust manifold heat deflector and exhaust pipe-to-manifold nuts.
5. Disconnect A/T vacuum line at intake manifold junction. Remove upper transmission-to-engine bolts. Remove A/T dipstick tube support at intake manifold. Raise vehicle. Drain crankcase and remove oil filter.
6. Disconnect starter wiring and remove starter. On A/T models, remove flywheel inspection cover and flexplate-to-converter nuts. On all applications, remove front engine mount nuts. Remove remaining transmission-to-engine bolts. Lower vehicle from hoist. Attach lifting device to engine. Remove engine from vehicle.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Fill or top off all fluid levels. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING .

Removal

1. Disconnect negative battery cable. Disconnect electrical connectors as necessary. Disconnect PCV hose from underside of upper intake manifold. Remove throttle linkage shield. CAUTION: When disconnecting throttle cable from ball stud, use screwdriver or similar tool to pry off. Removing by hand may damage cable.
2. Disconnect accelerator cable and speed control cable. Remove throttle body inlet hoses. Disconnect accelerator cable from bracket and set aside. Remove cable retracting spring. Disconnect and remove EGR tube.
3. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__fuel-pressure-release) under REMOVAL & INSTALLATION. Using Disconnect Tool (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 1)
4. Remove thermactor tube assembly from lower intake manifold. Remove thermactor by-pass valve bracket retaining nut from lower intake manifold. On Van models, remove transmission fill tube retaining nut.
5. On all models, remove upper intake manifold retaining nuts. Remove screw and washer attaching upper intake manifold support bracket to upper intake manifold. Remove upper intake manifold and throttle body as an assembly. Remove injector heat shield.
6. Disconnect exhaust pipes from exhaust manifolds. Mark and disconnect vacuum lines for installation reference. Disconnect power brake vacuum line (if equipped). Remove lower intake manifold and exhaust manifold-to-cylinder head bolts. Remove lower intake manifold and exhaust manifolds.

1. Clean mating surfaces of manifolds and cylinder head. Lightly coat mating surfaces with graphite grease. Install new intake/exhaust manifold gasket on cylinder head. NOTE: If installing original exhaust manifolds, install new exhaust manifold gaskets. If installing new exhaust manifolds, install exhaust manifolds without gaskets.
2. Position lower intake/exhaust manifold assembly on cylinder head. Ensure gasket remains in position. Tighten bolts and nuts in sequence to specification. (Scheme 2) See, at end of article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table. To complete installation, reverse removal procedure.

Scheme 2

CYLINDER HEAD

Note. Cylinder head can be removed with intake and exhaust manifolds connected.

1. Scribe hood hinge position and remove hood. Disconnect negative battery cable. Drain cooling system and crankcase. Remove throttle body inlet tubes. Discharge A/C system. Remove the A/C compressor and condenser.
2. Disconnect heater hoses from water pump and thermostat housing. Release pressure from fuel system. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__fuel-pressure-release) under REMOVAL & INSTALLATION. NOTE: Fan clutch/water pump hub has right-hand thread.
3. Using Disconnect Tool (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 1) DO NOT bend fuel rail. Remove radiator and shroud. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D), remove fan and clutch assembly.
4. Remove water pump pulley and fan drive belt. Disconnect accelerator cable and return spring from throttle body. Disconnect power brake vacuum line from intake manifold (if equipped). Disconnect transmission kickdown cable from throttle body (if equipped).
5. Disconnect exhaust pipes from exhaust manifolds. Disconnect body ground strap and negative battery cable from engine. Disconnect Electronic Engine Control (EEC) harness and engine wiring harness from all electrical components on engine.
6. Leaving wiring attached, remove alternator and set aside. Remove air pump and alternator/air pump bracket. Remove power steering pump with hoses attached and set aside. Remove power steering pump and A/C compressor bracket.
7. Remove coil bracket and set aside. Remove rocker arm cover. Loosen rocker arm bolts and rotate rocker arms aside. Mark and remove push rods for installation reference. Disconnect spark plug wires from spark plugs.
8. Remove cylinder head bolts. Lift cylinder head and manifold assemblies from engine using appropriate lifting device. DO NOT pry between cylinder head and block, as machined surfaces may be damaged.

