Engine 4.2L V6 - VIN [2]: Removal & Installation Ford Econoline E350

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.

Removal (Pickup)

1. Disconnect negative and positive battery cable. Mark hinges and remove hood. Drain cooling system. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE»(ref-54369-S13681438662001011700000) .
2. Remove upper front air deflector. Remove air cleaner outlet tube. Remove radiator. Remove fan blade and fan shroud. Disconnect throttle body control cables. Disconnect throttle control cable bracket and position aside.
3. Disconnect necessary vacuum and water lines. Disconnect necessary harness connectors and ground cables. Unbolt power steering reservoir and position aside. Disconnect A/C manifold line at compressor and position aside. Remove power steering pump retaining bolts and position pump aside.
4. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-54369-S03909529142001011700000) . Remove fuel injector supply manifold and injectors. Raise and support vehicle. Disconnect exhaust pipes from exhaust manifold. Remove starter.
5. Remove transmission. For A/T (E4OD), see «REMOVAL & INSTALLATION - A/T (E40D)»(ref-61330) article in TRANSMISSION SERVICING. For A/T (4R70W), see «SERVICING - A/T (4R70W)»(ref-58609) article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES.
6. Remove right and left engine mount through-bolt. Lower vehicle. Install engine lifting equipment. Remove transmission-to-engine retaining bolts. Remove engine.

Installation

1. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) .
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

Removal (Van)

1. Disconnect negative and positive battery cable(s). Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE»(ref-54369-S13681438662001011700000) . Remove air cleaner assembly and throttle body inlet tube.
2. Remove radiator air deflector. Remove radiator, fan shroud and cooling fan. Remove radiator inner grille. Remove radiator grille reinforcement panel. Remove stone deflector.
3. Remove headlight and side marker assemblies. Remove power steering cooler and auxiliary transmission cooler. Remove power steering cooler mounting brackets. Remove A/C condenser and plug openings. Disconnect hood latch cable and remove hood latch assembly.
4. Disconnect positive battery cable from power distribution box and position aside. Remove power steering reservoir retaining bolts and position aside. Remove upper and lower core support. Remove oil dipstick tube. Remove upper and lower intake manifold. See «INTAKE MANIFOLD»(ref-54369-S03909529142001011700000) .
5. Disconnect necessary harness and ground connections. Remove accessory drive belt. Disconnect low-pressure hose at power steering pump. Unbolt power steering pump and position aside. Remove lower radiator hose. Disconnect A/C manifold at compressor and position aside, plug openings. Disconnect A/C high-pressure hose at evaporator and plug openings.
6. Raise and support vehicle. Drain engine oil. Remove starter. Remove torque converter nuts. Remove oil pan-to-transmission bolts. Disconnect exhaust pipes at exhaust manifolds. Disconnect shift cable bracket. Remove engine mount nuts.
7. Lower vehicle. Support transmission. Remove transmission dipstick tube. Install engine lifting equipment. Remove transmission-to-engine retaining bolts. Remove engine.

1. To install, reverse removal procedure. Replace torque converter nuts with NEW ones. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) .
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. Remove the engine air cleaner outlet tube.
2. Disconnect the idle air control (IAC) valve electrical connector.
3. Remove the idle air control (IAC) valve assembly.
4. Remove the pushpin and the accelerator control splash shield.
5. Disconnect the accelerator cable end and, if equipped, the speed control actuator cable end.
6. Detach the accelerator cable (9A758) and, if equipped, the speed control actuator cable (9A825).
7. Remove the crankcase ventilation hose. Disconnect the spark plug wire holders.
8. Remove the twelve bolts in reverse order and remove the upper intake manifold. (Scheme 33)

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Inspect the intake manifold upper gasket. Install a new gasket, if necessary.
2. Position the upper intake manifold and tighten the upper intake manifold bolts in the sequence shown in two stages. See «TORQUE SPECIFICATIONS»(ref-54369-S08094804632001011700000) table.
3. Connect the spark plug wire holders.
4. Install the accelerator cable and, if equipped, the speed control actuator cable.
5. Attach the accelerator cable end and, if equipped, the speed control actuator cable end.
6. Position the accelerator control splash shield and install a new pushpin.
7. Install the idle air control (IAC) valve assembly.
8. Connect the idle air control (IAC) valve electrical connector.
9. Install the engine air cleaner outlet tube.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. Remove the upper intake manifold (9424). Refer to «UPPER INTAKE MANIFOLD»(ref-54369-S03909529142001011700000) .
2. Disconnect the fuel injector electrical connectors.
3. Disconnect the fuel injector electrical harness from the fuel injector supply manifold.
4. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
5. Remove the EGR valve to exhaust manifold tube upper fitting.
6. Remove the upper radiator hose from the lower intake manifold.
7. Disconnect the intake manifold runner control (IMRC) electrical connector and the fuel pressure regulator vacuum line.
8. Disconnect the fuel lines. Refer to FUEL LINE CONNECTORS
9. Disconnect the water bypass hose and the heated positive crankcase ventilation (PCV) system heater water hose.
10. Remove the (A) long lower intake manifold bolts, the (B) short lower intake manifold bolts and remove the lower intake manifold.
11. Remove and discard the lower intake manifold sealing components.

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. (Scheme 49)for intake manifold sealing component locations.
2. Install the lower intake manifold front and rear end seals. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated. Install the lower intake manifold front and rear end seals.
3. Install the intake manifold gaskets.
4. Position the lower intake manifold. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated. Position the lower intake manifold.
5. Loosely install the (A) long bolts and the (B) short bolts.
6. Tighten the bolts in the sequence shown in two stages. See «TORQUE SPECIFICATIONS»(ref-54369-S08094804632001011700000) table.
7. Connect the water bypass hose and the heated PCV system heater water hose.
8. Connect the fuel lines.
9. Connect the fuel pressure regulator vacuum line and the IMRC electrical connector.
10. Install the upper radiator hose to the lower intake manifold.
11. Connect the EGR valve vacuum hose.
12. Install the EGR valve to exhaust manifold tube upper fitting.
13. Connect the fuel injector electrical harness to the fuel injector supply manifold.
14. Connect the fuel injector electrical connectors.
15. Install the upper intake manifold. Refer to «UPPER INTAKE MANIFOLD»(ref-54369-S03909529142001011700000).

Removal

On left manifold, remove oil dipstick tube. On right manifold, remove EGR manifold tube. On both sides, disconnect oxygen sensor. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold retaining bolts in reverse order. (Scheme 61) Remove exhaust manifold and gasket.

To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. (Scheme 61) See TORQUE SPECIFICATIONS table.

Scheme 55

1. Disconnect negative battery cable. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-54369-S03909529142001011700000). Remove valve cover. Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-54369-S02467585812001011700000). Remove accessory drive belt.
2. If removing left cylinder head, unbolt power steering reservoir and position aside. Remove A/C compressor, with hoses attached, and position aside. Remove power steering bracket, with pump and hoses attached, and position aside.
3. If removing right cylinder head, remove generator. Remove accessory drive belt idler pulley. Remove generator bracket. CAUTION: Mark location of rocker arms and push rod if they are to be reused. Ensure they are installed in there original location.
4. If removing either cylinder head, remove rocker arms and push rods. Remove and discard cylinder head retaining bolts in reverse sequence. see scheme 38 Remove cylinder head and gasket.

1. Install NEW cylinder head gaskets on block with small hole at front of engine. Always use NEW cylinder head bolts. Lubricate cylinder head bolts with engine oil prior to installation.
2. Install cylinder head and tighten bolts to 14 ft. lbs. (19 N.m), in sequence. see scheme 38 Repeat sequence again, tightening bolts to 29 ft. lbs. (39 N.m). Repeat sequence again, tightening bolts to 36 Ft. Lbs. CAUTION: DO NOT loosen all cylinder head bolts at one time. Loosen and tighten each cylinder head bolt before preceding to next.
3. Working in order and on one bolt at a time, loosen bolt 3 revolutions and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000). To complete installation, reverse removal procedure.

Scheme 56

1. Disconnect negative battery cable. Remove accessory drive belt. Remove cooling fan and fan shroud. Raise and support vehicle. Mark pulley and damper position. Remove crankshaft pulley. Remove damper bolt.
2. Install Crankshaft Damper Remover (T58P-6316-D) and Crankshaft Damper Remover Adapter (T82P-6316-D). Remove damper. Using Seal Remover (T92C-6700-CH), remove oil seal from front cover.

To install, reverse removal procedure. Lubricate oil seal bore and seal lip with engine oil before installing. Apply silicone sealant to keyway of crankshaft damper before installing. Install seal. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect the battery ground cable, remove air cleaner assembly.
2. Raise vehicle, drain coolant from radiator, drain the engine oil.
3. Lower vehicle, remove upper radiator hose. Remove the fan shroud and the lower radiator hose.
4. Raise vehicle, remove 2 nuts holding the Crankshaft (CKP) sensor shield in place and remove the shield. Disconnect both the Knock sensor and (CKP) sensor harness connectors. Position wiring harness aside.
5. Remove transmission line support bracket bolt. Remove power steering support bracket bolts. Remove the A/C compressor mounting bracket nuts and position the A/C compressor aside.
6. Mark crankshaft pulley and damper position. Remove crankshaft pulley and damper. See «FRONT COVER OIL SEAL»(ref-54369-S09072416752001011700000).
7. Remove front oil pan bolts that intersect with the front cover.
8. Lower vehicle, remove the supply tube heater hoses. Detach wiring harness from the outlet tube and position aside.
9. Remove the heater water outlet tube (remove bolt). Remove water pump. See «WATER PUMP»(ref-54369-S20833821442001011700000).
10. Remove Cam Position Synchronizer. See «CAMSHAFT SYNCHRONIZER»(ref-54369-S10686600462001011700000).
11. Remove front cover crankshaft oil seal. See «FRONT COVER OIL SEAL»(ref-54369-S09072416752001011700000).
12. Remove the 4 water pump mounting studs.
13. Remove engine front cover stud bolts and cover bolt, remove CAP SCREW. see scheme 39
14. Slide the front cover off the dowels, remove the gasket and discard.

1. Clean off surfaces of the block, front engine cover and exposed oil pan flange.
2. Install front engine cover gasket, apply sealant (F6AZ-19562-A) to base of gasket where oil pan and block come together. Apply a bead of sealant in center of oil pan flange and around bolt holes. Apply a thin layer of sealant to front cover gasket mating surface (DO NOT over apply the sealant).
3. Tighten fasteners in 3 stages, as follows: Starting with bolt at about the 6 o'clock position (identified as bolt No. 1), tighten fasteners 1-11 and 13 in sequence to 16 Ft. lbs. (22 N.m). see scheme 39 NOTE: Apply a small amount of loctite® to threads of cap screw (do not over apply compound). Tighten CAP SCREW (No. 12) to 89 INCH. lbs. (10 N.m). Tighten all fasteners (except Cap Screw No. 12) an additional 90 degrees, in sequence.
4. Install Cam Position Synchronizer. See «CAMSHAFT SYNCHRONIZER»(ref-54369-S10686600462001011700000).
5. Install the heater water outlet tube, tighten to 71-97 INCH. lbs. (8-11 N.m).
6. Attach the wiring to the outlet tube, install both supply tube heater hoses.
7. Raise vehicle, install oil pan bolts, tighten to 80-106 INCH. lbs. (9-12 N.m).
8. Install NEW front cover crankshaft oil seal. See «FRONT COVER OIL SEAL»(ref-54369-S09072416752001011700000).
9. Install crankshaft pulley and damper. See «FRONT COVER OIL SEAL»(ref-54369-S09072416752001011700000) and «TORQUE SPECIFICATIONS»(ref-54369-S08094804632001011700000).
10. Connect (CKP) sensor and Knock sensor harness connectors. Install the (CKP) sensor shield (if removed).
11. Lower vehicle.
12. Install A/C compressor mounting bracket nuts, tighten to 30-40 Ft. lbs. (40-45 N.m).
13. Install power steering support bracket bolts, tighten to 30-40 Ft. lbs. (40-45 N.m).
14. Install accessory drive belt.
15. Install the lower radiator hose, the fan shroud and upper radiator hose.
16. Refill coolant system, refill the engine oil. Ensure oil drain plug has been tightened.
17. Reconnect the battery ground cable, install air cleaner assembly.
18. Start vehicle and check for leaks.

Scheme 57

Remove front cover. See FRONT COVER. Remove camshaft synchronizer. See CAMSHAFT SYNCHRONIZER. Rotate crankshaft until timing marks and keyways align. see scheme 40 Compress and install retaining pin to timing chain tensioner. see scheme 41 Remove timing chain and gears as an assembly. Remove timing chain tensioner.

To install, reverse removal procedure. Ensure all timing marks are properly aligned. see scheme 40 Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 58

Scheme 59

Remove upper and lower intake manifolds. See INTAKE MANIFOLD . Remove valve covers. Mark position of rockers push rods and lifters for installation reference. Remove rockers and push rods. Remove lifter retainer plates. Remove lifters.

To install, reverse removal procedure. Coat components with engine oil before installing. Tighten all nuts and bolts to specifications. See TORQUE SPECIFICATIONS .

Remove lifters. See LIFTER . Remove timing chains. See TIMING CHAINS . Remove balance shaft drive gear from camshaft. Remove camshaft thrust plate. Remove camshaft.

Coat camshaft bearings, journals and lobes with Engine Assembly Lubrication (D9AZ-19579-D). Install camshaft. To complete installation, reverse removal procedures. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable(s). Position crankshaft at TDC No. 1 compression stroke. Partially drain cooling system. Remove air cleaner assembly. Disconnect EGR vacuum hose from EGR valve. Remove EGR valve and adapter. Disconnect heater outlet tube and position aside.
2. Disconnect camshaft position sensor harness connector. Mark orientation of camshaft position sensor electrical connector. Remove camshaft position sensor. Remove camshaft synchronizer retaining bolt. Remove camshaft synchronizer.

Note. Oil pump driveshaft might come out with camshaft synchronizer. If so, retrieve oil pump driveshaft before proceeding.

1. Ensure crankshaft is still at TDC No. 1 compression stroke. Install synchro positioning tool on camshaft synchronizer by rotating tool until it engages notch in camshaft synchronizer housing. NOTE: During installation, arrow on synchro positioning tool will rotate clockwise as gears engage.
2. Install camshaft synchronizer so arrow on synchro positioning tool is 54 degrees from centerline of engine. see scheme 42 Install camshaft synchronizer retaining bolt.
3. Remove synchro positioning tool. Install camshaft position senor. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000).

Scheme 60

Remove timing chain. See TIMING CHAINS . Remove balance shaft drive gear from camshaft. Remove balance shaft thrust plate retaining bolts. Remove balance shaft.

To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATION. Ensure all timing mark are aligned. see scheme 40

Remove transmission. For A/T (E4OD), see REMOVAL & INSTALLATION - A/T (E40D) article in TRANSMISSION SERVICING. For A/T (4R70W), see SERVICING - A/T (4R70W) article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES. Remove flywheel. Using Rear Crankshaft Slinger Remover (T95P-6701- EH) and Slide Hammer (T50T-100-A), remove oil seal.

Clean and inspect all mating surface. Using Rear Seal Replacer (T82L-6701-A), install oil seal. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Partially drain cooling system. Remove upper radiator hose. Remove water outlet connection bolts. Remove water outlet connection. Remove water thermostat and gasket assembly.

Align notch in water thermostat and gasket asssembly with recess in water outlet connection. Position water outlet connection on lower intake manifold. Install 2 water outlet connection bolts. Connect upper radiator hose. Fill cooling system.

Drain cooling system. Remove cooling fan and shroud. Remove radiator. Remove accessory drive belt. Remove water pump pulley. Disconnect lower radiator hose from water pump. Disconnect water by-pass tube and engine harness clamp from water pump. Remove A/C support bracket from water pump. Remove water pump retaining bolts. Remove water pump and gasket. To install, reverse removal procedure. Tighten all nut and bolts to specifications. See TORQUE SPECIFICATIONS .

Removal (4x2 Pickup)

The oil pan on a 4x2 vehicle cannot be removed in-vehicle. Remove engine. See ENGINE. Remove oil pan retaining bolts in reverse sequence. see scheme 43 Remove oil pan and gasket.

Removal (4x4 Pickup)

1. With transmission in Neutral, raise and support vehicle. Mark front drive shaft and differential flange for installation. disconnect front drive shaft from differential and support drive shaft. Disconnect front halfshafts from differential, and support.
2. Disconnect vacuum lines from front axle tube. Using Hi-Lift Jack (014-00210) support front differential. Remove front differential support. Remove front differential mounting bolts. Lower front differential and position aside. Remove oil pan retaining bolts in reverse sequence. see scheme 43 Remove oil pan and gasket.

1. Disconnect negative battery cable(s). Drain cooling system. Remove engine cover. Remove air cleaner and outlet tube assembly. Remove cooling fan and fan shroud. Remove oil indicator tube. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-54369-S03909529142001011700000) . Raise and support vehicle.
2. Drain engine oil. Loosen transmission mount-to-rear crossmember nuts. Disconnect exhaust pipe at exhaust manifolds. Remove motor mount-to-subframe nuts. Remove flywheel inspection plate. Raise engine about 13" and position blocks between motor mounts and subframe. Remove oil pan retaining bolts. Remove oil pan and gasket.

To install, reverse removal procedure. Apply silicone sealant on front cover and seal retainer-to-cylinder block areas before installing gasket and oil pan. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 61

Raise and support vehicle. Drain engine oil. Remove oil filter. Remove oil pump retaining bolts. Remove oil pump and "O" ring.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, prime oil pump by filling inlet opening with oil, and rotating pump shaft until oil emerges from outlet opening.
2. Install and tighten oil pump-to-front cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54369-S05436149572001011700000) . To complete installation, reverse removal procedure.