How to replace Engine on Ford E series?

Ford E series Vans Engine replacing procedure:----


Engine
REMOVAL & INSTALLATION details are as follows:----

4.6L, 5.4L, & 6.8L Engines

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Properly recover the A/C system.
4. Remove the intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
5. Remove the accessory drive belt, except 6.8L engine. For additional information, refer to the following section, -Accessory Drive Belt, Removal & Installation.-
6. Remove the starter. For additional information, refer to the following section, -Starter, Removal & Installation.-
7. Remove the front bumper.
8. Disconnect the lower radiator hose from the radiator.
9. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
10. Remove the 4 exhaust Y-pipe flange nuts.
11. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished.
12. Disconnect the oil cooler coolant hoses and position aside.
13. Remove and discard the oil filter.
14. Loosen the threaded insert and remove and discard the oil cooler.
15. If equipped, disconnect the block heater electrical connector and two wiring harness retainers.
16. Remove the two bolts and the flexplate inspection cover.
17. Remove the cylinder block opening cover.
18. Rotate the crankshaft to access all of the torque converter nuts. Discard the torque converter nuts.
19. Remove the two transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
20. Remove the right hand lower transmission-to-engine bolt.
21. Remove the four engine support insulator-to-crossmember nuts.
22. Disconnect the power steering reservoir hose and the power steering pressure tube at the power steering pump.
23. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.
24. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
25. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
26. If equipped, remove the 3 bolts and position the A/C compressor aside.
27. Remove the radiator grille support.
28. Disconnect the upper radiator and the degas bottle coolant hoses from the radiator.
29. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan assembly.
30. Disconnect the degas bottle hose and power steering hose retainers from the fan shroud.
31. Remove the fan shroud, fan and fan clutch.
32. Remove the four bolts and the radiator support brackets.
33. Remove the radiator from the vehicle.
34. If equipped, disconnect the A/C pressure cutoff switch electrical connector.
35. If equipped, remove the nut and disconnect the compressor suction tube.
36. If equipped, remove the nuts and disconnect the compressor discharge tube and the condenser-to-evaporator tube from the A/C condenser core.
37. Remove the A/C condenser core.
38. Set the hood latch aside. Remove the 2 hood latch bolts and disengage the cable routing clip.
39. Remove the three bolts and position the power steering reservoir aside.
40. Remove the nut and the battery feed cable at the Power Distribution Box (PDB).
41. Disengage the harness routing clips and position aside the battery feed wiring harness.
42. If equipped, disconnect the air temperature sensor electrical connector.
43. Disconnect the front impact severity sensor electrical connector.
44. Disconnect the horn electrical connector.
45. Disconnect the transmission fluid cooler hose retainers.
46. Remove the bolt and position the transmission fluid cooler aside.
47. Remove the pin-type retainers and the right hand and left hand air deflectors.
48. Remove the four bolts and the two upper radiator support plates.
49. Remove the eight bolts and the upper radiator support.
50. Remove the bolt and disconnect the 2 headlamp wiring harness retainers.
51. Disconnect the 4 wiring harness retainers and position the wiring harness aside.
52. Remove the 12 bolts and the lower radiator support.
53. Disconnect the lower radiator coolant hose and position aside.
54. Remove the 3 bolts and the power steering pump.
55. Disconnect the alternator electrical connections.
56. Remove the 2 bolts and the generator.
57. Disconnect the quick connect coupling and remove the crankcase ventilation tube.
58. Disconnect the electrical connector.
59. Disconnect the engine wiring harness retainer and the two PCM electrical connectors.
60. Disconnect the 2 generator wiring harness retainers and position the wiring harness aside.
61. Disconnect the electrical connector, electrical connector retainer and remove the nut, ground strap and mounting bracket.
62. Remove the engine oil filler tube support strap bolt.
63. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube.
64. Disconnect the oil fill tube from the right hand valve cover.
65. Disconnect the coolant hose from the heater outlet tube and remove the heater outlet tube stud, 4.6L engines only.
66. Disconnect the Knock Sensor (KS) electrical connector and engine wiring harness retainers, 5.4L engine only.
67. Disconnect the coolant hose from the heater outlet tube, 5.4L engine only.
68. Remove the 2 heater outlet tube studs, 5.4L engine only.
69. Remove the heater outlet tube and discard the O-ring seals.
70. Remove the bolt and the ground strap and disconnect the right hand HO2S electrical connector and retainer.
71. Disconnect the transmission wiring harness retainers from the engine wiring harness.
72. Disconnect the left hand HO2S sensor electrical wiring harness retainer from the rear of the left hand cylinder head.
73. Disconnect the transmission wiring harness retainer and position the transmission wiring harness aside.
74. Disconnect the left hand HO2S sensor electrical connector and retainer.
75. Remove the 4 upper transmission-to-engine bolts and position the fuel tube support bracket aside.
76. Install the Engine Lifting Bracket.
77. Support the transmission with a jack.
78. Using a suitable floor crane, remove the engine assembly from the vehicle.

