Haynes Ford Full-Size Vans Owners Workshop Manual 1850105308, 9781850105305

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FORD

iH^ynei

VANS 1969 thru 1988 Six-cylinder in-line & V8 engines All full-size □ E-100 thru E-350

Owners Workshop Manual

'3 HAYNES',

BOSTON PUBLIC LIBRARY

Ford Full-size Vans

Owners Workshop Manual by Marcus Daniels, Curt Choate and John H Haynes Member of the Guild of Motoring Writers

Models covered: All full-size models from 1969 thru 1988 with 240 or 300 cu in inline six cylinder engines and 302, 351, 400 or 460 cu in V8 engines

ABCDE FGHIJ KLMNO

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgements We are grateful for the help and cooperation of the Ford Motor Company for their assistance with technical information, cer¬ tain illustrations and vehicle photos, and the Champion Spark Plug Company who supplied the illustrations of various spark plug conditions.

© Haynes Publishing Group 1986, 1988 A book in the Haynes Owners Workshop Manual Series Printed by J.H. Haynes & Co., Ltd. Sparkford Nr. Yeovil, Somerset BA22 7JJ, England

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 530 8 Library of Congress Catalog Card Number 88-82113 While every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Introductory pages About this manual Introduction to the Ford full-size vans Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting Jacking and towing Conversion factors Safety first! Automotive chemicals and lubricants Troubleshooting

5 5 7 9 9 16 16 17 18 19 20

Chapter 1 Tune-up and routine maintenance

27

Chapter 2 Part A Six cylinder inline engines

63

Chapter 2 Part B V8 engines

75

Chapter 2 Part C General engine overhaul procedures

91

Chapter 3 Cooling, heating and air conditioning systems

119

Chapter 4 Fuel and exhaust systems

127

Chapter 5 Engine electrical systems

150

Chapter 6 Emissions control systems

165

Chapter 7 Part A Manual transmission

180

Chapter 7 Part B Automatic transmission

192

Chapter 8 Clutch and driveline

200 •

Chapter 9 Brakes

214

Chapter 10 Steering and suspension systems

231

Chapter 11 Body

242

Chapter 12 Chassis electrical system

262

Wiring diagrams

275

Chapter 13 Supplement: Revisions and information on 1987 and later models

296

Index

312

4

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and pro¬ cedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. It is hoped that you will use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after having done the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal

lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered section you will be referred to any illustrations which apply to the procedures in that section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it is necessary to refer to another Chapter, the reference will be given as Chapter and Section number i.e. Chapter 1/16). Cross references given without use of the word "Chapter apply to Sections and/or paragraphs in the same Chapter. For exampjp, "see Section 8 means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat, facing forward. Even though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept respon¬ sibility for any errors in, or omissions from, the information given.

NOTE . . . .. A Note provides information necessary to properly complete a procedure or information which wil make the steps to be followed easier to understand. CAUTION , , . . A Caution indicates a special procedure or special steps which must be taken in the course of completing the procedure in which the Caution is found which are necessary to avoid damage to the assembly being worked on. WARNING ust be taken in the course of completing A Warning indicates a special procedure or special steps which m to avoid injury to the person performing the procedure in which the Warning is found which are necessary the procedure.

Introduction to the Ford full-size vans The Ford Econoline was first introduced in 1 961 as the E-100 Series. It was available with either a van, club wagon or pick-up body and a choice of three six-cylinder engines of various displacements. This manual covers all models equipped with inline six-cylinder and V8 engines from 1969 through 1988. The inline six-cylinder engine has a displacement of either 240 or 300 cubic inches and is standard equipment. An optional V8 engine, with a displacement of 302 351, 400 or 460 cubic inches, is also available, depending on the model year.

The standard transmission on all models is a three-speed manual, with mechanical or hydraulic clutch. An automatic transmission is available as an option. The front suspension uses twin I-beam axles pivoted at the inner ends and attached to the chassis by coil springs and radius rods. The rear suspension is a conventional semi-elliptical leaf spring arrangement. Short or long wheelbase versions are available, with a gross vehicle weight capacity ranging from 2300 to 1 1,000 lbs.

6

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to cor¬ rectly identify the component required.

VIN also appears on the Vehicle Certificate of Title and Registration. It contains valuable information such as where and when the vehicle was manufactured, the model year and the body style.

Body identification plate Vehicle identification number G>

•1369KG 9.50-16.5E ■16.5x6.75 •AT 35 PSI COLD

REAR GAWR: 5300 LB WITH TIRES RIMS

2404KG 9.50-16.5E 16.5x6.75 AT 75 PSI COLD

THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE VEHICLE IDENTIFICATION NO.

^JFJB

^FrBF25G. 5^GLA00000^ (a)

(b)

(c)

(d)

(e)

(f)

(g)

(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(h)

-TYPE TRUCK •7B

9M

EXTERIOR PAINT COLORS

WB

TYPE-GVW

BODY

TRANS

AXLE

TAPE

SPRING

133

F252

LA4

F

342

B

2 D 2 9

(a)(b)(cXd)

o

Name and Location of Manufacturer

© ©

Date of Manufacture

© © © ©

Front Tire Size

(12)

Front Gross Axle Weight Ratings in Pounds (LB) and Kilograms (KG)

Rim Size Front Tire Cold PSI Gross Vehicle Weight Rating in Pounds (LB) and Kilograms (KG)

©

Rear Gross Axle Weight Rating in Pounds (LB) and Kilograms (KG)

© © ©

Rear Tire Size Rim Size Rear Tire Cold PSI

Vehicle Identification Number (a) World Manufacturer Identifier (b) Brake System and Gross Vehicle Weight Rating (GVWR) Class for Ford completed Trucks and MPV's. For Buses and Incomplete Vehicles, the fourth digit determines the brake system (only). (c) Model or Line, Series Chassis Cab or Body Type (d) Engine Type (e) Check Digit (f) Model Year (Ford-Complete Trucks and MPV's) (g) Assembly Plant Code (h) Sequential Serial Number

(T5)

Type Vehicle

(u)

Exterior Paint Codes (two sets of figures designates a two-tone)

(15)

Wheelbase in Inches

(Ti)

Model Code and GVW

(17)

Interior Trim, Seat and Body'Cab Type~-i>

(TS)

Transmission Code

(19)

Rear Axle Code

(20)

Front Axle Code if so Equipped

(2j)

District/Special Order Codes

(22)

External Body Tape Stripe Code

(23)

Suspension Identification Codes (a) Aux./Opt. Usage Code (Front) (b) Front Spring Code (c) Aux./Opt. Usage Code (Rear) (d) Rear Spring Code

(24)

Front Axle Accessory Reserve Capacity in Pounds

(25)

Total Accessory Reserve Capacity in Pounds

Typical light truck certification label — 1986 shown, other years similar

8

Vehicle identification numbers

This plate is especially useful for matching the color and type of paint during repair work.

Emissions Control Information label and the actual VIN number on the door pillar.

Vehicle Emissions Control Information label Engine identification numbers The engine number is located on a label usually located on the rocker arm cover. Engine identification can also be done by referring to the

/FORD

The Emissions Control Information label is attached to the engine rocker arm cover on early models and to the radiator support bracket on later models. ----

EVAPORATIVE FAMILY

MOTOR COMPANY

VEHICLE EMISSION CONTROL INFORMATION

VACUUM HOSE ROUTING

IS

DQ

o

^SPARK PLUG

ENGINE FAMILY 4 3/5 0 NA EGR / Al R/C AT AL Y S T ENGINE DISPLACEMENT 5.0L TRANS MAN _ •""Trans GEAR ^NEUTRAL DRIVE

SHIFT SCHED

J iSV'Ti’ON 'TIMING*BTDC

FAST IDLE RPM

8

800

JA z o LU _J QC O
CO LU QC < CO

o z

o QC

-c

Electronic engine control wiring diagram — 5.0L, 5.8L and 7.5L engines — 1987 on (2 of 4)

QC LU

Electronic engine control wiring diagram — 5.0L, 5.8L and 7.5L engines — 1987 on (3 of 4)

310

Electronic engine control wiring diagram — 5.0L, 5.8L and 7.5L engines — 1987 on (4 of 4)

C171

C168

r 311

Index A Accelerator cable — 1 93, 1 94 Air conditioning system servicing — 126, 300 Air filter — 42 Alternator brush replacement — 161 general information — 1 59 removal and installation — 1 59 testing — 1 59 Antifreeze — 1 20 Automatic choke check and adjustment — 140 Automatic transmission band adjustment — 59 fluid and filter change — 58 fluid level check — 34 general information — 192 kickdown rod — 193 neutral start switch — 197 removal and installation — 199 shift linkage — 193, 198 throttle valve (TV) cable — 194 throttle valve (TV) linkage — 193 Axles bearing — 211, 212 general information — 207 oil seal — 211 removal and installation — 208, 209, 21 1

B Battery cables — 151 charging — 44 checking — 43 electrolyte — 33 replacement — 1 51 servicing — 44 Block cleaning — 107 inspection — 109 Blower motor — 1 23 Body front fender — 259 general information — 242 lubrication — 49 maintenance — 242 repair — 243, 244 upholstery and carpets — 243 Booster battery starting — 16 Brakes bleeding — 21 5 caliper — 220

checking — 40 drum brake shoes — 222, 224, 226 fluid level — 33 general information — 215 lines — 21 5 master cylinder — 226, 227 pads — 21 6, 220 parking brake — 228, 230 pedal — 228 power booster — 230 pressure differential valve — 215, 228 rotor — 221 wheel cylinders — 226 Break-in — 11 8 Bumpers — 261 Buying parts — 9

c Camshaft bearings — 1 10 inspection — 109 removal and installation six cylinder — 70 V8 - 86 Carburetor choke check — 37 disassembly and reassembly 2150 2V - 129 4180C 4V — 133 4350 4V — 130 external adjustments — 1 37 removal and installation — 1 28 servicing and overhaul general information — 128 Carrier assembly front oil seal — 21 3 removal and installation — 212 Catalytic converter — 179 Charging system general information — 1 59 testing — 1 59 Chassis lubrication — 49 Check engine warning light — 303 Chemicals — 1 9 Choke control system — 173 Clutch diagnosis — 23, 201 fluid level — 35 general information — 201 inspection — 202 linkage — 203 master cylinder — 35 pedal free play check and adjustment — 39 removal and installation — 204

Index pilot bearing — 203 release bearing — 202 removal and installation — 201 safety switch — 204 throw out bearing — 202 Coil - 1 55 Compression check — 51 Connecting rod inspection — 110 installation — 1 14 removal — 105 Conversion factors — 17 Coolant — 1 20 Coolant level — 32 Cooling system checking — 35 coolant level — 32 servicing — 50 temperature sending unit — 123 Crankshaft bearing clearance — 113, 114 damper — 69, 84 inspection — 111 installation — 113 oil seals — 73, 87 pilot bearing — 203 removal — 106 Cylinder head assembly — 105 cleaning — 103 disassembly — 1 02 inspection — 103 removal and installation six cylinder — 68 V8 - 83, 299

Damper — 69, 84 Deceleration throttle control system — 177 Differential carrier — 21 2 front oil seal — 21 3 general information — 207 oil change — 56 oil level check — 35 removal and installation — 212 Disc brake check — 40 Distributor checking — 53 removal and installation — 157 Distributor cap — 53 Door adjustment — 249 curing rattles — 244 latch — 246, 249 trim panel — 245 Drivebelts — 45 Drivetrain general information — 201, 204, 207 inspection — 206 lubrication — 49 Driveshaft — 204, 205, 206 Drum brakes adjustment — 42 checking — 40 Duraspark system rotor alignment (Duraspark III) — 155 stator removal and installation — 155 Dwell adjustment — 54 specifications — 28

E ECS checking — 37 general description — 166 EFI system general information — 145 EGR valve checking — 38 removal and installation — 170, 298 Electrical charging system general information — 1 59 testing — 1 59 Electrical troubleshooting — 263 Electronic Fuel Injection general information — 145 Emergency brake adjustment — 230 Emergency jump starting — 1 6 Emission control systems — 165 Engine block cleaning — 107 block inspection — 109 general information — 64, 76 oil and filter change — 46 oil level — 30 oil seals — 73, 87 overhaul - 101, 102, 112 rebuilding alternatives — 101 removal and installation — 73, 88, 102 Evaporative emissions control canister — 37, 167 Exhaust Gas Recirculation (EGR) system checking — 1 69 general description — 167 removal and installation — 169, 170, 298 Exhaust heat control valve checking — 36 general information — 179 Exhaust system checking — 36 general information — 143 removal and installation — 143

F Fenders — 259 Firing order — 28 Fluid level checks — 30 Flywheel — 67, 203 Front axles — 235 Front oil seal — 73, 87 Fuel filter replacement — 47 Fuel injection — 145 to 149 Fuel injector — 1 49 Fuel line replacement — 141, 302 Fuel pressure regulator — 149 Fuel pressure relief — 145 Fuel pump — 141, 142, 149 Fuel system checking — 36 Fuel tank — 1 42 Fuses — 272 Fusible links — 263

H Hazard flasher — 269 Head assembly — 105 cleaning and inspection — 102 disassembly — 102 removal and installation six cylinder — 68 V8 - 83, 299

313

314

Headlight adjustment — 264 dimmer switch — 265 sealed beam unit — 264 switch — 265 Heater blower motor — 1 23 cable adjustment — 125 case and core — 1 24 control assembly — 125 Hinges and locks — 244 Hood removal and installation — 257 Hoses — 51, 300 Hydraulic clutch fluid level — 35 Hydraulic system bleeding — 215

Index N Neutral safety switch — 197

o Oil and filter change — 46 Oil level — 30 Oil pan — 71 Oil pump — 72 Oil seals — 73, 87 Overhaul - 101, 102, 112 Oxygen sensor replacement — 298

I

P

Identification numbers — 7 Idle speed — 56 Ignition coil — 155 general information —152 points — 28, 54 rotor — 53 switch — 271 timing — 55 Ignition system inspection and testing (general information) — 1 54 Initial start-up — 1 1 8 Instrument panel removal and installation — 269 switches — 270 Intake manifold bolt torque check — 56 EFI - 147 six cylinder — 67, 299 V8 - 78, 299 Interior trim — 245 Introduction — 5

Parking brake adjustment — 230 PCV filter - 42 PCV valve - 38 Pilot bearing — 203 Piston inspection — 1 10 installation — 1 14 removal — 105 Piston ring installation — 1 1 2 Point gap — 28 Positive Crankcase Ventilation system checking — 38 filter replacement — 42 general information — 165 valve replacement — 38 Power brake booster — 230 Power steering bleeding — 240 fluid level — 35 maintenance — 45 pump — 240

J

R

Jacking — 1 6 Jumpstarting — 1 6

Radiator — 121 Radiator grille — 258, 259 Radius arm — 235 Rear oil seal — 73, 87 Rings — 11 2 Rocker arm cover six cylinder — 67 V8 - 82, 299 Rocker arms six cylinder — 68 V8 - 83 Rod bearing clearance — 1 14 bearing inspection — 1 1 1 inspection — 1 10 installation — 1 14 removal — 105 Rotor — 53 Routine maintenance intervals — 28, 297

K Kickdown rod — 193

L Lifters inspection — 1 1 0 removal and installation — 70, 86 Light bulbs — 265 Lubricants — 1 9 Lubrication — 49

M Main bearing clearance — 11 3 inspection — 1 11 Main oil seals — 73, 87 Maintenance schedule — 29, 297 Maintenance techniques — 9 Manual transmission oil change — 58 Manual transmission oil level check — 33, 298 Master cylinder — 226, 227 Metric conversion table — 1 7

s Safety — 18 Shift linkage — 1 80 Shock absorbers — 235, 236 Six cylinder inline engines general information — 64 removal and installation — 73 specifications — 63, 91, 297

Index Sliding door adjustment — 249 latch — 249 removal and installation — 257 Spark plug wires — 53 Spark plugs — 52, 1 54 Speedometer — 269 Speedometer pinion gear and seal — 1 98 Springs front — 233 rear — 235 Stabilizer bar — 235 Starter motor brush replacement — 163 removal and installation — 163 Starter solenoid — 1 64 Starting system general information — 1 62 testing — 1 62 Steering adjustment — 237, 239 column — 240 gear — 236, 240 general information — 232 lock - 271 maintenance — 35, 49 play — 39 power system bleeding — 240 pump — 240 tie-rod — 241 wheel — 267 Steering column switches — 266 Stop light switch — 266 Suspension front axle — 235 general information — 232 spindles — 232 springs — 233, 235 Suspension and steering check — 39 Switches - 265, 266, 271, 273

T Temperature sending unit — 123 TFI system ignition module — 1 56 Thermactor system — 170 Thermo-controlled air cleaner check — 37 general information — 173 vacuum motor replacement — 1 77 Thermostat — 1 20 Throttle body — 147 Throw out bearing — 202 Tie-rod — 241 Timing — 55 Timing cover and chain (V8 engine) - 84 Timing cover and gears (six cylinder engine) — 68 Tire changing — 1 6 Tires — 30, 42

Tools - 1 2 Top dead center — 1 57 Towing — 1 6 Transmission fluid level — 34 general information — 180, 192, 303 kickdown rod — 193 neutral start switch — 197 oil change — 58 oil level — 33, 298 overhaul — 183, 187, 303 removal and installation — 182, 183, 199 shift linkage — 180, 198 throttle valve (TV) cable — 1 94 throttle valve (TV) linkage — 193 Troubleshooting — 20 Tune-up — 29, 296, 297 Turn signal flasher — 269 switch — 266

u Underhood hose checking — 51 Universal joints — 206 Upholstery — 243

V V8 engine general information — 76 removal and installation — 88 specifications — 75, 94, 297 V-belts - 45 Valve adjustment — 51, 115 Valve servicing — 105 Valve spring, retainer and seal replacement (in vehicle) six cylinder — 64 V8 - 76 Vehicle Identification Numbers — 7 Vibration damper — 69, 84 Voltage regulator — 162

w Water pump checking — 122 removal and installation — 122 Wheel bearings — 59, 212 Wheel stud replacement — 213 Windshield glass — 244 Windshield washer fluid — 33 Wiper blades — 272 Wiper arm — 272 Wiper motor — 272 Wiring diagrams — 275 to 295, 304 to 311 Working facilities — 1 5

315

HAYNES AUTOMOTIVE MANUALS NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, _