7.5l v8 - VIN [g] 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 engine. VIN is located near windshield on left side of instrument panel. The VIN number is also on the Safety Compliance Certification Label attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

1. Rotate crankshaft and position No. 1 piston on TDC of compression stroke. Make chalk mark at points "A" and "B" on crankshaft pulley at TDC. (Scheme 35) Rotate crankshaft 360 degrees for mark "B".
2. Using Lifter Bleed-Down Wrench (T71B-6513-B), apply pressure to push rod end of rocker arm. Slowly bleed down lifter until lifter plunger is completely bottomed. See «VALVE CLEARANCE ADJUSTMENT»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table.
3. While holding lifter in this position, check clearance between rocker arm and valve stem tip using feeler gauge. If clearance is less than specified, install a.060" (1.52 mm) shorter push rod. If clearance is greater that specified, install a.060" (1.52 mm) longer push rod. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS.

VALVE CLEARANCE ADJUSTMENT (1)

Scheme 35

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

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

FUEL PRESSURE RELEASE

Remove fuel cap to release fuel tank pressure. Remove relief valve cap. Relief valve is located on fuel rail. Connect fuel pressure gauge to relief valve. Release fuel pressure into a suitable container.

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 cap seal in 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. Drain cooling system and crankcase. Mark hood hinges and remove hood. Disconnect battery and ground cables from cylinder block. Remove air cleaner and intake duct assembly with crankcase ventilation and carbon canister hoses attached.
2. Disconnect radiator hoses. Disconnect transmission cooler lines (if equipped). Disconnect oil cooler lines at oil filter adapter (if equipped). CAUTION: DO NOT attempt to disconnect engine oil cooler lines at quick-disconnect fittings behind or at oil cooler, or damage to fittings will occur.
3. Disconnect thermactor hoses. On models with A/C, discharge A/C system. Remove condenser and disconnect hoses at compressor. On all models, remove fan shroud, spacer, pulley and radiator. Remove and position alternator aside.
4. Disconnect oil pressure sending unit wire. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__fuel-pressure-release). Disconnect fuel supply and return lines; use Disconnect Tool (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line. (Scheme 36)
5. If hairpin-type clip is used, remove hairpin by bending tab downward so it will clear body. Using your hands, spread clip legs.125" (3 mm) and push legs into fitting. Pull hairpin clip from fitting. (Scheme 36)
6. Disconnect accelerator cable, transmission shift rod and speed control linkages from throttle body. Disconnect throttle bracket from upper intake manifold and set aside with cables attached. Disconnect EGR tube. Disconnect vacuum lines, carbon canister hose, heater hoses and electrical wiring from engine.
7. Disconnect brake booster hose. Remove bellhousing-to-engine upper bolts. Remove oil fill dipstick and tube. Raise and support vehicle. Remove starter. Separate exhaust pipes from manifolds. Disconnect engine mounts from frame brackets. On A/T models, remove converter inspection plate and flex plate-to-converter bolts.
8. On all models, remove remaining bellhousing-to-engine bolts. Lower vehicle and support transmission. Attach engine hoist and carefully separate engine from transmission. Carefully lift engine from vehicle without damaging rear cover plate.

Installation

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

Scheme 36

Removal (Van)

1. Remove engine cover. Disconnect battery. Drain cooling system. Remove air deflector, grille assembly and gravel deflector. Remove hood latch. Remove headlight and parking light assemblies. Remove air cleaner and air ducts.
2. Remove upper grille support, hood lock support and condenser upper mounting brackets (if equipped). On models with A/C, discharge A/C system. Remove condenser and disconnect lines at A/C compressor. On all models, remove radiator hoses and heater hoses from engine. Disconnect power steering hoses. Remove power steering pump and bracket from front of engine.
3. Disconnect A/T lines at radiator. Remove fan, shroud and radiator. Disconnect EGR tube. Disconnect thermactor air pump hoses. Remove air cleaner assembly. Disconnect accelerator cable, transmission shift rod and speed control linkages from throttle body.
4. Disconnect throttle bracket from upper intake manifold and set aside with cables attached. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect fuel inlet and return lines using Disconnect Tool (D87L-9280-A or B). (Scheme 36)
5. Raise and support vehicle. Drain crankcase and remove oil filter. Disconnect exhaust pipes from manifolds. Disconnect transmission filler tube from right cylinder head. Remove engine mount attaching bolts and nuts. Remove starter wiring and remove starter. NOTE: Right engine mount through bolt is installed from front of vehicle. Left engine mount through bolt is installed from rear.
6. Remove converter inspection cover bolts and remove cover. Remove flex plate-to-converter nuts. Remove bellhousing lower bolts. Remove ground strap from engine block. Lower vehicle and support transmission.
7. Disconnect engine wiring loom and position aside. Attach lifting device to engine. Remove upper bellhousing-to-engine bolts. Carefully remove engine from vehicle.

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

INTAKE MANIFOLDS

Note. On Pickup, it is possible to remove upper and lower intake manifolds as an assembly. On Van, upper manifold must be removed first.

Removal (Upper)

1. Disconnect negative battery cable. Disconnect throttle and A/T linkage (if equipped) from throttle body. Remove 2 bracket-to-intake manifold bolts. Set bracket and cables aside.
2. Disconnect electrical connectors and upper manifold vacuum hose connections as necessary. Disconnect EGR and PCV systems. Disconnect clean air supply hose of idle by-pass valve. Remove 4 upper intake manifold bolts. Remove upper intake manifold and throttle body as an assembly.

Clean all gasket surfaces. Position new gasket on lower intake manifold. Ensure new gasket is aligned. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

Removal (Lower)

1. Disconnect negative battery cable. Remove upper intake manifold as previously described. Position No. 1 piston on TDC of compression stroke. Remove distributor cap and wires. Mark distributor location for installation reference. Remove distributor.
2. Remove air cleaner and duct assembly. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__fuel-pressure-release) under REMOVAL & INSTALLATION. Disconnect fuel inlet and return lines with Disconnect Tool (D87L-9280-A or B).
3. If hairpin-type retainer is used, remove hairpin by bending tab downward so it clears body. Spread clip legs.125" (3 mm) and push legs into fitting. Gently pull hairpin clip from fitting. (Scheme 36)
4. Remove upper radiator hose. Disconnect coolant hoses at intake manifold and water pump. Label and disconnect vacuum hoses as necessary. Remove both thermactor exhaust air supply tubes. Remove ignition coil and mounting bracket.
5. Disconnect wiring harness from main wiring. Remove wiring harness and lower intake manifold as an assembly. Label and disconnect all other electrical wiring from intake manifold. Remove attaching bolts, and lift lower intake manifold and throttle body as an assembly.

1. Clean all gasket surfaces. Apply 1/8" (3 mm) bead silicone sealer to 4 corners of cylinder block seal mounting surface. Install manifold gasket, front seal and rear seal. Apply 1/16" (1.5mm) bead silicone sealer along full width of front and rear seal ends.
2. Install intake manifold within 15 minutes of applying sealer. Position intake manifold over 4 studs in cylinder heads. Check gasket and seal alignment before tightening.
3. Install manifold attaching bolts, studs and nuts. Tighten bolts in sequence to specification. (Scheme 37) See TORQUE SPECIFICATIONS table. Install fuel lines, electrical connectors and vacuum hoses. To install remaining components, reverse removal procedure.
4. Fill and bleed air from cooling system. See, in this article, «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__cooling-system-bleeding) under REMOVAL & INSTALLATION. Check and adjust ignition timing as necessary. Start engine and allow it to reach operating temperature. Turn off engine. Retorque bolts and nuts sequentially to 22-35 ft. lbs. (30-47 N.m) to complete installation.

Scheme 37

Removal

1. If removing right exhaust manifold, remove spark plug heat shield. If removing left exhaust manifold, disconnect EGR tube. On Van, remove power steering pump support bracket.
2. On all models, remove oil dipstick tube from left exhaust manifold. Disconnect spark plug wires. Disconnect exhaust pipe(s) from manifold(s). Remove exhaust manifold-to-cylinder head bolts. Remove exhaust manifold(s).

1. Inspect manifold(s) for cracks, damaged sealing surfaces, or other wear or damage. Replace manifold(s) as necessary. Clean cylinder head and manifold mating surfaces.
2. Clean mounting flange of manifold and exhaust pipe. Apply light film of graphite grease to manifold-machined surface. Position spark plug wire heat shields and exhaust manifold on cylinder head.
3. Install attaching bolts and washers, starting at fourth bolt hole from front of each manifold. Tighten bolts to specification, starting at center bolts and working outward. See, in this article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table.

1. Drain cooling system. Remove upper and lower intake manifolds. See «INTAKE MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__intake-manifolds) under REMOVAL & INSTALLATION. Disconnect exhaust pipes at manifolds. Remove drive belts. Remove thermactor air pump and bracket from right cylinder head. Remove alternator.
2. On models with A/C, discharge A/C system. Remove valves and hoses from compressor. Remove A/C compressor support bracket nuts from water pump. Remove and position compressor aside. Remove compressor mounting bracket from cylinder head.
3. On models without A/C, remove power steering pump bracket-to-left cylinder head bolts. Position pump and bracket aside. On Van, disconnect oil filler tube. On all models, remove valve covers.
4. Mark location for installation reference, and remove rocker arm assemblies and push rods. Remove cylinder head and exhaust manifold assemblies. Discard cylinder head gasket. Remove exhaust manifolds.

Inspection

Measure cylinder head and cylinder block mating surfaces for warpage. 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 to correct warpage. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

1. Clean gasket mating surfaces. Check flatness of cylinder head and block mating surfaces. If exhaust manifolds were removed, coat cylinder head and manifold port areas with a thin film of graphite grease, and install manifold on cylinder head.
2. Place 2 long head bolts in 2 rear lower bolt holes of left cylinder head. Place one long head bolt in rear lower bolt hole of right cylinder head. Keep bolts in position until heads are installed.
3. Position new head gaskets on block. DO NOT apply sealer to head gasket surfaces. Install cylinder head bolts. Tighten bolts in sequence to specification. (Scheme 38) See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table.
4. To complete installation, reverse removal procedure. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__cooling-system-bleeding) under REMOVAL & INSTALLATION. Evacuate and recharge A/C system (if equipped).

Scheme 38

HYDRAULIC VALVE LIFTERS

Note. Before replacing a noisy hydraulic valve lifter, ensure valve clearance is correct. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

1. Remove upper and lower intake manifolds. See, in this article, «INTAKE MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__intake-manifolds) under REMOVAL & INSTALLATION. Remove valve covers. Loosen rocker arm fulcrum bolts and turn to one side.
2. Mark location for installation reference and remove push rods. Mark lifter location for installation reference. Remove valve lifters with a magnet. If lifters are stuck in bores, use Hydraulic Lifter Puller (T70L-6500-A).

1. Service lifters as an assembly only. Disassemble and clean lifters before testing. Test lifters with hydraulic lifter test fluid. DO NOT interchange parts between lifters.
2. Leak-down rate on hydraulic lifters is 10-50 seconds with 1/16" (1.6 mm) plunger travel under 50-lb. (23 kg) load. Replace lifter if it fails leak-down test, or if it is worn or damaged.

Clean outside of valve lifters. Lubricate lifters and bores with engine oil before installation. Install lifters in their original bores. If any new lifters are installed, ensure lifter moves freely in bore. To complete installation, reverse removal procedure. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING under REMOVAL & INSTALLATION.

FRONT CRANKSHAFT OIL SEAL

Note. Front crankshaft seal can be replaced without removing timing chain cover.

Remove radiator fan, spacer and shroud. Remove drive belts. Remove crankshaft pulley and vibration damper. Place Seal Remover (T70P-6B070-B) onto timing chain cover plate over front seal. Tighten 2 bolts, forcing seal remover under seal flange. Alternately tighten 2 bolts, one-half turn at a time, until seal is removed from engine.

Coat new seal with polyethylene grease and install seal using Seal Installer (T70P-6B070-A). Ensure seal is fully seated. To install remaining components, reverse removal procedure.

TIMING CHAIN COVER

Note. Front crankshaft oil seal should be replaced whenever timing chain cover is removed.

1. Disconnect negative battery cable. Drain cooling system and crankcase. Remove fan and radiator shroud. Disconnect radiator hoses at engine. Disconnect oil cooler lines (if equipped) at radiator. Remove upper radiator support and remove radiator.
2. Remove all drive belts and water pump pulley. Remove alternator and air pump assemblies with brackets. Remove A/C compressor and support bracket (if equipped). Disconnect heater hose from water pump, and loosen by-pass hose clamp at pump.
3. Remove crankshaft pulley. Using Vibration Damper Remover (T58P-6316-D), remove vibration damper and Woodruff key from crankshaft. Remove timing chain cover-to-cylinder block bolts. Remove timing chain cover and water pump as an assembly.
4. Cut oil pan gasket even with cylinder block face. Discard timing chain cover gasket and pan gasket. Carefully remove old seal using a pin punch; DO NOT damage front crankshaft seal recess.

1. Install new timing chain cover oil seal. Coat gasket surface of oil pan with gasket sealer. Cut and position new gasket on oil pan. Apply silicone sealer at block-to-oil pan junction. Apply gasket sealer to timing chain cover and cylinder block gasket surfaces. Position new timing chain cover gasket in place.
2. Position timing chain cover on cylinder block. Install Timing Chain Cover Aligner (T68P-6019-A) on crankshaft. (Scheme 39) Coat threads of cover bolts with oil-resistant sealer and install bolts. It may be necessary to push cover downward to compress pan gasket.
3. While pushing in on Timing Chain Cover Aligner (T68P-6019-A), tighten oil pan-to-cover bolts. Remove timing chain cover aligner and tighten timing chain cover-to-cylinder block bolts. To complete installation, reverse removal procedure. Fill engine crankcase with proper grade oil. Fill and bleed air from cooling system. See, in this article, «COOLING SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Scheme 39

1. Position No. 1 piston on TDC of compression stroke. Remove timing chain cover. See «TIMING CHAIN COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__timing-chain-cover). Check alignment of camshaft gear and crankshaft gear timing marks. (Scheme 40)
2. Check timing chain defection (stretch) for excessive wear. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. Remove camshaft sprocket bolt and washer. Slide timing chain and sprockets forward and remove as an assembly.

Assemble and align timing chain and sprockets. (Scheme 40) Install chain and sprockets as an assembly. Lubricate timing chain with engine oil. Tighten bolts to specification. See, in this article, TORQUE SPECIFICATIONS table. To complete installation, reverse removal procedure.

Scheme 40

1. Remove timing chain cover, timing chain and sprockets. See «TIMING CHAIN COVER»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__timing-chain-cover) and TIMING CHAIN & SPROCKET. Remove intake manifolds. See «INTAKE MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__intake-manifolds) under REMOVAL & INSTALLATION. Remove valve covers.
2. Loosen all rocker arm bolts and rotate rocker arms aside. Remove push rods and valve lifters, keeping them in order for installation in original locations. NOTE: Use Hydraulic Lifter Puller (T70L-6500-A) to remove stuck lifters.
3. Remove A/C condenser-to-chassis bolts (if equipped) and set condenser aside. Remove front grille. Check camshaft end play. If not within specification, replace thrust plate. See «CAMSHAFT»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. Remove camshaft thrust plate. Carefully remove camshaft without damaging bearings or journals.

Measure camshaft bearing journals and lobes for wear. If measurements are not within specification, replace camshaft and valve lifters. See CAMSHAFT table under ENGINE SPECIFICATIONS.

1. Oil camshaft journals and apply polyethylene grease to camshaft lobes. Carefully slide camshaft into position. Install and tighten thrust plate. Recheck camshaft end play. Lubricate lifters with engine oil and install.
2. Lubricate rocker arms, fulcrum seats, valve stem tips and push rods with polyethylene grease before installing. Rotate crankshaft until No. 1 piston is on TDC of compression stroke.
3. Install rocker arm, fulcrum seats, oil deflection and fulcrum bolts to the appropriate valves. Refer to, in this article «VALVE CLEARANCE ADJUSTMENT»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ADJUSTMENTS. Rotate crankshaft 360 degrees and install rocker arm components on remaining valves.
4. Ensure fulcrum seat base is inserted into slot on cylinder head before tightening fulcrum bolts. To complete installation, reverse removal procedure. Use new gaskets where required.

CAMSHAFT BEARINGS

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

Remove engine from vehicle. See ENGINE under REMOVAL & INSTALLATION. Remove camshaft. See CAMSHAFT . Remove flywheel. Push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Using Camshaft Bearing Remover/Installer Set (T65L-6250-A), remove camshaft bearings.

Using camshaft bearing remover/installer, install bearings into place. Ensure oil holes in bearings and cylinder block are aligned. Install front bearing .040-.060" (1.02-1.52 mm) behind front face of cylinder block. Coat new rear bore plug with sealer and install. To complete installation, reverse removal procedure.

