1999 E-Series Workshop Manual

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1 Page 1 of 3 SECTION C: Engine 6.8L 1999 E-Series Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 06/30/1998 Oil Cooler Oil Filter Adapter Removal 1. Disconnect the battery ground cable (14301). 2. Raise and support the vehicle. Refer to Section Remove the left engine support insulator. Refer to Engine Support Insulators in this section. 4. Remove the lower radiator hose (8286). Refer to Section Drain the engine oil and remove the oil bypass filter (6714). 6. Loosen the threaded tube and remove the oil cooler (6A642) from the oil filter adapter (6881). 7. Remove one nut and two bolts and remove the oil filter adapter from the cylinder block (6010). 8. Remove the old oil filter adapter gasket (6840) and clean the gasket surface at the cylinder block.

2 Page 2 of 3 Installation 1. Follow the removal procedure in reverse order.

3 Page 3 of 3 2. Fill the engine cooling system. Refer to Section Fill the crankcase with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

4 Page 1 of 7 SECTION C: Engine 6.8L 1999 E-Series Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 06/30/1998 Engine Support Insulators Special Tool(s) Modular Lifting Bar 303-F047 ( ) or equivalent 3-Bar Engine Support 303-F070 Lift Bar Adapter, Modular Engine 303-F694 Removal 1. Remove the intake manifold. For additional information, refer to Intake Manifold Variable Resonance Induction System (VRIS) in this section. 2. Remove the fan shroud and the engine cooling fan. For additional information, refer to Section Remove the retainers and the shield.

5 Page 2 of 7 4. Remove the nut retaining the transmission oil filler tube and position the tube aside. 5. Detach the wiring harness retainer. 6. Remove the stud bolts. 7. Remove the two transmission-to-engine bolts. 8. Assemble the special tools.

6 Page 3 of 7 9. Install the special tools. 10. Install the special tool and support the engine. 11. Raise the vehicle. For additional information, refer to Section NOTE: The RH is shown, the LH is similar. Remove the nuts retaining the front engine support insulators (6038) to the engine support brackets.

7 Page 4 of For the RH front engine support insulator, remove the starter motor (11001). For additional information, refer to Section A. 14. Lower the vehicle. 15. Using the 3-Bar Engine Support, raise the engine. 16. Raise the vehicle. 17. NOTE: Engine is not shown for clarity. Remove the bolts and remove the front engine support insulators from the vehicle.

8 Page 5 of 7 Installation 1. To install, reverse the removal procedure.

9 Page 6 of 7

10 Page 7 of 7

11 Page 1 of 18 SECTION C: Engine 6.8L 1999 E-Series Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 06/30/1998 Intake Manifold Variable Resonance Induction System (VRIS) Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. 1. Disconnect the battery ground cable (14301). For additional information, refer to Section Relieve the fuel pressure. For additional information, refer to Section A. 3. Disconnect the fuel lines. For additional information, refer to Section A. 4. Remove the evaporative emission canister purge valve and mounting bracket. For additional information, refer to Section Drain the coolant system. For additional information, refer to Section Compress and slide the hose clamp and disconnect the water outlet hose. 7. Remove the engine vacuum harness. Disconnect the harness as shown. 1. EGR valve (EGR valve) (9D475) 2. EGR vacuum regulator solenoid 3. vacuum source 4. fuel pressure regulator (9C968)

12 Page 2 of Disconnect the exhaust gas recirculation (EGR) valve to exhaust manifold tube lower fitting.

13 Page 3 of Remove the differential pressure feedback EGR. For additional information, refer to Section Remove the EGR vacuum regulator solenoid. For additional information, refer to Section Remove the EGR valve. For additional information, refer to Section Remove the throttle body. For additional information, refer to Section D. 13. Remove the throttle body spacer and gasket. 14. Disconnect the five RH fuel injector electrical connectors.

14 Page 4 of Disconnect the five LH fuel injector electrical connectors.

15 Page 5 of Disconnect the water temperature indicator sender unit electrical connectors.

16 Page 6 of Disconnect and remove the ten ignition coils (12029). For additional information, refer to Section C. 18. Remove the drive belt (8620). For additional information, refer to Section Remove the generator (GEN) (10300). For additional information, refer to Section A. 20. Disconnect the hose clamps and remove the heater water hose (18472). 21. Remove the water thermostat (8575).

17 Page 7 of Remove the two studs retaining the heater water return tube. 23. Remove the bolts, the upper intake manifold and the intake manifold gaskets (9439). Discard the intake manifold gaskets. 24. Pull back and remove the heater water return tube. Inspect the O-rings and replace if required. 25. Separate the upper and lower intake manifolds (9424). Remove the ten bolts. Discard the intake manifold gasket.

18 Page 8 of Clean all mating surfaces. Installation 1. Position the lower intake manifold gasket (9461) and the upper intake manifold on the intake manifold and loosely install the ten bolts.

19 Page 9 of NOTE: Tighten the bolts in two stages. Tighten the bolts in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb/in) Stage 2: Tighten to 8-12 Nm ( lb/in)

20 Page 10 of Position the water return tube as shown. 4. Install the heater water return tube studs.

21 Page 11 of Install the upper intake manifold. Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts. 6. NOTE: Be sure to tighten the bolts in two stages. Tighten the bolts in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb/in) Stage 2: Tighten to Nm (15-22 lb/ft)

22 Page 12 of Install the thermostat. For additional information, refer to Section Install the heater water hose and position the clamp. 9. Connect the water temperature indicator sending unit electrical connector.

23 Page 13 of Install the generator. For additional information, refer to Section A. 11. Install the drive belt. For additional information, refer to Section Install the ignition coils. For additional information, refer to Section C. 13. Connect the five LH fuel injector electrical connectors.

24 Page 14 of Connect the five RH fuel injector electrical connectors.

25 Page 15 of Install a new throttle body spacer gasket and the throttle body spacer. 16. Install the throttle body. For additional information, refer to Section D. 17. Install the EGR valve. For additional information, refer to Section Install the EGR vacuum regulator solenoid. For additional information, refer to Section Install the differential pressure feedback EGR. For additional information, refer to Section Connect the EGR valve to exhaust manifold tube lower fitting.

26 Page 16 of Connect the engine emission vacuum harness. 1. EGR valve 2. EGR vacuum regulator solenoid 3. vacuum source 4. fuel pressure regulator

27 Page 17 of Connect the fuel lines. For additional information, refer to Section A. 23. Install the evaporative emission canister purge valve and mounting bracket. For additional information, refer to Section Connect the engine water outlet hose and position the hose clamp. 25. Install the air cleaner outlet tube (9B659). For additional information, refer to Section Fill the cooling system. For additional information, refer to Section

28 Page 18 of Install the engine cover. For additional information, refer to Section Connect the battery ground cable. For additional information, refer to Section

29 Page 1 of 3 SECTION : Engine Cooling 1999 E-Series Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/30/1998 Water Pump 4.6L, 5.4L and 6.8L Removal 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Remove the fan and fan clutch. For additional information, refer to Fan in this section. 3. Remove the accessory drive belt. For additional information, refer to Section Remove the water pump pulley. 1. Remove the bolts. 2. Remove the water pump pulley. 5. Remove the (A) bolts and the (B) water pump from the (C) engine. Installation 1. NOTE: New water pumps are shipped with a new O-ring in place. Only lubricate if the old pump is to be reinstalled.

30 Page 2 of 3 Install a new O-ring on the water pump. Coat the new O-ring with Ford Premium Engine Coolant E2FZ AA or B, in Oregon F5FZ CC, in Canada Motorcraft CXC-10 or equivalent meeting Ford specification ESE-M97B44-A. 2. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the O-ring can occur, causing the water pump to leak. Position the (A) water pump on the (B) engine and install the (C) bolts. 3. Position the pulley onto the water pump and install the bolts. 4. Install the accessory drive belt. For additional information, refer to Section Install the fan and fan clutch. For additional information, refer to Radiator Cooling Fan Blade/Fan Clutch and Fan Shroud in this section. 6. Refill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

31 Page 3 of 3

32 Page 1 of 4 SECTION A: Starting System Gasoline Engines 1999 E-Series Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/30/1998 Starter Motor Removal WARNING: When carrying out maintenance on the starting system, be aware that heavy gauge leads are connected directly to the battery. Make sure protective caps are in place when maintenance is complete. 1. Disconnect the battery ground cable (14301). For additional information, refer to Section Raise and support the vehicle. For additional information, refer to Section Remove the starter motor solenoid terminal cover (11N087). 4. Disconnect the starter motor electrical connections. 1. Remove the nuts (B+ and S). 2. Remove the battery cable. 3. Remove the starter solenoid wire. 5. Remove the nut and the starter motor ground cable.

33 Page 2 of 4 6. Remove the starter motor (11002). 1. NOTE: Most applications use two bolts; however, some use three bolts. Remove the bolts. 2. Remove the starter motor. Installation WARNING: When carrying out maintenance on the starting system, be aware that heavy gauge leads are connected directly to the battery (10653). Make sure the protective caps are in place when the maintenance is complete. 1. Install the starter motor. 1. Position the starter motor. 2. NOTE: Most applications use two bolts; however, some use three bolts. Install the bolts.

34 Page 3 of 4 2. Connect the starter motor ground cable and install the nut. 3. Connect the starter motor electrical connections. 1. Position the battery cable. 2. Position the starter solenoid wire. 3. Install the nuts. 4. Install the starter motor solenoid terminal cover.

35 Page 4 of 4 5. Lower the vehicle. 6. Reconnect the battery ground cable.

36 Page 1 of 5 SECTION : Engine Cooling 1999 E-Series Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 11/02/2002 Fan Special Tool(s) Holding Wrench, Fan Clutch Pulley (4.2L, 4.6L, 5.4L) (T84T-6312-C) Wrench, Fan Clutch Hub Nut (4.2L, 4.6L, 5.4L) (T84T-6312-D) Holding Wrench, Fan Clutch Pulley (6.8L, 7.3L) (94T-6312-AH) Wrench, Fan Clutch Hub Nut (6.8L, 7.3L) (T83T-6312-B) Removal and Installation All vehicles NOTE: The fan, fan clutch and shroud must be removed and installed together due to insufficient clearance to remove them separately. 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Remove the air cleaner assembly. For additional information, refer to Section Disconnect the radiator upper hose from the radiator. Position the radiator hose aside. 4. Disconnect the overflow hose from the radiator.

37 Page 2 of 5 5. Disconnect the coolant degas bottle hose from the shroud. Vehicles with 4.2L, 4.6L, 5.4L engine 6. CAUTION: The clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. Using the special tools, loosen the fan clutch. Vehicles with 6.8L, 7.3L engine

38 Page 3 of 5 7. CAUTION: The clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it. Using the special tools, loosen the fan clutch. All vehicles 8. Carefully rotate the fan and fan clutch assembly counterclockwise until the assembly is free from the water pump. Place the fan and fan clutch into the shroud opening. 9. If equipped, disconnect the retaining clips from the fan shroud. 10. Raise and support the vehicle. For additional information, refer to Section Disconnect the lower radiator hose retaining clamp from the shroud.

39 Page 4 of If equipped, disconnect the underbody splash shield from the shroud. 13. Lower the vehicle. 14. CAUTION: Use extreme care when removing or installing the fan, fan clutch and shroud. Failure to do so will cause damage to the radiator. Remove the mounting bolts, and the fan, fan clutch and shroud. 15. To install, reverse the removal procedure. Install an appropriately sized worm drive-type clamp in place of the constant tension clamp.

40 Page 5 of 5

41 Page 1 of 4 SECTION : Engine Cooling 1999 E-Series Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/30/1998 Radiator Cooling Fan Blade/Fan Clutch and Fan Shroud Removal 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Remove the air cleaner assembly. For additional information, refer to Section Remove the plastic rivet retainers and the air deflector. 4. Remove the upper radiator hose from the radiator. 5. Disconnect the overflow hose from the radiator. 6. CAUTION: The large clutch assembly nut has a right hand thread and must be rotated counterclockwise to remove it. Remove the (A) fan and fan clutch from the (B) water pump pulley (8509).

42 Page 2 of 4 7. Remove the (A) bolts and lift the (B) fan shroud (8146), fan and fan clutch from the vehicle. 8. Raise and support the vehicle. For additional information, refer to Section Remove the underbody splash shield, if equipped. 10. Remove the lower radiator hose. 11. Compress the (A) clamps and slide away from the (B) radiator. Twist the (C) transmission oil cooler hoses and remove from the radiator. 12. Lower the vehicle.

43 Page 3 of Remove the (A) bolts retaining the (B) support brackets to the (C) radiator support. Lift the radiator support brackets upwards and away from the (D) radiator. 14. Remove the radiator from the vehicle. Installation 1. To install, reverse the removal procedure.

44 Page 4 of 4 2. Install hose clamps where the shrink clamps were removed.

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