1992-2010 Ford Econoline Service & Repair Manual

4.2L V6 - VIN [2] Article Text 1998 Ford Econoline E250 For 1 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, November 14, 2010 09:49PM ARTICLE BEGINNING 1998-99 ENGINES 4.2L V6 - VIN 2 FORD Econoline E150, Econoline E250, Pickup F150 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, located on left front door pillar. ENGINE IDENTIFICATION CODES Engine Code 4.2L SFI ......................................................... 2 ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve tappets are used. Valve adjustment is not required. TROUBLE SHOOTING NOTE: For trouble shooting of mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION. REMOVAL & INSTALLATION * PLEASE READ THIS FIRST * CAUTION: 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. NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

4.2L V6 - VIN [2] Article Text (p. 2) 1998 Ford Econoline E250For 1 Copyright © 1998 Mitchell Repair In 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. Remove relief valve cap. Relief valve (service port) is located 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. Crank engine for 15 seconds to reduce system pressure. 3) To disconnect fuel lines, remove retaining clip from fuel line coupling. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line and (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. See Fig. 1. 4) Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover. 5) When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel-resistant "O" rings (Brown). Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary). 6) Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines are locked together and garter spring is over flared end of female fitting. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. NOTE: Install Black retaining clip on fuel supply line and Gray clip on fuel return line. Fig. 1: Disconnecting Fuel Lines Courtesy of Ford Motor Co. ENGINE

4.2L V6 - VIN [2] Article Text (p. 3) 1998 Ford Econoline E250For 1 Copyright © 1998 Mitchell Repair Information Compan Removal (Pickup) 1) Disconnect negative and positive battery cable. Mark hinges and remove hood. Drain cooling system. 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) Remove upper front air deflector. Remove air cleaner outlet tube. Remove radiator. Remove fan blade and fan shroud. Disconnect throttle body control cables. Disconnect throttle control cable bracket and position aside. 3) Disconnect necessary vacuum and water lines. Disconnect necessary harness connectors and ground cables. Unbolt power steering reservoir, and position aside. Disconnect A/C manifold line at compressor, and position aside. Remove power steering pump retaining bolts, and position pump aside. 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 could cause vehicle to shift during servicing. 4) Remove upper intake manifold. See INTAKE MANIFOLD. Remove fuel injector supply manifold and injectors. Raise and support vehicle. Disconnect exhaust pipes from exhaust manifold. Remove starter. 5) Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION section. For M/T, see appropriate article in CLUTCHES section. 6) Remove right and left engine mount through-bolt. Lower vehicle. Install engine lifting equipment. Remove transmission-to- engine retaining bolts. Remove engine. Installation 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) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). 3) Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. Removal (Van) 1) Disconnect negative and positive battery cable(s). Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS. Remove air cleaner assembly and throttle body inlet tube. 2) Remove engine cover. Remove radiator air deflector. Remove radiator, fan shroud and cooling fan. Remove radiator inner grille. Remove radiator grille reinforcement panel. Remove stone deflector.

4.2L V6 - VIN [2] Article Text (p. 4) 1998 For 3) Remove headlight and side marker assemblies. Remove power steering cooler and auxiliary transmission cooler. Remove power steering cooler mounting brackets. Remove A/C condenser, and plug openings. Disconnect hood latch cable, and remove hood latch assembly. 4) Disconnect positive battery cable from power distribution box, and position aside. Remove power steering reservoir retaining bolts, and position aside. Remove upper and lower core support. Remove oil dipstick tube. Remove upper and lower intake manifolds. See INTAKE MANIFOLD. 5) 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 A/C high-pressure hose at evaporator, and plug openings. 6) Raise and support vehicle. Drain engine oil. Remove starter. Remove torque converter nuts. Remove oil pan-to-transmission bolts. Disconnect exhaust pipes at exhaust manifolds. Disconnect shift cable bracket. Remove engine mount nuts. 7) Lower vehicle. Support transmission. Remove transmission dipstick tube. Install engine lifting equipment. Remove transmission- to-engine retaining bolts. Remove engine. Installation 1) To install, reverse removal procedure. Replace torque converter nuts with NEW ones. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. 2) When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). 3) Adjust all control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. INTAKE MANIFOLD Removal 1) Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect spark plugs wires and harness connectors at ignition coil. Disconnect control cables from throttle body. Remove throttle body control cable bracket, and position aside. 2) Disconnect necessary vacuum and water lines. Disconnect necessary harness connectors and ground cables. Remove engine vacuum regulator from intake manifold. Remove upper intake manifold retaining bolts. Remove upper intake manifold and gasket. 3) Disconnect fuel injector harness connectors. Disconnect EGR manifold from EGR valve. Remove IMRC. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS. 4) Mark position for installation, remove lower intake manifold retaining bolts in reverse order. See Fig. 3. Remove lower intake manifold and gaskets.