Inspection

1. Clean gasket mating surfaces. Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See, at end of article, «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS. Check cylinder block deck surface for warpage.
2. Resurface cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. If cylinder head or cylinder block warpage exceeds specification, DO NOT remove more than .010" (.25 mm) material from original surface of cylinder head or block.

1. Position new gasket over dowel pins on cylinder block. Using lifting device, carefully position cylinder head onto block. Ensure dowel pins engage in head. Coat head bolt threads with engine oil and install.
2. Tighten head bolts in sequence to specification. (Scheme 3) See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Lubricate push rod ends, rocker arm fulcrum seats and sockets with multipurpose grease, and install. To complete installation, reverse removal procedure.
3. Tighten nuts/bolts to specification. See, in this article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Scheme 3

1. Remove fan and shroud. Remove drive belt. Remove crankshaft pulley. Using Vibration Damper Remover (T58P-6316-D), remove vibration damper. Position Timing Gear Cover Seal Remover (T70P-6B070-B) onto seal and tighten 2 through bolts to force seal puller under the seal flange.
2. Alternately tighten 4 puller bolts 1/2 turn at a time. Remove oil seal from the timing gear cover. Clean seal recess in timing gear cover.

1. Lubricate crankshaft stub, vibration damper hub I.D. and sealing surface of timing gear cover seal with clean engine oil. DO NOT apply grease to seal. Position seal onto Timing Gear Cover Seal Installer (T70P-6B070-A).
2. Position Timing Gear Cover Seal Installer and seal onto the crankshaft end. Force seal into recess by tightening bolt. (Scheme 4) Remove timing gear cover seal installer. Apply a 1/4" (6 mm) bead of silicone sealer to keyway inside vibration damper hub.
3. Using Vibration Damper Installer (T52L-6306-AEE), install vibration damper. To complete installation, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article.

Scheme 4

1. Drain cooling system and crankcase. Remove shroud and radiator. Remove drive belts. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D), remove fan and clutch assembly.
2. Remove water pump pulley. Remove power steering pump and bracket. Remove crankshaft damper retaining bolt and washer. Using Vibration Damper Remover (T58P-6316-D), remove vibration damper.
3. Remove timing gear cover and front oil pan bolts. Loosen first 6 bolts on each side of oil pan. Lightly push down oil pan to relieve pressure on timing gear cover. Remove timing gear cover and gasket.

Note. Always replace timing gear cover oil seal whenever timing gear cover is removed.

1. Clean timing gear cover and cylinder block mating surfaces. Coat cylinder block and timing gear cover gasket surfaces with oil resistant sealer. Install timing gear cover gasket. Apply silicone sealer to block/pan junction and to oil pan gasket sealing surface.
2. Position timing gear cover on cylinder block. Hand-start timing gear cover and pan bolts. To aid timing gear cover alignment, slide Timing Gear Cover Aligner (T61P-6019-B) over crankshaft and into seal bore.
3. Tighten timing gear cover bolts first to obtain proper alignment, then tighten oil pan bolts. Remove timing gear cover aligner. Install and lubricate timing gear cover oil seal. See, in this article, «FRONT CRANKSHAFT OIL SEAL»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) .
4. Lubricate crankshaft stub, vibration damper hub I.D. and sealing surface of timing gear cover seal with clean engine oil. DO NOT apply grease to seal. Apply a 1/4" (6 mm) bead of silicone sealer to keyway inside vibration damper hub.
5. Using Vibration Damper Replacer (T52L-6306-AEE), install vibration damper. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

TIMING GEARS

Checking Timing Gear Backlash

1. Remove timing gear cover. See «TIMING GEAR COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) . Attach a dial indicator to engine block, with sensing stylus on camshaft gear tooth.
2. Using a dial indicator, measure gear backlash between camshaft gear and crankshaft gear at 6 equally spaced teeth. To obtain an accurate reading, hold gear firmly against block. Backlash should be .004-.010" (.10-.25 mm). If any of the 6 readings are not within specification, replace timing gears.

