7.5l v8 - VIN [l] Ford RV Cutaway E350

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

The eighth character of the Vehicle Identification Number (VIN) identifies engine. VIN is near windshield on left upper side of instrument panel. The VIN number is also on the Safety Compliance Certification Label, attached to left door lock pillar.

ENGINE IDENTIFICATION CODES

Scheme 13

1. Turn crankshaft to place No. 1 piston on TDC at end of compression stroke. Make chalk mark at points "A" and "B" on crankshaft pulley at TDC. (Scheme 13) Rotate crankshaft 360 degrees for mark "B".
2. Using Lifter Bleed-Down Wrench (T71B-6513-B), apply pressure to push rod end of rocker arm. Slowly bleed down lifter until lifter plunger is completely bottomed.
3. While holding lifter in this position, check clearance between rocker arm and valve stem tip with a feeler gauge. Desired collapsed lifter gap clearance is.100-.150" (2.54-3.81 mm). Allowable clearance is.075-.175" (1.90-4.45).
4. If clearance is less than specified, install a.060" (1.52 mm) shorter push rod. If clearance is greater, install a.060" (1.52 mm) longer push rod.

VALVE CLEARANCE ADJUSTMENT

ENGINE OVERHAUL

Note. See ENGINE OVERHAUL PROCEDURES article for detailed information on performing basic engine overhaul and checking procedures.

ENGINE REMOVAL

See ENGINE REMOVAL article in the ENGINE section.

Removal

1. Drain cooling system. Remove air cleaner and ducting. Disconnect coolant hoses at intake manifold and water pump. Remove PCV valve and hose. Label and disconnect all vacuum hoses at carburetor, vacuum control valve and intake manifold.
2. Disconnect spark plug wires and valve cover brackets. Disconnect high-tension lead at coil. Remove distributor cap and spark plug wires as an assembly.
3. Remove distributor with vacuum hoses attached. Disconnect accelerator linkage. Disconnect transmission kickdown linkage and speed control linkage bracket at carburetor (if equipped).
4. Remove accelerator linkage attaching bolts. Position all linkages out of way. Disconnect fuel line at carburetor.
5. Label and disconnect all electrical wiring from intake manifold. Remove coil and bracket assembly. Remove intake manifold and carburetor as an assembly.

Scheme 14

Scheme 15

1. Clean all gasket surfaces. Apply 1/8" bead silicone sealer to 4 corners of cylinder block seal mounting surface. Install manifold gasket and front and rear seals. Apply 1/16" bead silicone sealer along full width of front and rear seal ends. (Scheme 14)
2. Install intake manifold within 15 minutes of applying sealer. Position intake manifold over 4 studs in cylinder heads. Check for proper alignment of gaskets and seals before tightening. Tighten intake manifold. Repeat tightening sequence. (Scheme 15)
3. To complete installation, reverse removal procedure. Retighten intake manifold attaching nuts and bolts after engine has reached normal operating temperature.

If removing right exhaust manifold, remove air cleaner, ducting and heat shroud. Remove spark plug wires from spark plugs. Disconnect exhaust pipe from exhaust manifold. Remove attaching bolts and manifold, lifting bracket and spark plug heat shields.

Installation

1. Clean mating surfaces of cylinder head and manifold. Clean mounting flange of manifold and exhaust pipe. Apply light film of graphite grease to manifold machined surface.
2. Position spark plug wire heat shields and exhaust manifold on cylinder head. Install attaching bolts and washers, starting at fourth bolt hole from front of each manifold. Position lifting bracket under bolts at third exhaust port from front of engine.
3. On right exhaust manifold, install shoulder stud for air intake heat shroud at first and sixth bolt holes from front of manifold. Install shoulder stud for dipstick tube in first hole of left exhaust manifold. Tighten exhaust manifold. Using new gaskets, install and tighten exhaust pipes.

1. Drain cooling system. Remove intake manifold and carburetor as an assembly. Disconnect exhaust pipes at manifolds. Loosen alternator attaching bolts and remove bolt attaching alternator bracket to right cylinder head.
2. Loosen A/C drive belt (if equipped). Shut off compressor at service valves and remove valves and hoses from compressor. Remove A/C compressor support bracket attaching nuts from water pump. Remove and position compressor aside. Remove compressor mounting bracket from cylinder head.
3. Remove bolts attaching power steering reservoir bracket to left cylinder head (if equipped). Position reservoir and bracket out of the way. Remove valve covers. Remove rocker arm assemblies and push rods in sequence.
4. Remove cylinder heads and exhaust manifolds as assemblies. Discard cylinder head gaskets. Remove exhaust manifolds.

1. Clean gasket mating surfaces. Check flatness of cylinder head and block mating surfaces. If exhaust manifolds were removed, install on cylinder head.
2. Place 2 long head bolts in 2 rear lower bolt holes of left cylinder head. Place one long head bolt in rear lower bolt hole of right cylinder head. Keep bolts in position until heads are installed.
3. Position head gaskets on block. DO NOT apply sealer to head gasket surfaces. Install and tighten cylinder heads in 3 steps. (Scheme 16)
4. To complete installation, reverse removal procedure. Check and adjust valve clearance as needed. See «VALVE CLEARANCE ADJUSTMENT»(/ford/rv-cutaway-e350/1987-1987/remont/mechanical/#75l-v8-vin-l).

Scheme 16

Valve Arrangement

Right Bank - I-E-I-E-I-E-I-E (Front-to-rear).

Left Bank - E-I-E-I-E-I-E-I (Front-to-rear).

ROCKER ARM ASSEMBLY

1. Inspect all rocker arm components for excessive wear or damage and replace as necessary. Before installing rocker arm assembly, lubricate top of valve stem, fulcrum seat and socket area of rocker arm with polyethylene grease.
2. Insert fulcrum seat base in its slot on cylinder head before tightening fulcrum bolt. (Scheme 17)

Scheme 17

1. Remove valve cover and spark plug from cylinder to be serviced. Rotate crankshaft until piston is at TDC at end of compression stroke. Remove rocker arms and push rods from valves to be serviced.
2. Install an air hose with adapter into spark plug hole and turn on air supply. DO NOT remove air pressure until valves are supported. Install rocker arm fulcrum bolt. Using Spring Compressor (T70P-6049-A), compress valve spring and remove retainer locks. Remove retainer, spring and oil seal. (Scheme 18)

Note. For further information on valve spring and hydraulic lifter testing see ENGINE OVERHAUL PROCEDURES article.

Scheme 18

1. Hold valve closed and turn air pressure on again. Install new valve stem oil seals. Place spring in position over valve and position spring retainer in place. Compress valve spring and install retainer locks. (Scheme 18)
2. Apply polyethylene grease to push rod ends, valve stem tip, fulcrum seats and sockets. Install push rods and rocker arms. Turn off air pressure. Remove air hose and adapter. To complete installation, reverse removal procedure.

SPRING LENGTH SPECIFICATIONS

VALVE SPRING INSTALLED HEIGHT SPECIFICATIONS

VALVE STEM OIL SEALS

Umbrella-type oil seals are used on all valves. Lubricate valve stem with engine oil and install new seal with cup side down over valve guide. Use a 5/8" deep-well socket and light mallet to seat seal on valve stem.

VALVE GUIDES

When reaming guides, always use reamers in proper sequence. Always reface valve seats and valves after valve guides are reamed. Replacement valves are available with standard, .015" (.38 mm), and .030 (.76 mm) oversize stems.

HYDRAULIC VALVE LIFTERS

1. Service lifters as assemblies only. Disassemble and clean lifters before testing. Test lifters with hydraulic lifter test fluid. DO NOT interchange parts between lifters.
2. Leak-down rate on hydraulic lifters is 10-50 seconds, with 1/16" (1.6 mm) plunger travel under 50 lb. (23 kg) load. Replace lifter if it fails leak-down test, or is worn or damaged.

1. Drain cooling system and crankcase. Remove fan and radiator shroud. Disconnect radiator hoses at engine and oil cooler lines at radiator and remove radiator.
2. Remove all drive belts and water pump pulley. Remove air pump. Remove A/C compressor support bracket from water pump (if equipped). Disconnect heater hose from water pump and loosen by-pass hose clamp at pump.
3. Remove crankshaft pulley. Using Crankshaft Damper Remover (T58P-6316-D), remove vibration damper and Woodruff key from crankshaft. Disconnect and plug fuel line inlet at fuel pump and remove fuel pump. Remove bolts attaching front cover to cylinder block.
4. Remove front cover and water pump as an assembly. Using a knife, cut oil pan seal flush with cylinder block face. Discard front cover gasket and pan seal.

Scheme 19

1. Coat gasket surface of oil pan with gasket sealer. Cut and position required section of a new seal on oil pan. Apply silicone sealer at block-to-pan junction. Apply gasket sealer to front cover and cylinder block gasket surfaces.
2. Position front cover on cylinder block. Install Front Cover Seal Aligner (T68P-6019-A) on crankshaft. (Scheme 19) Coat threads of cover bolts with oil-resistant sealer and install bolts.
3. While pushing in on aligning tool, tighten oil pan-to-cover bolts. Remove aligning tool and tighten front cover-to-cylinder block bolts. To complete installation, reverse removal procedure.

With engine front cover removed, drive out old oil seal with pin punch. Clean seal recess in front cover.

Coat new seal with polyethylene grease and install seal using Seal Installer (T72J-1177). Ensure seal spring remains in proper position.

Checking Timing Chain Deflection

1. Remove engine front cover. Rotate crankshaft counter-clockwise (as viewed from front of engine) to take up slack on left side of timing chain. Establish a reference point on the block and measure from this point to left side of chain. (Scheme 20)
2. Rotate crankshaft clockwise to take up slack on right side of chain. Force left side of chain outward and measure distance between reference point and chain.
3. Deflection is the difference between the 2 measurements. If deflection exceeds.50" (12.7 mm), replace timing chain and sprockets.

Turn crankshaft until timing marks are aligned. Remove camshaft sprocket bolt and washer, 2-piece fuel pump eccentric and front oil slinger. Slide timing chain and sprockets forward and remove as an assembly.

1. Assemble timing chain and sprockets so sprocket timing marks are aligned. (Scheme 20) Install chain and sprockets as an assembly.
2. Lubricate timing chain with engine oil. To complete installation, reverse removal procedure.

Scheme 20

1. Remove radiator, front cover, timing chain and sprockets. Remove intake manifold and carburetor as an assembly. Remove valve covers.
2. Loosen all rocker arm bolts. Rotate rocker arms to one side. Remove push rods and valve lifters, keeping them in order for installation in original locations. NOTE: If lifters are stuck in bores, use Hydraulic Lifter Puller (T70L-6500-A) to remove lifters.
3. If equipped, remove A/C condenser and carefully secure condenser to left fender well. Remove grille. Remove camshaft thrust plate attaching bolts and remove camshaft, taking care not to damage camshaft bearings or journals.

1. Oil camshaft journals and apply polyethylene grease to camshaft lobes. Carefully slide camshaft into position. Install and tighten thrust plate.
2. Lubricate lifters with engine oil and install. Lubricate rocker arms, fulcrum seats, valve stem tips and push rods with polyethylene grease before installing.
3. To complete installation, reverse removal procedure. Use new gaskets where required. (Scheme 21)

Scheme 21

CAMSHAFT END PLAY

1. Loosen rocker arm fulcrum bolts to relieve load on camshaft. Push camshaft toward rear of engine. Install Dial Indicator and Bracket (D78P-4201-F,G), so that indicator point is on camshaft sprocket attaching bolt. Zero dial indicator.
2. Pull camshaft forward and release. Check dial indicator reading to obtain end play. If end play is greater than .009" (.22 mm), replace camshaft thrust plate.

