ENGINE-4.6 & 5.4L: Overhaul Ford Econoline E150

Disassembly

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1. Remove the hydraulic lash adjusters.
2. Install the special tool between the valve spring coils to prevent valve stem seal damage.
3. Use the special tool to compress the valve springs.
4. Remove the valves. Remove the valve spring retainer keys. Remove the valve spring retainers. Remove the valve springs. Remove the valves.
5. Remove the valve stem seals.
6. Remove the bolts, the bearing caps and the camshaft.
7. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
8. Remove the bolts, the bearing caps and the camshaft.
9. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
10. Clean the cylinder head sealing surfaces. 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.
11. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .

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1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
3. Tighten the bolts in the sequence shown.
4. Install the camshaft and the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the camshaft bearing caps. Install the bolts loosely.
5. Tighten the bolts in the sequence shown.
6. Install the valves in the valve guides located in the cylinder head.
7. Use the special tools to install the valve stem seals.
8. Install the valve springs and the valve spring retainers onto the valves.
9. Install the special tool between the valve spring coils to prevent valve stem seal damage.
10. Use the special tool to compress the valve springs. Install the valve spring retainer keys.
11. Install the hydraulic lash adjusters in their original locations.
12. Remove the special tool, unless the cylinder head is to be installed in-vehicle.

Piston - Pin Connecting Rod, Press Fit

MATERIAL

MATERIAL SPECIFICATIONS

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1. Press the piston pin out from the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the connecting rod and piston. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .

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1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Press the piston pin into the piston and rod assembly.

Piston - Pin Connecting Rod, Floating Pin

MATERIAL

MATERIAL SPECIFICATIONS

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1. Remove the clips.
2. Remove the piston pin from the piston and connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-210133) .

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1. Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.

Intake Manifold Assembly - 4.6L

MATERIAL

MATERIAL SPECIFICATIONS

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1. Remove the four bolts and the fuel injection supply manifold.
2. Remove the fuel injectors from the fuel injection supply manifold.
3. Discard the two O-ring seals from each fuel injector. Install new O-ring seals.
4. Remove the engine noise shield.
5. Remove the bolts.
6. Separate the upper and lower intake manifolds and discard the lower intake manifold gasket.
7. Remove the bolts from the intake manifold tuning valve and remove the valve.
8. Inspect all external and internal surfaces of the upper intake manifold. Inspect for cracks or other damage. Inspect for foreign material inside of the manifold. Clean the upper intake manifold sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
9. Allow the upper and lower intake manifolds to dry completely.

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1. Position the intake manifold tuning valve and install the bolts.
2. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.
3. Tighten the bolts in two stages using the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
4. Install the engine noise shield.
5. Install the fuel injectors into the fuel injection supply manifold.
6. Install the fuel injection supply manifold and the four bolts.

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1. Remove the fuel infection supply manifold.
2. Remove the fuel injectors from the fuel injection supply manifold.
3. Discard the two O-ring seals from each fuel injector. Install new O-ring seals.
4. Remove the engine noise shield.
5. Remove the water crossover tube. Inspect and install new gaskets as necessary.
6. Inspect all external and internal surfaces of the intake manifold. Inspect for cracks or other damage. Inspect for foreign material inside of the manifold. Clean the intake manifold with a suitable cleaner.

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1. Install the water crossover tube.
2. Install the engine noise shield.
3. Install the fuel injectors into the fuel injection supply manifold.
4. Install the fuel injection supply manifold.

Engine - 4.6L

SPECIAL TOOL(S)

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MATERIAL

MATERIAL SPECIFICATIONS

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1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2". Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper crankshaft main bearings.
7. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
8. Install the rear main bearing cap.
9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
10. Install the vertical main bearing cap fasteners and tighten in the sequence shown. Tighten to 40 Nm (30 lb-ft). Tighten an additional 90 degrees.
11. Tighten the jack screws against the cylinder block in the sequence shown. Tighten to 5 Nm (44 lb-in). Tighten to 10 Nm (89 lb-in).
12. Install the side bolts and tighten them in the sequence shown.
13. Use the special tools to install the piston and connecting rod with the upper connecting rod bearings in place.
14. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
15. Position the lower bearing and connecting rod, and install the new bolts loosely.
16. Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
18. Install the head gasket over the dowel pins.
19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
20. Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
21. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an addition 90 degrees. Stage 3: Tighten an addition 90 degrees.
22. Remove the special tools from both ends of the cylinder head.
23. Install the hydraulic lash adjusters in their original locations.
24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
25. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indicator tube. Install the bolt.
26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
27. Compress the tensioner plunger, using a vise.
28. Install a retaining clip on the tensioner to hold the plunger in during installation.
29. Remove the tensioner from the vise.
30. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
31. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
32. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
33. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
34. Remove the Crankshaft Holding Tool.
35. Install the crankshaft sprocket, making sure the flange faces forward.
36. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
37. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
38. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
39. Remove the retaining clip from the LH timing chain tensioner.
40. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
41. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
42. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
43. Remove the retaining clip from the RH timing chain tensioner.
44. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
45. Install the special tool between the valve spring coils to prevent valve stem seal damage.
46. Install the camshaft roller followers: Install the special tool. Compress the valve spring. Install the camshaft roller followers in their original locations.
47. Install the eight spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft).
48. Install the crankshaft sensor ring on the crankshaft.
49. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
50. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
51. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
52. Position the belt idler pulley and install the bolt.
53. Lubricate the engine front cover and the front seal inner lip with clean engine oil.
54. Use the special tools to install the crankshaft front seal into the engine front cover.
55. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
56. Use the special too to install the crankshaft pulley.
57. Tighten the new crankshaft pulley bolt in four stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). State 4: Tighten an additional 90 degrees.
58. Position the power steering pump and install the bolts
59. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
60. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
61. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
62. Tighten the bolts in the sequence shown.
63. If new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
64. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
65. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
66. Tighten the bolts in the sequence shown.
67. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
68. Install the crankcase ventilation tube on the LH valve cover.
69. Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
71. Connect the CKP sensor electrical connector.
72. Connect the oil pressure switch electrical connector.
73. Connect the KS electrical connector.
74. Connect the RH radio frequency interference capacitor electrical connector.
75. Connect the CMP sensor electrical connector.
76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
77. Install the cylinder block drain plugs
78. Position a new gasket and the oil filter adapter. Install the bolts and nut.
79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
80. If equipped, install the A/C compressor and the bolts.
81. Install the coolant pump. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the bolts.
82. Position the coolant pump pulley on the coolant pump and install the bolts.
83. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
84. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
86. Tighten the bolts in the sequence shown.
87. Install the oil drain plug before installing the oil pan.
88. Install the oil pump screen and pickup tube spacer.
89. Position the oil pump screen and pickup tube and install the bolts.
90. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
91. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
93. Install the oil pan gasket and the oil pan and loosely install the bolts.
94. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
95. Install the special tool.
96. Install the special tool.
97. Install the special tool and remove the engine from the work stand.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
100. Install the oil level indicator tube nut and insert the oil level indicator.
101. Using the special tools, install a new crankshaft rear seal.
102. Using the special tools, install the crankshaft rear oil slinger.
103. Install the flexplate and bolts: Tighten the bolts in the sequence shown.
104. Install the engine. For addition information, refer to «ENGINE - 4.6L»(ref-210135-S25959258862005121300000) .