Engine - 6.8L V10 - VIN [S]: 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

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-54524-S33859766072001011700000) .
2. Disconnect necessary harness and ground connections. Remove intake manifold. See «INTAKE MANIFOLD»(ref-54524-S38676948662001011700000) . Remove air deflector, radiator grille, radiator grille opening 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 and plug openings. 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 and plug openings.
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

1. To install, reverse removal procedure. Replace torque converter nuts with new ones. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000) .
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 charge A/C system.

1. Disconnect negative battery cable(s). Remove engine cover. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-54524-S33859766072001011700000).
2. Drain cooling system. Disconnect upper radiator hose from thermostat housing. Remove air cleaner and outlet tube assembly. Disconnect control cables from throttle body. Unbolt throttle body control cable bracket and position aside.
3. Disconnect necessary vacuum and water connections. Disconnect necessary harness and ground connections. Remove brake booster vacuum hose bracket. Remove EGR manifold tube. Remove spark plug wires. Remove accessory drive belt. Remove alternator.
4. Remove throttle body. Remove heater return tube. Remove thermostat. Remove upper intake manifold retaining bolts in reverse order of tightening sequence. (Scheme 110) Lift intake manifold assembly, disconnect manifold turning valve and remove intake manifold assembly from vehicle.
5. If separating upper and lower intake manifolds, remove lower intake manifold retaining bolts in reverse order of tightening sequence. (Scheme 111) Separate intake manifolds and remove gasket.

1. To install, reverse removal procedure. Use NEW gaskets and "O" rings. Tighten intake manifold bolts to specification in sequence. (Scheme 110)and (Scheme 111). See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000). CAUTION: Intake manifold bolts must be retightened to specification after engine has reached normal operating temperature.
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. 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.

Scheme 110

Scheme 111

Raise and support vehicle. Remove front fender splash shield. If removing left exhaust manifold, 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 112) Remove exhaust manifold and gasket.

To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. (Scheme 112) See TORQUE SPECIFICATIONS.

Scheme 112

1. Disconnect negative battery cable(s). Remove intake manifold. See «INTAKE MANIFOLD»(ref-54524-S38676948662001011700000). Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-54524-S15460338842001011700000). Remove timing chains. See «TIMING CHAINS»(ref-54524-S00971553402001011700000). Disconnect heater hoses.
2. Remove cylinder head bolts in reverse order of tightening sequence. (Scheme 113) Remove cylinder head and gasket.

1. Ensure proper gaskets are installed. Right and left cylinder head gaskets are not interchangeable. Install Crankshaft Holder (T93P-6303-A). Install Camshaft Holder (T96T-6256-B), one on each head.
2. Install cylinder heads and retaining bolts. Torque bolts in sequence and to specification. (Scheme 113) See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000). To complete installation, reverse removal procedure. Tighten nuts and bolts to specification.

Scheme 113

Disconnect negative battery cable(s). Remove engine cover. If removing left valve cover, remove air cleaner and outlet tube. Remove EGR manifold tube. If removing right valve cover, remove oil filler tube. If removing either valve cover, remove PCV tube from valve cover. Disconnect necessary harness connectors. Remove valve cover retaining bolts. Remove valve cover and gasket.

Installation (Left & Right)

1. Clean sealing surfaces on valve cover and cylinder head. Using gasket adhesive, glue valve cover gasket to valve cover. Apply a bead of silicone gasket adhesive to seam where cylinder head and front cover meet.
2. Install valve cover and tighten retaining bolts in sequence. (Scheme 114) To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000).
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 114

Disconnect negative battery cable(s). Remove cooling fan and fan shroud. Remove accessory drive belt. Remove crankshaft pulley bolt. Using Crankshaft Damper Remover (T58P-6316-D), remove crankshaft damper. Using Front Crankshaft Seal Remover (T74P-6700-A), remove front crankshaft seal.

Lubricate oil seal bore and seal lip with engine oil before installing. Using Seal Installer (T88T-6701-A), install oil seal. Apply silicone sealant to keyway of crankshaft damper before installing. Using Crankshaft Damper Replacer (T74P-6316-B), install crankshaft damper. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable(s). Remove valve covers. See «VALVE COVERS»(ref-54524-S03372003152001011700000) . Remove radiator. Remove water pump. See «WATER PUMP»(ref-54524-S22352048112001011700000) . Raise and support vehicle. Remove power steering pump retaining bolts and position aside. Disconnect crankshaft position sensor harness connector. Drain engine oil. Remove oil pan-to-front cover bolts.
2. Lower vehicle. Remove front oil seal. See «FRONT CRANKSHAFT OIL SEAL»(ref-54524-S33949515262001011700000) . Disconnect camshaft position sensor harness connector. Remove accessory drive belt. Remove left side accessory drive belt idler pulley. Remove front cover retaining bolts. 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 in sequence. (Scheme 115) See TORQUE SPECIFICATIONS.