CAM LOBE LIFT

1. Remove valve cover. Remove fulcrum bolt, fulcrum seat and rocker arm. Ensure push rod end is in valve lifter socket.
2. Use a Dial Indicator and Bracket (D78P-4201-F,G) to check lobe lift in consecutive order. Position dial indicator point (or Cup-Shaped Adapter 6565-AB) on end of push rod (in same plane as push rod movement).
3. Turn crankshaft until lifter and push rod are at lowest position. Zero dial indicator. Turn crankshaft slowly until push rod is fully raised. Compare dial indicator reading with specifications.
4. Maximum allowable lobe wear is .005" (.13 mm). If lobe lift is insufficient, replace camshaft and valve lifter(s) operating on worn lobe(s).

Remove engine from vehicle. Remove camshaft, flywheel and crankshaft. Push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Using Camshaft Bearing Remover/Installer (T65L-6250-A), remove camshaft bearings.

Using camshaft bearing installer/remover, install bearings into place. Oil holes in bearings and cylinder block must be aligned. Install front bearing .040-.060" (1.02-1.52 mm) rearward of front face of cylinder block. Coat new rear bore plug with sealer and install.

1. Remove cylinder heads, oil pan and oil pump. Place piston at bottom of its stroke and cover with a cloth to collect metal cuttings. Use ridge reamer to remove ridge or deposits from upper end of cylinder bore. NOTE: Never cut more than 1/32" into ring travel area when removing ridge.
2. Ensure all connecting rods and caps are marked for cylinder identification. Remove rod cap. Push piston and rod out top of cylinder. Use care not to damage crankshaft journal or cylinder wall. Install rod cap on mating rod.

1. Coat cylinder bore, piston and rings with engine oil. Position ring gaps. (Scheme 22) Install ring compressor. DO NOT allow ring gaps to change.
2. Position crankshaft journal at bottom of stroke. Install piston with notch in top of piston facing toward center of engine.
3. Install and tighten connecting rod cap. Check side clearance of connecting rods on each crankshaft journal. Install cylinder heads, oil pump and oil pan.

Scheme 22

FITTING PISTONS & RINGS

For information on measuring pistons and rings refer to ENGINE OVERHAUL PROCEDURES article.

PISTON SIZE CODES

Using an arbor press and using Piston Pin Remover/Installer (T68P-6135-A), press piston pin from piston and connecting rod. (Scheme 23)

Scheme 23

Scheme 24

1. Apply light coat of engine oil to all parts to be assembled. Assemble piston to connecting rod with numbered side of rod toward outside of engine and notch in piston head positioned forward. (Scheme 24)
2. Start piston pin in piston and connecting rod. Using arbor press and pin remover/installer, press pin into piston and connecting rod until end of pin is.063-.125" (1.6-3.2 mm) below chamfer of piston pin bore.

CONNECTING ROD BEARINGS & MAIN BEARINGS

Ensure rod caps are marked for cylinder identification. Place crankshaft journal of cylinder to be checked at bottom of stroke and remove rod cap. Measure connecting rod side clearance after the bearings and caps have been installed.

To check bearing clearances and for further information on connecting rod and main bearings see ENGINE OVERHAUL PROCEDURES article.

THRUST BEARING ALIGNMENT

1. Install thrust bearing cap after all other main bearing caps have been tightened. Install thrust bearing cap bolts finger tight.
2. Pry crankshaft forward against thrust surface of upper half of bearing. Hold crankshaft forward and pry thrust bearing cap to rear. Tighten thrust bearing cap bolts while retaining forward pressure on crankshaft.

1. Remove oil pan and oil pump (if required). Loosen all main bearing cap bolts to slightly lower crankshaft. DO NOT lower more than 1/32". Remove rear main bearing cap and remove lower oil seal half. Use seal remover to remove upper seal.
2. If seal remover is not available, install a small metal screw in one end of the seal. Pull on screw to remove seal. Use care not to damage crankshaft seal surface. If equipped, remove oil seal retaining pin from bearing cap. Pin is not used with split-lip type seal.