1. Drain cooling system and crankcase. Remove timing gear cover. See «TIMING GEAR COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y). Check camshaft end play. If end play is not within specification, replace camshaft thrust plate. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article.
2. Rotate engine (in direction of normal rotation) until camshaft and crankshaft gear timing marks are aligned. (Scheme 5) Using Camshaft Gear Puller (T82T-6256-A), remove camshaft gear. Using Vibration Damper Remover (T52L-6306-AEE), remove crankshaft gear. Remove Woodruff keys from camshaft and crankshaft.

Scheme 5

1. Ensure camshaft key spacer and thrust plate are correctly installed. Install Woodruff key into camshaft. Align camshaft gear keyway with camshaft key and install gear using Camshaft Gear Replacing Adapter (T65L-6306-A).
2. Install Woodruff key into crankshaft. Align crankshaft gear keyway with key and install crankshaft gear. Ensure timing marks on camshaft and crankshaft gears are still aligned.
3. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Fill or top off all fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Drain cooling system and crankcase. Remove radiator and shroud. Remove rocker arm cover. Rotate engine (in direction of rotation) until No. 1 piston is at TDC. Remove distributor cap.
2. Mark distributor rotor and housing for installation reference. Remove distributor. Loosen rocker arm bolts and turn rocker arms aside. Remove push rods and mark for installation reference.
3. Remove engine side cover to expose valve lifters. Remove lifters and mark for installation reference. Remove engine timing gear cover. See «TIMING GEAR COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) under REMOVAL & INSTALLATION. Check and note camshaft end play.
4. Replace camshaft thrust plate if end play is not within specification. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. Turn crankshaft to align gear timing marks. (Scheme 5)
5. Remove camshaft thrust plate bolts. Remove camshaft gear using Camshaft Gear Puller (T82T-6256-A). Remove Woodruff key, thrust plate and spacer. Carefully remove camshaft to avoid damaging lobes or bearings.

Inspect components for damage. Check camshaft journal diameter, lobe lift, and oil clearance. Replace components if damaged or not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS at end of article.

1. Coat camshaft lobes with multipurpose grease. Coat bearing journals with clean engine oil. Install Woodruff key, spacer and thrust plate on camshaft. Align gear keyway with key and install gear using Camshaft Gear Replacing Adapter (T65L-6306-A).
2. Install camshaft, spacer, thrust plate and gear as an assembly, ensuring timing marks are aligned. (Scheme 5) Tighten thrust plate bolts. Ensure camshaft end play is within specification. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article.
3. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Fill and bleed air from cooling system. See, in this article, «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

CAMSHAFT BEARINGS

Note. It may be necessary to remove crankshaft for access to camshaft bearings.

1. Remove engine. See «ENGINE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__engine) under REMOVAL & INSTALLATION. Install engine on engine stand. Remove flywheel/flexplate. Remove camshaft rear bearing bore plug.
2. Remove camshaft and crankshaft. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) and «CRANKSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__crankshaft) . Push pistons to top of cylinders. Use Camshaft Bearing Remover/Installer (T65L-6250-A) to remove cam bearings. To remove front bearing, place bearing puller in cam bore from rear of cylinder block.

To install cam bearings, reverse removal procedure. Ensure oil holes in bearings align with oil holes in cylinder block when installing camshaft bearings. Install front bearing so .020-.035" (.51-.89 mm) exists between front edge of bearing and face of cylinder block.

CRANKSHAFT

Note. Unless parts are being discarded, keep all crankshaft parts in the order that they were removed.

