7.3l v8 Diesel - VIN [m] 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.

The eighth character of the Vehicle Identification Number (VIN) identifies the engine. The VIN is stamped on a metal tab attached to top left end of instrument panel and is visible through windshield. VIN is also located on Vehicle Safety Compliance Certification Label on left door or left door post pillar.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE CHECK

Note. Valve lifters are set at zero lash. No adjustment is necessary. If valve train has been disassembled or worn parts are suspected, valve clearance can be checked. Information not available from manufacturer.

COOLING SYSTEM BLEEDING

1. Fill cooling system with 50/50 mixture of water and coolant. Pause several minutes for circulation. Fill radiator to filler neck seat. Disconnect heater outlet hose at water pump to bleed off trapped air. Fill radiator until coolant begins to escape.
2. Connect heater outlet hose. Fill radiator until coolant is between the cap seal in the filler neck to 1.5" (38 mm) below cap seal. Install radiator cap. Start engine and allow to warm up. Shut engine off. Allow engine to cool. Remove radiator cap and check coolant level. Top off radiator coolant as necessary.

Removal (Pickup)

1. Disconnect negative battery cable from both batteries. Scribe hood hinge location and remove hood. Drain cooling system. Remove air cleaner and intake duct assembly. Cover intake opening. NOTE: Fan and fan clutch assembly are secured with left-hand threads.
2. Disconnect fan shroud and place shroud over fan. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud. Remove A/T cooler lines from radiator (if equipped).
3. Remove radiator with hoses attached. Remove A/C compressor drive belt and A/C compressor; position on upper radiator support with lines attached (if equipped). Remove power steering pump drive belt. Remove power steering pump with hoses attached and position aside.
4. Disconnect all sending unit wires and alternator wiring from engine. Disconnect accelerator and cruise control cables from injection pump. Remove accelerator cable bracket from engine and position aside. Remove transmission kickdown rod from injection pump (if equipped).
5. Disconnect main wiring harness connector from right side of engine. Disconnect engine ground strap from rear of engine. Disconnect fuel return hose from left rear of engine. Remove vacuum supply hose from pump. Remove upper transmission-to-engine bolts. Disconnect heater hoses from engine. Raise vehicle.
6. Disconnect both battery ground cables at engine. Disconnect and plug fuel supply line at fuel supply pump. Disconnect starter cables and remove starter. Disconnect exhaust pipes from manifolds. Remove engine mount-to-engine nuts. Remove flywheel inspection plate.
7. Remove flexplate-to-converter bolts (if equipped). Lower vehicle. Support transmission with floor jack. Remove 4 lower transmission-to-engine bolts. Attach lifting device to engine. Lift engine to clear No. 1 crossmember. Pull engine forward, rotate 45 degrees to left and carefully lift engine from vehicle.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Check and top off all engine fluids. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING . Evacuate and recharge A/C system (if equipped).

Removal (Van)

1. Remove engine cover. Disconnect negative battery cable from both batteries. Drain coolant. Remove air cleaner and air intake hoses. On models equipped with A/C, discharge A/C system. Remove front bumper, grille, air deflector and gravel deflector.
2. Remove headlight and side light assemblies. Remove transmission oil cooler and brackets. Remove lower grille. Remove latch leaving cable attached. Remove fan shroud and radiator. Disconnect hoses from condenser and remove condenser. Disconnect oil cooler lines. NOTE: Fan and fan clutch assembly are secured with left-hand threads.
3. Using Fan Clutch Pulley Holder (T83T-9424-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove all belts. Disconnect hoses and electrical connectors from A/C compressor. Remove A/C compressor. Remove power steering pump with pressure hose attached.
4. Remove radiator hoses. Disconnect wiring from alternator. Disconnect wiring from engine sensors and switches as necessary. Disconnect heater hoses from heater core. Remove fuel filter assembly. Remove fuel return hose and transmission dipstick tube.
5. Remove the top 3 transmission-to-engine bolts. Raise vehicle. Disconnect starter and transmission electrical connectors. Remove exhaust manifold-to-exhaust pipe bolts. On vehicles with A/T, remove flywheel housing cover.
6. Remove torque converter nuts. Remove 4 engine mount nuts. Lower vehicle and support transmission. Attach engine hoist to engine. Remove remaining engine-to-transmission bolts. Remove engine and attach to engine stand.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Check and top off all engine fluids. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING . Evacuate and recharge A/C system (if equipped).

