How to Replace the Coil Pack on a 2004 4.6L E-250

In 1960, Ford released the Econoline series of full-size vans. The Econoline nomenclature remained in Fords lineup until 2003 when Ford changed the name to the E-series. The 2004 E-series came in three main distinctions: E-150, E-250 and E-350 Super Duty. The 2004 E-250 came standard with a 225-horsepower, 4.6-liter V-8 engine that used the similar coil-on-plug system ignition system as the Mustang and F-series. Replacing a coil pack on the E-250s 4.6-liter engine is tricky, as the format of the van required Ford to position the engine too far rearward to access the coil packs from under the hood.

Instructions

1

Open the storage bin door on the center console, if equipped. Press and hold the locking tabs inside the storage bin door, and pull the storage bin from the console. Look inside the cavity where the storage bin was and find the locking clip inside. Press and hold this locking clip; pull the center console from the truck.

2

Pull downward on the steering column cover the trim panel directly below the steering wheel to disengage its retaining clips. Remove the steering column cover from the van.

3

Unfasten the four latches on the interior engine cover, the carpeted cover under the dashboard and between the front seats, and pull the engine cover from the van, exposing the engine.

4

Sharply pull upward on the front part of the air intake tube -- the tube running from the front of the van to the air filter box -- to disengage its retaining clips. Pull the air intake tube toward the passengers side of the van to remove it from the air filter box.

5

Remove the four screws securing the air filter box, using a ratchet and socket. Press and hold the unlocking button on the mass airflow sensor wiring harness on the rear of the air filter box, and unplug the wiring harness.

6

Loosen the hose clamp securing the air filter box outlet tube to the air filter box using a flat-head screwdriver, and pull the air filter box from the van.

7

Pull the two roughly 1-inch-diameter tubes from the air filter box outlet tube. Loosen the hose clamp securing the air filter box outlet tube to the throttle body using a flat-head screwdriver, and pull the air filter box outlet tube from the van.

8

Look through the engine access hole inside the van to see the eight coil packs on the top of the engine, just above the valve covers.

9

Press and hold the unlocking button on the failed coils wiring harness, and unplug the harness. Remove the bolt securing the coil pack to the engine, using a ratchet and socket, and pull upward on the coil pack with a slight twisting motion to remove it from the engine.

10

Apply a dab of dielectric grease to the inside of the rubber boot on the new coil pack and spread the grease around the inside of the coil packs boot with a small flat-head screwdriver.

11

Align the boot with the top of the exposed spark plug and press the coil pack downward until you feel it click onto the spark plug. Hand-tighten the coil packs bolt, then torque it to 53 inch-pounds using an inch-pound torque wrench and socket.

12

Plug the wiring harness into the new coil pack.

13

Repeat steps 9 through 12 to replace any additional failed coil packs.

14

Press the air filter box outlet tube back onto the throttle body and tighten its hose clamp with a flat-head screwdriver. Press the two roughly 1-inch-diameter hoses into their respective inlets on the air filter outlet tube.

15

Plug the wiring harness into the MAF sensor on the air filter box and slide the air filter box into the end of the air filter box outlet tube. Tighten the hose clamp to secure the connection between the tube and the air filter box. Hand-thread the four air filter box-retaining bolts, then torque them to 80 inch-pounds.

16

Guide the rearmost end of the air intake tube into the inlet on the air filter box there is no hose clamp to secure this connection and align the retaining clips on the bottom of the front portion of the air intake tube with its slots in the upper radiator support bar. Press downward on the front of the air intake tube to lock the clips into place.

17

Set the engine cover into place over the engine access hole and clasp the four latches shut to secure the engine cover in place.

18

Guide the steering column cover into place under the steering wheel, aligning its retaining clips with the slots in the dashboard. Press the cover upward to lock its retaining tabs.

19

Position the center console into place over the engine cover, if equipped with a center console. Line up the retaining clips mechanism with the mount on the engine cover and press the console toward the front of the truck to snap it into place. Guide the storage compartment into the center console and slide it toward the front of the truck until its retaining tab snaps into place.