Engine 4.2L V6 - VIN [2]: Other Ford Econoline E350

FUEL PRESSURE RELEASE

1. Remove fuel cap to release fuel tank pressure. Remove relief valve cap. Relief valve (service port) is located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve (Schrader valve).
2. If fuel pressure gauge is not available, disconnect electrical connector to Inertia Fuel Shut Off (IFS) switch. IFS switch is located behind passenger side kick panel. Crank engine for 15 seconds to reduce system pressure.
3. To disconnect fuel lines, remove retaining clip from fuel line coupling. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line and (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. (Scheme 62)
4. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
5. When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel-resistant "O" rings (Brown). Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary).
6. Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines are locked together and garter spring is over flared end of female fitting. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

Note. Install Black retaining clip on fuel supply line and Gray clip on fuel return line.

Scheme 62

FRONT COVER

TIMING CHAINS

CAMSHAFT SYNCHRONIZER

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. DO NOT machine more than .010" (.25 mm) from original cylinder head surface to correct warpage. Replace cylinder head as necessary. See «CYLINDER HEAD»(ref-54369-S33970730362001011700000) 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»(ref-54369-S41094812702001011700000) table under ENGINE SPECIFICATIONS.
2. If installed height is not within specification, a spacer 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»(ref-54369-S41094812702001011700000) table.

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»(ref-54369-S33970730362001011700000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
2. If oversized valves or oversized valve stem oil seals are not available, valve guide may be replaced with NEW guide. Always use reamers in proper sequence (smallest first).

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

Valve Seat

1. Grind valve seat to 45 degrees. If seat width is too wide after grinding, use a 30-degree stone to lower seat or a 75-degree stone to raise seat. See «CYLINDER HEAD»(ref-54369-S33970730362001011700000) table under ENGINE SPECIFICATIONS.
2. Ensure valve seat angle, seat width and seat runout are within specification. See «CYLINDER HEAD»(ref-54369-S33970730362001011700000) 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.

Fitting Pistons

Check piston-to-bore clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. If clearance is not within specification, replace pistons and/or block. Oversize pistons are not available at this time.

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 too small, file end of ring until within specification. If ring gap exceeds specification, try another ring set. See «PISTONS, PINS & RINGS»(ref-54369-S41616994132001011700000) table under ENGINE SPECIFICATIONS.
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»(ref-54369-S41616994132001011700000) table. Ensure rings are properly spaced on piston before installing pistons into cylinder.

Rod Bearings

Use Plastigage to check rod bearing clearance. If proper oil clearance cannot be obtained, machine or replace crankshaft as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

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, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-54369-S27496142492001011700000) table under ENGINE SPECIFICATIONS.
3. Install all bearing caps except thrust bearing cap (No. 3 from front of engine). Tighten main bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) . 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. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) .
5. Ensure crankshaft end play is within specification. Replace thrust bearing if end play is not within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-54369-S27496142492001011700000) 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»(ref-54369-S20831432012001011700000) 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. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) . 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.

Oil Pressure

Oil pressure specification is 40-125 psi at 2500 RPM at normal operating temperature.

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

CAMSHAFT