Removal

Note. On Pickup, remove and cap line sensor on No. 1 cylinder to permit removal of fuel leak-off tees. On Van, remove and cap line sensor on No. 4 cylinder to permit removal of fuel leak-off tee.

1. Disconnect nozzle fuel inlet (high pressure) and fuel leak-off tees from each nozzle assembly and position out of the way. Cover open ends of fuel inlet lines and nozzles to prevent entry of dirt with Fuel System Protective Cap Set T83T-9395-A or equivalent.
2. Remove fuel leak-off lines as an assembly as follows: Remove pump to fuel return tube hose at fuel return elbow cap elbow at pump. Disconnect hose (from leak-off tee to fuel filter) at leak-off tee. Loosen two fuel return tube retaining clamps, one at intake manifold and one at engine lifting eye. Remove fuel return hose clamp at CDR valve bracket. With clamps removed, remove return lines and tees as an assembly by lifting tees off nozzles.
3. Remove injection nozzles by turning counterclockwise. Pull nozzle assembly with copper washer from engine. Be careful not to strike nozzle tip against any hard surface during removal. Cover nozzle assembly fuel inlet opening and nozzle tip with plastic cap to prevent entry of dirt, Fuel System Protective Cap Set T83T-9395-A or equivalent.
4. Place nozzle assemblies in a fabricated holder as they are removed from the heads. The holder should be marked with numbers corresponding to the cylinder numbering of the engine. Use of this holder permits nozzle installation into original location in the cylinder heads.

Scheme 18

1. Thoroughly clean nozzle bore in cylinder head before reinserting nozzle assembly with Nozzle Seat Cleaner T83T-9527-A or equivalent. Pay particular attention to seating surface, in order that no small particles of metal or carbon will cause assembly to be cocked or permit blow-by of combustion gases. Blow out particles with compressed air.
2. Remove protective cap and install a new copper gasket on nozzle assembly with a small dab of Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A) or equivalent.
3. Install nozzle assembly into cylinder head nozzle bore.
4. Tighten nozzle assembly to 35 ft. lb. (47 N.m).
5. Remove protective caps from nozzle assemblies and fuel lines.
6. Install leak-off tees and lines as an assembly by lowering onto nozzles. Connect clip and hose to fuel return elbow at pump. Install line to retaining clamps.
7. Connect high pressure fuel line(s) and tighten to specification listed at the end of this section, using Fuel Line Nut Wrench T83T-9396-A or equivalent.
8. Start engine.
9. If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.
10. Check for fuel leakage at high-pressure connections.

INJECTION PUMP

1. Disconnect ground cables from both batteries. On Van, remove engine cover. On all models, remove air cleaner. Cover intake opening in manifold.
2. Remove injection pump drive gear cover plate. Remove injection pump-to-drive gear bolts. Disconnect electrical connectors at injection pump. Remove fast idle solenoid bracket assembly for access to injection pump mounting nuts.
3. Disconnect accelerator cable and speed control cable from throttle lever. Remove accelerator cable bracket and cables. On Van, disconnect fuel inlet and return lines from fuel filter. Remove fuel filter. Disconnect 90-degree fuel return hose elbow at governor on injection pump. NOTE: DO NOT disconnect injection lines from pump when removing pump from engine unless pump is being replaced or serviced. Reference mark lines-to-pump position before disconnecting.
4. If removing injection pump with injection lines connected to pump, disconnect lines at injector nozzles. If removing injection pump without lines connected to pump, remove line retaining clips. CAUTION: Ensure No. 1 piston is at TDC of compression stroke before removing injector pump. Pulley "Y" marks should be aligned. (Scheme 20)
5. Disconnect lines from pump using Fuel Line Nut Wrench (T83T-9396-A). On all applications, remove 3 injection pump-to-injection pump drive gear cover nuts using Injection Pump Mounting Wrench (T86T-9000-B).
6. On Pickup, lift injection pump (or pump with lines connected) out of engine compartment. On Van, remove injection pump (or pump with lines attached) through passenger compartment.

Scheme 19

1. Install new "O" ring on injection pump drive gear end. Install pump into position, aligning dowel on pump drive shaft with hole in drive gear. If necessary, rotate pump drive shaft to align dowel with hole.
2. Install and hand tighten 3 injection pump-to-drive gear cover nuts. Align timing mark on top radius of injection pump with mark on injection pump drive gear cover. (Scheme 21) To complete installation, reverse removal procedure.