1. Remove oil pan. See «OIL PAN»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) under REMOVAL & INSTALLATION. Loosen all main bearing cap bolts to slightly lower crankshaft. DO NOT lower more than 1/32" (.79 mm). Remove rear main bearing cap and lower oil seal half. Use seal remover to remove upper seal.
2. If seal remover is not available, install a small metal screw in one end of seal. Carefully pull on screw to remove seal without damaging sealing surface.

1. Carefully clean oil seal grooves in bearing cap and block. Coat split-lip seal halves with engine oil. Carefully install upper seal into groove in cylinder block, with undercut side of seal toward front of engine. NOTE: DO NOT damage outside diameter of seal when installing in groove. DO NOT allow oil to get on area where sealer is applied.
2. Rotate seal on crankshaft journal until about 3/8" (9.5 mm) of seal protrudes below parting face. (Scheme 41) Tighten all main bearing cap bolts except the rear main. Install lower seal in rear main bearing cap, with undercut side of seal toward front of engine.
3. Allow seal to protrude about 3/8" (9.5 mm) above parting surface to mate with upper seal when cap is installed. Apply 1/16" (1.5 mm) bead of silicone sealer to both sides of cylinder block-to-cap mating surface and both sides of bearing cap. (Scheme 42)
4. Install and tighten rear main bearing cap before sealer sets (about 15 minutes). To complete installation, reverse removal procedure.

Scheme 41

Scheme 42

1. Remove engine cover (if equipped) and disconnect battery. Drain cooling system. Disconnect upper and lower radiator hoses. Disconnect and remove air cleaner assembly. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__fuel-pressure-release) under REMOVAL & INSTALLATION.
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 36) On E250/350, remove upper intake manifold. See, in this article, «INTAKE MANIFOLDS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g__intake-manifolds) under REMOVAL & INSTALLATION. On A/T models, disconnect transmission cooler lines at radiator.
3. On all models, disconnect engine cooler lines at oil filter adapter (if equipped). Remove fan assembly and shroud. Remove radiator. Remove power steering pump. Remove front engine mount through bolts. CAUTION: On Van, right engine through bolt is installed from front of vehicle. Left engine mount through bolt is installed from rear of vehicle.
4. Remove dipstick tube retaining nuts, and remove dipstick and tube. Remove oil filler tube and bracket (if equipped). On models with A/C, rotate or remove A/C lines at rear of compressor to clear dash.
5. On all models, raise and support vehicle. Drain engine oil and remove oil filter. Disconnect and remove muffler inlet pipe assembly. Disconnect control linkage at transmission. On A/T models, remove transmission dipstick assembly. On all models, remove drive shaft assembly.
6. Raise engine. Engine and transmission assembly will pivot around rear engine mount. Engine and transmission assembly must be raised approximately 4" (measure at front engine mounts), and remain centered in engine compartment. Support engine with wooden blocks.
7. Remove oil pan bolts and lower oil pan. Remove oil pump bolts and pick-up tube nut. Lower oil pump assembly into pan. Remove oil pan.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill or top off all fluids. Fill and bleed air from cooling system. See, in this article, COOLING SYSTEM BLEEDING under REMOVAL & INSTALLATION. Start engine and check for leaks.

Cylinder Head

1. Clean head gasket mating surface. Clean carbon from combustion chambers. Use care not to damage surfaces. Check cylinder head for cracks, burrs, nicks and warpage.
2. DO NOT machine more than .010" (.25 mm) from original cylinder head surface to correct warpage. Replace cylinder head as necessary. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS.

Valve Springs

1. Measure valve spring installed height from top of spring seat to underside of spring retainer. Ensure installed height is within specification. See «VALVES & VALVE SPRINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS.
2. 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. 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/#75l-v8-vin-g) table.

Valve Stem Oil Seals

Umbrella-type oil seals are used on all valves. Intake and exhaust valve stem seals are not interchangeable. Seals are identified with IN for intake and EX for exhaust. Lubricate valve stem with engine oil and install new seal with cup side down over valve guide.

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/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. 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

1. 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»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS.
2. Ensure valve seat angle, seat width and seat runout are within specification. See «CYLINDER HEAD»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. 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.

Pistons & Rod Assembly

Ensure pistons and rods are installed in their original cylinder. Ensure notch on piston top faces forward, and numbered side of rod faces outward. (Scheme 43) Check side play of connecting rod. See CONNECTING RODS table under ENGINE SPECIFICATIONS.

Scheme 43

Fitting Pistons

1. Check piston-to-bore clearance. See «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. Standard size pistons are color-coded Red, Blue or Yellow on the piston dome. See, in this article, «PISTONS PINS & RINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) 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/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS.

