Engine Page 1

Engine
2000-01 ENGINES
4.6L V8 - VIN W & 6
ENGINE IDENTIFICATION
Engine is identified by eighth character of Vehicle Identification Number (VIN). See
ENGINE
IDENTIFICATION CODES
table. VIN is located on top of instrument panel, near lower left corner of
windshield. VIN is also stamped on Vehicle Certification (VC) label mounted on left door pillar.
Engine code labels are located in engine compartment, in front of radiator and on right valve cover. Label
contains engine calibration number, engine build date, engine plant code and engine code.
Emission calibration number label is located on upper radiator shield. This label identifies engine calibration
number, engine code number and revision level. Numbers from labels are required when ordering replacement
p
arts.
ENGINE IDENTIFICATION CODES
Windsor and Romeo engine plants are producing the 4.6L engine. There are several differences between these
engines and many parts are not interchangeable.
The best way to determine manufacturer is by the VIN number. VIN W is a Romeo engine. VIN 6 is Windsor
engine. There are a couple external differences. The right valve cover on Windsor engine has 14 bolts, Romeo
engine has 11 bolts. Also on Windsor engine there is a W stamped on each valve cover in area of camshaft
sprocket.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Hydraulic valve lash adjusters are used. No valve adjustment is required.
TROUBLE SHOOTING
REMOVAL & INSTALLATION
Engine Type Fuel System Engine Plant VIN Code
4.6L SOHC SFI Romeo W
4.6L SOHC SFI Windsor 6
NOTE: To trouble shoot engine mechanical components, see ENGINE MECHANICAL in
BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.
CAUTION: When battery is disconnected, vehicle computer and memory systems
2000 Ford Pickup F350 Super Duty
2000-01 ENGINES 4.6L V8 - VIN W & 6
2000 Ford Pickup F350 Super Duty
2000-01 ENGINES 4.6L V8 - VIN W & 6
Helpmelearn Repair Manuals
Wednesday, November 08, 2006 7:35:52 PM Page 1 © 2004 Mitchell Repair Information Company, LLC.
Helpmelearn Repair Manuals
Wednesday, November 08, 2006 7:36:08 PM Page 1 © 2004 Mitchell Repair Information Company, LLC.

Contents Summary of Engine

  • Page 12000-01 ENGINES 4.6L V8 - VIN W & 6 ENGINE IDENTIFICATION Engine is identified by eighth character of Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certificat
  • Page 2may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines befor
  • Page 3cover. 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. Re
  • Page 4head retaining bolts in reverse order of tightening sequence. See Fig. 2 . 3. Lift upper and lower intake manifold assembly. Disconnect electrical connector at manifold tuning valve, and remove intake manifold assembly from vehicle. Remove upper intake manifold-to-lower intake manifold mounting bolt
  • Page 5Fig. 1: Exploded View Of Upper & Lower Intake Manifold Courtesy of FORD MOTOR CO.
  • Page 6Fig. 2: Upper Intake Manifold-To-Lower Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 7Fig. 3: Upper Intake Manifold-To-Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD Removal (All Models) WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel.
  • Page 8gasket. Installation To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. See Fig. 4 . See TORQUE SPECIFICATIONS . Fig. 4: Exhaust Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CYLINDER HEAD CAUTION: If cylinder head-to-block surface refin
  • Page 9CAUTION: Position camshaft so valves DO NOT extend below cylinder head surface, or ensure camshaft positioner is installed before installing cylinder head. See Fig. 9 . Install NEW cylinder head bolts. DO NOT reuse bolts. Coat bolt head-to-cylinder head surfaces with engine oil. DO NOT oil threads o
  • Page 10
  • Page 11Fig. 5: Cylinder Head Bolt Removal & Installation Sequence (Romeo Engine) Courtesy of FORD MOTOR CO.
  • Page 12
  • Page 13Fig. 6: Cylinder Head Bolt Removal & Installation Sequence (Windsor Engine) Courtesy of FORD MOTOR CO. Fig. 7: Securing Cylinder Head Bolts Courtesy of FORD MOTOR CO.
  • Page 14Fig. 8: Positioning Crankshaft Courtesy of FORD MOTOR CO.
  • Page 15Fig. 9: Installing Camshaft Positioner Courtesy of FORD MOTOR CO. VALVE COVERS 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 ho
  • Page 16retaining bolts. Retaining bolts are part of valve cover and should not be removed. 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 into valve cover. Apply a bead of silicone gasket
  • Page 17Fig. 10: Valve Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT COVER OIL SEAL
  • Page 18WARNING: Ensure air suspension system is shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing. Removal
  • Page 19Fig. 11: Front Cover Tightening Sequence Courtesy of FORD MOTOR CO. TIMING CHAINS Removal 1. Remove valve covers. See VALVE COVERS . Remove front cover. See FRONT COVER . Remove crankshaft position sensor pulse wheel from crankshaft. 2. CAUTION: DO NOT rotate engine with timing chain removed. Damage
  • Page 20Rotate crankshaft until No. 1 piston is at TDC. This positions crankshaft keyway 45 degrees from vertical position. See Fig. 12 . Camshaft keyways will point toward crankshaft. 3. CAUTION: Mark component location for reassembly reference. Components must be installed in original locations. Install C
  • Page 21Fig. 8 . Crankshaft keyway will point toward camshaft. 5. Install left timing chain on camshaft and crankshaft sprockets so copper link aligns with timing mark on sprockets. See Fig. 12 . Install crankshaft sprocket for right timing chain. Ensure sprocket is properly installed. 6. Install right timi
  • Page 22Fig. 12: Identifying Timing Marks Courtesy of FORD MOTOR CO. Fig. 13: Exploded View Of Timing Chain & Components Courtesy of FORD MOTOR CO.
  • Page 23Fig. 14: Identifying Crankshaft Sprocket & Timing Chain Timing Marks Courtesy of FORD MOTOR CO. Fig. 15: Compressing Timing Chain Tensioner Plunger Courtesy of FORD MOTOR CO. CAMSHAFT FOLLOWER & LASH ADJUSTER Removal 1. Remove valve covers. See VALVE COVERS . Rotate crankshaft until piston in cylind
  • Page 24is at bottom of its stroke, and camshaft lobe is at base circle. 2. Install valve spring spacer between valve spring coils to prevent valve stem oil seal damage. Using valve spring compressor, compress valve spring. Remove camshaft follower and lash adjuster. Inspection Inspect components for damage
  • Page 252. Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . Fig. 16: Camshaft Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 26Fig. 17: Removing Camshaft Caps (Romeo Engine) Courtesy of FORD MOTOR CO. CRANKSHAFT REAR OIL SEAL Removal 1. Remove transmission. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove oil pan. See OIL PAN . Remove flywheel. Remove rear oil seal retainer. 2. Using rear cr
  • Page 27Fig. 18: Seal Retainer Bolt Tightening Sequence Courtesy of FORD MOTOR CO. WATER PUMP Removal & Installation 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.
  • Page 28subframe. Remove oil pan retaining bolts in reverse sequence. See Fig. 19 . Remove oil pan. Removal (2WD Expedition & F150 Pickup) 1. Disconnect negative battery cable. Drain cooling system. Remove radiator air deflector. Remove air cleaner. Disconnect throttle cable and throttle position sensor ele
  • Page 29Fig. 19: Oil Pan Bolt Tightening Sequence (All Models) Courtesy of FORD MOTOR CO. OVERHAUL
  • Page 30NOTE: There are 2 different manufacturers of the 4.6L SOHC engine (Romeo and Windsor). There are several differences. See INTERNAL DIFFERENCES . See ENGINE IDENTIFICATION . INTERNAL DIFFERENCES Camshaft Sprockets Windsor engine uses an interference fit to secure sprocket to camshaft. Romeo engine us
  • Page 31Fig. 20: Identifying Romeo Piston & Rod Assembly Courtesy of FORD MOTOR CO.
  • Page 32Fig. 21: Identifying Windsor Piston & Rod Assembly Courtesy of FORD MOTOR CO.
  • Page 33Fig. 22: Exploded View of Romeo Crankshaft & Components Courtesy of FORD MOTOR CO.
  • Page 34Fig. 23: Exploded View of Windsor Crankshaft & Components Courtesy of FORD MOTOR CO. CYLINDER HEAD Cylinder Head CAUTION: If cylinder head-to-block surface refinishing is necessary, replace head. Check cylinder head for cracks or damage. If maximum warpage exceeds .004" (.10 mm), replace cylinder he
  • Page 35Valve 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
  • Page 36NEW connecting rod bolts. Piston & Rod Assembly Note direction of connecting rod installation on piston. Install piston and connecting rod in engine, with notch on top of piston toward front of engine. See Fig. 20 or Fig. 21 . Fitting Pistons 1. Standard service pistons are color-coded Red, Blue or
  • Page 37with 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.
  • Page 38Fig. 24: Main Bearing Cap Bolt Tightening Sequence (Romeo Engine) Courtesy of FORD MOTOR CO.
