2004 Ford E-150 Service and Repair Manual

This factory service and repair manual for the 2004 Ford E-150 is built around two naturally aspirated gasoline V8s. The 4.6L overhead-cam engine displaces 281 cubic inches and the 5.4L overhead-cam engine 330, and either could be ordered in the three-door standard passenger van or the two-door standard cargo van, in Base or XL trim. Procedures, specifications, torque values, wiring diagrams and diagnostics are arranged by system across the whole vehicle, from fuel delivery and ignition through to the chassis and body circuits.

Engines covered

• 4.6L V8 (281 cu in) — SOHC, naturally aspirated, gasoline
• 5.4L V8 (330 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 3-door standard passenger van
• 2-door standard cargo van

Trims covered

• Base
• XL

Known issues on the 2004 E-150. Five recalls sit on the federal record for this year. One concerns replacement fuel tanks with an unsealed extra sensor hole that could leak and feed a fire, another concerns an air filter element that could smolder or burn, and a third concerns a diode in the anti-lock braking module that could short. Two more cover wheelchair lifts fitted to converted vans. Owners have filed 36 complaints with NHTSA. Fuel storage, intake and braking are all documented here with their own procedures and diagnostics.