4.2L V6 - VIN [2] Article Text (p. 5) 1998 Ford Econoline E250For 1 Copyright © 1998 Installation 1) To install, reverse removal procedure. Use NEW gaskets and "O" rings. Lubricate fuel injector "O" rings with Light Grade Oil (ESE-M2C39-F) before installing. 2) Ensure alignment tabs on intake manifold gaskets align with holes in cylinder head. Tighten intake manifold bolts to specification in sequence. See Figs. 2 and 3. See TORQUE SPECIFICATIONS table. CAUTION: 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 replace garter spring (if necessary). 4) 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. See SERVICE & ADJUSTMENT SPECIFICATIONS article in ENGINE PERFORMANCE section. Fig. 2: Upper Intake Manifold Bolt Tightening Sequence Courtesy of Ford Motor Co. Fig. 3: Lower Intake Manifold Bolt Tightening Sequence Courtesy of Ford Motor Co.

4.2L V6 - VIN [2] Article Text (p. 6) 1998 Ford Econoline E250For 1 Copyright © 1998 Mitchell Repair Information Compan 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. 4. Remove exhaust manifold and gasket. Installation To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. See Fig. 4. See TORQUE SPECIFICATIONS table. Fig. 4: Exhaust Manifold Bolt Tightening Sequence Courtesy of Ford Motor Co. CYLINDER HEAD Removal 1) Disconnect negative battery cable. Remove upper and lower intake manifolds. See INTAKE MANIFOLD. Remove valve cover. Remove exhaust manifold. See EXHAUST MANIFOLD. Remove accessory drive belt. 2) If removing left cylinder head, unbolt power steering reservoir and position aside. Remove A/C compressor, with hoses attached, and position aside. Remove power steering bracket, with pump and hoses 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.

4.2L V6 - VIN [2] Article Text (p. 7) 1998 Ford Econoline E250For 1 Copyright © 1998 Mitchell Repair Information Compan 4) If removing either cylinder head, remove rocker arms and push rods. Remove and discard cylinder head retaining bolts in reverse sequence. See Fig. 5. Remove cylinder head and gasket. Inspection Check cylinder head for warpage, cracks and damage. Maximum warpage information is not available from manufacturer. CAUTION: DO NOT reuse cylinder head bolts. Installation 1) Install NEW cylinder head gaskets on block with small hole at front of engine. Always use NEW cylinder head bolts. Lubricate cylinder head bolts with engine oil prior to installation. 2) Install cylinder head and tighten bolts to 14 ft. lbs. (19 N.m), in sequence. See Fig. 5. Repeat sequence again, tightening bolts to 29 ft. lbs. (39 N.m). Repeat sequence again, tightening bolts to 36 ft. lbs (49 N.m). CAUTION: DO NOT loosen all cylinder head bolts at one time. Loosen and tighten each cylinder head bolt before proceeding to next. 3) Working in order and on one bolt at a time, loosen bolt 3 revolutions and tighten to specification. See TORQUE SPECIFICATIONS. To complete cylinder head installation, reverse removal procedure. Fig. 5: Cylinder Head Bolt Tightening Sequence Courtesy of Ford Motor Co. FRONT COVER OIL SEAL Removal 1) Disconnect negative battery cable. Remove accessory drive

