Engine - 4.6L Ford Econoline E150

Engine - 4.6L

SPECIAL TOOL(S)

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MATERIAL

MATERIAL SPECIFICATIONS

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1. Remove the engine. For additional information, refer to «ENGINE - 4.6L»(ref-210135-S25959258862005121300000) .
2. Remove the bolts and the flexplate.
3. Using the special tools, remove the crankshaft rear slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the bolts and the crankshaft rear seal retainer plate.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
8. Install the special tool.
9. Install the special tool.
10. Mount the engine on a suitable work stand.
11. Remove the RH and LH engine mounts.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
16. Disconnect the knock sensor (KS) electrical connector.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
18. Disconnect the oil pressure switch electrical connector.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
22. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
23. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
24. Remove the RH valve cover. Fully loosen the bolts and remove the valve cover. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
25. Remove the bolt and the belt idler pulley.
26. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
27. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
28. Use the special tool to remove the crankshaft front seal.
29. Remove the power steering pump.
30. Remove the four oil pan bolts.
31. Remove the fasteners.
32. Remove the engine front cover from the cylinder block.
33. Remove the crankshaft sensor ring from the crankshaft.
34. Remove the eight spark plugs.
35. Install the special tool between the valve spring coils to prevent valve stem seal damage.
36. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
37. Position the crankshaft with the keyway at the 12 o'clock position.
38. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
39. Remove the RH and LH timing chains and the crankshaft sprocket(s). Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket(s).
40. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.
41. Remove the RH exhaust manifold. Remove the nuts. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket.
42. Remove the LH exhaust manifold. Remove the nuts. Remove the LH exhaust manifold. Remove the LH exhaust manifold gasket.
43. Remove the bolt and the oil level indicator tube.
44. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .
45. Install the special tools on both ends of the cylinder head.
46. Remove the hydraulic lash adjusters.
47. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
48. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
49. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
50. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
51. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
52. Clean the oil filter adapter gasket surface at the cylinder block.
53. Remove the bolts.
54. Remove the coolant pump from the cylinder block.
55. Remove the bolts and the A/C compressor.
56. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
57. Remove the bolts, the oil pan and the oil pan gasket. Clean and inspect the sealing surfaces.
58. Remove the bolts and the oil pump screen and pickup tube.
59. Remove the oil pump screen and pickup tube spacer.
60. Remove the oil pump. Remove the bolts. Remove the oil pump.
61. Remove the bolts and the connecting rod cap. Discard the bolts.
62. Use the special tool to push the piston through the top of the cylinder block.
63. Remove the crankshaft bearing cap fasteners. Remove and discard the cross-mounted main cap bolts. Loosen the jack screws. Remove and discard the main cap bolts.
64. Remove the five main bearing caps and the lower crankshaft main bearings.
65. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.