Tune-Up - v8 Ford RV Cutaway E350

ENGINE IDENTIFICATION

Engine can be identified by the eighth character of the Vehicle Identification Number (VIN). VIN is located on a plate attached to upper left corner of instrument panel, near windshield.

Note. When ordering engine replacement parts, refer to the label located on the front of right rocker cover.

ENGINE CODES

TUNE-UP NOTES

Note. Always refer to Emission Control Label in engine compartment before attempting tune-up. If manual and label differ, always use emission label specifications.

Note. When performing tune-up procedures described in this article, the following notes and precautions must be followed.

For tune-up purposes, "Light Duty" refers to vehicles up to 8500 lbs. GVW. "Heavy Duty" refers to vehicles exceeding 8500 lbs. GVW.

If the Dura-Spark 2-piece distributor cap must be removed, first remove the top portion, then the rotor, then the bottom portion (adapter). When connecting a tachometer to the Dura-Spark ignition coil, install the tachometer alligator clip into the "DEC" (Tach Testing) cavity. If any spark plug wire is disconnected with this system, connection must first be greased with silicone grease before it is reattached.

Do not allow or create a condition of engine misfire in one or more cylinder for an extended period of time. Damage to catalytic converter may result due to loading converter with unburned air/fuel mixture.

ENGINE COMPRESSION

Test compression with all spark plugs removed and engine at normal operating temperature. Crank engine through at least 5 compression strokes before recording reading.

COMPRESSION SPECIFICATIONS

5.0L SPARK PLUG WIRE ROUTING

Note. Spark plug wire routing for 5.0L V8 engines must be correct. For additional information and illustrations, see 5.0L BUCK/JERK/MISS/SPARK KNOCK: INDUCTION CROSSFIRE .

SPARK PLUGS

SPARK PLUG TYPE

SPARK PLUG SPECIFICATIONS

HIGH TENSION WIRE RESISTANCE

Remove spark plug wires from plugs. Remove distributor cap with wires attached. Check resistance of each wire by connecting one ohmmeter lead to cap terminal and the other lead to spark plug end of wire. If resistance is over 7000 ohms per foot, replace wire.

Note. Whenever a high tension wire is disconnected, the interior of spark plug terminal boot must be coated with silicone grease before reconnection.

VALVE ARRANGEMENT

1. Right Bank - I-E-I-E-I-E-I-E (Front-to-rear).
2. Left Bank - E-I-E-I-E-I-E-I (Front-to-rear).

VALVE CLEARANCE

All engines are equipped with hydraulic lifters. Adjust all valves to zero lash.

DISTRIBUTOR

All 5.0L models are equipped with the TFI-IV EEC-IV ignition system. All 5.8L and 7.5L models are equipped with the Dura-Spark II ignition system. No internal adjustments are required on these systems.

Scheme 5

Scheme 6

Note. Spark plug wire routing for 5.0L V8 engines must be correct. For additional information and illustrations, see 5.0L BUCK/JERK/MISS/SPARK KNOCK: INDUCTION CROSSFIRE .

IGNITION TIMING

Note. Magnetic probe timing device may be used if instrument is available and engine is so equipped. Timing probe offset is 135 degrees ATDC. Timing instrument should be connected to No. 1 spark plug wire using an adapter or clip-on connector. Do not puncture spark plug wire or boot to make connection.

5.0L Light Duty Models

1. Turn off all lights and accessories. Set parking brake and place transmission in Neutral. Ensure A/C and heater are off. Connect timing light and disconnect the single wire in-line spout connector or remove the shorting bar from the double wire spout connector.
2. Start engine and warm to normal operating temperature. With engine at specified RPM check timing, and adjust if necessary. Reconnect spout connector or reinstall shorting bar. Check timing advance to verify distributor is advancing properly. Remove tachometer and shut off engine.

5.8L & 7.5L Heavy Duty Models

1. Turn off all lights and accessories. Place transmission in Neutral. Ensure A/C and heater are off. Disconnect and plug vacuum lines at distributor advance connection. Connect timing light and tachometer.
2. If engine is equipped with a Barometric Pressure Switch (12A243), disconnect switch from ignition module and place a jumper wire across the pins at ignition module connector (Black and Yellow wires).
3. Warm engine to normal operating temperature. With the engine running at specified RPM, adjust ignition timing. Remove test equipment and reconnect all components.

