Engine - 4.6L V8 - Vins [W,6]: Removal & Installation Ford Econoline E350

REMOVAL & INSTALLATION

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

Removal (Expedition, F150 & F250)

1. Disconnect negative battery cable. Remove hood. Drain cooling system. Remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-54454-S02296894172001011700000) .
2. On Expedition, remove air conditioning condenser, EGR manifold tube and unclip mega fuse holders from junction block bracket. Disconnect starter relay cables.
3. On all models, remove upper intake manifold. See «INTAKE MANIFOLD»(ref-54454-S21768435012001011700000) . Remove bulkhead connector cover. Disconnect necessary grounds and harness connectors. Disconnect necessary water and vacuum connections. Unbolt power steering bracket and position reservoir and bracket assembly aside. Remove ignition coils and brackets.
4. Raise and support vehicle. Remove starter. Remove A/C compressor. Remove transmission cooler line from block mounted clip. Remove transmission inspection cover, torque converter bolts and transmission-to engine bolts. Remove power steering retaining bolts and position power steering pump aside.
5. Disconnect dual converter "Y" pipe from exhaust manifolds and position aside. Remove right and left engine mount bolts. Lower vehicle and support transmission. Remove engine from vehicle.

Removal (E150)

1. Disconnect negative battery cable(s). Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-54454-S02296894172001011700000) .
2. Disconnect necessary harness and ground connections. Remove intake manifold. See «INTAKE MANIFOLD»(ref-54454-S21768435012001011700000) . Remove air deflector, radiator grille, radiator grille open panel and upper and lower core supports. Remove radiator, fan shroud and cooling fan.
3. Remove headlight and side marker assemblies. Remove A/C condenser. Remove accessory drive belt. Drain power steering fluid by disconnecting reservoir hose at power steering pump. Disconnect high pressure hose at power steering pump. Remove lower radiator hose. Disconnect suction hose at receiver-drier.
4. Raise and support vehicle. Disconnect dual converter "Y" pipe at exhaust manifold. Drain engine oil and remove oil filter. Remove oil cooler. Remove starter. Remove transmission-to-engine bolts.
5. Remove and discard torque converter nuts. Remove engine mount-to-subframe nuts. Lower vehicle. Remove transmission oil filler tube. Support transmission. Remove engine from vehicle.

Installation (All Models)

1. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000) .
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

1. Disconnect negative battery cable(s). Remove engine cover. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-54454-S02296894172001011700000). Drain cooling system. Disconnect upper radiator hose from thermostat housing. Remove air cleaner and outlet tube assembly. Remove throttle body. Remove EGR manifold tube.
2. Disconnect necessary vacuum and water connections. Disconnect necessary wiring connections. Remove spark plug wires. Remove accessory drive belt. Remove alternator. Remove intake manifold retaining bolts in reverse order of tightening sequence. (Scheme 63) Lift intake manifold, disconnect manifold turning valve and remove intake manifold from vehicle.

Installation

1. To install, reverse removal procedure. Use NEW gaskets and "O" rings. Lubricate fuel injector "O" rings with Light Grade Oil (ESE-M2C39-F) before installing.
2. Ensure alignment tabs on intake manifold gaskets align with holes in cylinder head. Tighten intake manifold bolts to specification in sequence. (Scheme 63) See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).
3. 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).
4. To install remaining components, reverse removal procedure. Adjust all control cables and fluid levels. Refill cooling system. When installing spark plug wires, ensure wires are in correct position on coils. See «SERVICE & ADJUSTMENT SPECIFICATIONS - 4.6L»(ref-23874) article in ENGINE PERFORMANCE.

Scheme 63

Raise and support vehicle. Remove front fender splash shield. If removing left side, remove EGR manifold tube and brake vacuum booster hose bracket. On either side, disconnect exhaust manifold flange. Remove exhaust manifold retaining nuts in reverse order of tightening sequence. (Scheme 64) Remove exhaust manifold and gasket.

To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. (Scheme 64) See TORQUE SPECIFICATIONS.