To install:

1. Position the engine assembly into the vehicle.
2. Remove the floor jack and supporting the transmission.
3. Position the shifter cable support bracket and tighten the two transmission-to-engine bolts to 44 ft. lbs. (60 Nm).
4. Install the right hand lower transmission-to-engine bolt and tighten to 44 ft. lbs. (60 Nm).
5. Install the four engine support insulator-to-support insulator bracket nuts and tighten to 66 ft. lbs. (90 Nm).
6. Position the shift cable mounting bracket, tighten the two bolts to 18 ft. lbs. (25 Nm) and connect the shift cable.
7. Install four new torque converter nuts and tighten to 26 ft. lbs. (35 Nm).
8. Install the cylinder block opening cover.
9. Position the flexplate inspection cover and tighten the two bolts to 25 ft. lbs. (34 Nm).
10. If equipped, install the A/C compressor and tighten the three bolts to 18 ft. lbs. (25 Nm).
11. Connect the A/C compressor electrical connector and the wiring harness retainer.
12. Connect the Crankshaft Position (CKP) sensor electrical connector.
13. Position the exhaust Y-pipe and tighten the four nuts to 30 ft. lbs. (40 Nm).
14. Position a new oil cooler on the oil filter adapter and install the threaded insert. Tighten to 43 ft. lbs. (58 Nm).
    
    WARNING

    The oil cooler must be replaced or severe damage to the engine can occur.
    
    
    
    NOTE

    Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
15. Install a new oil filter
16. Connect the two oil cooler coolant hoses.
17. Position the power steering pump and tighten the three bolts to 18 ft. lbs. (25 Nm).
18. Using the Teflon Seal Installer Set, install a new Teflon® seal on the power steering pressure tube.
19. Connect the Power Steering Pressure (PSP) tube and the power steering reservoir hose to the power steering pump and tighten to 15 ft. lbs. (20 Nm).
20. Connect the lower radiator coolant hose to the oil filter adapter coolant inlet.
21. Position the fuel tube support bracket and tighten the four upper transmission-to-engine bolts to 44 ft. lbs. (60 Nm).
22. Position the ground strap, install the bolt and connect the right hand HO2S electrical connector and retainer.
23. Connect the left hand Heated Oxygen Sensor (HO2S) sensor electrical connector and retainer.
24. Position the transmission wiring harness and connect the transmission wiring harness retainer.
25. Connect the left hand HO2S sensor electrical wiring harness retainer to the rear of the left hand cylinder head.
26. Connect the transmission wiring harness retainers to the engine wiring harness.
27. Insert the heater outlet tube over the new seals.
    