IGNITION TIMING SPECIFICATIONS (DEGREES BTDC@RPM)

HOT (SLOW) IDLE RPM

Note. Curb idle speed is controlled by the EEC-IV processor and the Idle Speed Control (ISC) device. If the control system is operating properly, these speeds are self-compensating and cannot be changed by standard adjustment techniques. Idle Speed Check

5.0L MPFI Light Duty Models

1. Turn off all lights and accessories. Set parking brake and block wheels. Bring engine to normal operating temperature and shut off. Ensure A/C and heater are off. Place transmission in Neutral.
2. Ensure throttle linkage is free and that travel is unobstructed. Ensure cruise control cable (if equipped) is not holding the throttle open. Check for vacuum leaks.
3. Place transmission in Neutral and run engine at 1800 RPM for at least 30 seconds. Place transmission in Drive (A/T), or Neutral (M/T). Allow engine to stabilize. Check idle speed.
4. If curb idle speed is 675 RPM or less (auto. trans.), or 775 RPM or less (man. trans.), do not adjust. If speed exceeds specified RPM, turn off engine. Disconnect the positive terminal of the battery, and then reconnect. Repeat step 3).
5. If speeds still exceed specifications, EEC-IV Diagnosis/Repair will be necessary. Repeat step 3). If idle speed is still not correct, back out throttle plate stop screw until RPM reaches 580-620 RPM (A/T), or 680-720 RPM (M/T). (Scheme 7)
6. Back out screw an additional 1/2 turn to bring the throttle plate linkage into the nominal operating range of the ISC system.

5.0L CURB IDLE SPEED (RPM)

Scheme 7

5.8L 4-Bbl. Light Duty Models

1. Turn off all lights and accessories. Set parking brake and block wheels. Bring engine to normal operating temperature and shut off. Ensure A/C and heater are off. Place transmission in Drive.
2. Disconnect and plug vacuum hoses at air by-pass valve, EGR valve and purge control valves. Check and/or adjust curb idle RPM to specification. Adjust by turning curb idle speed screw. (Scheme 8)
3. Place transmission in Park and rev the engine. Place transmission in Drive and recheck curb idle RPM. Adjust if necessary.
4. Connect an external vacuum source and apply 10 in. Hg of vacuum to the Vacuum Operated Throttle Modulator (VOTM) kicker. Check and/or adjust VOTM kicker speed if necessary. Adjust by loosening kicker lock-out nut and turning kicker to specified RPM. Remove vacuum source, tighten lock nut and reconnect all vacuum lines.

5.8L 4-BBL. LIGHT DUTY CURB IDLE SPEED (RPM)

Scheme 8

5.8L 4-Bbl. Heavy Duty Models

1. Turn off all lights and accessories. Set parking brake and block the wheels. Place transmission in Neutral or Park and warm engine to normal operating temperature. Ensure A/C and heater are off.
2. Disconnect and plug vacuum hoses at EGR valve and air cleaner. Place transmission in Drive or Neutral and check and/or adjust curb idle RPM. Adjust RPM by turning curb idle speed screw. (Scheme 9)and (Scheme 10).
3. Place transmission in Neutral or Park. Rev engine momentarily and place transmission in Drive or Neutral and recheck curb idle RPM. Readjust if necessary.
4. On dashpot equipped models, check and/or adjust clearance. Completely depress dashpot so that clearance between dashpot and throttle lever at closed throttle position is.085"-.115" (2.16-2.92 mm). Reconnect all vacuum hoses.