Scheme 20

DRIVE GEAR - INJECTION PUMP

1. Disconnect negative cable from both batteries. On Van, remove engine cover. On all models, remove air cleaner. Cover opening in intake manifold. Remove injection pump. See «INJECTION PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__injection-pump). Remove injection pump drive gear cover. DO NOT remove drive gear.
2. Using Glow Plug Socket (D83T-6002-2), remove glow plugs. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. If injection pump drive gear dowel is at 4 o'clock position as viewed from front of engine, No. 1 cylinder is on compression stroke.
3. Ensure timing mark on vibration damper is set at TDC. Ensure "Y" timing mark on injection pump drive gear is aligned with "Y" timing mark on camshaft gear. (Scheme 20)
4. Without removing injection pump drive gear, slide gear back enough to expose top of camshaft gear. Note permanently dyed camshaft gear teeth adjacent to "Y" mark on camshaft gear. Remove injection pump drive gear.

1. Clean gasket and sealing surfaces. Ensure No. 1 piston is at TDC of compression stroke. See steps 2) and 3) of removal procedure. Install drive gear, ensuring "Y" timing marks are properly aligned.
2. Apply a 1/8" (3.2 mm) bead of silicone sealer along bottom surface of drive gear cover. Apply thread sealing compound to drive gear cover bolt threads. Install drive gear cover and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. NOTE: With drive gear cover installed, gear remains stationary and cannot jump timing.
3. Install injection pump. Install air cleaner. Reconnect negative cables to both batteries. Run engine and check for oil, fuel and coolant leaks.

1. Disconnect battery ground cable from both batteries. Remove air cleaner. Cover intake opening in manifold. On Van, disconnect fuel inlet and return lines from fuel filter. Remove fuel filter and bracket as an assembly.
2. On all models, remove injection pump. See «INJECTION PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__injection-pump) under REMOVAL & INSTALLATION. On Pickup, disconnect fuel return hoses from No. 7 and No. 8 (rear) injector nozzles. Disconnect return hose to fuel tank. On all models, remove glow plug harness and controller. Remove engine wiring harness from engine.
3. Remove engine harness ground cable from rear of left cylinder head. Remove intake manifold-to-cylinder head bolts. Remove intake manifold. Remove valley cover (if necessary) by removing drain plug and Crankcase Depression Regulator (CDR) valve tube. Remove valley cover.

1. Clean gasket mating surfaces. If valley cover was removed, install new valley cover with 1/8 (3.2 mm) bead of silicone sealer at ends of cylinder block.
2. Install new gaskets with intake manifold. Tighten bolts to specification in sequence. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. (Scheme 22) To install remaining components, reverse removal procedure.

Scheme 21

Disconnect negative battery cable from both batteries. Raise and support vehicle. Disconnect exhaust pipes from manifolds. If removing right manifold, lower vehicle. If removing left manifold, leave vehicle in raised position. Remove bolts and remove exhaust manifold(s).

To install, reverse removal procedure. Apply anti-seize to manifold bolts. Install and tighten exhaust manifold bolts to specification in sequence. See TORQUE SPECIFICATIONS table at end of article. (Scheme 23)

Scheme 22

CYLINDER HEADS

Note. The following cylinder head removal and installation procedures are for right cylinder head. Procedures for left cylinder head are similar. New cylinder heads and gaskets are interchangeable. Used cylinder heads should be installed in their original positions.

1. Disconnect battery ground cable from both batteries. Drain cooling system. Disconnect fan shroud and position shroud over fan. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud. NOTE: Fan and fan clutch assembly are secured with left-hand threads.
2. Disconnect wiring harness electrical connector from top of fuel filter. Remove alternator. Remove vacuum pump. On Pickup, remove fuel filter inlet, outlet and return lines. Cap lines and fittings to prevent fuel system contamination.
3. Remove fuel filter and bracket. On all models, remove alternator and vacuum pump mounting bracket. Remove heater hose from cylinder head. On all models, remove injection pump. Refer to «INJECTION PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__injection-pump) under REMOVAL & INSTALLATION.
4. Remove intake manifold and valley cover. Refer to «INTAKE MANIFOLD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) under REMOVAL & INSTALLATION. Raise vehicle. Disconnect exhaust pipe from exhaust manifolds. Remove transmission dipstick tube-to-cylinder head bolt (if equipped). Lower vehicle. CAUTION: Pre-combustion chamber inserts may fall out of cylinder head when cylinder head is removed. Ensure pre-combustion chambers DO NOT fall into combustion chamber when installing cylinder head.
5. Remove engine oil dipstick tube bolts. Remove exhaust manifold. See «EXHAUST MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) under REMOVAL & INSTALLATION. Remove engine oil dipstick, dipstick tube and "O" ring.
6. Remove valve cover. Keeping in order of removal, remove rocker arms and push rods. Remove injector nozzles and glow plugs. Remove and discard cylinder head bolts. Remove cylinder head.

Inspection

1. Clean all carbon from cylinder head combustion chambers. Remove all gasket material from cylinder head and cylinder block. DO NOT scratch mating surfaces. CAUTION: NEVER machine cylinder head or cylinder block mating surfaces. This reduces valve-to-piston clearance, causing engine damage. If cylinder head or cylinder block surface warpage exceeds specification, replace with new unit.
2. To obtain correct warpage measurement, remove pre-combustion chambers from cylinder head before measuring surface. Drive out pre-combustion chambers using a 1/4 x 8" (6.35 x 203 mm) brass drift.
3. Measure cylinder head warpage. If warpage exceeds specification, replace cylinder head. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.
4. Measure warpage of cylinder block deck surface. If warpage exceeds specification, replace cylinder block. See «CYLINDER BLOCK»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.

1. Lubricate and install pre-combustion chambers into cylinder head. Seat pre-combustion chamber within its bore by tapping with plastic mallet. Install cylinder head(s). DO NOT use sealer on head gaskets.
2. Install and tighten new head bolts to specification in sequence. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. (Scheme 24) To complete installation, reverse removal procedure. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Scheme 23

Remove intake manifold and valley cover. See INTAKE MANIFOLD under REMOVAL & INSTALLATION. Remove valve covers, rocker arms and push rods, marking all components for installation to original location. Remove lifter guide retainers. Remove valve lifters, marking each one for installation to original location.

1. Clean valve lifters in solvent or diesel fuel. Check valve lifter-to-bore oil clearance. If oil clearance is not within specification, replace valve lifter. See «VALVE LIFTERS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.
2. Replace lifter if any part shows pitting, scoring, galling or evidence of non-rotation. Ensure lifter roller operates smoothly and without excessive play.

1. Lubricate valve lifters and bores with clean engine oil. Install valve lifters in original positions in block. Install valve lifter guide retainers.
2. Install push rods with copper-colored end toward rocker arm. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article.

FRONT CRANKSHAFT OIL SEAL

Note. Fan and fan clutch assembly are secured with left-hand threads.

1. Front crankshaft oil seal can be removed without removing timing gear cover. Disconnect battery cables from both batteries. Disconnect fan shroud and place shroud over fan. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud.
2. Remove accessory drive belts. Raise and support vehicle. Remove crankshaft pulley. Remove vibration damper-to-crankshaft bolt. Install Crank/Cam Gear and Damper Remover (T83T-6316-A), and remove vibration damper. Pry oil seal out with screwdriver.

Note. On some timing gear covers, 3 nuts are welded to front surface of cover around the outer circumference of oil seal. Seal Installer (T83T-6700-A) consists of 3 pieces: seal installer, large square washer and bridge assembly. Bridge assembly is used to install seal only if timing gear cover is equipped with welded nuts.

1. Coat sealing surface of new seal with multipurpose grease. Install oil seal using Seal Installer (T83T-6700-A). Place seal into seal installer. If necessary, rotate crankshaft to align damper key with seal installer. Install seal and seal installer over end of crankshaft.
2. If timing gear cover is equipped with welded nuts, attach bridge to welded nuts. Draw seal into timing gear cover by rotating center screw clockwise. Seal installer should bottom on timing gear cover.
3. If timing gear cover is not equipped with welded nuts, install Crank/Cam Gear Installer (T83T-6316-B) onto crankshaft end. Draw seal into timing gear cover by rotating center screw clockwise. Seal installer should bottom on timing gear cover.
4. On all engines, apply a 1/8" (3.2 mm) bead of silicone sealer around outside diameter of oil seal where it contacts timing gear cover. Lubricate sealing surface of damper with engine oil. Install vibration damper using Crank/Cam Gear and Damper Installer (T83T-6316-B).
5. To prevent oil leakage past vibration damper keyway, apply silicone sealer to engine side of damper washer in area of keyway. Install and tighten vibration damper bolt and crankshaft pulley to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. To complete installation, reverse removal procedure.

TIMING GEAR COVER

Note. Fan and fan clutch assembly are secured with left-hand threads.