1. Remove engine and attach to engine stand. See «ENGINE»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__engine) under REMOVAL & INSTALLATION. Remove spark plugs. Remove oil pan. See «OIL PAN»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) under REMOVAL & INSTALLATION. Remove timing gear cover. See «TIMING GEAR COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) under REMOVAL & INSTALLATION.
2. Using Camshaft Gear Puller (T82T-6256-A), remove camshaft gear. Using Vibration Damper Remover (T52L-6306-AEE), remove crankshaft gear. Remove flywheel. Remove oil pump. Rotate crankshaft to position connecting rod caps at bottom of stroke. Remove connecting rod cap nuts. Tap cap with plastic mallet to separate from rod.
3. Remove connecting rod caps. Cover connecting rod bolts with protective rubber caps. Use wooden hammer handle to tap piston into cylinder bore. Ensure main bearing caps are marked. Remove crankshaft main bearing caps.
4. Carefully remove crankshaft. To install, reverse removal. Once bearings are installed apply a coat of heavy engine oil to crankshaft and bearings. Tighten nut/bolts to specifications. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article.

1. Remove starter and transmission. See TRANSMISSION REMOVAL & INSTALLATION article in the TRANSMISSION SERVICING Section. Remove clutch assembly (if equipped). Remove flexplate/flywheel. Remove engine rear cover plate. Using an awl, punch hole in oil seal metal surface between lip and block.
2. Carefully pry oil seal from recess without damaging seal surface. Clean oil seal recess in block and main bearing cap.

1. Inspect and clean crankshaft surface. Lightly coat crankshaft and sealing surface of new oil seal with engine oil. Place seal in position with lip facing inward, and install seal using seal installer.
2. Keep installer straight in respect to center line of crankshaft. Seal is properly installed when seal installer contacts cylinder block. Coat threads of flywheel bolts with oil resistant sealer. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article.

WATER PUMP

Note. Fan clutch/water pump hub has right-hand thread.

Drain cooling system. Remove accessory drive belt by using a 5/8" (16 mm) open-end wrench. Lift belt tensioner away from belt. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D), remove fan and clutch assembly. Remove water pump pulley. Disconnect coolant hoses from water pump. Remove water pump.

1. Clean all gasket mating surfaces. Coat new gasket on both sides with gasket sealer and position gasket on water pump. Install water pump and tighten attaching bolts.
2. To install remaining components, reverse removal procedure. Fill and bleed air from cooling system. See, in this article, «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Drain engine oil and cooling system. Remove upper intake manifold and throttle body. See «INTAKE & EXHAUST MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) under REMOVAL & INSTALLATION. Disconnect negative battery cable. Raise and support vehicle. Remove starter. Remove both front engine mount-to-engine mount bracket nuts.
2. Raise engine and place 1" (25.4 mm) wood blocks between front engine mount insulators and frame brackets. Remove oil pan bolts. Lower pan and remove oil pump bolts and pick-up tube nut. Lower oil pump assembly into pan. Remove pan.

1. To install, reverse removal procedure. Apply silicone sealant at front and rear corners of oil pan surface and cylinder block, and where timing gear cover meets the cylinder block.
2. Install oil pan bolts and tighten using specified procedure. (Scheme 6) To install remaining components, reverse removal procedure. Tighten bolts to specification. See, at end of article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table. Fill or top off fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Scheme 6

1. Remove engine cover, air cleaner and air inlet tubes from throttle body. Position idle air by-pass valve aside. Unbolt fan shroud and let it rest on fan. Remove oil filler tube bracket. Drain engine oil and cooling system. Remove upper and lower radiator hoses.
2. Put vehicle on jack stands. Remove front engine mount nuts. Raise engine approximately 3" and place wooden block under engine mounts. Remove oil pan bolts. Remove oil pick-up tube from oil pump. Remove oil pan and gaskets.