5.8L 4-BBL HEAVY DUTY CURB IDLE SPEED (RPM)

Scheme 9

Scheme 10

7.5L 4-Bbl. Heavy Duty Models - Idle & Decel Throttle Control Speed

1. Turn off all lights and accessories. Block wheels and set parking brake. Place transmission in Neutral and warm engine to normal operating temperature. Ensure A/C and heater are off. Remove air cleaner.
2. On California models, disconnect and plug decal throttle control kicker diaphragm vacuum hose. Connect a slave vacuum hose from an engine manifold vacuum source to the decal throttle control kicker.
3. Run engine at 2500 RPM for 15 seconds and release throttle. If Decel throttle control RPM is not within specification, adjust the kicker. (Scheme 11) Disconnect slave vacuum hose and allow engine to return to idle.
4. On all models, check and/or adjust curb idle RPM with transmission in Drive or Neutral by turning curb idle adjusting screw. (Scheme 10)and (Scheme 11). Rev engine momentarily and return to idle and check RPM. Readjust if necessary.
5. On California models, reconnect decel throttle vacuum hose to the diaphragm. On dashpot equipped models, check and/or adjust clearance. Completely depress dashpot so that clearance between dashpot and throttle lever at closed throttle position is.085"-.115" (2.16-2.92 mm). Reconnect all vacuum hoses and reinstall air cleaner.

7.5L 4-BBL. HEAVY DUTY CURB IDLE SPEED (RPM)

Scheme 11

IDLE MIXTURE

Note. The following procedures apply to 5.8L 4-Bbl. Light Duty models only. Idle mixture adjustment is not part of a normal tune-up. Idle mixture should only be adjusted during carburetor overhaul/repair or if vehicle fails emissions testing.

Mixture Screw Plug Removal

1. Remove carburetor from engine and drain excess fuel. Turn carburetor over and center punch the throttle body about 5/16" (8 mm), from the face of each idle screw. (Scheme 12) Using a 1/8" (3 mm) drill bit, drill about 1/16" (1.5 mm) deep.
2. Tip the bit so that bit is pointing towards the screw cavity (about 60 degrees with respect to throttle body face). Drill through until bit contacts the tamper resistant plug. With a 1/8" (3 mm), diameter or less punch, gently tap out tamper resistant plug. Repeat procedure on other side of carburetor.
3. If it is necessary to remove the screws for cleaning, check position of screws by counting number of turns to seat screw. Remove and clean screws. After cleaning, seat screws and back them out to previously noted number of turns. Reinstall carburetor.

Scheme 12

Note. If CO and HC emissions are not within specifications perform appropriate electrical system diagnostic procedure.

Propane Enrichment Procedure - 5.8L 4-Bbl. Light Duty Models

1. Turn off all lights and accessories. Apply parking brake and block wheels. Ensure A/C and heater are off. Disconnect and plug vacuum hose at automatic brake release (if equipped). Connect tachometer. Idle engine for 3 to 5 minutes to ensure Hot Idle Compensator (HIC) is in a closed position throughout testing (if equipped).
2. Disconnect fresh air tube from air cleaner duct or adaptor. Install propane hose approximately 3/4 of the way into the air tube or duct. Secure with tape if necessary. Disconnect and plug vacuum hose at dump valve. Check ignition timing and readjust to specification if necessary. NOTE: Leave all hoses connected to air cleaner assembly during relocation. However, air cleaner must be in place when measuring engine speeds.
3. Check and/or adjust curb idle RPM to specification. Remove PCV valve from grommet and allow PCV valve to draw underhood air. Disconnect crankcase vent hose at air cleaner and allow hose to draw underhood air. With transmission in Neutral, run engine at 2500 RPM for 15 seconds before each mixture check.
4. With engine idling at normal temperature and transmission in Drive or Neutral, slowly open propane metering valve and watch for engine speed RPM gain. The propane cartridge must be in a vertical position. When engine speed reaches maximum RPM and begins to drop off, note speed gain RPM.
5. If measured gain is higher than specification, turn the mixture screws counterclockwise (rich) and simultaneously repeat steps 3) and 4) until measured speed gain meets "Reset RPM" specification.
6. If measured gain is lower than specification, turn the mixture screws clockwise (lean) and simultaneously repeat steps 3) and 4) until measured speed gain meets "Reset RPM" specification.
7. If there is no measured speed gain (zero RPM), observe the tachometer and adjust the mixture screws clockwise (lean) and note drop in engine speed. If measured drop is more than 40 RPM, return mixture screws to the position before adjustment.
8. Install tamper resistant components. (Scheme 12) Reinstall PCV valve in grommet. Reinstall and reconnect all other hoses and components. Ensure air cleaner is securely installed.