  • Page 39Fig. 25: Main Bearing Cap Bolt Tightening Sequence (Windsor Engine) Courtesy of FORD MOTOR CO. 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 table under ENGINE SPE
  • Page 402. 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. CAUTION: Before boring cylinder block, install main bearing caps and tighten bolts to specification. See TORQU
  • Page 41Camshaft Sprocket Bolt 82-95 (110-130) Connecting Rod Bolt (1) Step 1 15-18 (20-25) Step 2 30-33 (41-45) Step 3 Additional 90-120 Degrees Crankshaft Damper Bolt Step 1 66 (90) Step 2 Loosen 360 Degrees Step 3 35-39 (47-53) Step 4 Additional 85-90 Degrees Cylinder Head Bolt (1)(2) Step 1 28-31 (37-43
  • Page 42Windsor Engine (1) Step 1 20-24 (27-33) Step 2 Additional 85-95 Degrees Oil Pan Bolt (8) Step 1 (10) Step 2 15 (20) Step 3 Additional 60 Degrees Oxygen Sensor 27-33 (37-45) Pick-Up Tube-To-Main Bearing Cap Nut 15-22 (20-30) Power Steering Pump-To-Mount Nut 15-22 (20-30) Thermostat Housing Bolt 15-22
  • Page 43(7) Tighten bolts to 89 INCH lbs. (10 N.m). (8) Tighten bolts in sequence. See Fig. 19 . (9) Tighten bolts in sequence. See Fig. 16 . (10) Tighten bolts to 18 INCH lbs. (2 N.m). ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS Application Specification Displacement 281 Cu. In. (4.6L) Bore 3.55" (90.2 mm
  • Page 44Standard .0006-.0177 (.015-.450) Service Limit .020 (.50) CYLINDER HEAD Application Specification Maximum Warpage (1) Intake & Exhaust Valve Seats Seat Angle 45° Seat Width Intake Valve .05"-.06"(1.3-1.5mm) Exhaust Valve .07"-.08"(1.9-2.1mm) Maximum Seat Runout .001" (.025 mm) Valve Guides Valve Ste
  • Page 45Rod Fit Romeo Engine .0006-.0016 (.015-.041) Windsor Engine .0003-.0009 (.008-.023) Rings No. 1 End Gap Standard .005-.010 (.13-.25) Limit .030 (.75) Side Clearance Standard .0016-.0035 (.041-.089) Limit .049 (1.24) No. 2 End Gap Standard .012-.022 (.30-.56) Limit .030 (.75) Side Clearance Standard
  • Page 46Stem Diameter .2735-.2744" (6.949-6.970 mm) Valve Face Runout .002" (.05 mm) Valve Springs Free Length 2.101" (53.37 mm) Out-Of-Square 2.0 Degrees Lbs. @ In. (kg @ mm) Pressure Expedition Valve Closed 65 @ 1.57" (29.5 @ 39.9 mm) Valve Open 150 @ 1.10" (68.0 @ 28.2 mm) E150 & F150 Valve Closed 55 @ 1
  • Page 472000-01 ENGINES 5.4L V8 - VIN L ENGINE IDENTIFICATION Engine is identified by eighth character of Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certification
  • Page 48battery. 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. FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS WARNING: Fuel system is under pressure. Release pressure be
  • Page 49Courtesy of FORD MOTOR CO. ENGINE WARNING: Air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to
  • Page 50accessory 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-conve
  • Page 513. 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. Fig. 2: Upper Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 52Fig. 3: Lower Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD WARNING: Air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in
  • Page 53Removal Raise and support vehicle. Remove front fender splash shield. Remove wheel opening molding on 4WD models. 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 n
  • Page 54Fig. 4: Exhaust Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CYLINDER HEAD Removal 1. Remove the engine. See ENGINE . Remove the flexplate or flywheel. Mount the engine on a suitable work stand. Remove exhaust manifold. See EXHAUST MANIFOLD . 2. Remove timing chains. See TIMING CHAIN
  • Page 55tightening sequence. See Fig. 5 . Remove cylinder head and gasket. Inspection CAUTION: If cylinder head-to-block surface refinishing is necessary, DO NOT remove more than .010" (.25 mm) from cylinder head surface. Check cylinder head for warpage, cracks and damage. See CYLINDER HEAD table under ENGI
  • Page 56Fig. 5: Cylinder Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. VALVE COVERS
  • Page 57Removal (Expedition, Navigator & Pickup - Left) 1. Disconnect negative battery cable(s). Remove air cleaner. Unbolt power steering reservoir bracket, and position reservoir and bracket assembly aside. 2. Disconnect PCV hose from valve cover. Disconnect control cables from throttle body. Unbolt throt
  • Page 58Fig. 6: Valve Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT CRANKSHAFT SEAL WARNING: Air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in infla
  • Page 59WARNING: Air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing. Removal 1
  • Page 60Fig. 7: Front Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. TIMING CHAINS Removal 1. Remove front cover. See FRONT COVER . Remove crankshaft position sensor pulse wheel from crankshaft. Using crankshaft positioner, position crankshaft as shown in illustration. See Fig. 8 . Install camsha
  • Page 61Remove 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. Inspection Inspect components for damage. Inspect friction surfaces on tensioner arms and chain
  • Page 62Fig. 8: Installation Of Crankshaft Positioner Courtesy of FORD MOTOR CO.
  • Page 63Fig. 9: Securing Timing Chain Tensioner Plunger Courtesy of FORD MOTOR CO. Fig. 10: Marking Timing Chain Links Courtesy of FORD MOTOR CO.
  • Page 64Fig. 11: View Of Timing Chain & Components Courtesy of FORD MOTOR CO.
  • Page 65Fig. 12: Identifying Crankshaft Sprocket & Timing Chain Timing Marks Courtesy of FORD MOTOR CO. CAMSHAFT FOLLOWER & LASH ADJUSTER Removal 1. Remove valve covers. See VALVE COVERS . Rotate crankshaft until piston in cylinder to be serviced is at bottom of its stroke, and camshaft lobe is at base circ
  • Page 66with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). CAMSHAFT CAUTION: DO NOT remove camshaft before removing camshaft followers. Camshaft will bend and be damaged from side loading. CAUTION: DO NOT rotate engine at any time when cylinder heads are insta
  • Page 67Fig. 13: Camshaft Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. THERMOSTAT
  • Page 68Removal 1. Partially drain the cooling system. Disconnect the upper radiator hose. Remove the 2 thermostat housing bolts. Remove the thermostat housing. See Fig. 14 . 2. Remove the thermostat and the "O" ring seal. See . Discard the "O" ring seal. Installation 1. Use a new "O" ring seal to position
  • Page 69Fig. 15: Removing/Installing Thermostat Courtesy of FORD MOTOR CO. WATER PUMP Removal & Installation 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, re
  • Page 702. Remove the throttle cable bracket bolts and position the bracket and cables aside. Disconnect the vapor management valve hose. Remove the crankcase ventilation tube and the Idle Air Control (IAC) valve fresh air tube. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum line and the main v
  • Page 71Fig. 16: Removing & Installing Throttle & Speed Control Cables (Expedition & F150) Courtesy of FORD MOTOR CO.
  • Page 72Fig. 17: Disconnecting & Connecting Throttle Position Sensor & EGR Vacuum Regulator Solenoid Courtesy of FORD MOTOR CO.
  • Page 73Fig. 18: Locating Evaporative Emission Canister Purge Solenoid Courtesy of FORD MOTOR CO.
  • Page 74Fig. 19: Locating Brake Booster Vacuum Tube Bracket Bolt Courtesy of FORD MOTOR CO.
  • Page 75Fig. 20: Locating Differential Pressure Feedback Sensor Courtesy of FORD MOTOR CO.
  • Page 76Fig. 21: Removing & Installing Differential Feedback Sensor Bracket Nut Courtesy of FORD MOTOR CO.
  • Page 77Fig. 22: Removing & Installing EGR Tube Courtesy of FORD MOTOR CO.
  • Page 78Fig. 23: Removing & Installing Throttle Body Adapter Plate Courtesy of FORD MOTOR CO.
  • Page 79Fig. 24: Removing & Installing Fan Shroud Courtesy of FORD MOTOR CO.
  • Page 80Fig. 25: Removing & Installing Engine Lift Bracket Courtesy of FORD MOTOR CO.
  • Page 81Fig. 26: Identifying Heavy Duty Engine Support Courtesy of FORD MOTOR CO.
  • Page 82Fig. 27: Removing & Installing Starter Solenoid Wires Courtesy of FORD MOTOR CO.
  • Page 83Fig. 28: Removing & Installing Starter Ground Cable Nut Courtesy of FORD MOTOR CO. Installation CAUTION: DO NOT use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic sc
  • Page 84CAUTION: Ensure the "O" ring is in place and not damaged. A missing or damaged "O" ring can cause foam in the lubrication system, low oil pressure, and severe engine damage. Install a NEW "O" ring and lubricate with clean engine oil. Position the oil pump screen and pickup tube. Install oil pump scr
  • Page 85and the bolts. See Fig. 16 . 14. Connect the throttle cable, speed control actuator cable and throttle return spring. See Fig. 16 . Install the generator. See appropriate article in STARTING & CHARGING SYSTEMS. Install the radiator air deflector. Fill the engine to proper level with appropriate engi
  • Page 86Fig. 29: Oil Pan Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 87Fig. 30: View Of Torque Angles Courtesy of FORD MOTOR CO. Removal (Expedition, Navigator & Pickup - 4WD) 1. Turn the air suspension switch off. Air suspension switch is located behind right kick panel. Raise and support the vehicle on a hoist. On vehicles equipped with the Dual Overhead Camshaft (DO
  • Page 88to the axle solenoid may become disconnected or damaged. On vehicles equipped with a Single Overhead Camshaft (SOHC), support the front axle housing with a jack stand and remove the front axle mount bolt and axle support bolts. See Fig. 31 . Remove the front axle support from vehicle. Remove the rig
  • Page 89Fig. 32: Removing & Installing Front Axle Housing Mount Bolts Courtesy of FORD MOTOR CO. Installation NOTE: If the oil pan and the oil pan gasket are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner (F4AZ-19A536-RA). Allow to dry until
  • Page 90z Stage 3: Tighten an additional 60 degrees. See Fig. 30 . 3. On vehicles equipped with the Dual Overhead Camshaft (DOHC), install the front axle assembly. See appropriate article in DRIVE AXLES. On vehicles equipped with a Single Overhead Camshaft (SOHC), position the front axle housing and loosely
  • Page 91Fig. 33: Identifying Front & Rear Sealing Points Courtesy of FORD MOTOR CO. Removal (F250-F350 Super Duty)
  • Page 92NOTE: Differential feedback sensor is also referred to as EGR transducer. 1. Disconnect the negative battery cable. Partially drain the radiator and disconnect the upper radiator hose at the radiator. Remove the air cleaner outlet tube. Remove the throttle cable snow shield. Disconnect the throttle
  • Page 93bolts and partially lower the oil pan. Remove the 2 oil pump pickup tube bolts from the oil pump pickup tube and let them drop into the oil pan. 11. Remove the rear oil pump pickup tube support bolt and the oil pump pickup tube and let them drop into the oil pan. Remove the oil pan and the oil pan g
  • Page 94Fig. 35: Locating EGR Transducer & Throttle Position Sensor Courtesy of FORD MOTOR CO. Fig. 36: Disconnecting & Connecting Electronic Vacuum Regulator Harness Connector
  • Page 95Courtesy of FORD MOTOR CORP. Fig. 37: Removing & Installing Throttle Body Adapter Courtesy of FORD MOTOR CO.
  • Page 96Fig. 38: Removing & Installing Engine Mount Nuts Courtesy of FORD MOTOR CO. Fig. 39: Removing & Installing Transmission Pan-To-Case Bolts For Transmission Jack Adapter
  • Page 97Courtesy of FORD MOTOR CO. Fig. 40: Identifying High Lift Transmission Jack & Adapter Courtesy of FORD MOTOR CO. Installation CAUTION: DO NOT use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which ma
  • Page 98NOTE: The oil pump screen cover and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle. NOTE: Clean and inspect the mating surfaces and install a NEW oil pump pickup tube "O" ring seal. Lubricate oil pump pickup tube "O" ring with Ford SAE 5W-30 Super Premium Motor Oil
  • Page 99z Stage 1: Tighten to 71-89 INCH lbs. (8-10 N.m). z Stage 2: Tighten an additional 85-95 degrees. See Fig. 30 . 12. Connect the Electronic Vacuum Regulator (EVR solenoid electrical and vacuum harness. See Fig. 36 . Connect the EGR valve vacuum line. Install the EGR tube. 13. Hand-tighten the upper a
  • Page 100Valve 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 to install oil seals. Valve Guides 1. NOTE: DO NOT ream valve guides from standa
  • Page 101CAUTION: Connecting rod bearing caps are mechanically fractured during manufacturing and cannot be serviced or interchanged. Mark connecting rod and cap for reassembly reference. DO NOT attempt to repair connecting rods. Replace connecting rod if out of specification. Install NEW connecting rod bolt
  • Page 1021. Measure main bearing clearances using Plastigage. 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
  • Page 103Fig. 41: Main Bearing Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. 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 table under ENGINE SPECIFICATIONS.
  • Page 104CAUTION: 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 .50" (12.7 mm) below top of cylinder block head surface and .50" (12.7 mm) above piston when at bottom of cylinder bore.
  • Page 105Application Ft. Lbs. (N.m) Connecting Rod Bolt (1) Step 1 30-33 (41-45) Step 2 Additional 90-120 Degrees Crankshaft Damper Bolt Step 1 66 (89) Step 2 Loosen 360 Degrees Step 3 35-39 (47-53) Step 4 Additional 85-90 Degrees Cylinder Head Bolt (1)(2) Step 1 27-32 (37-43) Step 2 Additional 85-95 Degrees
  • Page 106Starter Bolts 15-20 (20-27) Thermostat Housing Bolts 20 (27) Timing Chain Tensioner Bolts 15-22 (20-30) Torque Converter Nuts 20-34 (27-46) Transmission Pan-To-Case Bolts 10-12 (14-16) Water Pump Bolts 15-22 (20-30) Water Pump Pulley Bolts 15-22 (20-30) INCH Lbs. (N.m) Balance Shaft Bolts 71-106 (8-
  • Page 107(5) Tighten bolts in sequence. See Fig. 41 . (6) Tighten bolts in sequence. See Fig. 29 . (7) Tighten bolts to 18 INCH lbs. (2 N.m) (8) Tighten bolts in sequence. See Fig. 13 . (9) Tighten bolts to 15-22 ft. lbs. (20-30 N.m). ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS Application Specification Dis
  • Page 108Pins Diameter .8662-.8663 (22.001-22.003) Pin-To-Piston Clearance .0002-.0004 (.005-.010) Rod Fit .0003-.0009 (.008-.023) Rings No. 1 End Gap .005-.011 (.13-.28) Side Clearance (1) No. 2 End Gap .010-.016 (.25-.40) Side Clearance (1) No. 3 (Oil) End Gap (Steel Rail) (1) Side Clearance .006-.026 (.15
  • Page 109Maximum Seat Runout .001" (.025 mm) Valve Guides Valve Stem-To-Guide Oil Clearance Intake Valve .0008-.0027" (.020-.069 mm) Exhaust Valve .0018-.0037" (.046-.094 mm) (1) If maximum warpage is exceeded, replace cylinder head. BALANCE SHAFT Application In. (mm) Bearing Bore Diameter 1.0625-1.0635 (26.
  • Page 110Application Specification Valves Intake Face Angle 45.25-45.75° Head Diameter 1.747-1.757" (44.37-44.63 mm) Minimum Margin .031" (.80 mm) Stem Diameter .2746-.2754" (6.975-6.995 mm) Valve Face Runout .002" (.05 mm) Exhaust Face Angle 45.25-45.75° Head Diameter 1.334-1.343" (33.88-34.12 mm) Minimum M
  • Page 1111998-2001 ENGINES 5.4L V8 - VIN M, Z & 3 ENGINE IDENTIFICATION Engine is identified by eighth character of Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certi
  • Page 112PROCEDURES article in GENERAL INFORMATION before disconnecting battery. 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. FUEL PRESSURE RELEASE & FUEL LINE CONNECTI
  • Page 113Fig. 1: Disconnecting Fuel Lines Courtesy of FORD MOTOR CO. ENGINE WARNING: Shut off air suspension system prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, w
  • Page 114Installation 1. To install, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . 2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace
  • Page 115plug wires. Remove accessory drive belt. Remove generator. 4. Remove throttle body. Remove heater return tube. Remove thermostat. Remove intake manifold retaining bolts in reverse order of tightening sequence. See Fig. 2 . Lift intake manifold assembly, disconnect manifold turning valve and remove i
  • Page 116Fig. 2: Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD WARNING: Shut off air suspension system prior to hoisting, jacking or towing an air
  • Page 117suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing. Removal Raise and support vehicle. Remove front fender splash shield. Remove wheel opening molding on
  • Page 118Fig. 3: Exhaust Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CYLINDER HEAD Removal 1. On 1998 models, disconnect negative battery cable(s). Remove intake manifold. See INTAKE MANIFOLD . On 1999 and newer models, remove the engine. See ENGINE . 2. On all models, remove exhaust manifol
  • Page 119TIMING CHAINS . 3. On 1998 models, disconnect heater hoses. On 1998 Pickups, remove heater pipe-to-engine mounting studs. Remove heater pipe and discard "O" ring. On all models, remove cylinder head bolts in reverse order of tightening sequence. See Fig. 4 . Remove cylinder head and gasket. Inspecti
  • Page 120Fig. 4: Cylinder Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. VALVE COVERS
  • Page 121Removal (Pickup - Left) 1. Disconnect negative battery cable(s). Remove air cleaner. Unbolt power steering reservoir bracket, and position reservoir and bracket assembly aside. 2. Disconnect PCV hose from valve cover. Disconnect control cables from throttle body. Unbolt throttle body control cable b
  • Page 122Fig. 5: Valve Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT CRANKSHAFT SEAL WARNING: Shut off air suspension system prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or
  • Page 123WARNING: Shut off air suspension system prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing. Removal 1. Discon
  • Page 124Fig. 6: Front Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. TIMING CHAINS Removal 1. Remove front cover. See FRONT COVER . Remove crankshaft position sensor pulse wheel from crankshaft. Using crankshaft positioner, position crankshaft as shown in illustration. See Fig. 7 . Install camsha
  • Page 125Remove 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. Inspection Inspect components for damage. Inspect friction surfaces on tensioner arms and chain
  • Page 126Fig. 7: Installation Of Crankshaft Positioner Courtesy of FORD MOTOR CO.
  • Page 127Fig. 8: Securing Timing Chain Tensioner Plunger Courtesy of FORD MOTOR CO. Fig. 9: Marking Timing Chain Links Courtesy of FORD MOTOR CO.
  • Page 128Fig. 10: View Of Timing Chain & Components Courtesy of FORD MOTOR CO.