1. To install, reverse removal procedure. Apply silicone sealant at front and rear corners of oil pan surface and cylinder block, and where timing gear cover meets the cylinder block.
2. Install oil pan bolts and tighten using specified procedure. (Scheme 6) To install remaining components, reverse removal procedure. Tighten bolts to specification. See, at end of article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table.
3. Fill or top off fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y__cooling-system-bleeding) under REMOVAL & INSTALLATION.

OVERHAUL

Note. For valve lifter specifications, see VALVE LIFTERS table under ENGINE SPECIFICATIONS at end of article.

1. Clean head gasket mating surface. Clean carbon from combustion chambers. DO NOT damage surfaces. Check cylinder head for cracks, burrs, nicks and warpage.
2. Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. DO NOT machine more than .010" (.25 mm) from original cylinder head surface.

Valve Springs

1. Measure valve spring installed height from surface of cylinder head spring pad to underside of spring retainer. If installed height is not within specification, a .03" (.8 mm) shim can be installed between cylinder head and valve spring to obtain correct height.
2. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not within specification. See «VALVES & VALVE SPRINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article.

Valve Stem Oil Seals

When installing new valve stem seals, ensure oil seal bottoms on valve guide. Oversized valve stem seals must be installed when oversized valves are used.

Valve Guides

1. Valve guides must be reamed for an oversized valve if valve stem oil clearance exceeds specification. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. Valves are available with .015" (.38 mm) and .030" (.76 mm) oversize stems.
2. If oversized valves or oversized valve stem oil seals are not available, valve guide may be bored out to use a service bushing. Always use reamers in proper sequence (smallest first).

Note. Always grind valve seat after valve guide has been reamed or service bushing has been installed.

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of article. Valve seats must be ground when valve guide is reamed or replaced. Seat replacement information is not available from manufacturer.

Valves

1. Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See «VALVES & VALVE SPRINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article.
2. Oversize valves are available in .015" (.38 mm) and .030" (.76 mm). When servicing valve stem tip, DO NOT remove more than .010" (.25) from end of valve stem.

Seat Correction Angles

Grind valve seat to a true 45-degree angle. If seat width is too wide after grinding, use a 30-degree stone to lower seat or a 60-degree stone to raise seat. See CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of article.

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

Note direction of connecting rod installation on piston before removal. Ensure pistons and rods are installed in cylinder from which they were removed. When installing piston in bore, ensure arrow on top of piston is facing front of engine and bearing tang on connecting rod is facing camshaft. (Scheme 7)

Scheme 7

Note. Make all measurements with piston and block are at normal room temperature of 70°F (21°C).

Fitting Pistons

1. Check piston-to-bore clearance. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. Standard size pistons are color-coded Red, Blue or Yellow on the piston dome. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table. Oversize pistons are also available.
2. If bore diameter is in lower one-third of specification, use a Red coded piston. If bore diameter is in middle one-third of specification, use a Blue coded piston. If bore diameter is in upper one-third of specification, use Yellow coded piston. Use proper size piston to obtain specified clearance. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table.

Piston Rings

1. Select rings for bore diameter. Place ring in cylinder bore in which it will be installed. Use piston to square ring in bore and place ring below normal ring wear area. Measure ring end gap. If ring gap is not within specification, try another ring set. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article.
2. Check side clearance of rings after installing on piston. Ensure clearance is within specification around entire circumference. Replace piston and/or rings if clearance is not within specification. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table. Ensure rings are properly spaced on piston before installing pistons into cylinder. (Scheme 8)

Scheme 8

Piston Pin Replacement

1. Remove bearing inserts from connecting rod and cap. Mark pistons and pins to ensure assembly to original location. Remove piston rings. Using a press and Piston Pin Remover/Replacer (T81P-6135-A), press piston pin from piston and connecting rod.
2. Before assembling piston and rod, ensure connecting rod pin bore diameter and piston diameter are within specification. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. Apply light coat of engine oil to parts to be assembled. When installing piston pin, ensure piston and connecting rod are assembled as shown. (Scheme 7)

Rod Bearings

1. Use Plastigage to check rod bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any other bearing combination other than what is listed. See, in this article, UNDERSIZE MAIN & ROD BEARING COMBINATIONS table.
2. If bearing combinations cannot bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. Refer to, at the end of this article, «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS.