Scheme 64

1. Disconnect negative battery cable(s). Remove intake manifold. See «INTAKE MANIFOLD»(ref-54454-S21768435012001011700000). Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-54454-S07594398632001011700000). Remove timing chains. See «TIMING CHAINS»(ref-54454-S22767029392001011700000). Disconnect heater hoses. Remove cylinder head bolts in sequence. (Scheme 65)or (Scheme 68). Remove cylinder head and gasket.

1. Ensure proper gaskets are installed. Right and left cylinder head gaskets are not interchangeable. Rotate crankshaft 90 degrees counterclockwise from vertical position. See STEP 1 in Fig. (Scheme 68). Ensure no piston is at TDC.
2. Coat bolt head-to-cylinder head surfaces with engine oil. DO NOT oil threads of cylinder head bolts. Ensure rear cylinder head bolts are installed in cylinder head and secured by rubber bands before installing cylinder head. (Scheme 67) Install cylinder heads.
3. Tighten cylinder head bolts to specification and in sequence. (Scheme 65)or (Scheme 66). See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000). If camshaft positioner was not used during cylinder head installation, rotate camshafts using flats matched at center of camshaft until both cams are in time. Install Camshaft Positioner (T91P-6256-A) on flats of camshaft. This will prevent camshafts from rotating.
4. Rotate crankshaft 45 degrees clockwise. See STEP 2 in Fig. (Scheme 68). This will position crankshaft so cylinder No. 1 is at TDC. DO NOT rotate crankshaft past TDC position. Timing chains can now be installed. See «TIMING CHAINS»(ref-54454-S22767029392001011700000). To install remaining components, reverse removal procedure.

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Removal (Left)

Disconnect negative battery cable(s). Remove air cleaner. On Expedition and F150, unbolt power steering reservoir bracket and position reservoir and bracket assembly aside. On all models, disconnect PCV hose from valve cover. Remove EGR manifold tube. Remove valve cover retaining bolts. Remove valve cover and gasket.

Removal (Right)

On E150, remove air cleaner, oil filler tube and engine cover. On all models, disconnect PCV valve hose from valve cover. Remove valve cover retaining bolts. Remove valve cover and gasket.

Installation (All Models Left & Right)

1. Clean sealing surfaces on valve cover and cylinder head. Using gasket adhesive, glue valve cover gasket into valve cover. Apply a bead of silicone gasket adhesive to seam where cylinder head and front cover meet.
2. Install valve cover and valve cover mounting bolts. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000) .
3. 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).

Scheme 70

Scheme 71

1. Disconnect negative battery cable. Release belt tensioner, and remove accessory drive belt. Remove cooling fan and fan shroud. On E150, remove air cleaner assembly.
2. Raise and support vehicle. Remove crankshaft damper retaining bolt and washer. Using Puller (T58P-6316-D), remove crankshaft damper. Using Seal Remover (T74P-6700-A), remove oil seal from front cover.

To install, reverse removal procedure. Lubricate oil seal bore and seal lip with engine oil before installing. Use Seal Installer (T88T-6701-A1 and A2) to install oil seal. Apply silicone sealant to keyway of crankshaft damper before installing. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Remove cooling fan and shroud. Remove accessory drive belt. Remove water pump pulley. Raise and support vehicle. Remove power steering pump and secure aside.
2. Remove oil pan-to-front cover bolts. Remove crankshaft damper retaining bolt and washer. Using Puller (T58P-6316-D), remove crankshaft damper. Lower vehicle. Remove A/C refrigerant line retainer from right coil bracket, if necessary.
3. Remove both valve covers. See «VALVE COVERS»(ref-54454-S11553223222001011700000). Disconnect ignition coils, radio interference capacitor and camshaft position sensor harness connectors. Remove coil brackets, and lay coil brackets with spark plug wires on top of engine.
4. Remove idler belt pulley. Disconnect crankshaft position sensor and remove sensor. Remove front cover retaining bolts/studs in reverse order of tightening sequence. (Scheme 72) Remove front cover and gasket.