  • Page 129Fig. 11: Identifying Crankshaft Sprocket & Timing Chain Timing Marks Courtesy of FORD MOTOR CO. CAMSHAFT FOLLOWER & LASH ADJUSTER Removal 1. Remove valve covers. See VALVE COVERS . Rotate crankshaft until piston in cylinder to be serviced is at bottom of its stroke, and camshaft lobe is at base circ
  • Page 130CAMSHAFT CAUTION: DO NOT remove camshaft before removing camshaft followers. Camshaft will bend and be damaged from side loading. CAUTION: DO NOT rotate engine at any time when cylinder heads are installed and timing chains are removed. Severe piston and valve damage will occur. Removal Remove camsh
  • Page 131Fig. 12: Camshaft Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CRANKSHAFT REAR OIL SEAL
  • Page 132Removal 1. Disconnect negative battery cable(s). Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in AUTOMATIC TRANSMISSIONS. Remove flywheel/flexplate. 2. Using rear crankshaft slinger remover and slide hammer, remove crankshaft oil slinger. Using rear crankshaft sea
  • Page 133Fig. 13: Exploded View of Supercharger and Intake Manifold (Lightning Only) Courtesy of FORD MOTOR CO. THERMOSTAT Removal 1. Partially drain the cooling system. Disconnect the upper radiator hose. Remove the 2 thermostat housing bolts. Remove the thermostat housing. See Fig. 14 . 2. Remove the therm
  • Page 134housing and the bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . 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 read
  • Page 135Fig. 15: Removing/Installing Thermostat Courtesy of FORD MOTOR CO. WATER PUMP Removal & Installation 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, re
  • Page 1362. Remove the throttle cable bracket bolts and position the bracket and cables aside. Disconnect the vapor management valve hose. Remove the crankcase ventilation tube and the Idle Air Control (IAC) valve fresh air tube. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum line and the main v
  • Page 137Fig. 16: Removing & Installing Throttle & Speed Control Cables (Expedition & F150) Courtesy of FORD MOTOR CO.
  • Page 138Fig. 17: Disconnecting & Connecting Throttle Position Sensor & EGR Vacuum Regulator Solenoid Courtesy of FORD MOTOR CO.
  • Page 139Fig. 18: Locating Evaporative Emission Canister Purge Solenoid Courtesy of FORD MOTOR CO.
  • Page 140Fig. 19: Locating Brake Booster Vacuum Tube Bracket Bolt Courtesy of FORD MOTOR CO.
  • Page 141Fig. 20: Locating Differential Pressure Feedback Sensor Courtesy of FORD MOTOR CO.
  • Page 142Fig. 21: Removing & Installing Differential Feedback Sensor Bracket Nut Courtesy of FORD MOTOR CO.
  • Page 143Fig. 22: Removing & Installing EGR Tube Courtesy of FORD MOTOR CO.
  • Page 144Fig. 23: Removing & Installing Throttle Body Adapter Plate Courtesy of FORD MOTOR CO.
  • Page 145Fig. 24: Removing & Installing Fan Shroud Courtesy of FORD MOTOR CO.
  • Page 146Fig. 25: Removing & Installing Engine Lift Bracket Courtesy of FORD MOTOR CO.
  • Page 147Fig. 26: Identifying Heavy Duty Engine Support Courtesy of FORD MOTOR CO.
  • Page 148Fig. 27: Removing & Installing Starter Solenoid Wires Courtesy of FORD MOTOR CO.
  • Page 149Fig. 28: Removing & Installing Starter Ground Cable Nut Courtesy of FORD MOTOR CO. Installation CAUTION: DO NOT use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic sc
  • Page 150CAUTION: Ensure the "O" ring is in place and not damaged. A missing or damaged "O" ring can cause foam in the lubrication system, low oil pressure, and severe engine damage. Install a NEW "O" ring and lubricate with clean engine oil. Position the oil pump screen and pickup tube. Install oil pump scr
  • Page 151and the bolts. See Fig. 16 . 14. Connect the throttle cable, speed control actuator cable and throttle return spring. See Fig. 16 . Install the generator. See appropriate article in STARTING & CHARGING SYSTEMS. Install the radiator air deflector. Fill the engine to proper level with appropriate engi
  • Page 152Fig. 29: Oil Pan Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 153Fig. 30: View Of Torque Angles Courtesy of FORD MOTOR CO. Removal (Pickup - 4WD) 1. Turn the air suspension switch off. Air suspension switch is located behind right kick panel. Raise and support the vehicle on a hoist. On vehicles equipped with the Dual Overhead Camshaft (DOHC), remove the front ax
  • Page 154to the axle solenoid may become disconnected or damaged. On vehicles equipped with a Single Overhead Camshaft (SOHC), support the front axle housing with a jack stand and remove the front axle mount bolt and axle support bolts. See Fig. 31 . Remove the front axle support from vehicle. Remove the rig
  • Page 155Fig. 32: Removing & Installing Front Axle Housing Mount Bolts Courtesy of FORD MOTOR CO. Installation NOTE: If the oil pan and the oil pan gasket are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner (F4AZ-19A536-RA). Allow to dry until
  • Page 156z Stage 3: Tighten an additional 60 degrees. See Fig. 30 . 3. On vehicles equipped with the Dual Overhead Camshaft (DOHC), install the front axle assembly. See appropriate article in DRIVE AXLES. On vehicles equipped with a Single Overhead Camshaft (SOHC), position the front axle housing and loosely
  • Page 157Fig. 33: Identifying Front & Rear Sealing Points Courtesy of FORD MOTOR CO. Removal (Van)
  • Page 1581. 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 moto
  • Page 1592. Valve guides may also be replaced with a NEW 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
  • Page 160Piston 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
  • Page 161See Fig. 34 . Side adjusting screws have left-hand threads. Tighten side bolts. Fig. 34: Main Bearing Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. Cylinder Block 1. Using a feeler gauge and straightedge, inspect cylinder block deck for warpage. If not within
  • Page 162specification, resurface or replace cylinder block. See CYLINDER BLOCK 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 .50" (12.7 mm)
  • Page 163TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Connecting Rod Bolt (1) Step 1 30-33 (41-45) Step 2 Additional 90-120 Degrees Crankshaft Damper Bolt Step 1 66 (89) Step 2 Loosen 360 Degrees Step 3 35-39 (47-53) Step 4 Additional 85-90 Degrees Cylinder Head Bolt (1)(2) Van Step
  • Page 164Step 1 27-32 (37-43) Step 2 Additional 85-95 Degrees Main Bearing Cap Side Bolt (5) Step 1 20-24 (27-33) Step 2 Additional 85-95 Degrees Oil Pan Bolt (6) Step 1 (7) Step 2 15 (20) Step 3 Additional 60 Degrees Starter Bolts 15-20 (20-27) Supercharger Pulley Adapter Bolt 35 (48) Thermostat Housing Bol
  • Page 165(3) Tighten bolts in sequence. See Fig. 3 . (4) Tighten bolts in sequence. See Fig. 6 . (5) Tighten bolts in sequence. See Fig. 34 . (6) Tighten bolts in sequence. See Fig. 29 . (7) Tighten bolts to 18 INCH lbs. (2 N.m) (8) Tighten bolts in sequence. See Fig. 12 . (9) Tighten bolts to 19 ft. lbs. (2
  • Page 166Pickup .0008-.0018 (.020-.045) Lightning -.0002-.0100 (-.005-.025) Diameter Code 1 (1) Code 2 3.5502-3.5506 (90.175-90.185) Code 3 (1) Pins Diameter Van .8662-.8663 (22.003-22.005) Pickup .8658-8659 (21.9915-21.9935) Lightning .8661-.8662 (22.0005-22.0030) Pin-To-Piston Clearance Lightning .0002-.00
  • Page 167Center-To-Center Length 6.657 (169.10) Maximum Bend (1) .0015 (.038) Maximum Twist (1) .0020 (.050) Side Play Standard .0049-.0187 (.125-.475) Service Limit .019 (.48) (1) Measured from bore-to-bore. CYLINDER HEAD Application Specification Maximum Warpage (1) .004" (.10 mm) Intake & Exhaust Valve Se
  • Page 168Lobe Lift Intake Van .259 (6.58) Pickup .280 (7.11) Exhaust Van .259 (6.58) Pickup .295 (7.50) Oil Clearance .001-.003 (.03-.08) CYLINDER BLOCK Application In. (mm) Cylinder Bore Standard Diameter Grade 1 3.5512-3.5516 (90.200-90.210) Grade 2 3.5516-3.5520 (90.210-90.220) Grade 3 3.5520-3.5524 (90.2
  • Page 169Van 1.976" (50.20 mm) Pickup 2.101" (53.37 mm) Out-Of-Square Van & Lightning 2.0° Pickup 2.5° Lbs. @ In. (kg @ mm) Pressure Valve Closed 65 @ 1.57 (29.5 @ 40.0) Valve Open 150 @ 1.10 (68.0 @ 28.0)
  • Page 1702000-01 ENGINES 6.8L V10 - VIN S ENGINE IDENTIFICATION NOTE: This article also applies to Cab & Chassis. Engine is identified by eighth character of Vehicle Identification Number (VIN). VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Ce
  • Page 171assemblies before removal. FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS WARNING: Fuel system is under pressure. Release pressure before servicing fuel system components. 1. Remove fuel cap to release fuel tank pressure. Connect EFI Pressure Gauge (T80L-9974-B) to relief valve on right rear corner o
  • Page 172Removal (Excursion & F250-F550 Super Duty) 1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS . 2. Disconnect necessary harness and grou
  • Page 1733. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and charge A/C system. INTAKE MANIFOLD Removal (Excursion & F250-F550 Super Duty) 1. Disconnect negative battery cable. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .
  • Page 174Fig. 2: Upper Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO.
