Engine - 4.6L V8 - Vins [W,6]: Other Ford Econoline E350

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS

1. Remove fuel cap to release fuel tank pressure. Connect EFI Pressure Gauge (T80L-9974-B) to relief valve on right rear corner of fuel rail. Release pressure using valve on pressure gauge.
2. Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
3. Install Spring Lock Coupling Remover (D87L-9280-A for 3/8" line or D87L-9280-B for 1/2" line) on fuel line coupling so it enters cage opening. (Scheme 85)
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, fit new fuel resistant "O" rings (Brown) on fuel lines. 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 lock together and garter spring is over female fitting flared end.
7. Install retaining clip. Install Black retaining clip on fuel supply line and Gray clip on fuel return line. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

Scheme 85

CYLINDER HEAD

FRONT COVER OIL SEAL

FRONT COVER

OIL PAN

Note. Removal and installation procedures for Expedition, F150 and, F250 2-wheel drive vehicles are unavailable from manufacturer.

Camshaft Sprockets

Windsor engine uses an interference fit to secure sprocket to camshaft. Romeo engine use a bolt and spacer to secure sprocket to camshaft.

Connecting rods

Windsor engine uses a larger connecting rod has a full floating piston pin with 2 retainers. (Scheme 86) Romeo engine uses a press fit piston pin without retainers. (Scheme 87)

Windsor engine has no oil feed reservoir in cylinder head and uses single cam caps. Romeo engine has oil feed reservoir and uses a ladder style cam cap.

Main Bearings

Windsor engine has larger main bearing caps and uses dowels between main bearing caps and block. (Scheme 88) Romeo engine has smaller main bearing caps and uses jack screws between main bearing caps and block. (Scheme 89)

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Check cylinder head for cracks or damage. If maximum warpage exceeds .004" (.10 mm), replace cylinder head.

Valve Springs

Inspect valve spring free length, out-of-square and pressure. Replace valve spring if not as specified. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Use Seal Installer (T91T-6571-A) to install oil seals.

Valve Guides

Note. DO NOT ream valve guides from standard to maximum oversize in one step. Ream guides in gradual steps, so guides are reamed in true relation to valve seat. Valve seats must be ground when valve guide is reamed or replaced.

1. Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(ref-54454-S05996139772001011700000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
2. Valve guides may also be bored out and replaced with a service guide if oversize valves are not available or guide is damaged. Ream valve guides until proper stem-to-guide clearance exists.

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available.

Valves

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

Valve Seat Correction Angles

If seat width is too wide after grinding seat, use a 60-degree stone to remove stock from bottom of valve seat (raise seat) or a 30-degree stone to remove stock from top of seat (lower seat).

Fitting Pistons

1. Standard service pistons are color-coded Red, Blue, and Yellow on dome of piston. Measure piston skirt diameter at 90-degree angle to piston pin, 1.62" (42.0 mm) below piston top. Replace piston if piston diameter is not within specification. See «PISTONS, PINS & RINGS»(ref-54454-S24364218952001011700000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore at 1/2" below top of piston travel and 1/2" above bottom of piston travel. Ensure piston clearance is within specification. See «PISTONS, PINS & RINGS»(ref-54454-S24364218952001011700000) table.
3. If piston clearance is not within specification, choose a selective fit piston to bring piston clearance within specification. See «PISTONS, PINS & RINGS»(ref-54454-S24364218952001011700000) table, for selective fit piston sizes.
4. If piston clearance cannot be corrected using a selective fit piston, bore all cylinders to nearest oversize.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position oil control ring expander with gap positioned straight forward and rails with gaps 180 degrees apart, aligned with piston pin. Install compression rings with gaps staggered, so ring gaps do not align.

Rod Bearings

1. Ensure piston and connecting rod are installed in engine with notch on top of piston toward front of engine. (Scheme 86)or (Scheme 87).
2. Check bearing clearances using Plastigage method. Ensure bearing oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-54454-S00802471412001011700000) and «CONNECTING RODS»(ref-54454-S35428088932001011700000) tables under ENGINE SPECIFICATIONS. If oil clearance exceeds specification, grind crankshaft to fit.010" (.25 mm) undersize bearings. Tighten connecting rod bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).

Crankshaft & Main Bearings

Note. When checking bearing clearances using Plastigage, side bolts and side adjusting screws do not need to be installed.

1. Measure main bearing clearances using Plastigage method. Main bearing caps are marked for location, with No. 1 at front and No. 5 at rear of engine. Arrow on main bearing cap must point toward front of engine. Lubricate bearing shells with assembly lube or heavy oil before installation.
2. Install main bearing inserts in cylinder block. Lay crankshaft into cylinder block. Push crankshaft rearward. Roll thrust washer into cylinder block, ensure coating on bearing is facing crankshaft thrust surface.
3. Install main bearing caps using NEW bolts, do not fully tighten. Using a pry bar push crankshaft forward to seat thrust washer. While holding crankshaft forward, evenly pry No. 5 main cap rearward (DO NOT COCK). Tighten main bearing cap bolts to specification in 2 steps using proper sequence. See Fig. (Scheme 90) or (Scheme 91). See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).
4. Tighten side adjusting screws against cylinder block to specification in 2 steps using proper sequence. (Scheme 90)or 24. Side adjusting screws have left-hand threads. Tighten side bolts.

Scheme 90

Scheme 91

Cylinder Block

1. Using a feeler gauge and straightedge, inspect cylinder block deck for warpage. If not within specification, resurface or replace cylinder block. See «CYLINDER BLOCK»(ref-54454-S30585493712001011700000) table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.025 mm) from original cylinder block head surface.
2. Check cylinder bore diameter, out-of-round and taper. Cylinder bore is measured at 1/2" below top of cylinder block head surface and 1/2" above piston when at bottom of cylinder bore.
3. Bore cylinder block if measurements are not within specification. See «CYLINDER BLOCK»(ref-54454-S30585493712001011700000) table.

Oil Pressure

With engine at normal operating temperature, normal oil pressure is 20-45 psi (1.4-3.2 kg/cm 2 ) at 1500 RPM.

OIL PUMP

Note. Disassembly and inspection procedures are not available.