Scheme 115

1. Remove front cover. See «FRONT COVER»(ref-54524-S31488761452001011700000). On 6.8L engine, remove balance shafts. See «BALANCE SHAFT»(ref-54524-S01545140312001011700000). On all models, remove crankshaft position sensor pulse wheel from crankshaft. Using Crankshaft Positioner (T93P-6303-A), position crankshaft as shown. (Scheme 116) Install Camshaft Holder (T96T-6256-B), one on each cylinder head.
2. Remove right and left timing chain tensioners. Remove timing chain tensioner guides. Remove crankshaft positioner. Remove right and left timing chains and crankshaft sprockets. Remove timing chain guides.

1. Using edge of a vise, compress tensioner plunger. Using a small screwdriver, release ratchet mechanism and retract ratchet arm. While holding ratchet arm in, install paper clip to hold ratchet assembly and plunger in during installation. (Scheme 117)
2. If copper links are not visible, fold timing chain in half and mark two links on one end and one link on other end of timing chains. (Scheme 118) Install timing chain guides. Using Crankshaft Positioner (T93P-6303-A), ensure that crankshaft is aligned properly. (Scheme 116) NOTE: Be sure upper half of left timing chain is below and lower half of right timing chain is above timing chain tensioner guide dowels. (Scheme 119)
3. Install right and left timing chains. Ensure timing marks and copper link are properly aligned. (Scheme 120) Install timing chain tensioner guides. Install timing chain tensioners. Remove paper clip from timing chain tensioners. On 6.8L engine, install balance shafts. Ensure balance shaft timing mark is aligned. (Scheme 121) On both engines, complete installation by reversing removal procedure. Tighten all nuts and bolt to specification. See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000).

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. Remove valve covers. See «VALVE COVERS»(ref-54524-S03372003152001011700000) . 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. On 6.8L engine, remove balance shaft. On both engines, remove camshaft cap bolts in reverse order of tightening sequence. (Scheme 122) Remove camshaft caps and camshaft.

1. Coat components with engine oil, and install components. Install all bolts for camshaft caps, and tighten them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. (Scheme 122) CAUTION: Ensure proper procedure is used when installing timing chains to prevent engine damage. See «TIMING CHAINS»(ref-54524-S00971553402001011700000).
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-54524-S30133867522001011700000) table under ENGINE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000).

Scheme 122

Remove valve covers. See VALVE COVERS. Position cylinder No. 1 at TDC of compression stroke. Remove balance shaft caps in reverse order of tightening sequence. (Scheme 123) Remove balance shaft.

Coat components with engine oil, and install components. Install all bolts for balance shaft caps, and tighten them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. (Scheme 123)

Scheme 123

1. Disconnect negative battery cable(s). Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate article in CLUTCHES. Remove flywheel/flexplate.
2. Using Rear Crankshaft Slinger Remover (T95P-6701-AH) and Slide Hammer (T50T-100-A), remove crankshaft oil slinger. Using Rear Crankshaft Seal Remover (T95P-6701-BH) and Slide Hammer (T50-100-AR), remove rear crankshaft oil seal.

Clean and inspect all mating surfaces. Using Rear Crankshaft Seal Replacer (T95P-6701-BH) and Rear Crankshaft Seal Adapter (T95P-6701-DH), install rear crankshaft 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 specification. See TORQUE SPECIFICATIONS .

1. Drain cooling system. Remove cooling fan and fan shroud. Remove accessory drive belt. Remove water pump pulley. Remove water pump retaining bolts. Remove 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-54524-S19377138732001011700000) . 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 upper radiator hose. Remove motor mount-to-subframe nuts. Remove flywheel inspection plate. Raise engine and position blocks between motor mounts and subframe.
3. Remove oil pan retaining bolts in reverse order of tightening sequence. (Scheme 124) Lower oil pan and remove oil pump pick-up tube. Remove oil pan with pick-up tube inside 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 124) See «TORQUE SPECIFICATIONS»(ref-54524-S19377138732001011700000).
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).

Scheme 124

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 oil pump retaining bolts. 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 .