UNDERSIZE MAIN & ROD BEARING COMBINATIONS (1)

Crankshaft & Main Bearings

1. When checking main bearing clearance in vehicle, position a jack under adjoining bearing counterweight being checked. Remove only one main bearing cap at a time.
2. Use Plastigage to check main bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any other bearing combination other than what is listed. See UNDERSIZE MAIN & ROD BEARING COMBINATIONS table.
3. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. Refer to, at end of article, «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS.
4. Install all bearing caps except thrust bearing cap (No. 5 from front of engine). Tighten main bearing cap bolts to specifications. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table at end of article. Install No. 5 bearing cap and tighten bolts finger tight. Pry crankshaft forward and pry No. 5 bearing cap to rear of engine to align thrust bearing. While retaining forward pressure on crankshaft, tighten bearing cap bolts to specifications. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table.
5. Ensure crankshaft end play is within specification. Replace thrust bearing if end play is not within specification. See «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table.

Cylinder Block

1. Using a feeler gauge and straightedge, check cylinder block head gasket surface for warpage. Check cylinder bore for wear, taper, out-of-round and piston fit. See «CYLINDER BLOCK»(/ford/econoline-e350/1985-1999/remont/mechanical/#49l-6-cyl-vin-y) table under ENGINE SPECIFICATIONS at end of article. CAUTION: DO NOT machine more than .010" (.25 mm) of material from original cylinder block head surface.
2. Install all main bearing caps and tighten to specification before honing cylinder bore. Ensure bearing caps are installed in their original location, with arrow on cap pointing towards front of engine.
3. Use ONLY a spring-loaded type cylinder hone. After honing, thoroughly clean bore with detergent and water solution. Rinse solution from bore thoroughly with clean water. Wipe bore clean with lint-free cloth. Lubricate cylinder bores with engine oil.

ENGINE OILING SYSTEM

Oil supply from pan is forced through lubrication system by rotor oil pump. Oil flows through full-flow oil filter, which routes oil into main oil gallery. (Scheme 9)

Oil gallery supplies oil to all internal engine bearings and lifters. Oil from lifters is forced through push rods to lubricate valve train. Timing gears are lubricated by splash method. Spring-loaded oil pressure relief valve is located in pump body and is nonadjustable.

Scheme 9

Crankcase Capacity

Crankcase capacity is 5 qts. (4.75L). Add 1 qt. (.95L) when replacing oil filter.

Oil Pressure

Normal oil pressure at 2000 RPM should be 40-60 psi (2.8-4.2 kg/cm 2 ) with engine at normal operating temperature.

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump retaining bolts and remove oil pump assembly. Disassemble oil pump. Note location of component installation for reassembly reference.

Inspect components for damage. Measure rotor end play, rotor tip clearance and outer rotor-to-housing clearance. Measure relief valve-to-bore clearance and relief valve tension. Replace oil pump assembly if measurements are not within specifications. See OIL PUMP SPECIFICATIONS table.

Note. Oil pump is serviced as an assembly only. Replace assembly if measurements are not within specification. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, prime oil pump by filling inlet opening with oil and rotating pump shaft until oil emerges from outlet opening.
2. Install and tighten oil pump-to-cylinder block bolt to specification. See TORQUE SPECIFICATIONS table. To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

PISTONS PINS & RINGS

PISTONS PINS & RINGS

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

VALVE LIFTERS

VALVE LIFTERS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• TORQUE SPECIFICATIONS
• FUEL PRESSURE RELEASE
• COOLING SYSTEM BLEEDING
• ENGINE
• CRANKSHAFT