1. Disconnect negative battery cables from both batteries. Drain cooling system. Remove air cleaner. Cover intake opening in manifold. Disconnect fan shroud and place shroud over fan. Using Fan Clutch Pulley Holder (T83T-9424-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud.
2. Remove injection pump and injection pump drive gear cover. See «DRIVE GEAR - INJECTION PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__drive-gear-injection-pump) under REMOVAL & INSTALLATION. Remove water pump. See «WATER PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__water-pump) under REMOVAL & INSTALLATION.
3. Raise and support vehicle. Remove crankshaft pulley. Using Crank/Cam Gear and Damper Remover (T83T-6316-A), remove vibration damper. Disconnect ground cables from front of engine.
4. Remove timing gear cover-to-oil pan bolts. Lower vehicle. Remove timing gear cover-to-engine block bolts. Remove timing gear cover. Remove oil seal from timing gear cover.

1. Coat sealing surface of new oil seal with multipurpose grease and install seal. Clean gasket surfaces of engine block, oil pan, timing gear cover and water pump.
2. Apply silicone sealer to sealing surfaces of cylinder block and timing gear cover. Install timing gear cover gasket to cylinder block. Apply a 1/8" (3.2 mm) bead of silicone sealer to front of oil pan, including oil pan-to-cylinder block junction.
3. Place timing gear cover into position, aligning holes in timing gear cover with fabricated oil pan dowel pins (if necessary) and fabricated cylinder block dowel pins (if necessary). Install 2 bolts at top of timing gear cover and one bolt at bottom left of cover.
4. Remove fabricated dowels (if used). Install remaining timing gear cover bolts and oil pan bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article.
5. When installing water pump, apply silicone sealant to bolts as shown. see scheme 19To prevent oil leakage past keyway, apply silicone sealer to engine side of vibration damper washer (in area of keyway).
6. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. Fill and bleed air from cooling system. Refer to «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Remove engine from vehicle. See «ENGINE»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) under REMOVAL & INSTALLATION. Remove injection pump, intake manifold and hydraulic valve lifters. Remove timing gear cover. See the following: «INJECTION PUMP»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__injection-pump). «INTAKE MANIFOLD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m). «HYDRAULIC VALVE LIFTERS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m). «TIMING GEAR COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__timing-gear-cover).
2. Disconnect fuel lines from fuel pump. Remove fuel pump. Remove camshaft Allen screw and washer. Using Gear Puller (T83T-6316-A), remove camshaft gear. Using Gear Puller (T77F-4220-B1), remove fuel pump cam and thrust flange spacer from camshaft. (Scheme 25) Remove thrust plate. Remove camshaft from engine.

Scheme 24

Measure camshaft bearing journals for wear. If journal diameter is not within specification, replace camshaft and valve lifters. See CAMSHAFT table under ENGINE SPECIFICATIONS at end of article.

1. Lubricate camshaft journals with engine oil. Coat camshaft lobes with multipurpose grease. Install camshaft into bore. Install thrust plate. Ensure camshaft end play is within specification. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.
2. Install thrust flange spacer and fuel pump cam using Crank/Cam Gear and Damper Installer (T83T-6316-B). Position camshaft to align timing marks on gears. (Scheme 20)
3. Install camshaft gear using crank/cam gear and damper installer. Tighten camshaft gear Allen screw to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. To complete installation, reverse removal procedure.

CAMSHAFT BEARINGS

Note. All camshaft bearings are interchangeable except front bearing, which is wider than others.

1. Remove engine from vehicle. See «ENGINE»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) under REMOVAL & INSTALLATION. Remove camshaft. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) under REMOVAL & INSTALLATION. Remove flywheel, crankshaft and rear cylinder block camshaft core plug.
2. DO NOT damage piston cooling jets at bottom of cylinder wall. Push pistons to top of cylinders. Using Camshaft Bearing Remover/Installer (T65L-6250-A), remove camshaft bearings.

1. Install camshaft bearings using Camshaft Bearing Remover/Installer (T65L-6250-A). Ensure bearing oil holes are properly aligned with oil holes in cylinder block.
2. Install front bearing .020-.050" (.51-1.27 mm) below front face of cylinder block. Check bearing installation with straightedge and feeler gauge. Install new cylinder block camshaft core plug. To complete installation, reverse removal procedure.

Remove transmission. Remove clutch assembly (if equipped). Remove flywheel/flexplate. Remove rear engine cover-to-engine bolts and remove rear cover. Position rear cover on arbor press as shown. (Scheme 26) Using arbor press and 4 1/8" (105 mm) diameter spacer, remove rear oil seal from cover.

Scheme 25

1. Clean rear cover and engine block gasket surfaces. Remove old silicone sealer from oil pan sealing surface. Clean surface with solvent and dry thoroughly. CAUTION: Install new oil seal, from engine block side of rear cover, even with seal bore inner surface.
2. Apply thin coat of gasket adhesive to seal bore I.D. in rear cover. Using an arbor press and Rear Crankshaft Seal Installer (T83T-6701-A), install new rear crankshaft oil seal.
3. Apply a 1/8" (3.2 mm) bead of silicone sealer around O.D. of rear seal and edge of rear cover. Apply gasket adhesive to engine block and rear cover gasket surfaces. Install rear cover gasket to engine block.
4. To aid rear cover alignment, install Rear Seal Pilot (T83T-6701-B) on crankshaft. Immediately before installing rear cover, apply 1/4" (6.35 mm) bead of silicone sealer to oil pan sealing surface, including corner of cylinder block-to-pan junction.
5. Position rear cover on engine block. Install bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. Remove rear seal pilot from crankshaft. To complete installation, reverse removal procedure.

1. Disconnect negative cable from both batteries. Remove engine oil dipstick and transmission dipstick and tube (A/T models). Remove air cleaner and install Intake Manifold Cover (T83T-9424-A). NOTE: Fan and fan clutch assembly are secured with left-hand threads.
2. Drain cooling system and remove lower radiator hose. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly.
3. Disconnect power steering return hose from pump and plug openings. Disconnect alternator wiring harness and fuel line heater connector from alternator. Raise and support vehicle. Disconnect and plug transmission cooler lines (if equipped).
4. Disconnect and plug fuel pump inlet line. Drain engine oil and remove oil filter. Disconnect exhaust pipe at manifolds. Remove muffler inlet pipe from muffler flange. Remove upper inlet pipe mounting stud on right-side exhaust manifold.
5. Remove front engine mount nuts from crossmember. On A/T models, remove 2 bolts securing shift linkage bell crank to transmission. Allow linkage to hang freely. On all models, lower vehicle. On Van, install Rotunda Engine Lifting Brackets (014-00312) to front of engine.
6. Connect Rotunda Engine Lifting Brackets (T70P-6000) to lift sling and raise engine until transmission contacts body. On Pickup, install lifting sling to lifting eyes on intake manifold and raise engine until transmission contacts body.
7. Use wooden blocks to support engine; block right side up 2" and left side up 2 3/4". Remove flywheel inspection plate. Move fuel pump inlet line to rear crossmember. Remove oil pan bolts.
8. Remove transmission mount nuts. Using a transmission jack, raise transmission approximately 1". Lower oil pan. It may be necessary to release oil pan from cylinder block by prying on oil pan at front and rear of pan, on left side of cylinder block in dowel holes.
9. On Pickup, remove oil pump bolts and pick-up tube nut. Lower oil pump assembly into oil pan. On all models, remove oil pan. It may be necessary to rotate crankshaft to remove oil pan.

1. To install, reverse removal procedure. Apply a 1/8" (3.2 mm) bead of silicone sealant on pan rails and a 1/4" (6.4 mm) bead of sealant on oil pan sealing surfaces of front and rear covers.
2. To install remaining components, reverse removal procedure. Fill or top off all fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Removal & Disassembly

1. Disconnect negative cable from both batteries. Drain cooling system. Disconnect fan shroud and position shroud over fan. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud. NOTE: Fan and fan clutch assembly are secured with left-hand threads.
2. Raise vehicle. Drain crankcase and remove oil filter. On Pickup, remove left engine mount insulator-to-frame nut. Raise vehicle slightly.
3. Install a 1" wood block between engine mount insulator and frame. Lower engine on block. On all models, remove oil cooler-to-engine block bolts. Remove oil cooler.
4. To disassemble, use a soft-faced hammer and gently tap front and rear (filter) headers to loosen "O" rings. (Scheme 27) Separate headers from tube assembly. Thoroughly clean tube assembly and headers in solvent. Drain residue and blow dry with compressed air.