To install, reverse removal procedure. Apply Sealant (E3AZ-19562-A) at front cover-to-oil pan, cylinder block and valve cover areas. Apply silicone sealant to keyway of crankshaft damper before installing. Tighten bolts to specification. (Scheme 72) See TORQUE SPECIFICATIONS.

Scheme 72

Note. To identify Romeo Engine Production (REP) or Windsor Engine Production (WEP) see ENGINE IDENTIFICATION .

1. Remove valve covers. See «VALVE COVERS»(ref-54454-S11553223222001011700000). Remove front cover. See «FRONT COVER»(ref-54454-S35093508322001011700000). Remove crankshaft position sensor pulse wheel from crankshaft. On Romeo (REP) engines, see next step. On Windsor (WEP) engines, go to step 3
2. On REP engines, rotate the crankshaft until both camshaft keyways are 90 degrees from the cam cover surface. (Scheme 73) Install the Cam Positioning Tool (T91P-6256-A) and the Camshaft Positioning Tool Adapters (T92P-6256-A) on the camshaft. (Scheme 69)
3. On WEP engines, use the Camshaft Positioning Tool (T96T-6256-AR) to position the camshaft to TDC. (Scheme 74)and (Scheme 73). Install the camshaft holding tool on the camshaft. (Scheme 75)
4. On REP and WEP engines, make sure the Copper links line up with the dots on the camshaft sprockets. Remove retaining bolts, right chain tensioner, right tensioner arm and right chain guide. (Scheme 76) Remove right timing chain and crankshaft sprocket. Note direction of sprocket for installation reference. If necessary for clearance, remove retaining bolt, washer, camshaft sprocket and spacer.
5. Remove retaining bolts, left chain tensioner, left tensioner arm and left chain guide. (Scheme 76) Remove left timing chain and crankshaft sprocket. Note direction of sprocket for installation reference. If necessary for clearance, remove retaining bolt, washer, camshaft sprocket and spacer.

1. If removed, install spacers, camshaft sprockets and retaining bolts. Ensure components are installed in original locations. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).
2. Install crankshaft sprocket for left timing chain. If Copper links are not visible on timing chain, fold timing chain in half and mark each end link for timing purposes. (Scheme 77) These links will be referred to as Copper links when installing.
3. Ensure No. 1 piston is at TDC. This positions crankshaft keyway 45 degrees from vertical position. See STEP 2 in illustration. (Scheme 68)
4. Install left timing chain on camshaft and crankshaft sprockets so Copper link aligns with timing mark on sprockets. (Scheme 73) Install crankshaft sprocket for right timing chain. Ensure sprocket is properly installed.
5. Install right timing chain on camshaft and crankshaft sprockets so Copper link aligns with timing mark on sprockets. Lubricate tensioner arms with engine oil. Install tensioner arms. Install chain guides.
6. Chain tensioners must be bled down so tensioner plunger is compressed in housing before installing. Place chain tensioner in soft-jawed vise. Using small pick, hold ratchet lock mechanism away from ratchet stem. (Scheme 78) Slowly close vise to depress tensioner plunger.
7. When tensioner plunger is compressed in housing, continue to hold ratchet lock mechanism and install lock pin in hole on tensioner housing. Ensure ratchet stem is even with tensioner housing before installing lock pin. (Scheme 78)
8. Position the left and right timing chain tensioner guides on the dowel pins. While holding pressure on guides, install both chain tensioners and retaining bolts on cylinder block. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).
9. Remove lock pins from both chain tensioners. On REP engines, remove Cam Positioning Tool and the camshaft positioning tool adapters from the camshaft. On WEP engines, remove the camshaft holding tool and camshaft positioning tool from the camshaft.
10. On REP and WEP engines, ensure all timing marks align. (Scheme 73) Install the crankshaft sensor ring on the crankshaft. To install remaining components, reverse removal procedure. Before installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.
11. 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).

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Remove valve covers. See «VALVE COVERS»(ref-54454-S11553223222001011700000) . Rotate crankshaft until piston in cylinder to be serviced is at bottom of its stroke and camshaft lobe is at base circle.
2. Install Valve Spring Spacer (T91P-6565-AH) between valve spring coils to prevent valve stem oil seal damage. Using Valve Spring Compressor (T91P-6565-A), compress valve spring. Remove camshaft follower and lash adjuster.