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/#75l-v8-vin-g) table.
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/#75l-v8-vin-g) table. Ensure rings are properly spaced on piston before installing pistons into cylinder. (Scheme 44)

Scheme 44

Piston Pin Replacement

1. Using an arbor press and Piston Pin Remover/Installer (T68P-6135-A), press piston pin from piston and connecting rod. (Scheme 45) Ensure connecting rod piston pin bore and piston pin are within specification. See «CONNECTING RODS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) and PISTONS PINS & RINGS tables under ENGINE SPECIFICATIONS.
2. Apply light coat of engine oil to all parts to be assembled. Assemble piston to connecting rod, with numbered side of rod toward outside of engine and notch in piston head toward front of engine. (Scheme 43)
3. Position piston pin in piston and connecting rod. Using arbor press and pin remover/installer, press pin into piston and connecting rod until end of pin is 1/16 - 1/8" (1.6-3.2 mm) below chamfer of piston pin bore.

Scheme 45

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. Refer to, in this article, UNDERSIZE MAIN & ROD BEARING COMBINATIONS table.
2. 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 the end of this article «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) 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, in the end of this article, «UNDERSIZE MAIN & ROD BEARING COMBINATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table.
3. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See, at the end of this article «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. NOTE: Ensure main bearing oil holes are aligned with cylinder block oil holes.
4. Install all bearing caps except thrust bearing cap (No. 3 from front of engine). Tighten main bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table. Install No. 3 bearing cap and tighten bolts finger tight.
5. 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. See, in this article, «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical/#75l-v8-vin-g) table.
6. 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/#75l-v8-vin-g) 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/#75l-v8-vin-g) table under ENGINE SPECIFICATIONS. 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 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

Engine lubrication is a force-feed system. The oil is supplied under full pressure to crankshaft, connecting rods, camshaft bearing and valve lifters. A controlled volume of oil is supplied to rocker arms and push rods. All other moving parts are lubricated by splash or gravity flow. Oil flows through oil filter before entering main oil gallery. (Scheme 46)

Scheme 46

Crankcase Capacity

Crankcase capacity is 5 qts. (4.75L). Add one additional quart (.95L) when replacing oil filter.

Oil Pressure

Normal oil pressure at 2000 RPM should be 40-65 psi (2.8-4.6 kg/cm 2 ) with engine at operating temperature.

Oil Pressure Relief Valve

Nonadjustable oil pressure regulator valve is located in pump body.

Removal & Disassembly

Oil pump and oil pan must be removed together. See OIL PAN under REMOVAL & INSTALLATION. Disassemble oil pump. Note direction of component installation for reassembly reference.

1. Clean all parts thoroughly. Check pump housing, outer rotor, inner rotor, shaft and pump cover for damage, scoring or excessive wear. See OIL PUMP SPECIFICATIONS table. Remove rotor assembly from pump housing. Using feeler gauge, measure inner-to-outer rotor tip clearance.
2. Install rotor assembly in pump housing. Place a straightedge over rotor assembly and housing. Insert feeler gauge between straightedge and housing to measure rotor end play. Using a feeler gauge, measure clearance between outer rotor and pump housing.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. Ensure oil pump spins freely after reassembly. To install, prime oil pump by filling inlet opening with oil and rotating pump shaft until oil emerges from outlet opening.
2. Install oil pump assembly and pan. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

1. Remove negative battery cable. Drain cooling system. Remove fan shroud and fan. Loosen power steering pump attaching bolts. Remove A/C compressor (if equipped). Remove A/C compressor and power steering bracket.
2. Remove all drive belts. Remove air pump, alternator and bracket. Disconnect all hoses from water pump and loosen by-pass hose clamp at pump. Remove remaining bolts and remove water pump. Remove separator plate from water pump and discard gaskets.

Clean all gasket surfaces. To install, reverse removal procedure. Use new gaskets coated on both sides with water-resistant sealer. Fill and bleed air from cooling system. See, in this article, COOLING SYSTEM BLEEDING under REMOVAL & INSTALLATION.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS 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
• VALVE CLEARANCE ADJUSTMENT
• FUEL PRESSURE RELEASE
• COOLING SYSTEM BLEEDING
• INTAKE MANIFOLDS
• VALVE CLEARANCE ADJUSTMENT
• TIMING CHAIN COVER