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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 221 (ENGINE - 4.2L)INSTALLATIONENGINESPECIAL TOOL(S)
2004 Ford Econoline E150, Van Cargo, 4.6 W

Special Tool(s)

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Special Tool(s)
WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool
G01536091Courtesy of FORD MOTOR CO.
  1. Install the engine.
  2. Install the bolts.
    Fig 2: Installing Bolts
    G01536092Courtesy of FORD MOTOR CO.
  3. Install the transmission dipstick tube. Use a new O-ring.
  4. Remove the engine lifting equipment.
  5. Raise the vehicle.
  6. Install the nuts (left side shown).
    Fig 3: Installing Nuts
    G01536093Courtesy of FORD MOTOR CO.
  7. Install the shift cable routing bracket retaining bolt.
    • Position the wiring harness and engage the routing clips.
    • Connect the wiring at the daytime running lamp module, if so equipped.
    • Connect the wiring at the horn.
    • Connect the wiring at the front air bag sensor.
  8. Install the bolts on the right side.
    Fig 4: Installing Bolts On Right Side
    G01536094Courtesy of FORD MOTOR CO.
  9. Install the nuts retaining the exhaust pipe at the exhaust manifolds (9430).
  10. Install the bolts on the left side.
    Fig 5: Installing Bolts On Left Side
    G01536095Courtesy of FORD MOTOR CO.
  11. Install the torque converter. Turn the crankshaft to access the nut studs.
    Fig 6: Installing Torque Converter
    G01536096Courtesy of FORD MOTOR CO.
  12. Install the torque converter access cover.
  13. Install the starter motor (11002). For additional information, refer to STARTERS - EXCEPT DIESEL .
  14. Lower the vehicle.
  15. Connect the A/C high-pressure line at the evaporator. Discard the O-ring.
  16. Install the A/C manifold and tube (19D734). Use new O-rings.
    Fig 7: Installing A/C Manifold And Tube
    G01536097Courtesy of FORD MOTOR CO.
  17. Install the lower radiator hose (8286).
  18. Connect the oil cooler coolant hoses.
    Fig 8: Connecting Oil Cooler Coolant Hoses
    G01536098Courtesy of FORD MOTOR CO.
  19. Connect the degas bottle supply hose.
    Fig 9: Connecting Degas Bottle Supply Hose
    G01536099Courtesy of FORD MOTOR CO.
  20. Install the power steering pump (3A674).
  21. Install the pump retaining bolts.
  22. Connect the low-pressure line at the power steering pump.
    Fig 10: Installing Pump Retaining Bolts
    G01536100Courtesy of FORD MOTOR CO.
  23. Install the accessory upper radiator hose (8260). For additional information, refer to ACCESSORY DRIVE .
  24. Install the lower intake manifold (9424). For additional information, refer to LOWER INTAKE MANIFOLD .
  25. Install the intake manifold spacer assembly. For additional information, refer to INTAKE MANIFOLD - SPACER ASSEMBLY .
  26. Install the oil level indicator extension tube and oil level indicator.
    Fig 11: Installing Oil Level Indicator Extension Tube
    G01536101Courtesy of FORD MOTOR CO.
  27. Install the bolt retaining the routing bracket and the oil level indicator tube (6754).
  28. Install the bolt and the lower core support.
  29. Install the headlamp dash panel junction wiring harness.
    Fig 12: Installing Headlamp Dash Panel Junction Wiring Harness
    G01536102Courtesy of FORD MOTOR CO.
  30. Install the bolts and the upper core support.
    Fig 13: Installing Bolts And Upper Core Support
    G01536103Courtesy of FORD MOTOR CO.
  31. Position the power steering reservoir and install the bolts.
  32. Install the battery feed wire wiring harness to the power distribution box.
    • Engage the routing clips.
    • Install the nut and cable.
    • Install the cover at the power distribution box.
    Fig 14: Installing Battery Feed Wire Wiring Harness To Power Distribution Box
    G01536104Courtesy of FORD MOTOR CO.
  33. Install the hood latch (16700).
    1. Install the retaining bolts.
    2. Install the cable routing clip.
    Fig 15: Installing Retaining Bolts
    G01536105Courtesy of FORD MOTOR CO.
  34. Install the air conditioning condenser. For additional information, refer to AIR CONDITIONING .
  35. Remove the bolts and the transmission/power steering cooler mounting brackets.
    Fig 16: Removing Transmission/Power Steering Cooler Mounting Brackets
    G01536106Courtesy of FORD MOTOR CO.
  36. Install the auxiliary transmission cooler. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
  37. Install the power steering cooler. For additional information, refer to POWER STEERING .
  38. Install the front end stone deflector. For additional information, refer to FRONT END BODY PANELS .
  39. Install the radiator grille opening panel reinforcement (8A284). For additional information, refer to FRONT END BODY PANELS .
  40. Install the side marker lamps. For additional information, refer to EXTERIOR LIGHTING .
  41. Install the headlamps. For additional information, refer to EXTERIOR LIGHTING .
  42. Install the radiator inner grille (8150). For additional information, refer to FRONT END BODY PANELS .
  43. Install the radiator fan shroud and fan. For additional information, refer to ENGINE COOLING .
  44. Install the radiator air deflector. For additional information, refer to FRONT END BODY PANELS .
  45. Install the air cleaner assembly and the throttle body inlet tube.
  46. Charge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  47. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  48. Connect the battery ground cable.
  49. Add the correct amount of oil to the engine and forward to the transmission.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.