    NOTE

    Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.
28. Connect the coolant hose to the heater outlet tube and tighten the heater outlet tube stud to 18 ft. lbs. (25 Nm), 4.6L engines only.
29. Tighten the two heater outlet tube studs to 30 ft. lbs. (40 Nm), 5.4L engine only.
30. Connect the coolant hose to the heater outlet tube, 5.4L engine only.
31. Connect the KS electrical connector and engine wiring harness retainers, 5.4L engine only.
32. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut.
33. Connect the oil fill tube to the right hand valve cover.
34. Install the engine oil filler tube support strap bolt.
35. Position the engine wiring harness support bracket, install the ground strap and nut, and connect the electrical connector to the bracket and tighten to 18 ft. lbs. (25 Nm).
36. Position the generator wiring harness and connect the two generator wiring harness retainers.
37. Connect the engine wiring harness retainer and the two PCM electrical connectors.
38. Connect the electrical connector.
39. Position the crankcase ventilation tube and connect the quick connect coupling.
40. Install the alternator and connect the electrical connector.
41. Position the lower radiator support and tighten the 12 bolts to 15 ft. lbs. (20 Nm).
42. Position the wiring harness and connect the 4 wiring harness retainers.
43. Connect the two headlamp wiring harness retainers and position the ground wire and tighten the bolt to 89 inch lbs. (10 Nm).
44. Position the upper radiator support and tighten the eight bolts to 15 ft. lbs. (20 Nm).
45. Position the two upper radiator support plates and tighten the four bolts to 15 ft. lbs. (20 Nm).
46. Position the right hand and left hand air deflectors and install the pin-type retainers.
47. Position the transmission fluid cooler and tighten the bolt to 89 inch lbs. (10 Nm).
48. Connect the transmission fluid cooler hose retainers.
49. Connect the horn electrical connector.
50. Connect the front impact severity sensor electrical connector.
51. If equipped, connect the air temperature sensor electrical connector.
52. Route the battery feed wiring harness to the Power Distribution Box (PDB) and insert the routing clips.
53. Install the battery feed cable to the PDB and the nuts.
54. Position the power steering reservoir and tighten the three bolts to 15 ft. lbs. (20 Nm).
55. Position the hood latch, connect the cable position retainer and tighten the bolts to 106 inch lbs. (12 Nm).
56. If equipped, install the A/C condenser core in the vehicle.
57. If equipped, connect the compressor discharge tube and the condenser-to-evaporator tube to the A/C condenser core and tighten the nuts to 11 ft. lbs. (15 Nm).
58. If equipped, connect the compressor suction tube and tighten the nut to 11 ft. lbs. (15 Nm).
59. If equipped, connect the A/C pressure cutoff switch electrical connector.
60. Position the radiator in the vehicle.
61. Position the radiator support brackets and tighten the four bolts to 15 ft. lbs. (20 Nm).
62. Position the fan shroud and the fan and fan clutch in the vehicle, and tighten the two bolts to 53 inch lbs. (6 Nm).
63. Connect the degas bottle hose and power steering hose retainers to the fan shroud.
64. Using the Fan Pulley Holding Wrench and Fan Clutch Nut Wrench, install the fan blade and the fan clutch. Tighten to 133 Nm (98 lb-ft).
65. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
66. Install the radiator grille support.
67. Connect the transmission cooler tubes.
68. Connect the lower radiator hose to the radiator.
69. Install the front bumper.
70. Install the starter.
71. Install the intake manifold.
72. Refill the engine with oil to the correct level.
73. Refill the transmission with fluid to the correct level.
74. Fill and bleed the power steering system.
75. Start the engine and check for leaks.
76. Evacuate and recharge the air conditioning system

6.0L Engine

Specific to:

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Remove the radiator assembly. For additional information, refer to the following section, -Radiator, Removal & Installation.-
4. Remove the front bumper.
5. Remove the two pushpin retainers and the front bumper shields.
6. Remove the radiator grille support.
7. Remove the six pushpin retainers and the side shields.
8. Matchmark the hood latch location. Disconnect the cable retainer. Remove the two bolts and position the hood latch aside.
9. Disconnect the pushpin retainers and the transmission cooler hose. Remove the bolt and the transmission cooler.
10. Disconnect the horn electrical connector.
11. Remove the four bolts and the radiator upper support brackets.
12. Remove the eight bolts and the radiator upper support.
13. Disconnect the front impact severity sensor electrical connector.
14. Remove the bolt for the ground wire. Disconnect the pushpin retainers and position aside the headlamp wire harness.
15. Remove the four pushpins and the side shields. Position the power steering cooler aside.
16. Remove the 12 bolts and the lower radiator support.
17. Remove the intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
18. Remove the right hand fan stator stand-off. Remove the bolt and position the cable aside.
19. Disconnect the A/C electrical connector.
20. Remove and discard the O-ring seal and gasket. Cap or plug the A/C openings as needed.
21. Remove the bolt and disconnect the A/C pressure switch electrical connector.
22. Remove the three bolts and A/C compressor.
23. Disconnect the heater hose and position the heater hose aside.
24. Remove the bolt and idler pulley.
25. Remove the two nuts and the coolant hose shield.
26. Loosen the clamp and disconnect the engine coolant fill hose.
27. Disconnect the vacuum pump hose.
28. Remove the three stud bolts and the vacuum pump.
29. Remove the 2 power steering upper mounting bolts.
30. Remove the left hand fan stator stand-off.
31. Remove the 2 bolts and position the power steering pump aside.
32. Remove the lower radiator hose.
33. Disconnect the fuel tube spring lock couplings.
34. Disconnect the Crankshaft Position (CKP) sensor electrical connector and retaining clips.
35. Disconnect the Injection Control Pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
36. Disconnect the Camshaft Position (CMP) sensor electrical connector and retaining clips.
37. Disconnect the electrical connector and wire retainers at the transmission.
38. Disconnect the glow plug module electrical connectors.
39. Disconnect the Exhaust Pressure (EP) sensor electrical connector and pushpin retainer.
40. Disconnect the left hand glow plug electrical connector.
41. Disconnect the engine-to-vehicle electrical connectors.
42. Disconnect the two PCM electrical connectors and position the engine wiring harness aside.
43. Remove the three bolts and the oil filter assembly.
44. Remove the engine-to-transmission bolt for the transmission cooler tubes.
45. Remove the nut and remove the transmission cooling tubes support bracket off the stud.
46. Remove the torque converter cover.
47. Remove and discard the 6 torque converter nuts.
48. Disconnect the block heater electrical connector.
49. Remove the nut. Disconnect the battery cable bracket at the starter and position aside.
50. Remove the starter solenoid protective cap.
51. Disconnect the starter motor electrical connections.
52. Remove the one stud bolt, two bolts and the starter motor.
53. Remove the right and left cylinder block drain plugs and drain the coolant from the block.
54. Apply clean engine oil to the O-ring seals and reinstall the cylinder block drain plugs and tighten to 15 ft. lbs. (20 Nm).
55. Remove the four engine mount nuts.
56. Remove the two lower engine-to-transmission bolts.
57. Remove the two mounting bolts from the lifting bracket and remove the tubes.
58. Disconnect the glow plug wire retainer and remove the nut and the oil indicator and tube and discard the O-ring seal.
59. Disconnect the EP tube at the exhaust manifold.
60. Remove the two nuts and glow plug module.
61. Remove the three nuts and the glow plug module mounting bracket.
62. Remove the left hand valve cover.
63. Remove the ICP sensor and plug the opening.
64. Install the engine lifting adapters.
65. Install the engine lifting attachment and heavy duty floor crane.
66. Drain the engine oil.
67. Remove the mounting bolts and position back the oil pan until the oil pickup tube bolts are accessible.
68. Remove the 2 bolts and let the oil pickup tube go into the oil pan. Remove the oil pan and remove the press-in-place gasket and discard.
69. Remove and discard the oil pickup tube O-ring seal.
70. Position a suitable transmission jack under the transmission.
71. Remove the four upper engine-to-transmission bolts.
72. Raise the engine.
73. Remove the mounting bolts and the left engine mount.
74. Remove the mounting bolts and the right engine mount.
75. Remove the engine from the vehicle.
    
    NOTE

    The engine must be moved to the driver side for removal.

To install:

1. Raise the engine high enough to clear the No. 1 crossmember and position the engine into the vehicle.
2. Position the engine mounts in the vehicle.
3. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top four engine-to-transmission bolts and tighten to 35 ft. lbs. (47 Nm).
4. Lower the engine until it is just above the motor mounts and install the four right hand engine mounting bolts and tighten to 59 ft. lbs. (80 Nm).
5. Install the left hand engine mounting bolts and tighten to 59 ft. lbs. (80 Nm).
6. Remove the transmission jack.
7. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
8. Install a new press-in-place gasket into the upper oil pan.
9. Position the oil pan in the vehicle and install the oil pickup tube and tighten the two bolts to 115 inch lbs. (13 Nm).
10. Install the oil pan and tighten the mounting bolts. For additional information, refer to the following section, -Oil Pan, Removal & Installation.-
11. Install the oil pan drain plug and tighten to 32 ft. lbs. (44 Nm).
12. Lower the engine.
13. Install the factor engine lifting bracket.
14. Install the ground strap and tighten the bolt to 106 inch lbs. (12 Nm).
15. Loosely install the turbocharger exhaust pipe.
16. Install the ICP sensor and tighten to 106 inch lbs. (12 Nm).
17. Remove any protective covering that was placed over the cylinder head.
18. Install the left hand valve cover and gasket. Tighten the mounting bolts to 80 inch lbs. (9 Nm).
19. Install the glow plug module mounting bracket and tighten the nuts to 71 inch lbs. (8 Nm).
20. Connect the EP tube to the exhaust manifold and tighten to 22 ft. lbs. (30 Nm).
21. Position the oil indicator and tube, install the retaining nut and connect the glow plug wire retainer.
22. Position the fuel tubes and install the two mounting bolts for the fuel tube bracket.
23. Install the two lower engine-to-transmission bolts and tighten to 35 ft. lbs. (47 Nm).
24. Install the four engine mount-to-crossmember nuts and tighten to 66 ft. lbs. (90 Nm).
25. Install the starter. For additional information, refer to the following section, -Starter, Removal & Installation.-
26. Connect the block heater electrical connector.
27. Install the torque converter nuts and tighten to 26 ft. lbs. (35 Nm). Install the torque converter cover.
28. Position the transmission cooler tube support bracket on the stud and tighten the nut to 106 inch lbs. (12 Nm).
29. Install the engine-to-transmission bolt for the transmission cooler tubes and tighten to 35 ft. lbs. (47 Nm).
30. Install the oil filter assembly and tighten the bolts to 18 ft. lbs. (24 Nm).
31. Position the engine wiring harness and connect the PCM electrical connectors.
32. Connect the 2 engine-to-vehicle electrical connectors.
33. Connect the left hand glow plug electrical connector.
34. Connect the pushpin retainer and EP sensor electrical connector.
35. Connect the electrical connector and wire retainers at the transmission.
36. Connect the glow plug module electrical connectors.
37. Connect the Camshaft Position (CMP) sensor electrical connector and retaining clips.
38. Position the wiring and connect the glow plug and ICP sensor electrical connectors.
39. Connect the Crankshaft Position (CKP) sensor electrical connector and retaining clips.
40. Connect the fuel tube spring lock couplings and install the retaining clips.
41. Install the lower radiator hose.
42. Install the power steering pump and tighten the bolts to 18ft. lbs. (25 Nm).
43. Install the left hand fan stator stand-off and tighten the bolts to 35 ft. lbs. (47 Nm).
44. Tighten the two power steering upper mounting bolts to 18 ft. lbs. (25 Nm).
45. Position the vacuum pump and tighten the three stud bolts to 35 ft. lbs. (47 Nm).
46. Connect the vacuum pump hose.
47. Connect the engine coolant fill hose and tighten the clamp.
48. Position the coolant hose shield and tighten the nuts to 53 inch lbs. (6 Nm).
49. Install the idler pulley and tighten the bolt to 35 ft. lbs. (47 Nm).
50. Connect the heater hose.
51. Install the A/C compressor and tighten the bolts to 18 ft. lbs. (25 Nm).
52. Connect the A/C pressure switch electrical connector and tighten the bolt to 21 ft. lbs. (28 Nm).
53. Connect the A/C fitting and tighten the nut to 133 inch lbs. (15 Nm).
54. Connect the A/C compressor electrical connector.
55. Position back the cable and install the bolt. Install the right hand fan stator stand-off.
56. Install the intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
57. Install the lower radiator support and tighten the bolts to 15 ft. lbs. (20 Nm).
58. Position back the power steering cooler. Position back the side deflectors and install the 4 pushpin retainers.
59. Position the headlamp wire harness and connect the pushpin retainers. Install the bolt for the ground wire.
60. Connect the front impact severity sensor electrical connector.
61. Install the radiator upper support and tighten the eight bolts to 15 ft. lbs. (20 Nm).
62. Install the radiator upper support brackets and tighten the four bolts to 106 inch lbs. (12 Nm).
63. Connect the horn electrical connector.
64. Position the transmission cooler and loosely install a bolt.
65. Connect the transmission cooler hose and the pushpin retainers.
66. Position the hood latch and tighten the four bolts to 106 inch lbs. (12 Nm). Connect the cable retainer.
67. Position the side shields and install the six pushpin retainers.
68. Install the radiator grille support.
69. Install the front bumper shields and two pushpin retainers.
70. Install the front bumper.
71. Install the radiator assembly.
72. Refill the engine with oil to the correct level.
73. Ensure the engine cooling system is filled to the correct level.
74. Check and top off the transmission fluid level.
75. Connect the negative battery cable.

This will help.Thanks.

FOR MORE HELP GO TO: ---

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