Scheme 25

1. Carefully clean oil seal grooves in bearing cap and block. Dip split-lip seal halves in engine oil. Carefully install upper seal into groove in cylinder block, with undercut side of seal toward front of engine. NOTE: Avoid damage to outside diameter of seal when installing in groove. DO NOT allow oil to get onto area where sealer will be applied.
2. Rotate seal on crankshaft journal until about 3/8" of seal protrudes below parting surface. (Scheme 25)
3. Tighten all main bearing cap bolts except rear main. Install lower seal in rear main bearing cap with undercut side of seal toward front of engine.
4. Allow seal to protrude about 3/8" above parting surface to mate with upper seal when cap is installed. Apply 1/16" bead of silicone sealer to both sides of cylinder block-to-cap mating surface and to both sides of bearing cap. (Scheme 26)
5. Install and tighten rear main bearing cap before sealer sets up (about 15 minutes). To complete installation, reverse removal procedure.

Scheme 26

ENGINE OILING SYSTEM

Distributor driven oil pump provides full-pressure lubrication to all camshaft and crankshaft bearings. Engine feeds oil through hydraulic valve lifters and hollow push rods to rocker arms and upper valve train area. Timing chain and sprockets are lubricated by drainage from No. 1 camshaft bearing. (Scheme 27)

Scheme 27

OIL PAN

See OIL PAN REMOVAL article in the ENGINE section.

Crankcase Capacity

Crankcase capacity is 5 quarts (4.75L). Add 1 quart (.95L) when replacing oil filter.

Oil Filter

Change filter at first oil change and at every other oil change thereafter.

Normal Oil Pressure

Normal oil pressure at operating temperature should be 40-65 psi (2.8-4.6 kg/cm 2 ) at 2000 RPM.

Oil Pressure Regulator Valve

Oil pressure regulator valve is located in pump body. Valve is nonadjustable.

Raise engine at least 4" from engine mounts. Loosen oil pan attaching bolts and lower pan. Remove oil pump and oil inlet tube and lay assembly in pan. Remove pan with pump assembly.

Disassembly

Remove oil inlet tube from pump. Remove pump cover. Remove inner rotor, shaft and outer rotor from oil pump. Drill small hole in oil pressure relief valve cap. Insert self-threading sheet metal screw into cap and pull cap from chamber. Remove spring and plunger.

Inspection

1. Clean all parts thoroughly. Check pump housing, outer rotor, inner rotor, shaft and pump cover for damage, scoring or excessive wear. Remove rotor assembly from pump housing. Using feeler gauge, measure inner-to-outer rotor tip clearance.
2. Install rotor assembly in pump housing. Place a straight-edge over rotor assembly and housing. Insert feeler gauge between straightedge and housing to measure rotor end play. Using a feeler gauge, measure clearance between outer rotor and pump housing.
3. Measure shaft outside diameter and housing bearing inside diameter. Difference between readings is shaft-to-housing bearing clearance.
4. Relief valve spring pressure is 20.6-22.6 lbs. (9-10 kg) at 2.49" (63.5 mm). Inspect relief valve spring for worn or collapsed condition. Check relief valve plunger for scores and free operation in bore. Check clearance between relief valve plunger and bore.

OIL PUMP SPECIFICATIONS

Assembly

Clean and oil all parts thoroughly. Install relief valve plunger, spring and cap. Stake cap into position. To complete assembly, reverse disassembly procedure.

Prime oil pump. To install oil pump, reverse removal procedure. Use new gaskets.

1. Drain cooling system. Remove fan shroud and fan. Loosen power steering pump attaching bolts. Remove upper A/C compressor bracket. Remove A/C idler pulley and bracket assembly (if equipped).
2. Remove all drive belts. Remove air pump, alternator and bracket, and power steering pump. Disconnect all hoses from water pump, and loosen by-pass hose clamp at pump. Remove remaining attaching bolts and water pump. Remove separator plate from water pump and discard gaskets.

To install, reverse removal procedure. Use new gaskets coated on both sides with water-resistant sealer.

Note. For further information on cooling systems, refer to ENGINE COOLING SYSTEM article in the ENGINE section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS (1)

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS (1)

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• VALVE CLEARANCE ADJUSTMENT