Engine - Motorhome Chassis

Engine - Motorhome Chassis

Special Service Tool(s):

Special Service Tool(s)

Installation
1. Install the Modular Lifting Bar and lifting equipment.
2. Remove the engine from the engine stand.

3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean and inspect the mating surfaces of the cylinder block and the retainer plate.






4. NOTE: If the retainer plate is not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone around the rear oil seal retainer sealing surface.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.






5. Install the retainer plate. Tighten the bolts in the sequence shown to 8-12 Nm (71-106 lb-in).






6. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal.
7. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Installer to install the crankshaft oil slinger.






8. Install the flexplate.
9. Position the engine on the second crossmember and engine mount assembly.






10. Install the four nuts.
11. Remove the Modular Lifting Bar and lifting equipment.






12. Install the upper intake manifold.
- Position the new intake manifold gaskets.
- Position the intake manifold.
- Loosely install eleven bolts.
13. Install the water thermostat and housing. Loosely install the bolts.






14. Tighten the bolts in two stages, in the sequence shown.
- Stage 1: Tighten to 2Nm (17lb-in).
- Stage 2: Tighten to 20-30 Nm 15-22 lb-ft).






15. Connect the cylinder head temperature sensor.






16. Install the radio interference capacitor (LH).
- Position the capacitor.
- Install the bolt.






17. Install the ignition coils.
- Install the ignition coils.
- Install the bolts.
18. Install the generator.






19. Connect the water temperature indicator sender unit electrical connector.






20. Connect the five LH fuel injector electrical connectors.






21. If equipped, install the EVR solenoid bracket.
- Position the bracket.
- Install the bolts.






22. NOTE: The EGR valve is shown removed for clarity.

If equipped, connect the EVR solenoid electrical and vacuum harness.






23. If equipped, connect the EGR valve vacuum line.






24. If equipped, install the EGR valve to exhaust manifold tube.
- Hand-tighten the fittings.
- Tighten the upper fitting to 40-60 Nm (30-44 lb-ft).
- Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).






25. If equipped, install the EGR transducer bracket.






26. If equipped, connect the EGR transducer vacuum lines.






27. If equipped, connect the EGR transducer and the throttle position sensor connectors.






28. Connect the idle air control motor electrical connector and the bypass hose.






29. Connect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.






30. Install the RH radio interference capacitor.
- Position the capacitor.
- Install the bolt.
31. Partially raise the engine in the vehicle.






32. Install the frame extensions.
- Position the frame extensions.
- Install eight nuts and bolts.

33. Raise the engine.






34. NOTE: Install the top nuts and bolts first to assist in aligning the side nuts and bolts.

Install twelve nuts and bolts.
35. Install the transmission.
36. Install the oil filter.






37. NOTE: Transmission shown removed for clarity. Connect the right front brake line.
38. Install the front axle.
39. Install the transmission cooler tubes.
- Position the cooler tubes.
- Install brass unions.
- Connect the cooler tubes to the transmission.






40. Install the cable bracket.






41. Connect the ground strap.
42. Install the starter motor.






43. Connect the crankshaft position sensor.
44. Install the A/C compressor.






45. Install the power steering pump.
- Position the power steering pump.
- Install two bolts.
46. Install the drive belt.






47. Connect the vacuum lines.






48. Connect the lower radiator hose.






49. Connect the connectors.






50. Install the oil level indicator tube bolt.
51. Install the engine cooling fan.
52. Lower the vehicle on the hoist.






53. Install the transmission shift control cable bolts.






54. Install the upper bolts.






55. Connect the generator wiring.






56. Connect the oil fill hose.






57. Connect the vacuum hoses.






58. Connect the heater hoses.
59. Install the transmission fill tube.






60. Connect the heated oxygen sensors.






61. Connect the fuel lines.






62. Connect the vacuum lines.






63. Connect the vacuum line.






64. Connect the upper radiator hose.






65. Install the accelerator cable bracket.
- Position the bracket.
- Install the bolts.






66. Connect the throttle control cable, the speed control actuator cable and the throttle return spring.






67. Install the accelerator cable splash shield.






68. Install the air cleaner outlet tube.
69. Install the engine cover.






70. Connect the air cleaner outlet tube to the air cleaner assembly.






71. Install the transmission fluid and engine oil level indicators.
72. Install the bolt.
73. Install the grille opening panel.
74. Connect the battery ground cable.
75. Fill and bleed the engine cooling system.
76. Charge the A/C system.