PROPANE MIXTURE ADJUSTMENT (RPM)

COLD (FAST) IDLE RPM

Note. No fast idle adjustments are possible on 5.0L MPFI engines. Before adjusting Cold (Fast) Idle RPM, check and/or adjust Hot (Slow) Idle RPM to specification.

5.8L 4-Bbl.

1. Turn off all lights and accessories. Block wheels and set parking brake. Ensure A/C and heater are off. Bring engine to normal operating temperature.
2. On Light Duty models, disconnect and plug vacuum hoses at EGR valve, air by-pass valve and purge control valves. On Heavy Duty models, disconnect and plug vacuum hoses at EGR valve and air cleaner.
3. Place fast idle adjusting screw on highest step of fast idle cam. Check fast idle RPM and adjust if necessary. (Scheme 13) Rev engine momentarily. Recheck fast idle RPM. Readjust if necessary. Reconnect all vacuum hoses.

5.8L 4-BBL. FAST IDLE SPEED (RPM)

Scheme 13

7.5L 4-BBL. Heavy Duty Models

1. Turn off all lights and accessories. Block wheels and set parking brake. Ensure A/C and heater are off. With transmission in neutral, bring engine to normal operating temperature. Remove air cleaner.
2. On all models, disconnect and plug vacuum hose at EGR valve. On California models, disconnect and plug hose at throttle decal control diaphragm and evaporative emission purge valve hose at EGR valve.
3. On all models, depress throttle lever and manually rotate the fast idle cam until fast idle screw rests on highest step (man. trans.), or second step (auto. trans.), of fast idle cam. (Scheme 13) Check fast idle RPM and adjust if necessary. Reconnect all hoses and reinstall air cleaner.

7.5L 4-BBL. FAST IDLE SPEED (RPM)

Electric Choke (Holley 4180C-4V 4-BBL.)

Light duty vehicles provide 12 volts for choke operation from a relay located on the right inner fender panel. Heavy Duty vehicles use a 7.2 volts system which is supplied directly from the alternator stator terminal.

Inspection

1. With engine at normal operating temperature, remove air cleaner and plug vacuum lines. Ensure all vacuum lines and electrical wires are connected properly. Check tightness of carburetor flange mounting bolts.
2. Open the throttle to 1/4 open position. Rotate choke plate to closed position and release. Choke plate should return to full open position. Correct any interference or binding.

Testing

1. With ignition off, check continuity between choke cap terminal and ground. If circuit is open, check ground connection to choke base. If ground circuit to choke base is functional and there is no continuity between choke cap terminal and ground, replace choke.
2. On vehicles equipped with an alternator powered choke, connect a test light to the choke cap wire and ground. Start the vehicle. If continuity is not indicated correct any open circuit between alternator and choke cap. If no open is found, service alternator as required.
3. On vehicles equipped with relay system, use a test light to check continuity to choke cap wire. Check with engine running. If circuit is open, check 12 volt supply to relay, and relay operational feed from alternator stator. Check relay operation and replace as necessary.
4. Check choke cap resistance. Ensure contact surfaces are clean to avoid false readings. Resistance should be 1-30 ohms.

Adjustment

To adjust choke position, carburetor must be removed from vehicle. This will allow access to the pulldown diaphragm vacuum passage on the underside of the throttle body. Refer to appropriate article in FUEL SYSTEMS section.

FUEL PUMP

Note. 5.0L MPFI models, and 7.5L 4-Bbl. models with Hot Fuel Handling use electric fuel pumps. All other applications use mechanical fuel pumps.

Mechanical Fuel Pump - Volume Test

1. On 5.8L and 7.5L 4-Bbl. models, remove air cleaner. Disconnect fuel line at filter. Place a container (one pint minimum), at end of disconnected fuel line. With high tension wire disconnected from coil, crank engine 10 seconds. If fuel flow is within specification, proceed to pressure test. If not, proceed to next step.
2. If fuel flow is low, repeat test using remote vented can of gasoline. Remove fuel pump inlet hose. Connect a length of fuel line hose to fuel pump inlet and insert other end into remote can of gasoline. If fuel flow is within specification, problem is plugged intake fuel filter or a kinked, leaking or plugged fuel line or hose.