  • Page 175Fig. 3: Lower Intake Manifold Bolt Tightening Sequence Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD Removal Raise and support vehicle. Remove front fender splash shield. If removing left exhaust manifold, remove EGR
  • Page 176manifold 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. See Fig. 4 . Remove exhaust manifold and gasket. Installation To install, reverse removal procedure. Tighten exhaus
  • Page 177Removal 1. Disconnect negative battery cable(s). Remove intake manifold. See INTAKE MANIFOLD . Remove exhaust manifold. See EXHAUST MANIFOLD . Remove timing chains. See TIMING CHAINS . Disconnect heater hoses. 2. Remove cylinder head bolts in reverse order of tightening sequence. See Fig. 5 . Remove
  • Page 178Removal (Excursion & F250-F550 Super Duty) Disconnect negative battery cable. Remove air cleaner and outlet tube. Disconnect PCV hose. Disconnect fuel injector electrical connectors. On left side, disconnect fuel pressure regulator vacuum hose and lift fuel charging wiring off valve cover studs. On
  • Page 179Fig. 6: Valve Cover Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT CRANKSHAFT OIL SEAL Removal 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 cranksh
  • Page 180FRONT COVER Removal 1. Disconnect negative battery cable(s). Remove valve covers. See VALVE COVERS . Remove radiator. Remove water pump. See WATER PUMP . Raise and support vehicle. Remove power steering pump retaining bolts, and position aside. Disconnect crankshaft and camshaft position sensor harn
  • Page 181NOTE: Two balance shafts are used, one per head. Removal 1. Remove front cover. See FRONT COVER . Remove balance shaft bearing caps and remove balance shafts. See BALANCE SHAFT . Remove crankshaft position sensor pulse wheel from crankshaft. Ensure crankshaft keyway is at 12 o'clock position. Using
  • Page 182Fig. 8: Installation Of Crankshaft Positioner Courtesy of FORD MOTOR CO.
  • Page 183Fig. 9: Securing Timing Chain Tensioner Plunger Courtesy of FORD MOTOR CO. Fig. 10: Marking Timing Chain Links Courtesy of FORD MOTOR CO.
  • Page 184Fig. 11: View Of Timing Chain & Components Courtesy of FORD MOTOR CO.
  • Page 185Fig. 12: Identifying Crankshaft Sprocket & Timing Chain Timing Marks Courtesy of FORD MOTOR CO. Fig. 13: Identifying Balance Shaft Timing Marks
  • Page 186Courtesy of FORD MOTOR CO. CAMSHAFT FOLLOWER & LASH ADJUSTER Removal 1. Remove intake manifold. See INTAKE MANIFOLD . Remove valve covers. See VALVE COVERS . 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 Sp
  • Page 187within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Installation 1. Coat components with engine oil, and install components. Install and finger tighten all bolts for camshaft caps. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. See Fig. 14 . CAUTION: Ensure proper proced
  • Page 188Fig. 14: Camshaft Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. BALANCE SHAFT Removal 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. See Fig. 15 . Remove balance shaft.
  • Page 189Inspection Measure balance bore I.D. and journal O.D. to determine oil clearance. Replace balance shaft if measurements are not within specification. See BALANCE SHAFT table under ENGINE SPECIFICATIONS. Installation Coat components with engine oil, and install components. Install all bolts for balan
  • Page 190Removal 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 S
  • Page 191Removal (F350 Econoline Van) 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 upp
  • Page 192Check 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 O
  • Page 193manufacturing and cannot be serviced or interchanged. Mark connecting rod and cap for reassembly reference. DO NOT attempt to repair connecting rods. Replace connecting rod if out of specification. Install NEW connecting rod bolts. DO NOT reuse bolts. Piston & Rod Assembly Note direction of connecti
  • Page 194NOTE: When checking bearing clearances using Plastigage, side bolts and side adjusting screws do not need to be installed. Fig. 17: Connecting Rod Bearing Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. Crankshaft & Main Bearings 1. Measure main bearing clearances using Plastigage. Main bear
  • Page 1952. Install main bearing inserts in cylinder block. Lay crankshaft into cylinder block. Push crankshaft rearward. Roll rear lower thrust washer into back of No. 6 main boss. Push crankshaft forward and install front lower thrust washer. Install upper thrust washer to back side of No. 6 bearing cap. O
  • Page 196Fig. 18: Main Bearing Cap Bolt Tightening Sequence Courtesy of FORD MOTOR CO. CAUTION: Before boring cylinder block, install main bearing caps and tighten bolts
  • Page 197to specification. See TORQUE SPECIFICATIONS . This prevents main bearing bores from being distorted when cylinder block is bored. 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 CY
  • Page 198TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Connecting Rod Bolt (2000) (1) Step 1 29-33 (39-45) Step 2 Additional 90-120 Degrees Connecting Rod Bolt (2001) (1) Step 1 32 (43) Step 2 Additional 90-120 Degrees Crankshaft Damper Bolt Step 1 66 (90) Step 2 Loosen 360 Degrees S
  • Page 199Idler Pulley Bolt 15-22 (20-30) Main Bearing Cap Bolts 1-12 (2000) (1)(5) Step 1 22-32 (34-43) Step 2 Additional 85-95 Degrees Main Bearing Cap Bolts 1-12 (2001) (1)(5) Step 1 30 (40) Step 2 Additional 85 Degrees Main Bearing Cap Side Bolts 13-24 (2000) (5) Step 1 20-24 (26-33) Step 2 Additional 85-
  • Page 200Lower Step 1 2 (18) Step 2 71-106 (8-12) Upper Step 1 2 (18) Step 2 (9) Oil Pump-To-Cylinder Block Bolt 2000 71-106 (8-12) 2001 89 (10) Valve Cover Bolts 89 (10) (1) Use new bolts. DO NOT reuse bolts. (2) Tighten bolts in sequence. See Fig. 5 . (3) Tighten bolts in sequence. See Fig. 4 . (4) Tighten
  • Page 201Oil Clearance .0009-.0019 (.024-.048) Connecting Rod Bearings Journal Diameter 2.0859-2.0867 (52.983-53.003) Journal Out-Of-Round .0003 (.008) Journal Taper .0002 (.004) Oil Clearance .0010-.0025 (.025-.064) CONNECTING RODS Application In. (mm) Bore Diameter Piston Pin Bore .8666-.8671 (22.012-22.02
  • Page 202Side Clearance (1) No. 3 (Oil) End Gap (Steel Rail) .006-.026 (.15-.66) Side Clearance (1) (1) Information is unavailable from manufacturer. CYLINDER BLOCK Application In. (mm) Cylinder Bore Standard Diameter Grade 1 3.5512-3.5516 (90.200-90.210) Grade 2 3.5516-3.5520 (90.210-90.220) Grade 3 3.5520-
  • Page 203Pressure Valve Closed 65 @ 1.57" (29.5 @ 40.0 mm) Valve Open 150 @ 1.10" (68.0 @ 28.0 mm) (1) Information not available from manufacturer. CYLINDER HEAD Application Specification Maximum Warpage (1) .004" (.10 mm) Intake & Exhaust Valve Seats Seat Angle 44.5-45.0° Seat Width .075-.083" (1.90-2.10 mm
  • Page 2042000-01 ENGINES 7.3L V8 Turbo Diesel ENGINE IDENTIFICATION NOTE: This article also applies to Cab & Chassis. The Power Stroke 7.3L diesel engine may be identified by eighth character of Vehicle Identification Number (VIN). VIN is stamped on a metal tab located near lower left corner of windshield. V
  • Page 205CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. COOLING SYSTEM BLEEDING
  • Page 206CAUTION: Use only specified type "O" rings on fuel lines, as they are made of special material. Use of improper type "O" rings may result in a fuel leak. 2. Ensure fuel lines and spring lock coupling are clean. Replace any missing or damaged "O" rings. Lubricate "O" rings and inside of female fittin
  • Page 207Fig. 1: Identifying, Removing & Installing Spring Lock Coupling Courtesy of FORD MOTOR CO.
  • Page 208Fig. 2: Identifying, Removing & Installing Push Lock Coupling Courtesy of FORD MOTOR CO. ENGINE Removal (Excursion & F250-F550 Super Duty) 1. Disconnect negative battery cables. On M/T models, remove transmission. See appropriate CLUTCHES article in TRANSMISSIONS. On all models, remove air inlet duc
  • Page 2093. Using Fan Clutch Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T9T-6312-B), remove fan and fan clutch assembly from water pump. Place fan and fan clutch assembly in fan shroud. 4. Remove fan shroud along with fan and fan clutch assembly. Disconnect remaining coolant hoses from radiator. On A/T
  • Page 2102. On all models, drain cooling system. Remove front bumper, grille, air deflector and gravel deflector. 3. Remove headlight and park light assemblies. Position transmission oil cooler aside. On A/C equipped models, disconnect A/C refrigerant lines from condenser and plug line openings. Remove conde
  • Page 211engine high enough to clear No. 1 crossmember. Pull engine forward and remove engine. Installation 1. To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Use NEW torque converter-to-flexplate nuts when installing transmission. Fill transmission wit
  • Page 212Fig. 3: Locating Fuel System Components Courtesy of FORD MOTOR CO. FUEL HEATER Removal & Installation
  • Page 2131. Fuel heater is located inside fuel filter/water separator housing, just below fuel filter/water separator filter. Remove fuel filter/water separator filter from fuel filter/water separator housing. See FUEL FILTER/WATER SEPARATOR . 2. Remove 2 attaching screws and remove filter heater thermostat
  • Page 214Fig. 4: Locating Oil Rail Drain Plug & Fuel Injector Retaining Bolt Courtesy of FORD MOTOR CO.
  • Page 215Fig. 5: Locating Oil Deflector, Oil Deflector Retaining Bolt Fuel Injector Shoulder Bolt & Rocker Arm Bolts Courtesy of FORD MOTOR CO. 4. Using Fuel Injector Remover (T94T-9000-AH1), remove fuel injector from cylinder head. See Fig. 6 . Ensure all cushion rings, seals and copper washer are still on
  • Page 216Fig. 6: Removing & Installing Fuel Injector Courtesy of FORD MOTOR CO.
  • Page 217Fig. 7: Locating Back-Up Ring, Cushion Rings, Seals & Copper Washer On Fuel Injector Courtesy of FORD MOTOR CO. Installation 1. If fuel injector sleeves are not being installed, go to step 3) . If installing fuel injector sleeve in cylinder head, use Fuel Injector Sleeve Brush (D94T-9000-D) and clea
  • Page 218Fig. 8: Applying Sealant On Fuel Injector Sleeve Courtesy of FORD MOTOR CO. CAUTION: Two different fuel injectors may be available, a 49 state fuel injector and a California fuel injector. These fuel injectors must not be interchanged, as Powertrain Control Module (PCM) is calibrated for specified f
  • Page 219CAUTION: DO NOT tap on top of fuel injector to seat fuel injector in fuel injector sleeve or fuel injector will be damaged. Ensure copper washer does not fall from fuel injector during fuel injector installation. 5. Lubricate fuel injector, back-up ring, cushion rings and seals with clean engine oil
  • Page 220Fig. 9: High-Pressure Oiling System Courtesy of FORD MOTOR CO. Removal 1. On Van, remove air cleaner housing and air inlet duct. Remove accessory drive belt and belt idler pulley, if required. 2. On all models, loosen clamps and remove compressor manifold from turbocharger for access to high- pressu
  • Page 221TORQUE SPECIFICATIONS . CAUTION: High-pressure oil pump drive gear must be fully seated on shaft of high-pressure oil pump before installing high-pressure oil pump drive gear bolt and washer. End of shaft should be even with front edge of high-pressure oil pump drive gear. 2. Ensure high-pressure oi
  • Page 222front cover are clean. Install NEW gasket on front cover and apply RTV sealant on front cover before installing high-pressure oil pump reservoir. 2. Ensure high-pressure oil pump reservoir is filled with clean engine oil. Ensure seal is properly seated when installing compressor manifold on turbocha
  • Page 223Installation 1. Ensure right rear turbocharger pedestal assembly-to-cylinder block bolt is installed before installing turbocharger on cylinder block. To install, reverse removal procedure using NEW "O" rings. Ensure seal is properly seated when installing compressor manifold on turbocharger. 2. Ens
  • Page 2241. Disconnect negative battery cables. Remove interior engine cover. When removing passenger-side exhaust manifold, remove air cleaner assembly. Remove oil level indicator tube and retaining nut. 2. Raise and support vehicle. Remove exhaust inlet pipe-to-exhaust manifold bolt/nuts. Exhaust inlet pip
  • Page 225Fig. 11: Removing & Installing Air Cleaner Outlet Tube Courtesy of FORD MOTOR CO.
  • Page 226Fig. 12: Disconnecting & Connecting Fuel Injector/Glow Plug Wire Harness Connector Courtesy of FORD MOTOR CO.
  • Page 227Fig. 13: Locating Engine Control Sensor & Lower Generator Electrical Connectors Courtesy of FORD MOTOR CO.
  • Page 228Fig. 14: Removing & Installing Breather Assembly Courtesy of FORD MOTOR CO.
  • Page 229Fig. 15: Disconnecting & Connecting Glow Plug Harness Connector Courtesy of FORD MOTOR CO.
  • Page 230Fig. 16: Disconnecting & Connecting Fuel Injector Harness Connector Courtesy of FORD MOTOR CO. Removal & Installation (Right Side - Excursion & "F" Series) 1. Disconnect negative battery cable. If vehicle is equipped with dual batteries, disconnect both negative battery cables. Disconnect the Manifo
  • Page 2315. To install, reverse the removal procedure. Install NEW valve cover gasket. Install positive and negative battery cables to battery. Tighten valve cover bolts and battery cable terminals to specification. See TORQUE SPECIFICATIONS . Fig. 17: Locating Manifold Absolute Pressure Sensor (Excursion &
  • Page 232Fig. 18: Removing Air Charge Cooler Inlet Tube (Excursion & "F" Series) Courtesy of FORD MOTOR CO.
  • Page 233Fig. 19: Removing & Installing Heater Hoses (Excursion & "F" Series) Courtesy of FORD MOTOR CO.
  • Page 234Fig. 20: Removing & Installing Heater Hose Stand-Offs (Excursion & "F" Series) Courtesy of FORD MOTOR CO.
  • Page 235Fig. 21: Removing & Installing Wiring Harness (Excursion & "F" Series) Courtesy of FORD MOTOR CO.
  • Page 236Fig. 22: Removing & Installing Oil Level Indicator Tube (Excursion & "F" Series) Courtesy of FORD MOTOR CO. Removal & Installation (Left Side - "E" Series) 1. Disconnect negative battery cable. If vehicle is equipped with dual batteries, disconnect both negative battery cables. Remove the air cleane
  • Page 2377. To install, reverse the removal procedure. Install NEW valve cover gasket. Tighten valve cover bolts and both negative battery cable terminals to specification. See TORQUE SPECIFICATIONS . Fig. 23: Removing & Installing Vacuum Line At Oil Filler Tube (E550) Courtesy of FORD MOTOR CO.
  • Page 238Fig. 24: Removing & Installing Inlet Duct ("E" Series) Courtesy of FORD MOTOR CO. Removal & Installation (Right Side - "E" Series) 1. Disconnect negative battery cable. If vehicle is equipped with dual batteries, disconnect both negative battery cables. Remove the engine cover.
  • Page 2392. Remove the air cleaner assembly. See Fig. 25 . Loosen the clamp, and disconnect the air inlet tube from the resonator. See Fig. 26 . Remove the 3 nuts and the turbocharger heat shield. 3. Remove the resonator retaining bolt and the resonator from the vehicle. See Fig. 27 . Remove the resonator br
  • Page 240Fig. 26: Locating Air Inlet Tube Clamp Courtesy of FORD MOTOR CO.
  • Page 241Fig. 27: Locating Resonator Retaining Bolt Courtesy of FORD MOTOR CO. CYLINDER HEAD WARNING: When servicing cylinder head, use care when working with engine wiring harness for fuel injectors, as Injector Driver Module (IDM) supplies 115 volts DC to each fuel injector on engine wiring harness. DO NOT
  • Page 242engine ground cable. Remove generator mounting bracket and generator as an assembly. Remove A/T oil dipstick and dipstick tube. Remove screws from Manifold Absolute Pressure (MAP) sensor, and position sensor aside. 5. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling e
  • Page 243engine damage caused by hydrostatic lock. Installation 1. Ensure fuel and oil are removed from cylinders before installing cylinder head. To install, reverse removal procedure using NEW cylinder head gasket. Lightly coat threads of cylinder head bolts with engine oil before installing. CAUTION: DO N
  • Page 244Fig. 28: Cylinder Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. Removal (Van) 1. Disconnect negative battery cables. Remove interior engine cover. Remove air cleaner assembly. Remove headlight and park light assemblies. CAUTION: Fan clutch assembly uses right-hand threads to hold assembly
  • Page 245pump. Place fan and fan clutch assembly in fan shroud. 3. Remove fan shroud along with fan and fan clutch assembly. Disconnect transmission oil cooler lines and coolant hoses from radiator. Remove radiator. 4. On A/C equipped models, discharge A/C system using approved refrigerant recovery/recycling
  • Page 246Installation 1. Ensure fuel and oil are removed from cylinders before installing cylinder head. To install, reverse removal procedure using NEW cylinder head gasket. Lightly coat threads of cylinder head bolts with engine oil before installing. CAUTION: DO NOT apply excessive amount of engine oil on
  • Page 247NOT scratch sealing surfaces on crankshaft and front cover. CAUTION: DO NOT clean vibration damper in petroleum based solvent or rubber dampening element in vibration damper will be damaged. Installation 1. Ensure all sealing surfaces are clean. Coat outside sealing surface of seal with multipurpose
  • Page 2483. Disconnect engine wiring harness wires from fuel injectors and glow plugs. DO NOT pierce any wires in engine wiring harness. Remove valve cover gasket from cylinder head. 4. Remove rocker arm assembly bolts. See Fig. 5 . Remove rocker arm assembly. Note direction of push rod installation, as Copp
  • Page 249Fig. 29: Identifying Rocker Arm Assembly Components Courtesy of FORD MOTOR CO. Removal (Van)
  • Page 2501. Disconnect negative battery cables. Remove air cleaner assembly. Remove interior engine cover. When servicing rocker arm and push rod on passenger-side cylinder head, remove oil dipstick tube mounting bracket. Remove remaining components for access to valve cover. Go to step 3) . 2. When servicin
  • Page 251to prevent bent valves and engine damage when installing rocker arm assembly. 2. Lubricate ends of push rods with engine oil. Install push rods in original location. Ensure Copper end of push rod is facing upward. Rotate engine until timing mark on vibration damper is at 11 o'clock position. This mu
  • Page 252Fig. 30: Locating Camshaft Follower Guide Courtesy of FORD MOTOR CO. Fig. 31: Exploded View Of Valve Lifter Courtesy of FORD MOTOR CO. FRONT COVER Removal
  • Page 2531. Manufacturer recommends removing engine for servicing front cover. Remove engine. See ENGINE . Remove water pump. See WATER PUMP . Remove vibration damper bolt and washer. Using puller, remove vibration damper. NOTE: If necessary to remove high-pressure oil pump or high-pressure oil pump reservoi
  • Page 254Fig. 33: Applying Sealant On Front Cover Courtesy of FORD MOTOR CO. CAMSHAFT Removal 1. Remove front cover. See FRONT COVER . Using dial indicator, check gear backlash on camshaft gear. Replace camshaft gear if gear backlash exceeds specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. 2. R
  • Page 255specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. 4. Rotate crankshaft so camshaft timing mark and crankshaft timing mark are aligned. See Fig. 34 . Remove camshaft thrust plate bolts. See Fig. 34 . Remove camshaft, camshaft gear and camshaft thrust plate as an assembly. 5. If necessary
  • Page 256Installation 1. If installing camshaft thrust plate and camshaft gear on camshaft, install camshaft thrust plate on camshaft. Ensure key is installed in camshaft and camshaft gear keyway and key are free of burrs. CAUTION: DO NOT heat camshaft gear at more than 500°F (260°C) or camshaft gear will be
  • Page 257CAUTION: Front camshaft bearing must be installed to specified installed depth to prevent damage to engine components. 2. Install front camshaft bearing in cylinder block so front camshaft bearing installed depth is .020- .050" (.51-1.27 mm). Front camshaft bearing installed depth is measured from f
  • Page 258SPECIFICATIONS . Fig. 35: Identifying Dual Mass Flywheel Components (Excursion & F250-F550 Super Duty With M/T) Courtesy of FORD MOTOR CO. CRANKSHAFT REAR OIL SEAL Removal 1. Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSIONS. For M/T, see appr
  • Page 2593. Install and tighten crankshaft rear oil seal retaining bolts. To install remaining components, reverse removal procedure. WATER PUMP Removal 1. Disconnect negative battery cables. Partially drain cooling system. Remove upper radiator hose. Disconnect coolant recovery hose from radiator. CAUTION:
  • Page 260Fig. 36: Removing & Installing Thermostat Housing (Excursion & "F" Series Shown; "E" Series Similar) Courtesy of FORD MOTOR CO. Installation 1. Use a NEW "O" ring seal to position the water thermostat in the upper intake manifold. 2. Install the thermostat housing. See Fig. 36 . Install the thermost
  • Page 261tube and gasket. Installation 1. Using NEW gasket, install oil pump pick-up tube if removed. Install and tighten oil pump pick-up tube- to-front cover bolts and oil pump pick-up tube support bracket nut at top of main bearing cap to specification. See TORQUE SPECIFICATIONS . 2. Apply a 1/8" (3.2 mm)
  • Page 2622. Measure valve spring installed height from bottom of spring seat in cylinder head to bottom of surface of spring retainer. Ensure valve spring installed height is within specification. Valve Stem Oil Seals Valve stem seals are used on intake and exhaust valves. No special installation procedure i
  • Page 26331 . Inspect all components for damage. Ensure plunger moves freely in plunger body. Replace valve lifter if plunger fails to move freely in plunger body or if any components are damaged. Valve lifter must be replace as an assembly. CYLINDER BLOCK ASSEMBLY Piston & Rod Assembly 1. Ensure connecting
  • Page 264NOTE: No. 1 (upper) compression ring contains one identification mark and No. 2 (lower) compression rings contains 2 identification marks. Ensure compression rings are installed in correct location with identification mark toward top of piston. Install piston rings on piston, with identification mar
  • Page 265ASSEMBLY under REMOVAL & INSTALLATION. Crankshaft & Main Bearings 1. Ensure main bearing caps are marked or location and direction of installation before removing from cylinder block. Ensure connecting rod journals, crankshaft main bearing journal diameter, taper and out- of-round are within specifi
  • Page 2663. If compressor wheel or turbine wheel does not contact housing while rotating shaft assembly, bearings in turbocharger are okay. Go to next step. If compressor wheel or turbine wheel contacts housing while rotating shaft assembly, bearings in turbocharger are defective. Replace turbocharger. 4. In
  • Page 267Removal 1. Remove all hose connections attached to fuel filter assembly. Place suitable container at end of drain hose to catch fuel and open filter drain. Remove water drain hose from fuel filter assembly. 2. Remove fuel outlet hose, located between fuel pump and filter housing. Remove fuel return
  • Page 268
  • Page 269Fig. 39: Fuel Filter Assembly Courtesy of FORD MOTOR CO. ENGINE OILING ENGINE LUBRICATION SYSTEM NOTE: Engine contains a high-pressure oiling system and a low-pressure oiling system. High-Pressure Oiling System High-pressure oiling system supplies oil pressure for fuel injector operation. See Fig. 9
  • Page 270Fig. 40: Engine Low-Pressure Engine Oiling System Courtesy of FORD MOTOR CO. Crankcase Capacity Crankcase capacity is 14 qts. (13.2L) with oil filter. Oil Pressure Oil pressure should be 40-70 psi (2.8-4.9 kg/cm 2 ) at 3300 RPM, with engine at normal operating temperature. HIGH-PRESSURE OIL PUMP For
  • Page 271LOW-PRESSURE OIL PUMP Removal & Disassembly 1. Low-pressure oil pump is located on front cover. See Fig. 40 . Remove vibration damper. See CRANKSHAFT FRONT SEAL under REMOVAL & INSTALLATION. 2. Remove bolts, low-pressure oil pump body, outer gerotor and inner gerotor. See Fig. 41 . Inspection 1. Ins
  • Page 272OIL COOLER ASSEMBLY CAUTION: If main bearing or rod bearing failure exists, oil cooler must be replaced. Removal & Disassembly 1. Disconnect negative cables. Drain cooling system. Raise and support vehicle. 2. Disconnect exhaust pipe at turbocharger for access to oil cooler if necessary. Remove oil
  • Page 2732. Lower engine. Install driver-side engine mount. Tighten oil cooler rear header-to-cylinder block bolts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Adjust engine oil level. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING unde
  • Page 274Connecting Rod Cap Nut Stage 1 53 (71) Stage 2 80 (108) Crankshaft Rear Oil Seal Retaining Bolts 20 (15) Crankshaft Vibration Dampener Bolt 212 (258) Cylinder Head Bolt (1) Step 1 65 (88) Step 2 85 (115) Step 3 95 (129) Drive Gear Access Cover Retaining Bolts 20 (27) Engine Mount Nut 71-94 (96-127)
  • Page 275Main Bearing Cap Bolt Step 1 75 (102) Step 2 95 (129) Muffler Assembly Mounting Nuts 37 (50) Number Two Crossmember Mounting Bolts 66 (90) Oil Cooler Front Header-To-Cylinder Block Bolt 18 (25) Oil Cooler Rear Header-To-Cylinder Block Bolt 18 (25) Oil Level Indicator Tube Adaptor Nut 24 (33) Oil Pan
  • Page 276INCH Lbs. (N.m) Battery Cable Battery Post Terminals 62 (7) Breather Assembly Retainers 89 (10) Exhaust Backpressure Control Valve-To-Compressor Housing Bolt 62-80 (7.0-9.0) Fuel Injector Retaining Bolt 108 (12.2) Fuel Injector Shoulder Bolt 124 (14) Oil Deflector Retaining Bolt 124 (14) Oil Rail Dr
  • Page 277Journal Taper .00026 (.0066) Per 1.0 (25 mm) Oil Clearance .0015-.0045 (.038-.114) CONNECTING RODS Application In. (mm) Bore Diameter Pin Bushing Bore 1.3085-1.3088 (33.236-33.244) Crankpin Bore 2.6905-2.6915 (68.339-68.364) Crankpin Bore Maximum Out-Of-Round .0005 (.013) Crankpin Bore Maximum Taper
  • Page 278Cylinder Bore Standard Diameter 4.1096-4.1103 (104.384-104.402) Maximum Taper .0005 (.013) Maximum Out-Of-Round .0005 (.013) Maximum Deck Warpage (1) (1) Warpage should not exceed .0030" (.076 mm) within a 6.0" (152 mm) area or .0060" (.152 mm) overall. Cylinder block may be resurfaced. DO NOT remov
  • Page 279Seat Width .065-.095" (1.65-2.41 mm) Maximum Seat Runout .002" (.05 mm) Exhaust Valve Seat Angle 37.5° Seat Width .065-.095" (1.65-2.41 mm) Maximum Seat Runout .002" (.05 mm) Valve Guides Intake & Exhaust Valve Guide I.D. .3736-.3746" (9.490-9.514 mm) Valve Stem-To-Guide Maximum Oil .0055" (.140 mm)
  • Page 2802000-01 ENGINES 4.2L V6 - VIN 2 ENGINE IDENTIFICATION Engine model may be identified by eighth character of Vehicle Identification Number (VIN). VIN is stamped on a plate located on top of instrument panel, near lower left of windshield. VIN number is also stamped on vehicle certification label, loc
  • Page 281located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve (Schrader valve). 2. If fuel pressure gauge is not available, disconnect electrical connector to Inertia Fuel Shutoff (IFS) switch. IFS switch is located behind passenger-side kick panel
  • Page 282Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS . 2. Remove upper front air deflector. Remove air cleaner outlet tube. Remove radiator. Remove fan blade and fan shroud. Di
  • Page 2835. Disconnect necessary harness and ground connections. Remove accessory drive belt. Disconnect low- pressure hose at power steering pump. Unbolt power steering pump, and position aside. Remove lower radiator hose. Disconnect A/C manifold at compressor, plug openings, and position aside. Disconnect
  • Page 284CAUTION: Intake manifold bolts must be retightened to specification after engine has reached normal operating temperature. 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 replac
  • Page 285Fig. 3: Upper Intake Manifold Bolt Tightening Sequence (Pickup - 2001) Courtesy of FORD MOTOR CO.
  • Page 286Fig. 4: Intake Manifold Spacer Assembly Bolt Tightening Sequence (Van - 2001) Courtesy of FORD MOTOR CO. Fig. 5: Lower Intake Manifold Bolt Tightening Sequence
  • Page 287Courtesy of FORD MOTOR CO. EXHAUST MANIFOLD Removal On left manifold, remove oil dipstick tube. On right manifold, remove EGR manifold tube. On both sides, disconnect oxygen sensor. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold retaining bolts in reverse order. See Fig. 6 .
  • Page 288hoses attached, and position aside. 3. If removing right cylinder head, remove generator. Remove accessory drive belt idler pulley. Remove generator bracket. CAUTION: Mark location of rocker arms and push rod if they are to be reused. Ensure they are installed in their original location. 4. If remov
  • Page 289Fig. 7: Cylinder Head Bolt Tightening Sequence Courtesy of FORD MOTOR CO. FRONT COVER OIL SEAL Removal 1. Disconnect negative battery cable. Remove accessory drive belt. Remove cooling fan and fan shroud. Raise and support vehicle. Mark pulley and damper position. Remove crankshaft pulley. Remove da
  • Page 290WARNING: Air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Air suspension switch is located behind right kick panel. Failure to do so can result in accidental deflation or inflation of air springs, which may cause vehicle to shift during servicing
  • Page 2915. Raise vehicle, disconnect Crankshaft (CKP) sensor harness connector. Position wiring harness aside. 6. Remove power steering support bracket bolts. Remove power steering support bracket nuts and remove the bracket. 7. Remove crankshaft pulley and damper. See FRONT COVER OIL SEAL . 8. Remove front
  • Page 29212) in the first tightening sequence. Tighten fasteners in 3 stages, as follows: z Starting with bolt at about the 6 o'clock position (identified as bolt No. 1), tighten fasteners 1-11 and 13 in sequence to 16 Ft. lbs. (22 N.m). See Fig. 8 . z NOTE: Apply a small amount of loctite(R) to threads of c
  • Page 293NOTE: If sealant (F6AZ-19562-A) is exposed for longer than 7 minutes, wipe off sealant and re-apply. Install front engine cover gasket, apply sealant (F6AZ-19562-A) to base of gasket where oil pan and block come together. Apply a bead of sealant in center of oil pan flange and around bolt holes. App
  • Page 2941. Disconnect negative battery cable. 2. Drain coolant, remove water pump. See WATER PUMP . 3. Raise and support vehicle. Remove crankshaft damper and pulley. See FRONT COVER OIL SEAL . 4. Disconnect Crankshaft Position (CKP) sensor harness connector. 5. Remove front oil pan bolts that intersect wit
  • Page 29512) in the first tightening sequence. Tighten fasteners in 3 stages, as follows: z Starting with bolt at about the 6 o'clock position (identified as bolt No. 1), tighten fasteners 1-11 and 13 in sequence to 16 Ft. lbs. (22 N.m). See Fig. 8 . z NOTE: Apply a small amount of loctite(R) to threads of c
  • Page 296Fig. 8: Front Cover Tightening Sequence Courtesy of FORD MOTOR CO. TIMING CHAINS CAUTION: DO NOT rotate engine with timing chain removed. Damage to valve/piston may result. Removal Remove front cover. See FRONT COVER . Remove camshaft synchronizer. See CAMSHAFT SYNCHRONIZER . Rotate crankshaft until
  • Page 297To install, reverse removal procedure. Ensure all timing marks are properly aligned. See Fig. 9 . Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fig. 9: Identifying Timing Marks Courtesy of FORD MOTOR CO.
  • Page 298Fig. 10: Installing Timing Chain Tensioner Lock Pin Courtesy of FORD MOTOR CO. LIFTER Removal Remove upper and lower intake manifolds. See INTAKE MANIFOLD . Remove valve covers. Mark position of rockers push rods and lifters for installation reference. Remove rockers and push rods. Remove lifter ret
  • Page 299Inspection Measure camshaft bore I.D., journal O.D., oil clearance and lobe lift. Replace camshaft if measurements are not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Installation Coat camshaft bearings, journals and lobes with Engine Assembly Lubrication (D9AZ-19579-D). In
  • Page 300Fig. 11: Aligning Camshaft Synchronizer Courtesy of FORD MOTOR CO. BALANCE SHAFT
  • Page 301Removal Remove timing chain. See TIMING CHAINS . Remove balance shaft drive gear from camshaft. Remove balance shaft thrust plate retaining bolts. Remove balance shaft. Installation To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATION . Ensure all
  • Page 302Removal (4WD Pickup) 1. With transmission in Neutral, raise and support vehicle. Mark front drive shaft and differential flange for installation reference. Disconnect front drive shaft from differential and support drive shaft. Disconnect front halfshafts from differential, and support aside. 2. Dis
  • Page 303Fig. 12: Oil Pan Bolt Tightening Sequence Courtesy of FORD MOTOR CO. OVERHAUL CYLINDER HEAD Cylinder Head 1. Clean head gasket mating surface. Clean carbon from combustion chambers. DO NOT damage surfaces. Check cylinder head for cracks, burrs, nicks and warpage. 2. DO NOT machine more than .010" (.
  • Page 3042. If installed height is not within specification, a spacer can be installed between cylinder head and valve spring to obtain correct height. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not within specification. See VALVES & VALVE SPRINGS tabl
  • Page 305engine. NOTE: Take measurements with components at a stabilized room temperature of about 70°F (21°C). Fitting Pistons Check piston-to-bore clearance. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. If clearance is not within specification, replace pistons and/or block. Oversize pistons
  • Page 306cylinder bore for wear, taper, out-of-round and piston fit. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) of material from original cylinder block head surface. 2. Install all main bearing caps and tighten to specification before honing cylind
  • Page 307Gear Radial Clearance .002-.006 (.05-.15) NOTE: Oil pump is serviced as an assembly only. Replace assembly if measurements are not to specifications. Reassembly & Installation 1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, prime oil
  • Page 308Step 4 (3) Loosen 3 Revolutions Step 5 Short Bolt 2000 15-22 (20-30) 2001 18 (25) Long Bolt 2000 29-37 (40-50) 2001 33 (45) Step 6 2000 Additional 175-185 Degrees 2001 Additional 180 Degrees EGR Valve Tube Fitting Bolt 25-34 (37-47) Engine Mount Through-Bolt 51-67 (69-91) Engine-To-Transmission Bolt
  • Page 309Main Bearing Cap Bolt 2000 Step 1 37 (50) Step 2 Additional 90 Degrees 2001 Step 1 37 (50) Step 2 Additional 120 Degrees Oil Baffle Plate Nuts 2000 30-37 (40-50) 2001 24 (32) Oil Drain Plug 19 (26) Oil Pan-To-Transmission Bolt 33 (45) Oil Pump Inlet Tube 18 (25) Oil Pump Screen Cover 2000 Bolt 14-22
  • Page 310Step 1 44 (5) Step 2 89 (10) 2001 On-Vehicle Step 1 44 (5) Step 2 106 (12) Off-Vehicle Step 1 44 (5) Step 2 89 (10) Upper (10) 2000 Step 1 59 (7) Step 2 66 (8) Step 3 Additional 90 Degrees 2001 Step 1 53 (6) Step 2 89 (10) Oil Pan-To-Cylinder Block (11) Step 1 44 (5) Step 2 89 (10) Timing Pointer 71
  • Page 311TORQUE SPECIFICATIONS (VAN) Application Ft. Lbs. (N.m) A/C Compressor Mounting Bracket Bolts 29-40 (40-55) Nuts 16-21 (21-29) Balance Shaft Thrust Plate Bolt (1) Camshaft Sprocket Bolt 30-36 (41-49) Camshaft Thrust Plate Bolt (1) Connecting Rod Cap Nut (2) Crankshaft Damper Bolt On-Vehicle 118 (160)
  • Page 312On-Vehicle 2001 (6) , (7) Step 1 (Bolts 1-11 & 13) 16 (22) Step 2 (Bolts 12) (8) 7 (10) Step 3 (Bolts 1-11 & 13) Additional 90 Degrees Off-Vehicle (6) , (7) Step 1 (Bolts 1-11 & 13) 16 (22) Step 2 (Bolts 12) (8) 7 (10) Step 3 (Bolts 1-11 & 13) Additional 90 Degrees Front Engine Mounting Bolts/Nuts 5
  • Page 313Step 2 89 (10) Upper Step 1 71 (8) Step 2 Additional 90 Degrees Oil Pan-To-Cylinder Block (11) Step 1 35-44 (4-5) Step 2 80-106 (9-12) Timing Pointer 71-106 (8-12) Valve Cover Bolt On-Vehicle Front Outer Center Nut 71-102 (8-11.5) Rear Outer Center Nut 71-106 (8-12) All Other Bolts and Nuts (Except
  • Page 314Except 2001 Van 9.17:1 2001 Van 9.26:1 Fuel System SFI CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS Application In. (mm) Crankshaft End Play .00003-.0787 (.007-.200) Main Bearings Journal Diameter 2.5190-2.5198 (63.983-64.003) Journal Out-Of-Round .0012 (.030) Journal Taper .0006 (.016) Journal Runout
  • Page 315Length N/A Piston Fit N/A Rod Fit N/A Rings End Gap No. 1 .007-.013 (.17-.33) No. 2 .01-.02 (.3-.55) No. 3 .006-.026 (.15-.65) Side Clearance .0012-.0031 (.030-.080) CYLINDER BLOCK Application In. (mm) Cylinder Bore Standard Diameter 3.81 (96.800) Maximum Taper .002 (.05) Maximum Out-Of-Round .002 (
  • Page 316Application Specification Maximum Warpage (1) .003" (.08 mm) Valve Seats Seat Angle 44.75° Seat Width .06-.08" (1.5-2.0 mm) Maximum Seat Runout .001" (.025 mm) Valve Guides Intake Valve Valve Guide Bore I.D. .3433-.3443" (8.720-8.745 mm) Valve Stem-To-Guide Oil Clearance .0007-.0027" (.020-.069 mm)