ENGINE-4.6 & 5.4L: Removal & Installation Ford Econoline E150

Removal

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210135-S10244877072005121300000) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft with the keyway at the 12 o'clock position.
4. Install and fully tighten the special tools on both camshafts.
5. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
6. Remove the RH and LH timing chains and the crankshaft sprocket. 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.
7. Remove both timing chain guides. Remove the bolts. Remove both timing chain guides.

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1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. Remove the tensioner from the vise.
4. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
5. Install the timing chain guides.
6. Install the special tool.
7. Pre-position the camshafts. Rotate the LH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.
8. Position the crankshaft so the number one cylinder is at TDC with the special tool.
9. Remove the special tool.
10. Install the crankshaft sprocket, making sure the flange faces forward.
11. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
12. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
13. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
14. Remove the retaining clip from the LH timing chain tensioner.
15. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) link on the timing chain.
16. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
17. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
18. Remove the retaining clip from the RH timing chain tensioner.
19. Remove the special tool.
20. As a post-check, verify correct alignment of all timing marks.
21. Remove the special tool.
22. Position the crankshaft sensor ring on the crankshaft.
23. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210135-S10244877072005121300000) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210135-S10244877072005121300000) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.
4. Install the special tools on the camshaft.
5. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
6. Remove the timing chains and crankshaft sprocket.
7. Remove the timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.

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1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. 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.
4. Install the crankshaft sprocket, making sure the flange faces forward.
5. Install the timing chain guide. Position LH timing chain guide. Install and tighten the bolts. Position the RH timing chain guide. Install and tighten the RH bolts.
6. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
7. Remove the special tool.
8. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
9. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
10. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
11. Remove the retaining clip from the LH timing chain tensioner.
12. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
13. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
14. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
15. Remove the retaining clip from the RH timing chain tensioner.
16. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
17. Remove special tools from the camshaft.
18. Install the crankshaft sensor ring on the crankshaft.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-210135-S10244877072005121300000) .

Installation

1. Use the special tools to install the valve stem seals.
2. Install the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-210135-S33257409272005121300000) .

1. Remove the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) .
2. Remove the valve tappets.

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1. Install the valve tappets in their original locations.
2. Install the camshaft roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER»(ref-210135-S14562991402005121300000) .

1. Remove the crankshaft sprocket (6306). For additional information, refer to «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(ref-210135-S32465188892005121300000) or «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(ref-210135-S03830668532005121300000) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-210135-S34324257092005121300000) .
3. Remove the bolts and the oil pump.

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1. Clean and inspect the mating surfaces.
2. Position the oil pump, and install the bolts loosely. Tighten the bolts in the sequence shown.
3. Install the oil pan. For additional information, refer to «OIL PAN»(ref-210135-S34324257092005121300000) .
4. Install the crankshaft sprocket. For additional information, refer to «TIMING DRIVE COMPONENTS - WINDSOR ENGINE (5.4L)»(ref-210135-S32465188892005121300000) or «TIMING DRIVE COMPONENTS - ROMEO ENGINE (4.6L)»(ref-210135-S03830668532005121300000) .

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1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-210156) .
2. Remove the bolts and the flexplate.
3. Remove the bolts and the flexplate.

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1. Position the flexplate. Loosely install the bolts, then tighten the bolts in the sequence shown.
2. Position the flexplate. Loosely install the bolts, then tighten the bolts in the sequence shown.
3. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70W/4R75W»(ref-210156) .