Mechanical Fuel Pump - Pressure Test

Remove air cleaner. Connect suitable pressure tester to end of fuel line. Start engine and let run for at least thirty seconds. Read pressure and if not within specification, replace fuel pump. Reinstall air cleaner.

Electric Fuel Pump - Pressure Test 5.0L

Disconnect fuel return line at fuel rail. Connect hose to container. Connect pressure gauge at diagnostic valve on fuel rail. Disconnect wiring connector at fuel tank and apply 12 volts to pump with jumper wire.

Electric Fuel Pump - Volume Test 7.5L

On 7.5L 4-Bbl. models, with optional Hot Fuel Handling, disconnect fuel line just before the vapor separator unit. Connect a hose from fuel line to a suitable container. If fuel flow is not within specification, electrically check fuel pump. If still not within specification, replace pump-sender assembly.

FUEL PUMP SPECIFICATIONS

5.0L

A fuel supply pressure regulator is attached to the fuel injector rail. It regulates fuel supply pressure to the injectors. A spring loaded valve sets nominal fuel pressure and is regulated by engine vacuum. Pressure is reduced by returning excess fuel to the fuel tank.

All Light Duty models are equipped with the TFI-IV EEC-IV ignition system. All Heavy Duty models are equipped with the Dura-Spark II ignition system. No adjustments are required on any of these systems.

DISTRIBUTOR PICK-UP COIL RESISTANCE

IGNITION COIL

IGNITION COIL RESISTANCE - OHMS @ 75°F (24°C)

ALTERNATOR REGULATOR

Two models of Motorcraft electronic voltage regulators are used. No adjustment is required or possible. They are similar in appearance, but different internally and must not be interchanged.

EMISSION CONTROL

For information on emission control systems, see EMISSION CONTROL section.

MAINTENANCE INDICATOR LIGHT

Control unit for maintenance light is located under dash, near steering column. Control unit may be hidden behind bracket on some models. Maintenance light is triggered after 2000 key starts (approximately 60,000 miles).

Reset Procedure

1. Turn key switch off. Remove tape from timer reset hole. Lightly push a Phillips screwdriver into the hole marked "RESET". With light pressure on screwdriver. Turn key switch to "RUN" position.
2. Light should stay on while screwdriver is pressed down. Hold screwdriver down for approximately 5 seconds. Remove screwdriver. Light should go out within 2 seconds. If not, repeat steps 1) and 2).
3. Cycle ignition switch from "OFF" to "ON" position. Light should glow for 2 to 5 seconds. This verifies proper reset procedure has been completed.

Note. Some models are equipped with a nonresettable control unit. Replace it with a resettable type.

FUEL SYSTEMS

CARBURETOR & FUEL INJECTION

BATTERY

BATTERY SPECIFICATIONS

STARTER

Motorcraft positive engagement type.

STARTER SPECIFICATIONS

ALTERNATOR

ALTERNATOR (WITH EXTERNAL VOLTAGE REGULATOR) SPECIFICATIONS

ALTERNATOR (WITH INTERNAL VOLTAGE REGULATOR) SPECIFICATIONS

BELT ADJUSTMENT

The 5.0L engine uses a single serpentine drive belt. An automatic belt tensioner is used. No adjustment is required. When installing a new belt ensure all V-ribs contact pulley. DO NOT use deflection method to check tension. Replace automatic tensioner assembly if belt tension is below specification. When installing new tensioner, ensure locating pin is in bracket mounting hole.

5.8L & 7.5L BELT ADJUSTMENT (1)

SERVICE INTERVALS

REPLACEMENT INTERVALS

CAPACITIES

ENGINE OIL & FUEL CAPACITIES

COOLING CAPACITIES

DIFFERENTIAL, STEERING, TRANSFER CASE & TRANSMISSION CAPACITIES

SYSTEM REFRIGERANT CAPACITIES