4.2L V6 - VIN [2] Article Text (p. 8) 1998 Ford belt. Remove cooling fan and fan shroud. Raise and support vehicle. Mark pulley and damper position. Remove crankshaft pulley. Remove damper bolt. 2) Install Crankshaft Damper Remover (T58P-6316-D) and Crankshaft Damper Remover Adapter (T82L-6316-B). Remove damper. Using Seal Remover (T92C-6700-CH), remove oil seal from front cover. Installation To install, reverse removal procedure. Lubricate oil seal bore and seal lip with engine oil before installing. Apply silicone sealant to keyway of crankshaft damper before installing. Install seal. Tighten bolts to specification. See TORQUE SPECIFICATIONS. FRONT COVER 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 accidental deflation or inflation of air springs, which may cause vehicle to shift during servicing. CAUTION: 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. Removal (Pickup) 1) Disconnect the battery ground cable, remove air cleaner assembly. 2) Raise vehicle, drain coolant from radiator, drain the engine oil. 3) Lower vehicle, remove upper radiator hose. Remove the fan shroud and the lower radiator hose. Remove the accessory drive belt. 4) Raise vehicle, remove the 2 nuts holding the Crankshaft (CKP) sensor shield in place and remove the shield. Disconnect both the Knock (KS) sensor and CKP sensor harness connectors. Position wiring harness aside. 5) Remove transmission line support bracket bolt. Remove power steering support bracket bolts. Remove the A/C compressor mounting bracket nuts and position the A/C compressor aside. 6) Mark crankshaft pulley and damper position. Remove crankshaft pulley and damper. See FRONT COVER OIL SEAL. 7) Remove front oil pan bolts that intersect with the front cover. Remove the Allen-head(R) bolt at front engine cover. 8) Lower vehicle, remove the supply tube heater hoses. Detach wiring harness from the outlet tube and position aside. 9) Remove the heater water outlet tube (remove bolt). Remove water pump. See WATER PUMP. 10) Remove Cam Position Synchronizer. See CAMSHAFT SYNCHRONIZER. 11) Remove the 4 water pump mounting studs.

4.2L V6 - VIN [2] Article Text (p. 9) 1998 Ford Econoline E25 CAUTION: Failure to remove Cap Screw which may be over looked, may damage the cover if not removed. 12) Remove engine front cover stud bolts and bolt. Remove CAP SCREW. See Fig. 6 13) Slide the front cover off the dowels, remove the gasket and discard. Installation (Pickup) CAUTION: Failure to prevent foreign material from entering the engine block or front engine cover will result in engine damage. To prevent damage to engine components, seal coolant and oil passages. Prevent foreign material from entering the oil pan. CAUTION: DO NOT use a surface conditioning pad or any other type of fibrous abrasive disc to clean gasket surfaces. Failure to follow these directions will result in engine damage. 1) Clean off surfaces of the block, front engine cover and exposed oil pan flange. NOTE: If sealant (F6AZ-19562-A) is exposed for longer than 7 minutes, wipe off sealant and re-apply. 2) 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. Apply a thin layer of sealant to front cover gasket mating surface (DO NOT over apply the sealant). NOTE: There are 13 fasteners securing the front engine cover. The CAP SCREW will be identified as fastener No. 12. DO NOT tighten the CAP SCREW (No. 12) in the first tightening sequence. 3) Tighten fasteners in 3 stages, as follows: * 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. 6. NOTE: Apply a small amount of loctite(R) to threads of cap screw (do not over apply compound). * Tighten CAP SCREW (No. 12) to 89 INCH. lbs. (10 N.m). * Tighten all fasteners (except Cap Screw No. 12) an additional 90 degrees, in sequence. 4) Apply a bead of sealant in center of oil pan flange and around bolt holes. Apply a thin layer of sealant to front cover gasket

4.2L V6 - VIN [2] Article Text (p. 10) 1998 For mating surface (DO NOT over apply the sealant). Install front cover. 5) Install the front engine cover. Tighten bolts to 15-20 Ft. lbs. (20-30 N.m). 6) Install water pump mounting studs, tighten to 15-20 Ft. lbs. (20-30 N.m). 7) Install Cam Position Synchronizer. Install water pump. See WATER PUMP. Install the heater water outlet tube, tighten to 71-97 INCH. lbs. (8-11 N.m). 8) Attach the wiring to the outlet tube, install both supply tube heater hoses. 9) Raise vehicle, install Allen-head(R) bolt, tighten to 15- 20 Ft. lbs. (20-30 N.m). Install oil pan bolts, tighten to 80-106 INCH. lbs. (9-12 N.m). 10) Install crankshaft pulley and damper. See FRONT COVER OIL SEAL and TORQUE SPECIFICATIONS. 11) Install A/C compressor mounting bracket nuts, tighten to 30-40 Ft. lbs. (40-45 N.m). 12) Install power steering support bracket bolts. Install transmission line support bracket bolt. 13) Connect (CKP) sensor and Knock sensor harness connectors. Install the (CKP) sensor shield. 14) Lower vehicle, install accessory drive belt. 15) Install the lower radiator hose, the fan shroud and upper radiator hose. 16) Refill coolant system, refill the engine oil. Ensure oil drain plug has been tightened. 17) Reconnect the battery ground cable, install air cleaner assembly. 18) Start vehicle and check for leaks. Fig. 6: Front Cover Tightening Sequence Courtesy of Ford Motor Co. Removal (Van) 1) Disconnect negative battery cable.

1992-2010 Ford Econoline Service & Repair Manual

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