Reassembly & Installation

1. Lubricate all "O" rings and "O" ring mating surfaces with clean engine oil. Install large "O" ring and then small "O" ring onto oil cooler tube (bundle). Push assembly together, ensuring locating clips align in slots.
2. To install, position oil cooler assembly on cylinder block with new gaskets and tighten to specification. Refer to «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article. On Pickup, raise engine. Remove wood block and lower vehicle. Install engine mount insulator washer and nut.
3. On all models, apply thin coat of oil to oil filter gasket surface and install filter. Lower vehicle. To complete installation, reverse removal procedure.
4. Fill or top off all fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cooling-system-bleeding) under REMOVAL & INSTALLATION. Start engine and check for oil and coolant leaks.

Scheme 26

Cylinder Head

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. If cylinder head warpage exceeds specification, replace cylinder head. DO NOT machine cylinder head to correct warpage. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.
3. Check pre-combustion chambers for cracks. Pre-combustion chamber cracks are acceptable if cracking is within the fire ring. (Scheme 28) If cracking extends past fire ring, replace pre-combustion chamber insert.

Scheme 27

Valve Springs

Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS at end of article.

Valve Stem Oil Seals

Valve stem seals are used on intake valves only. Lubricate and install a new valve stem oil seal using Valve Stem Seal Replacer (T83T-6571-A).

Valve Stem Oil Shields

Both intake and exhaust valves use valve stem oil shields. Intake and exhaust oil shields are not interchangeable. Intake oil shield is smaller than exhaust oil shield. Using hand pressure, install new oil shield into underside of spring retainer until shield snaps into place.

Valve Guides

1. Check valve stem-to-guide clearance. If clearance is not within specification, replace valve guide insert. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article. To replace valve guide insert, drill out old valve guide insert. Ream drilled insert bore for replacement guide.
2. Carefully install replacement valve guide insert into bore using press. If necessary, chill replacement insert to ease installation. Finish reaming replacement valve guide stem bore with recommended reamer size. Always reface valve seat after valve guide has been reamed.

Valve Seat

1. If seat width is too wide after grinding, use a 15-degree stone to lower seat or a 60-degree stone to raise seat. Refer to «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article. Ensure valve seat angle, seat width and seat runout are within specification.
2. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table. Valve seats must be ground when valve guide is reamed or replaced. Use Exhaust Valve Seat Remover/Replacer (D83T-6084-A) to remove and install exhaust valve seats. Intake valve seat replacement information is not available from manufacturer.

Valves

Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS at end of article.

Piston & Rod Assembly

Ensure weight pad on connecting rod is facing away from valve indentations on top of piston. (Scheme 29) Ensure pistons and rods are installed in same cylinders from which they were removed. Ensure valve indentations on top of piston face center of cylinder block when installed. (Scheme 30)

Scheme 28

Scheme 29

Fitting Pistons

1. Measure piston diameter 1.23" (31.2 mm) below lower land of oil ring. Measure at piston pin center line, at 90-degree angle to piston pin. Measure cylinder bore for out-of-round, taper and piston-to-cylinder bore clearance.
2. If measurements are not within specification, hone or bore cylinders. See «CYLINDER BLOCK»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cylinder-block-specifications) and «PISTONS, PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) tables under ENGINE SPECIFICATIONS at end of article. If cylinder block needs to be bored, pistons are available in .010" (.25 mm), .020" (.51 mm) and .030" (.76 mm) oversize.

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»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m), PINS & RINGS 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»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m), PINS & RINGS table.
3. Top and intermediate rings are identified by one dot (top ring) and 2 dots (intermediate ring) stamped on surface of ring, near end gap. Ensure rings are properly spaced on piston before installing pistons into cylinder. (Scheme 31)

Scheme 30

Rod Bearings

Use Plastigage to check rod bearing clearance. If clearance is not within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. Refer to CRANKSHAFT , MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of article.

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 clearance is not within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) , MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS at end of article.
3. Install all bearing caps except thrust bearing cap (No. 3 from front of engine). Ensure bearing caps are installed in their original location. Tighten main bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__torque-specifications) table at end of article. Install No. 3 bearing cap and tighten bolts finger tight.
4. Pry crankshaft forward and pry No. 3 bearing cap to rear of engine to align thrust bearing. While retaining forward pressure on crankshaft, tighten bearing cap to specification. Refer to «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table.
5. Ensure crankshaft end play is within specification. Replace thrust bearing if end play is not within specification. See «CRANKSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) , MAIN & CONNECTING ROD BEARINGS table.

