Ford Full-Size Van Repair Manual: E-100, E-150, E-200, E-250, E-300, E-350, Club Wagon 1961-1988

• Ford E-100
• Ford E-150
• Ford E-200
• Ford E-250
• Ford E-300
• Ford E-350

VALVE SEATS

REMOVAL AND INSTALLATION

8-420 (6.9L) AND 8-444 (7.3L) DIESEL
(See Figures 143 and 144)

NOTE: The diesel is the only engine covered in this guide which has removable valve seats.

1. Using Ford Rotuda tool 14-0309, or equivalent, the exhaust valve seats may be removed. Position the remover collet into the insert and rotate the collet nut clockwise to expand the collet jaws under the lip of the seat insert.



2. Rotate the top nut clockwise to remove the insert.


NOTE: If an oversize insert is required, the cylinder head should be sent out to a qualified machine shop.


3. To install a new exhaust valve seat, drive the seat in place using Rotunda tool 14-0309, or equivalent, and a hammer.

Valve seat inserts are supplied for service in standard size 0.015 in. (0.381mm) oversize and 0.030 in (0.762mm) oversize.


VALVE GUIDES | REAMING VALVE GUIDES

If it becomes necessary to ream a valve guid to install with an oversize stem, a reaming kit is available which contains a oversize reamers and pilot tools.

When replacing a standard size valve with an oversize valve always use the reamer in sequence (smallest oversize first, and then next smallest, etc.) so as not to overload the reamers.

Always reface the valve seat after the valve guide has been reamed, and use a suitable scraper to brake the sharp corner at the top of the valve guide.

HEADLIGHT SWITCH | REMOVAL AND INSTALLATION
(See Figure 61)

1. Remove the headlamp control knob and shaft by pressing the knob release button on the switch housing, with the knob in the full ON position.



2. Pull the knob and shaft assembly out of the switch.



3. Remove the switch, and then remove the wiring connector from the switch.



4. To install the switch, connect the wiring connector to the headlamp switch, position the switch in the instrument panel, and install the bezel and mounting nut.



5. Install the knob and shaft assembly by inserting it all the way into the switch until a distinct click is heard. In some instances it may be necessary to rotate the shaft slightly until it engages the switch contact carrier.



6. Connect the battery ground cable.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams