Operation CHARM: Car repair manuals for everyone.
Home >> Ford >> 1996 >> E 250 Van L6-300 4.9L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair
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Engine: Service and Repair

REMOVAL AND INSTALLATION
1. Disconnect battery ground cable and drain cooling system.
2. Install protective seat covers, then remove hood cover and air cleaner assembly.
3. Relieve fuel system pressure as outlined under Fuel Delivery Air Induction/ Service And Repair/ Fuel Pressure Relief Procedure.
4. Remove front bumper, then the grille and lower gravel deflector as an assembly.
5. Disconnect radiator hose from engine, then remove alternator splash shield, if equipped, and the lower radiator hose from radiator.
6. On models equipped with automatic transmission, disconnect transmission oil cooler lines from radiator.
7. Remove radiator and fan shroud, if equipped.
8. Disconnect heater hoses from engine.
9. Disconnect alternator from mounting bracket and position aside.
10. Remove steering pump drive belt, then disconnect pump and support from mounting bracket and position aside.
11. Disconnect and plug fuel line from fuel rail. Label, then disconnect all EFI electrical connectors and vacuum lines that will interfere with engine removal.
12. Disconnect distributor and sender unit wires and the brake booster hose from engine.
13. Disconnect electronic engine control harness from all sensors, if equipped.
14. Disconnect accelerator cable and remove bracket from engine.
15. On models equipped with automatic transmission, disconnect kickdown cable from bell crank.
16. Remove exhaust manifold heat deflector, then the exhaust pipe-to-manifold attaching nuts.
17. Disconnect transmission vacuum line from intake manifold and junction.
18. Remove upper transmission-to-engine attaching bolts.
19. On models equipped with automatic transmission, remove transmission dipstick tube support bolt from intake manifold.
20. Raise and support vehicle, then drain engine oil.
21. Disconnect wires from starter, then remove starter motor.
22. Remove flywheel inspection cover, then the four converter attaching nuts and front engine support nuts.
23. Remove oil filter, then the remaining transmission to engine retaining nuts.
24. Lower vehicle, then remove engine assembly using suitable lifting equipment.
25. Reverse procedure to install. Tighten engine to transmission bolts to 40-50 ft lb.
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