Cylinder Block

1. Check cylinder bore for wear, taper, out-of-round and piston fit. Using a feeler gauge and straightedge, check cylinder block deck surface for warpage. If deck surface warpage exceeds specification, replace cylinder block. DO NOT machine cylinder block to correct warpage. See «CYLINDER BLOCK»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table under ENGINE SPECIFICATIONS at end of article.
2. Install all main bearing caps and tighten to specification before honing cylinder bore. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table. Ensure bearing caps are installed in their original location, with arrow on cap pointing toward 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

Full pressure lubrication through a full flow oil filter and oil cooler is supplied by a gear-driven oil pump. Main oil gallery feeds oil through passages to camshaft and crankshaft. Valve lifter gallery feeds valve lifters. Rocker arms are fed through hollow push rods.

Scheme 31

Oil Cooler Assembly

Oil flows from pump to oil cooler located on left side of engine block. (Scheme 27)and (Scheme 32). Oil flows around the outside of heat exchanger tubes inside oil cooler. Coolant flows through heat exchanger tubes where heat is transferred to coolant. If oil is found in coolant or coolant is found in oil, check oil cooler for leakage. Areas of possible leakage include "O" rings, heat exchanger tubes inside cooler, front header and rear header.

Crankcase Capacity

Crankcase capacity is 10 qts. (9.5L) including filter change.

Oil Pressure

Normal oil pressure at 3300 RPM should be 40-70 psi (2.81-4.92 kg/cm 2 ).

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. On Pickup, remove oil pump retaining bolts. Remove oil pump and pick-up tube assembly. On Van, remove oil pump from oil pan. Disassemble oil pump. Note direction of component installation for reassembly reference.

Inspect components for damage and wear. Check oil pump drive gear backlash. If backlash is not .006-.010" (.15-.25 mm), replace oil pump. Oil pump is serviced as an assembly.

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»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table. To complete installation, reverse removal procedure.

1. Disconnect ground cables from both batteries. Drain coolant from radiator until coolant level is below thermostat. Loosen and remove alternator and vacuum pump drive belts. Remove alternator. Position alternator aside.
2. Remove vacuum pump and bracket. Position pump aside. Remove all but the lowest alternator/vacuum pump mounting casting bolt. Loosen the lowest bolt and pivot the alternator/vacuum pump casting outboard.
3. Remove the water outlet housing attaching bolts. Bend the radiator upper hose upward and remove the thermostat and gasket. (Scheme 33)

Scheme 32

Scheme 33

1. Clean the water outlet housing gasket surfaces. Coat a new outlet housing gasket with Perfect Seal Sealing Compound (B5A-19554-A). Position the water outlet housing gasket on intake manifold opening.
2. Install thermostat in crankcase opening with the copper pellet or element toward engine and the thermostat flange positioned in the recess. If thermostat is improperly installed, it will cause a restricted flow of coolant. Position the water outlet housing against the crankcase. Install and tighten the attaching bolts to 20 ft. lbs. (27 N.m).
3. Reposition the alternator/vacuum pump casting. Install attaching bolts. Install vacuum pump with bracket. Install alternator and drive belt. Fill and bleed the cooling system. Connect ground cables to both batteries. Operate the engine until normal operating temperature is reached, then check the coolant level. Inspect cooling system for leaks.

WATER PUMP

Note. Fan and fan clutch assembly are secured with left-hand threads.

1. Disconnect ground cables from both batteries. Drain cooling system. Disconnect fan shroud and place shroud over fan. Using Fan Clutch Pulley Holder (T83T-6312-A) and Fan Clutch Nut Wrench (T83T-6312-B), remove fan and clutch assembly. Remove fan shroud.
2. Remove accessory drive belts. Disconnect heater hose from water pump. Remove heater hose fitting from water pump. Remove water pump pulley. Remove alternator adjusting arm and adjusting arm bracket.
3. Remove A/C compressor with hoses attached and set aside. Remove A/C brackets. Remove power steering pump with hoses attached and set aside. Remove power steering bracket. Note bolt location and remove water pump bolts. Remove water pump.

Water Pump. Scheme 34

1. Clean gasket surfaces and bolt threads. Coat 2 top bolts and 2 bottom bolts with silicone sealer. see scheme 19 Install water pump and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m) table at end of article.
2. To complete installation, reverse removal procedure. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#73l-v8-diesel-vin-m__cooling-system-bleeding) under REMOVAL & INSTALLATION. Start engine and check for coolant leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

PISTONS PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• TORQUE SPECIFICATIONS
• COOLING SYSTEM BLEEDING
• INJECTION PUMP
• DRIVE GEAR - INJECTION PUMP
• WATER PUMP
• TIMING GEAR COVER
• CYLINDER BLOCK
• TORQUE SPECIFICATIONS