1. To install, reverse removal procedure. Coat components with engine oil before installing. Before installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.
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).

Remove camshaft followers and lash adjusters. See CAMSHAFT FOLLOWER & LASH ADJUSTER. Remove timing chains. See TIMING CHAINS. Remove camshaft cap bolts in reverse order of tightening sequence. (Scheme 79) On Romeo engines, tap camshaft caps in designated areas to remove camshaft caps. (Scheme 80) On both engines. remove camshaft caps and camshaft.

1. Coat components with engine oil, and install components. Install all bolts for both camshaft caps, and tighten them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. (Scheme 79) Loosen all bolts 2 turns. Retighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. Repeat procedure for each camshaft.
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-54454-S21317117912001011700000) table under ENGINE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).

Scheme 79

Scheme 80

1. Remove transmission. See «TRANSMISSION REMOVAL & INSTALLATION»(ref-1734) article in TRANSMISSION SERVICING article. Remove oil pan. See «OIL PAN»(ref-54454-S15094237832001011700000) . Remove flywheel. Remove rear oil seal retainer.
2. Using Rear Crankshaft Slinger Remover (T95P-6701-AH) and Slide Hammer (T50T-100-A), remove oil slinger. Using Rear Crankshaft Seal Remover (T95P-6701-EH), remove oil seal.

Clean and inspect all mating surface. Install rear seal retainer. (Scheme 81) Using Rear Crankshaft Seal Replacer (T95P-6701-BH) and Rear Crankshaft Seal Adapter (T95P-6701-DH), install rear seal. With rear crankshaft adapter still installed, use Rear Crankshaft Slinger Replacer (T95P-6701-CH) and seal replacer to install seal slinger. To complete installation, reverse removal procedure. Tighten bolts to specifications. See TORQUE SPECIFICATIONS.

Scheme 81

1. Partially drain the cooling system. Disconnect the upper radiator hose. Remove the 2 thermostat housing bolts. Remove the thermostat housing. (Scheme 82)
2. Remove the thermostat and the "O" ring seal. See. Discard the "O" ring seal.

1. Use a new "O" ring seal to position the thermostat in the upper intake manifold. Install the thermostat housing and the bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000) . Connect the upper radiator hose. Fill and the cooling system.
2. Start the engine and allow to idle until normal operating temperature is reached. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch. Shut the engine off and allow it to cool. Check the engine for coolant leaks. Check the engine coolant level and fill as necessary.

Scheme 82

Scheme 83

1. Drain cooling system. Remove cooling fan and shroud. Release belt tensioner, and remove accessory drive belt. Remove water pump pulley. Remove retaining bolts, water pump and "O" ring.
2. To install, reverse removal procedure. Lubricate "O" ring with coolant before installing. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000) . Fill cooling system.

1. Disconnect negative battery cable(s). Remove engine cover. Remove air cleaner and outlet tube assembly. Remove cooling fan and fan shroud. Remove oil indicator tube. Remove throttle body. Raise and support vehicle.
2. Drain engine oil. Drain cooling system. Remove radiator hose. Remove motor mount-to-subframe nuts. Remove flywheel inspection plate. Raise engine and position blocks between motor mounts and subframe. Remove oil pan retaining bolts in reverse sequence. (Scheme 84) Remove oil pan.

Removal (4x4)

Raise and support vehicle. Remove front axle housing. Drain engine oil. Remove oil pan retaining bolts in reverse sequence. (Scheme 84) Remove oil pan.

1. 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 in sequence. (Scheme 84) See «TORQUE SPECIFICATIONS»(ref-54454-S21709665962001011700000).
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 84

Remove oil pan and pick-up tube. See OIL PAN under REMOVAL & INSTALLATION. Remove timing chains and crankshaft sprockets. See TIMING CHAINS under REMOVAL & INSTALLATION. Remove retaining bolts, and remove oil pump.

To install, reverse removal procedure. Ensure flat areas of oil pump rotor aligns with flat areas of crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS .