Engine - 4.6l (3v) Ford Explorer Sport Trac II

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

a The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

a Refer to the procedure in this article.

Note. Refer to the exploded view under the assembly procedure in this article.

The 4.6L (3V) is a V-8 engine with the following features

1. Single overhead camshafts
2. Three valves per cylinder
3. Sequential multi-port fuel injection (SFI)
4. Aluminum cylinder heads
5. Cast iron cylinder block
6. Variable camshaft timing (VCT)
7. Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
8. Distributorless ignition system
9. Electronic returnless fuel system

Identification

Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all of the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their applications.

Code Information

The engine code information label, located on the side of the valve cover and the front side of the valve cover, contains the following

1. Engine build date
2. Engine plant code
3. Engine code

Induction System

The sequential multi-port fuel injection (SFI) provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel injectors

1. are mounted in the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. are connected in series with the fuel rail pressure and temperature sensor.
5. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel rail pressure and temperature sensor. The fuel rail pressure and temperature sensor

1. is positioned upstream from the fuel injectors on the fuel rail.

Valve Train

The valve train operates as follows

1. Ball-tip hydraulic lash adjusters provide automatic lash adjustment.
2. Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Lubrication System

The engine lubrication system operates as follows

1. Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
2. Oil is pumped through the oil filter on the left front side of the cylinder block.
3. Oil enters the main gallery where it is distributed to the crankshaft main journals and to both cylinder heads.
4. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.
5. The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed non-serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash adjusters and the primary and secondary timing chain tensioners.
6. The camshaft lobe and roller followers are lubricated by splash created through valve train operation.

Oil Pump

The lubrication system of the 4.6L (3V) engine is designed to provide optimum oil flow to critical components of the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure, both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Scheme 65

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the Introduction - Gasoline Engines article.

Intake Manifold

Material

Scheme 66

REMOVAL

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information) article.
2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
3. Remove the fuel rail and injectors. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-and-engine-controls-46l-3v) article.
4. Disconnect the electronic throttle body (TB) electrical connector.
5. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
6. Disconnect the throttle position (TP) sensor electrical connector.
7. Disconnect the PCV hose from the heated PCV fitting on the intake manifold.
8. Remove the bolts and position the heated PCV fitting aside. Remove and discard the O-ring seal.
9. Detach the wiring harness retainers from the intake manifold.
10. Disconnect the charge motion control valve (CMCV) electrical connector.
11. Remove the bolts and position the intake manifold forward.
12. Disconnect the brake booster vacuum hose from the rear of the intake manifold.
13. Disconnect the vacuum hose from the rear of the intake manifold.
14. Remove the intake manifold and the gaskets. Discard the gaskets.

INSTALLATION

1. Using new intake manifold gaskets, position the intake manifold.
2. Connect the vacuum hose to the rear of the intake manifold.
3. Connect the brake booster hose to the rear of the intake manifold.
4. Install the intake manifold bolts and tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
5. Connect the CMCV electrical connector.
6. Attach the wiring harness retainers to the intake manifold.
7. Install a new O-ring seal, position the heated PCV fitting and install the bolts.
8. Connect the PCV hose to the heated PCV fitting on the intake manifold.
9. Connect the TP sensor electrical connector.
10. Connect the EVAP hose to the intake manifold.
11. Connect the electronic TB electrical connector.
12. Install the fuel rail and injectors. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-and-engine-controls-46l-3v) article.
13. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.

Valve Cover - LH

Material

Scheme 67

Scheme 68

1. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
2. Remove the bolt and position the oil level indicator and tube aside.
3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
4. Disconnect the PCV hose from the valve cover.
5. Remove the nut and position the cooling fan wiring harness bracket aside.
6. Disconnect the 2 pin-type retainers from the valve cover.
7. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
8. Detach the wiring harness retainers from the valve cover studs.
9. Disconnect the EVAP canister purge valve electrical connector.
10. Disconnect the EVAP canister-to-EVAP canister purge valve EVAP hose from the EVAP canister purge valve.
11. Loosen the 10 bolts and remove the LH valve cover and gasket. Discard the gasket.

1. Clean the gasket mating surfaces. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Clean the valve cover gasket groove in the valve cover with soap and water or a suitable solvent.
2. Install a new gasket on the LH valve cover.
3. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
4. Position the LH valve cover with a new gasket and tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
5. Connect the EVAP canister-to-EVAP canister purge valve EVAP hose to the EVAP canister purge valve.
6. Connect the EVAP canister purge valve electrical connector.
7. Attach the wiring harness retainers to the valve cover studs.
8. Connect the VCT solenoid electrical connector.
9. Connect the 2 pin-type retainers to the valve cover.
10. Position the cooling fan wiring harness bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
11. Connect the PCV hose to the valve cover.
12. Connect the EVAP tube to the intake manifold.
13. Position the oil level indicator tube and install the bolt. Tighten to 10 Nm (89 lb-in).
14. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.

Valve Cover - RH

Material

Scheme 69

1. Remove the air cleaner (ACL) and the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
2. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
3. Disconnect the engine wiring harness from the PCM. Disconnect the 2 PCM electrical connectors. Disconnect the in-line electrical connector. Detach the wiring harness retainer from the PCM bracket and position the wiring harness aside.
4. Disconnect the RH variable camshaft timing (VCT) oil control solenoid electrical connector.
5. Detach the 2 wiring harness retainers from the RH valve cover studs.
6. Detach the wiring harness pin-type retainer from the front of the RH valve cover.
7. Detach the heater hose retainer from the RH valve cover.
8. Disconnect the crankcase breather tube from the RH valve cover.
9. Loosen the 9 RH valve cover bolts and remove the RH valve cover and the RH valve cover gasket. Discard the gasket.

1. Clean the gasket mating surfaces. Clean the valve cover mating surface of the RH cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Clean the RH valve cover gasket groove with soap and water or a suitable solvent.
2. Install a new gasket on the RH valve cover.
3. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the RH cylinder head.
4. Position the RH valve cover with a new gasket on the cylinder head and tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
5. Connect the crankcase breather tube to the RH valve cover.
6. Attach the heater hose retainer to the RH valve cover.
7. Attach the wiring harness pin-type retainer to the front of the RH valve cover.
8. Attach the wiring harness retainers to the RH valve cover studs.
9. Connect the RH VCT oil control solenoid electrical connector.
10. Connect the engine wiring harness to the PCM. Position the wiring harness and attach the wiring harness pin-type retainer to the PCM bracket. Connect the in-line electrical connector. Connect the 2 PCM electrical connectors.
11. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
12. Install the air cleaner and the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.

Scheme 70

1. For additional information, refer to the procedures in this article.

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)

Scheme 71

Scheme 72

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the cooling fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/explorer-sport-trac/ii-2006-2010/remont/accessory-drive-belts/#accessory-drive-system) article.
4. Remove and discard the crankshaft pulley bolt and washer.
5. Using the special tool, remove the crankshaft pulley.

1. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 90 N.m (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 N.m (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/explorer-sport-trac/ii-2006-2010/remont/accessory-drive-belts/#accessory-drive-system) article.
5. Install the cooling fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Front Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Seal 303-335 (T88T-6701-A) Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)

Material

1. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__crankshaft-pulley) .
2. Using the special tool, remove the crankshaft front seal.

1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__crankshaft-pulley) .

Scheme 73

1. For additional information, refer to the procedures in this article.

REMOVAL AND INSTALLATION

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) article.
2. Remove the 6 bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft) in the sequence shown.
3. To install, reverse the removal procedure.

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Impact Slide Hammer 100-001 (T50T-100-A) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Rear Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH)

Scheme 74

Scheme 75

Material

1. Remove the flexplate. For additional information, refer to «Flexplate»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .
2. Remove the engine-to-transmission spacer plate.
3. Using the special tools, remove the crankshaft oil slinger. Discard the crankshaft oil slinger.
4. Using the special tools, remove the crankshaft rear seal. Discard the crankshaft rear seal.

1. Using the special tools, install the crankshaft rear seal.
2. Using the special tools, install the crankshaft rear oil slinger.
3. Install the engine-to-transmission spacer plate.
4. Install the flexplate. For additional information, refer to «Flexplate»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .

Crankshaft Rear Seal with Retainer Plate

Special Tools Illustration Tool Name Tool Number Impact Slide Hammer 100-001 (T50T-100-A) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Rear Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH)

Material

1. Remove the flexplate. For additional information, refer to «Flexplate»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .
2. Remove the engine-to-transmission spacer plate.
3. Remove the oil pan. For additional information, refer to «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .
4. Using the special tools, remove the crankshaft oil slinger. Discard the crankshaft oil slinger.
5. Using the special tools, remove the crankshaft rear seal. Discard the crankshaft rear seal.
6. Remove the 6 bolts and the crankshaft rear seal retainer plate.

1. Clean and inspect the mating surfaces.
2. Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the engine block.
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
4. Using the special tools, install the crankshaft rear seal.
5. Using the special tools, install the crankshaft rear oil slinger.
6. Install the oil pan. For additional information, refer to «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .
7. Install the engine-to-transmission spacer plate.
8. Install the flexplate. For additional information, refer to «Flexplate»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .

Engine Front Cover

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Installer, Crankshaft Front Seal 303-335 (T88T-6701-A) Installer, Crankshaft Front Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)

Scheme 76

Material

Scheme 77

Scheme 78

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the drain plug and drain the engine oil. To install, tighten to 23 Nm (17 lb-ft).
3. Remove the cooling fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
4. Remove the RH side idler pulley. For additional information, refer to «ACCESSORY DRIVE»(/ford/explorer-sport-trac/ii-2006-2010/remont/accessory-drive-belts/#accessory-drive-system) article.
5. Remove the RH valve cover. For additional information, refer to «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
6. Remove the LH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) .
7. Remove the nut and position the RH radio interference capacitor aside.
8. Disconnect the RH camshaft position (CMP) sensor electrical connector.
9. Remove the nut and the cooling fan wiring harness bracket.
10. Remove the nut and position the LH radio interference capacitor aside.
11. Disconnect the LH CMP sensor electrical connector.
12. Remove the bolts and the coolant pump pulley.
13. Remove the nuts and detach the battery cable bracket from the power steering pump stud bolts.
14. Detach the wiring harness retainer from the power steering pump stud bolt.
15. Remove the stud bolts and position the power steering pump aside. Support the power steering pump with a length of mechanic's wire.
16. Remove the nut and detach the power steering pressure (PSP) hose bracket from the battery cable bracket.
17. Remove the nut and detach the battery cable bracket from the engine front cover.
18. Remove the nut and detach the transmission cooler tube bracket from the engine front cover.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
20. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
21. Using the special tool, remove the crankshaft pulley.
22. Using the special tool, remove the crankshaft front seal. Discard the crankshaft front seal.
23. Remove the oil pan-to-engine front cover bolts.
24. Remove the engine front cover bolts and stud bolts.
25. Remove the engine front cover from the engine front cover-to-cylinder block dowel. Remove and discard the engine front cover gaskets.

1. Clean the mating surfaces with silicone gasket remover, metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
2. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block mating surface and the oil pan-to-cylinder block mating surface at the locations shown.
3. Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 W706508 Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53 12 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
5. Loosely install the oil pan-to-engine front cover bolts, then tighten the bolts in 2 stages in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
6. Lubricate the engine front cover and a new crankshaft front seal inner lip with clean engine oil.
7. Using the special tools, install the crankshaft front seal.
8. Apply silicone gasket sealant to the Woodruff key slot in the crankshaft pulley.
9. Using the special tool, install the crankshaft pulley.
10. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
11. Connect the CKP sensor electrical connector.
12. Attach the transmission cooler tube bracket to the engine front cover and install the nut. Tighten to 12 Nm (9 lb-ft).
13. Attach the battery cable bracket to the front cover and install the nut. Tighten to 10 Nm (89 lb-in).
14. Attach the PSP hose bracket to the battery cable bracket and install the nut. Tighten to 10 Nm (89 lb-in).
15. Position the power steering pump and install the stud bolts. Tighten to 25 Nm (18 lb-ft).
16. Attach the wiring harness retainer to the power steering pump stud bolt.
17. Position the battery cable bracket on the power steering pump stud bolts and install the nuts. Tighten to 10 Nm (89 lb-in).
18. Position the coolant pump pulley and install the bolts. Tighten the bolts to 25 Nm (18 lb-ft).
19. Connect the LH CMP sensor electrical connector.
20. Position the LH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
21. Position the cooling fan wiring harness bracket and install the nut.
22. Connect the RH CMP sensor electrical connector.
23. Position the RH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
24. Install the LH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) .
25. Install the RH valve cover. For additional information, refer to «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
26. Install the RH side idler pulley. For additional information, refer to «ACCESSORY DRIVE»(/ford/explorer-sport-trac/ii-2006-2010/remont/accessory-drive-belts/#accessory-drive-system) article.
27. Install the cooling fan shroud. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
28. Fill the engine with clean engine oil.

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039 Locking Tool, Camshaft Phaser Sprocket 303-1046

Scheme 79

Material

1. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__engine-front-cover) .
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft keyway at the 12 o'clock position.
4. The No. 1 cylinder must be coming up on the exhaust stroke with the crankshaft keyway at the 12 o'clock position. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.
5. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
6. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
7. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
8. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
9. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
10. Remove the bolts, the LH timing chain tensioner and tensioner arm.
11. Remove the bolts, the RH timing chain tensioner and tensioner arm.
12. 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.
13. Remove the LH and RH timing chain guides. Remove the bolts. Remove both timing chain guides.
14. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
15. Using the special tool, remove the bolt and the LH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
16. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
17. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
18. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
19. Remove the RH camshaft.
20. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
21. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
22. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
23. Remove the LH camshaft.
24. Remove all of the remaining roller followers from the cylinder heads.

1. Install the LH and RH camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
2. Install the LH and RH camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely. Tighten to 10 N.m (89 lb-in) in the sequence shown.
3. Install the camshaft phaser sprockets and new camshaft phaser bolts finger-tight.
4. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. Stage 1: Tighten to 40 N.m (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
5. Install the crankshaft sprocket, making sure the flange faces forward.
6. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.
7. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
8. Compress the tensioner plunger, using a vise.
9. Install a retaining clip on the tensioner to hold the plunger in during installation.
10. Remove the tensioner from the vise.
11. If the colored links are not visible, mark one link on one end and one link on the other end and use as timing marks.
12. Install the 4 bolts and the LH and RH timing chain guides. Tighten to 10 N.m (89 lb-in).
13. 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 colored (marked) link on the chain.
14. Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
15. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts. Tighten to 25 N.m (18 lb-ft).
16. Remove the retaining clip from the LH timing chain tensioner.
17. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single colored (marked) chain link.
18. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. Tighten to 25 N.m (18 lb-ft).
20. Remove the retaining clip from the RH timing chain tensioner.
21. As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.
22. Install the crankshaft sensor ring on the crankshaft.
23. Using the special tool, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation.
24. Install the engine front cover. For additional information, refer to «Engine Front Cover»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__engine-front-cover) .

Valve Train Components - Exploded View

Note. LH side.

Scheme 80

Note. RH side.

Scheme 81

1. For additional information, refer to the procedures in this article.

Camshaft - LH

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039 Wedge, Timing Chain 303-1175

Material

Note. The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the LH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) .
3. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
5. Remove the LH CMP sensor and the bolt.
6. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step.
9. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. Install the special tool in the LH timing chain as shown.
11. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
13. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
14. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
15. Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer.
16. Remove the camshaft.
17. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to «Camshaft Phaser and Sprocket»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-phaser-and-sprocket) .

1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight.
3. Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. Install the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely.
5. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
6. Remove the special tools.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes.
9. Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
11. Connect the CMP electrical connector.
12. Tighten the camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the LH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) .

Camshaft - RH

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039 Wedge, Timing Chain 303-1175

Material

Note. The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the RH valve cover. For additional information, refer to «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
3. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH camshaft position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step.
9. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. Install the special tool in the RH timing chain as shown.
11. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
13. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
14. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
15. Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer.
16. Remove the camshaft.
17. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to «Camshaft Phaser and Sprocket»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-phaser-and-sprocket) .

1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight.
3. Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. Install the camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely.
5. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
6. Remove the special tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes.
9. Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. Tighten the new camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the RH valve cover. For additional information, refer to «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .

Camshaft Phaser and Sprocket

Special Tools Illustration Tool Name Tool Number Locking Tool, Timing Chain 303-1175

1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to «Camshaft - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-rh) .
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to «Camshaft - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-lh) .
3. Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins. If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin. If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed.
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket.

1. If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket.
2. Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to «Camshaft - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-rh) .
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to «Camshaft - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-lh) .

Camshaft Roller Follower

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039

Material

1. Depending on the roller follower being serviced, remove the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
3. Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced.
5. Inspect the roller follower. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

1. Using the special tool, compress the valve spring and install the camshaft roller follower.
2. Repeat the previous step for each roller follower being serviced.
3. Depending on the valve being serviced, install the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039

Material

1. Depending on the valve spring being serviced, remove the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
2. Remove the spark plug. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
3. Rotate the crankshaft until the piston for the valve spring being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
4. Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position. Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer and the valve spring.
8. Inspect the valve spring. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

1. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys.
2. Relieve the air pressure from the cylinder.
3. Using the special tool, compress the valve spring and install the camshaft roller follower.
4. Install the spark plug. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
5. Depending on the valve spring being serviced, install the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .

Valve Seals

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039 Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)

Scheme 82

Material

1. Depending on the valve seal being serviced, remove the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .
2. Remove the spark plug. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
3. Rotate the crankshaft until the piston for the valve seal being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
4. Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position. Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer, the valve spring and the valve seal. Discard the valve seal.
8. Inspect the components. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

1. Position a new valve seal onto the valve stem.
2. Using the special tool, install the new valve seal.
3. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys.
4. Relieve the air pressure from the cylinder.
5. Using the special tool, compress the valve spring and install the camshaft roller follower.
6. Install the spark plug. For additional information, refer to «ENGINE IGNITION - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/ignition-system/#engine-ignition-system-46l-3v) article.
7. Depending on the valve seal being serviced, install the LH or RH valve cover. For additional information, refer to «Valve Cover - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-lh) or «Valve Cover - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-cover-rh) .

Hydraulic Lash Adjuster

Material

1. Remove the camshafts. For additional information, refer to «Valve Train Components - Exploded View»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__valve-train-components-exploded-view) and «Camshaft - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-lh) and «Camshaft - RH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__camshaft-rh) .
2. Remove the remaining roller followers from the cylinder head being serviced.
3. Remove the hydraulic lash adjusters that are being serviced.
4. Inspect the hydraulic lash adjusters. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
5. To install, reverse the removal procedure.

Scheme 83

Scheme 84

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Detach the evaporative emission (EVAP) canister purge valve from the bracket and position the valve aside.
3. Remove the intermediate steering shaft pinch bolt and disconnect the intermediate steering shaft from the lower steering column shaft.
4. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds.
5. Remove the nuts and position the battery cable bracket aside.
6. Remove the bolts and the LH exhaust manifold heat shield.
7. Remove and discard the pushpin.
8. Remove the 8 nuts, the LH exhaust manifold and the gaskets. Deflect the inner fender splash shield and remove the manifold between the splash shield and the frame rail. Discard the nuts and the gaskets.
9. Remove and discard the 8 LH exhaust manifold studs.

1. Inspect the LH exhaust manifold gasket mating surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
2. Install 8 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position the new gaskets, the LH exhaust manifold and install new nuts finger-tight. Deflect the inner fender splash shield and install the exhaust manifold between the splash shield and the frame rail.
4. Tighten the exhaust manifold nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
5. Position the inner fender splash shield and install a new pushpin.
6. Install the heat shield and the bolts. Tighten to 10 Nm (89 lb-in).
7. Position the battery cable bracket and install the nuts. Tighten to 10 Nm (89 lb-in).
8. Connect the dual converter Y-pipe to the exhaust manifolds and install the 4 nuts. Tighten to 40 Nm (30 lb-ft).
9. Connect the intermediate steering shaft to the lower steering column shaft and install the pinch bolt. Tighten to 48 Nm (35 lb-ft).
10. Attach the EVAP canister purge valve to the bracket.

Scheme 85

Scheme 86

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds.
3. Remove the bolts and the RH exhaust manifold heat shield.
4. Remove the pushpins and the RH splash shield.
5. Remove the 8 nuts, the RH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
6. Remove and discard the 8 RH exhaust manifold studs.

1. Inspect the exhaust manifold gasket mating surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
2. Install 8 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position the new gaskets, the RH exhaust manifold and install new nuts finger-tight.
4. Tighten the nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
5. Position the RH splash shield and install the pushpins.
6. Position the heat shield and install the bolts. Tighten to 10 Nm (89 lb-in).
7. Connect the dual converter Y-pipe to the exhaust manifolds and install the nuts. Tighten to 40 Nm (30 lb-ft).

Scheme 87

Scheme 88

1. For additional information, refer to the procedures in this article.

Oil Pan

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the front axle, if equipped. For additional information, refer to «FRONT DRIVE AXLE/DIFFERENTIAL - DANA 30»(/ford/explorer-sport-trac/ii-2006-2010/remont/differentials-drive-axles/#front-drive-axledifferential-dana-30) article.
3. Remove the stabilizer bar. For additional information, refer to «FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)»(/ford/explorer-sport-trac/ii-2006-2010/remont/suspension-front/#front-suspension-system-rear-wheel-drive-rwd) article.
4. Remove the drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
5. Remove the nut and position the power steering pressure (PSP) hose bracket aside.
6. Remove the nut and position the battery cable bracket aside.
7. Disconnect the oil temperature sensor electrical connector.
8. Remove the bolts and the oil drain splash shield.
9. If equipped with a block heater, detach the block heater wiring harness retainers from the LH side oil pan bolts.
10. Remove the bolts, the oil pan and the gasket. Discard the gasket.

1. Clean and inspect the sealing surfaces with silicone gasket remover, metal surface prep, and a plastic scraper. Follow the directions on the packaging.
2. Apply silicone gasket and sealant in 2 places as shown.
3. Apply silicone gasket and sealant in 2 places as shown.
4. Position a new oil pan gasket and the oil pan and install the bolts finger-tight.
5. Tighten the bolt in 3 stages in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
6. If equipped with a block heater, attach the block heater wiring harness retainers to the LH oil pan bolts.
7. Position the oil drain splash shield and install the bolts. Tighten to 12 Nm (9 lb-ft).
8. Connect the oil temperature sensor electrical connector.
9. Attach the battery cable bracket and install the nut. Tighten to 10 Nm (89 lb-in).
10. Attach the PSP hose bracket and install the nut. Tighten to 10 Nm (89 lb-in).
11. Install the stabilizer bar. For additional information, refer to «FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)»(/ford/explorer-sport-trac/ii-2006-2010/remont/suspension-front/#front-suspension-system-rear-wheel-drive-rwd) article.
12. Install the front axle, if equipped. For additional information, refer to «FRONT DRIVE AXLE/DIFFERENTIAL - DANA 30»(/ford/explorer-sport-trac/ii-2006-2010/remont/differentials-drive-axles/#front-drive-axledifferential-dana-30) article.
13. Fill the engine with clean engine oil.

Oil Pump Screen and Pickup Tube

Material

1. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) and «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .
2. Remove the bolts and the oil pump screen and pickup tube.

1. Position the oil pump screen and pickup tube and install the bolts. Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 N.m (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 N.m (18 lb-ft).
2. Install the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) and «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .

Material

1. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) and «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .
2. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__timing-drive-components) .
3. Remove the bolts and the oil pump screen and pickup tube.
4. Remove the 3 bolts and the oil pump.

1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
2. Position the oil pump and install the bolts. Tighten to 10 N.m (89 lb-in).
3. Position the oil pump screen and pickup tube and install the bolts. Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 N.m (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 N.m (18 lb-ft).
4. Install the timing drive components. For additional information, refer to «Timing Drive Components»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__timing-drive-components) .
5. Install the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) and «Oil Pan»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__oil-pan) .

Oil Filter Adapter

Material

Scheme 89

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Drain the engine oil. Install the drain plug and tighten to 23 Nm (17 lb-ft).
4. Disconnect the engine oil pressure switch electrical connector.
5. Disconnect the lower radiator hose and position it aside.
6. Remove and discard the engine oil filter. To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
7. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
8. Remove and discard the oil filter adapter gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
9. To install, reverse the removal procedure. Fill the engine with clean engine oil.
10. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Oil Level Indicator and Tube

Material

Scheme 90

1. Remove the LH exhaust manifold. For additional information, refer to «Exhaust Manifold - LH»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .
2. Remove the oil level indicator and tube bolt. To install, tighten to 10 Nm (89 lb-in).
3. Remove the oil level indicator and tube from the cylinder block.
4. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.

Engine Support Insulators

Special Tools Illustration Tool Name Tool Number 3-Bar Engine Support 303-F070 Engine Support Bracket 303-639

Scheme 91

Scheme 92

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the throttle body (TB). For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.6L (3V)»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-and-engine-controls-46l-3v) article.
4. Remove the generator. For additional information, refer to «GENERATOR AND REGULATOR»(/ford/explorer-sport-trac/ii-2006-2010/remont/charging-system/#charging-system-generator-and-regulator) article.
5. Disconnect the PCV valve hose from the heated PCV fitting.
6. Remove the bolts and position the heated PCV fitting aside.
7. Disconnect the evaporative emission (EVAP) hose from the intake manifold.
8. Remove the 5 pushpins and the splash shield.
9. Remove the RH engine support insulator upper nuts. To install, tighten to 90 Nm (66 lb-ft).
10. Remove the LH engine support insulator through bolt. To install, tighten to 103 Nm (76 lb-ft).
11. Install the special tools and raise the engine approximately 70 mm (2.75 in).
12. Remove the RH engine support insulator lower nut. To install, tighten to 90 Nm (66 lb-ft).
13. Remove the RH engine support insulator.
14. Remove the stabilizer bar bracket bolts and allow the stabilizer bar to hang freely. To install, tighten to 55 Nm (41 lb-ft).
15. Support the differential housing with a suitable jack stand.
16. Disconnect the vent hose from the differential housing vent tube.
17. Remove and discard the 3 bolts and 3 flagnuts. To install, tighten to 66 Nm (49 lb-ft).
18. Lower the differential housing approximately 25 mm (1 in).
19. Remove the LH engine support insulator nut. To install, tighten to 90 Nm (66 lb-ft).
20. Remove the engine support insulator.
21. To install, reverse the removal procedure. If equipped, install new differential housing bolts and flagnuts.

Special Tools Illustration Tool Name Tool Number Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the windshield washer hose.
3. Remove the 4 bolts and the hood.
4. Remove the intake manifold. For additional information, refer to «Intake Manifold»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__intake-manifold) .
5. Open the cover, remove the nuts and disconnect the wiring harness terminals.
6. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
8. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
9. Disconnect the electrical connector.
10. Disconnect the heated PCV fitting coolant hose.
11. Detach the wiring harness retainer from the cooling fan wiring harness bracket.
12. Loosen the nuts.
13. Remove the bolts and the alternator, the alternator bracket and the wiring harness as an assembly.
14. Disconnect the heater hose.
15. Remove the upper radiator hose.
16. Remove the bolts, the coolant crossover manifold, the gaskets, the heated PCV fitting and the heated PCV fitting coolant hose as an assembly. Discard the gaskets.
17. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
18. Detach the heater hose retainer from the RH valve cover.
19. Disconnect the in-line electrical connector and the 2 PCM electrical connectors, and detach the wiring harness pin-type retainer.
20. Disconnect the heater hose.
21. Remove the nut and disconnect the ground wire.
22. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) article.
23. Remove the 3 screws, the 3 pushpins and the inner fender splash shield.
24. Remove the nut and detach the power steering pressure (PSP) hose bracket.
25. Remove the nut and detach the wiring harness bracket.
26. Remove the nuts and detach the wiring harness bracket.
27. Detach the wiring harness retainer from the power steering pump stud bolt.
28. Remove the stud bolts and position the power steering pump aside.
29. Disconnect the lower radiator hose from the oil filter adapter.
30. Disconnect the A/C clutch electrical connector and detach the wiring harness retainer. Remove the nut and detach the A/C hose bracket.
31. Remove the 2 nuts, the stud bolt and position the A/C compressor aside.
32. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
33. Remove the oil temperature sensor.
34. Remove the bolt and detach the wiring harness bracket from the RH engine support insulator bracket.
35. Remove the pushpins and the RH splash shield.
36. Remove the RH engine support insulator nuts.
37. If equipped, disconnect the block heater electrical connector and detach the wiring harness retainers.
38. Remove the LH engine support insulator through bolt.
39. Install the special tool.
40. Attach a suitable floor crane to the special tool installed in the previous step and remove the engine from the vehicle.

Cylinder Head

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Compressor, Valve Spring 303-1039 Locking Tool, Camshaft Phaser Sprocket 303-1046 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Remover, Crankshaft Front Seal 303-107 (T74P-6700-A) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Material

All cylinder heads

1. Remove the engine. For additional information, refer to «Engine»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .
2. Mount the engine on a suitable work stand.
3. Remove the special tool.
4. Disconnect the crankshaft position sensor electrical connector and detach the wiring harness retainer.
5. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
6. Disconnect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
7. Detach the wiring harness retainers.
8. Remove the nut and the RH radio ignition interference capacitor.
9. Disconnect the oil pressure sensor electrical connector.
10. Disconnect the LH CMP sensor electrical connector and detach the wiring harness retainers.
11. Remove the nut and the cooling fan wiring harness bracket.
12. Remove the nut and detach the LH radio interference capacitor.
13. Detach the wiring harness retainers from the LH valve cover studs.
14. Disconnect the 4 RH and 4 LH ignition coil electrical connectors.
15. Detach the wiring harness retainers from the RH valve cover studs.
16. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
17. Detach the electrical connector retainers and remove the engine wiring harness.
18. Remove the breather tube from the RH valve cover. Disconnect the quick connect fittings. Push the connector toward the valve cover to release pressure. Push the release tab clockwise. Disconnect the quick connect fitting.
19. Remove the PCV tube from the LH valve cover. Disconnect the quick connect fittings. Push the connector toward the valve cover to release pressure. Push the release tab clockwise. Disconnect the quick connect fitting.
20. Remove and discard the oil filter.
21. Remove the 8 bolts and the 8 ignition coils.
22. Remove the bolt and position the oil level indicator aside.
23. Loosen the 10 bolts and remove the LH 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.
24. Loosen the 9 bolts and remove the RH 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 5 bolts, the coolant pump pulley and the RH side accessory drive belt idler pulley.
26. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
27. Using the special tool, remove the crankshaft seal.
28. Remove the 4 oil pan-to-engine front cover bolts.
29. Remove the engine front cover fasteners.
30. Remove the engine front cover from the cylinder block.
31. Remove the crankshaft sensor ring from the crankshaft.
32. Position the crankshaft keyway at the 12 o'clock position.
33. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.
34. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
35. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
36. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
37. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
38. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
39. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
40. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
41. 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.
42. Remove the LH and RH timing chain guides. Remove the 2 bolts. Remove both timing chain guides.
43. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
44. Using the special tool, remove the bolt and the LH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
45. Remove the bolts in the sequence shown. Remove the RH cylinder head front camshaft bearing cap, then the remaining bearing caps.
46. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
47. Remove the RH camshaft.
48. Remove the bolts in the sequence shown. Remove the LH cylinder head front camshaft bearing cap, then the remaining bearing caps.
49. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
50. Remove the LH camshaft.
51. Remove all of the remaining roller followers from the cylinder heads.
52. Remove the hydraulic lash adjusters from the LH cylinder head.
53. Install the special tool onto the LH cylinder head.
54. Remove the bolts and the LH exhaust manifold heat shield.
55. Remove the nuts, the LH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
56. Remove and discard the 8 LH exhaust manifold studs.
57. Remove the hydraulic lash adjusters from the RH cylinder heads.
58. Install the special tool onto the RH cylinder head.
59. Remove the bolts and the RH exhaust manifold heat shield.
60. Remove the nuts, the RH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
61. Remove and discard the 8 RH exhaust manifold studs.
62. Remove the nut and the ground strap.
63. Remove the stud bolt and the heater supply tube and hoses as an assembly. Discard the O-ring seals.
64. Remove the 20 bolts and the cylinder heads. Discard the cylinder head gaskets. Discard the cylinder head bolts.
65. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence. 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.
66. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Compressor, Valve Spring 303-1039 Installer, Connecting Rod 303-442 (T93P-6136-A) Locking Tool, Camshaft Phaser Sprocket 303-1046 Modular Engine Lift Bracket 303-F047 (014-00073) Remover, Crankshaft Front Seal 303-107 (T74P-6700-A) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Slinger 303-514 (T95P-6701-AH) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Slide Hammer 100-001 (T50T-100-A)

Material

Note. Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

Note. The flexplate, the spacer plate, the crankshaft rear seal, the crankshaft rear oil slinger and the rear seal retainer plate must be removed before mounting the engine on the engine stand.

Note. For additional information, refer to the exploded view under the Assembly procedure in this article.

1. Remove the 6 bolts and the flexplate.
2. Remove the spacer plate.
3. Using the special tools, remove the crankshaft rear oil slinger.
4. Using the special tools, remove the crankshaft rear seal.
5. Remove the 8 bolts and the crankshaft rear seal retainer plate. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean and inspect the sealing surfaces.
6. Mount the engine on a suitable work stand.
7. Remove the special tool.
8. Disconnect the crankshaft position sensor electrical connector and detach the wiring harness retainer.
9. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
10. Disconnect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
11. Detach the wiring harness retainers.
12. Remove the nut and the RH radio ignition interference capacitor.
13. Disconnect the oil pressure sensor electrical connector.
14. Disconnect the LH CMP sensor electrical connector and detach the wiring harness retainers.
15. Remove the nut and the cooling fan wiring harness bracket.
16. Remove the nut and detach the LH radio interference capacitor.
17. Detach the wiring harness retainers from the LH valve cover studs.
18. Disconnect the 4 RH and 4 LH ignition coil electrical connectors.
19. Detach the wiring harness retainers from the RH valve cover studs.
20. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
21. Remove the nut and the ground strap.
22. Detach the electrical connector retainers and remove the engine wiring harness.
23. Remove the stud bolt and the heater supply tube and hoses as an assembly. Discard the O-ring seals.
24. Remove the breather tube from the RH valve cover. Disconnect the quick connect fittings. Push the connector toward the valve cover to release pressure. Push the release tab clockwise. Disconnect the quick connect fitting.
25. Remove the PCV tube from the LH valve cover. Disconnect the quick connect fittings. Push the connector toward the valve cover to release pressure. Push the release tab clockwise. Disconnect the quick connect fitting.
26. Remove the 8 bolts and the 8 ignition coils.
27. Remove the bolts and the LH engine support insulator bracket.
28. Remove and discard the oil filter. Remove the bolts and the oil filter adapter.
29. Remove the bolts and the LH exhaust manifold heat shield.
30. Remove the nuts, the LH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
31. Remove and discard the 8 LH exhaust manifold studs.
32. Remove the bolt and the oil level indicator tube.
33. Remove the bolts and the RH engine support insulator bracket.
34. Remove the bolts and the RH exhaust manifold heat shield.
35. Remove the nuts, the RH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
36. Remove and discard the 8 RH exhaust manifold studs.
37. Loosen the 9 bolts and remove the RH 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.
38. Loosen the 10 bolts and remove the LH 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.
39. Remove the bolt and the RH CMP sensor.
40. Remove the bolt and the LH CMP sensor.
41. Remove the bolt and the CKP sensor.
42. Remove the 7 bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
43. Remove the 3 bolts and the accessory drive belt tensioner.
44. Remove the 4 coolant pump bolts.
45. Remove the coolant pump from the cylinder block. Discard the O-ring seal.
46. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
47. Using the special tool, remove the crankshaft front oil seal.
48. Remove the bolts, oil pan and oil pan gasket. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
49. Remove the engine front cover fasteners.
50. Remove the engine front cover from the cylinder block.
51. Remove the crankshaft sensor ring from the crankshaft.
52. Position the crankshaft keyway at the 12 o'clock position.
53. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.
54. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
55. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
56. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
57. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
58. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
59. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
60. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
61. 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.
62. Remove the LH and RH timing chain guides. Remove the 2 bolts. Remove both timing chain guides.
63. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
64. Using the special tool, remove the bolt and the LH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
65. Install the special tool onto the LH cylinder head.
66. Install the special tool onto the RH cylinder head.
67. Remove the bolts in the sequence shown. Remove the RH cylinder head front camshaft bearing cap, then the remaining bearing caps.
68. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
69. Remove the RH camshaft.
70. Remove the remaining roller followers from the RH cylinder head.
71. Remove the hydraulic lash adjusters from the RH cylinder head.
72. Remove the bolts in the sequence shown. Remove the LH cylinder head front camshaft bearing cap, then the remaining bearing caps.
73. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
74. Remove the LH camshaft.
75. Remove the remaining roller followers from the LH cylinder head.
76. Remove the hydraulic lash adjusters from the LH cylinder head.
77. Remove the 20 bolts and the cylinder heads. Discard the cylinder head gaskets. Discard the cylinder head bolts.
78. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence. 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.
79. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
80. Remove the bolts, the oil pump screen and pickup tube and the spacer.
81. Remove the 3 bolts and the oil pump.
82. 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.
83. Remove the bolts and the connecting rod caps. Discard the bolts.
84. Use the special tool to push the piston through the top of the cylinder block.
85. Disassemble the 8 pistons. For additional information, refer to «Piston»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__piston) .
86. Remove the fasteners. Remove and discard the cross-mounted main cap bolts. Loosen the jack screws. Remove and discard the main bearing cap bolts and the stud bolt.
87. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
88. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-1039 Installer, Valve Stem Oil Seal 303-383 (T91T-6571-A)

Material

Note. LH side shown, RH side similar.

Scheme 93

DISASSEMBLY

1. Remove the bolts and the variable camshaft timing (VCT) housing. Discard the gasket.
2. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
3. Install the camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts finger-tight.
4. Using the special tool, compress the valve spring and remove the valve spring retainer keys.
5. Remove the valve spring retainer, the valve spring and the valve seal. Discard the valve seal.
6. Remove the valve from the cylinder head.
7. Repeat the previous 3 steps for each valve.
8. Inspect the components. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
9. Remove the 2 bolts and the cylinder head camshaft front bearing cap.
10. Remove the remaining bolts in the sequence shown and remove the cylinder head camshaft bearing caps.
11. Remove the camshaft.
12. Check the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

ASSEMBLY

1. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. Install the camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts finger-tight.
3. Install the valve into the cylinder head.
4. Position a new valve seal onto the valve stem.
5. Using the special tool, install the new valve seal.
6. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys.
7. Repeat the previous 2 steps for each valve.
8. Remove the 2 bolts and the cylinder head camshaft front bearing cap.
9. Remove the remaining bolts in the sequence shown and remove the cylinder head camshaft bearing caps.
10. Remove the camshaft.
11. Install a new gasket, the VCT housing and the bolts. Tighten to 10 N.m (89 lb-in).

Piston

Material

Scheme 94

Scheme 95

1. Remove the piston rings from the piston. Discard the piston rings.
2. Mark the piston and the connecting rod on the same side for assembly reference.
3. Remove the piston pin retainers and the piston pin.
4. Separate the piston from the connecting rod.
5. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.

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.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston.

Special Tools Illustration Tool Name Tool Number Alignment Pins, Cylinder Head 303-1040 (SR-015486) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Compressor, Valve Spring 303-1039 Installer, Connecting Rod 303-442 (T93P-6136-A) Installer, Crankshaft Front Seal 303-635 Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH) Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Seal 303-335 (T88T-6701-A) Locking Tool, Camshaft Phaser Sprocket 303-1046 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Material

Scheme 96

Scheme 97

1. Install the crankshaft main bearings. Install the crankshaft upper main bearings into the cylinder block. Install the crankshaft lower main bearings into the bearing caps. Make sure all oil passages are aligned. Lubricate all main bearings with clean engine oil.
2. Lubricate the crankshaft bearing journals with clean engine oil. Install the crankshaft onto the upper crankshaft main bearings.
3. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
4. Install the thrust washer on the rear (No. 5) main bearing cap and install the rear (No. 5) main bearing cap.
5. 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.
6. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.
7. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Tighten the jackscrews against the cylinder block in the sequence shown in 2 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
9. Install the side bolts and tighten them in the sequence shown. Tighten to 21 Nm (15 lb-ft).
10. Check the crankshaft end play. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
11. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
12. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
13. Assemble the pistons. For additional information, refer to «Piston»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__piston) .
14. Make sure the ring gaps (oil spacer-A, oil ring-B and compression ring-C) are correctly spaced around the circumference of the piston.
15. Use the special tools to install the connecting rod with the upper connecting rod bearing in place. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil.
16. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
17. Position the lower bearing and connecting rod and install the new bolts loosely.
18. Tighten the bolts in 2 stages, in the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees.
19. Position the oil pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
20. Install the pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
21. Position the oil pump screen and pickup tube and install the bolts. Tighten to 25 Nm (18 lb-ft). Tighten to 10 Nm (89 lb-in).
22. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the 20 cylinder head bolts loosely.
23. Tighten the LH cylinder head bolts in 3 stages, 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.
24. Tighten the RH cylinder head bolts in 3 stages, 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.
25. Remove the special tool from the LH cylinder head.
26. Remove the special tool from the RH cylinder head.
27. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
28. Install the LH and RH camshafts.
29. Install the LH and RH camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely. Tighten to 10 Nm (89 lb-in) in the sequence shown.
30. Position the camshaft phaser sprockets and install new camshaft phaser bolts finger-tight.
31. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
32. Install the crankshaft sprocket, making sure the flange faces forward.
33. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.
34. Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position.
35. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
36. Compress the tensioner plunger, using a vise.
37. Install a retaining clip on the tensioner to hold the plunger in during installation.
38. Remove the tensioner from the vise.
39. 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.
40. Install the 4 bolts and the LH and RH timing chain guides. Tighten to 10 Nm (89 lb-in).
41. 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.
42. Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.
43. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
44. Remove the retaining clip from the LH timing chain tensioner.
45. 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) chain link.
46. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.
47. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
48. Remove the retaining clip from the RH timing chain tensioner.
49. As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.
50. Install the crankshaft sensor ring on the crankshaft.
51. Using the special tool, install all of the camshaft roller followers.
52. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
54. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 W706508 Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53 12 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
55. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
56. Using the special tools, install the crankshaft front oil seal into the engine front cover.
57. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
58. Using the special tool, install the crankshaft pulley.
59. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
60. Position the coolant pump and install the 4 bolts loosely.
61. Tighten the 4 coolant pump bolts. Tighten to 25 Nm (18 lb-ft).
62. Position the accessory drive belt tensioner and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
63. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts. Tighten to 25 Nm (18 lb-ft).
64. Install the crankshaft position (CKP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
65. Install the LH camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 lb-in).
66. Install the RH CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
67. Apply silicone gasket and sealant in 2 places where the engine front cover meets the RH cylinder head.
68. Position the RH valve cover and gasket on the cylinder head and tighten the 9 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
69. Apply silicone gasket and sealant in 2 places where the engine front cover meets the LH cylinder head.
70. Position the LH valve cover and gasket on the cylinder head and tighten the 10 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
71. Inspect the RH exhaust manifold for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
72. Install 8 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
73. Position new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
74. Position the RH heat shield and install the bolts. Tighten to 10 Nm (89 lb-in).
75. Position the RH engine support insulator bracket and install the bolts. Tighten to 72 Nm (53 lb-ft).
76. Position the oil level indicator tube and install the bolt. Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation. Tighten to 10 Nm (89 lb-in).
77. Inspect the LH exhaust manifold for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
78. Install 8 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
79. Position new gaskets, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
80. Position the LH exhaust manifold heat shield and install the bolts. Tighten to 10 Nm (89 lb-in).
81. Clean the oil filter adapter sealing surfaces using silicone gasket remover, metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
82. Position the oil filter adapter and install the bolts. Tighten to 25 Nm (18 lb-ft).
83. Install a new oil filter. Tighten the oil filter until the gasket makes contact, then use an oil filter strap wrench to tighten the filter an additional 270 degrees.
84. Position the LH engine support insulator bracket and install the bolts. Tighten to 72 Nm (53 lb-ft).
85. Install the 8 ignition coils and the 8 bolts. Tighten to 6 Nm (53 lb-in).
86. Connect the PCV hose to the LH valve cover.
87. Connect the breather tube to the RH valve cover.
88. Position the heater supply tube and the hoses as an assembly and install the stud bolt. Tighten to 10 Nm (89 lb-in).
89. Position the engine wiring harness and attach the electrical connectors to the heater supply tube bracket.
90. Position the ground strap and install the nut. Tighten to 10 Nm (89 lb-in).
91. Connect the cylinder head temperature (CHT) sensor electrical connector.
92. Attach the wiring harness retainers to the RH valve cover studs.
93. Connect the RH and LH ignition coil electrical connectors.
94. Attach the wiring harness retainers to the LH valve cover studs.
95. Position the LH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
96. Position the cooling fan wiring harness and install the nut. Tighten to 25 Nm (18 lb-ft).
97. Connect the LH camshaft position sensor and attach the wiring harness retainers.
98. Connect the oil pressure sensor electrical connector.
99. Position the RH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
100. Attach the wiring harness retainers.
101. Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
102. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
103. Connect the crankshaft position sensor electrical connector and attach the wiring harness retainer.
104. Install the special tool.
105. Using a suitable floor crane, remove the engine from the engine stand.
106. Inspect the crankshaft 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.
107. Apply a bead of gasket maker to the crankshaft rear seal retainer mating surface on the engine block.
108. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
109. Tighten the 6 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
110. 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.
111. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
112. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
113. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
114. Tighten the 16 bolts in 3 stages, in the sequence shown. Stage 1: Tighten to 2 N.m (18 lb-in). Stage 2: Tighten to 20 N.m (15 lb-ft). Stage 3: Tighten an additional 60 degrees.
115. Using the special tools, install a new crankshaft rear seal.
116. Using the special tools, install the crankshaft rear oil slinger.
117. Install the spacer plate.
118. Position the flexplate and install the bolts in the sequence shown. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent

Material

1. Position the engine in the vehicle and remove the floor crane.
2. Remove the special tool.
3. Install the LH engine support insulator through bolt. Tighten to 103 Nm (76 lb-ft).
4. If equipped, attach the block heater wiring harness retainers and connect the block heater electrical connector.
5. Install the RH engine support insulator nuts. Tighten to 90 Nm (66 lb-ft).
6. Position the RH splash shield and install the pushpins.
7. Position the battery cable bracket on the RH engine support insulator bracket and install the bolt. Tighten to 15 Nm (11 lb-ft).
8. Install the oil temperature sensor. Tighten to 15 Nm (11 lb-ft).
9. Position the A/C compressor and install the 2 nuts and the stud bolt. Tighten to 25 Nm (18 lb-ft).
10. Position the A/C hose bracket and install the nut. Attach the wiring harness retainer and connect the A/C clutch electrical connector. Tighten to 20 Nm (15 lb-ft).
11. Connect the lower radiator hose to the oil filter adapter.
12. Position the power steering pump and install the stud bolts. Tighten to 25 Nm (18 lb-ft).
13. Attach the wiring harness retainer to the power steering pump stud bolt.
14. Position the wiring harness bracket and install the nuts. Tighten to 10 Nm (89 lb-in).
15. Position the wiring harness bracket and install the nut. Tighten to 10 Nm (89 lb-in).
16. Position the power steering pressure hose bracket and install the nut. Tighten to 10 Nm (89 lb-in).
17. Position the inner fender splash shield and install the 3 pushpins and 3 screws.
18. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) article.
19. Position the ground wire and install the nut. Tighten to 12 Nm (9 lb-ft).
20. Connect the heater hose.
21. Attach the wiring harness pin-type retainer, and connect the 2 PCM electrical connectors and the in-line electrical connector.
22. Attach the heater hose retainer to the RH valve cover.
23. Connect the evaporative emission (EVAP) canister purge valve electrical connector.
24. Position new gaskets, the coolant crossover, the heated PCV fitting and the heated PCV fitting hose as an assembly and install the bolts. Tighten to 10 Nm (89 lb-in).
25. Install the upper radiator hose.
26. Connect the heater hose.
27. Position the alternator, alternator bracket and the wiring harness as an assembly and install the bolts. Tighten to 10 Nm (89 lb-in).
28. Tighten the nuts Tighten to 25 Nm (18 lb-ft).
29. Attach the wiring harness retainer to the cooling fan wiring harness bracket.
30. Connect the heated PCV fitting coolant hose.
31. Connect the electrical connector.
32. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
33. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
34. Connect the wiring harness terminals, install the nuts and close the cover. Tighten to 12 Nm (9 lb-ft).
35. Install the intake manifold. For additional information, refer to «Intake Manifold»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v__intake-manifold) .
36. Position the hood and install the 4 bolts. Tighten to 12 Nm (9 lb-ft).
37. Connect the windshield washer hose.
38. Fill the engine with clean engine oil.
39. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
40. Carry out the fluid level check for the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60»(/ford/explorer-sport-trac/ii-2006-2010/remont/automatic-trans/#automatic-transmission-6r60) article.

Special Tools Illustration Tool Name Tool Number Alignment Pins, Cylinder Head 303-1040 (SR-015486) Compressor, Valve Spring 303-1039 Installer, Crankshaft Front Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Seal 303-335 (T88T-6701-A) Locking Tool, Camshaft Phaser Sprocket 303-1046 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Material

All cylinder heads

1. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
2. Tighten the LH cylinder head bolts in 3 stages, 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.
3. Remove the special tool from the LH cylinder head.
4. Install the hydraulic lash adjusters into the LH cylinder head.
5. Remove the oil level indicator tube, install a new O-ring seal, and lubricate the O-ring seal with clean engine oil. Position the oil level indicator tube loosely in the engine block before installing the LH exhaust manifold.
6. Inspect the LH exhaust manifold gasket mating surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
7. Install 8 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
8. Position new gaskets, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
9. Position the LH exhaust manifold heat shield and install the bolts. Tighten to 10 Nm (89 lb-in).
10. Tighten the RH cylinder head bolts in 3 stages, 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.
11. Remove the special tool from the RH cylinder head.
12. Install the hydraulic lash adjusters into the RH cylinder head.
13. Inspect the RH exhaust manifold gasket mating surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article.
14. Install 8 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
15. Position new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
16. Position the RH heat shield and install the bolts. Tighten to 10 Nm (89 lb-in).
17. Position the heater supply tube and the hoses as an assembly and install the stud bolt. Tighten to 10 Nm (89 lb-in).
18. Position the ground strap and install the nut. Tighten to 10 Nm (89 lb-in).
19. Install the LH and RH camshafts.
20. Install the LH and RH camshaft bearing caps in their original locations. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely. Tighten to 10 Nm (89 lb-in) in the sequence shown.
21. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.
22. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
23. Install the crankshaft sprocket, making sure the flange faces forward.
24. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o'clock position.
25. Rotate the camshaft sprockets to position the RH camshaft sprocket timing mark in the 11 o'clock position and the LH camshaft sprocket timing mark in the 12 o'clock position.
26. Inspect the RH and LH timing chain tensioners. Install new tensioners, as necessary.
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 4 bolts and the LH and RH timing chain guides. Tighten to 10 Nm (89 lb-in).
32. 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.
33. Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.
34. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
35. Remove the retaining clip from the LH timing chain tensioner.
36. 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) chain link.
37. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the copper (marked) chain link.
38. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
39. Remove the retaining clip from the RH timing chain tensioner.
40. As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.
41. Install the crankshaft sensor ring on the crankshaft.
42. Using the special tool, install all of the camshaft roller followers.
43. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
44. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.
45. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 W706508 Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53 12 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
46. Loosely install the 4 bolts, then tighten the bolts in 2 stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees.
47. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
48. Using the special tools, install the crankshaft front oil seal into the engine front cover.
49. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
50. Using the special tool, install the crankshaft pulley.
51. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
52. Install the RH side accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts. Tighten to 25 Nm (18 lb-ft).
53. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
54. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
55. Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
56. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
57. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
58. Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
59. Position the oil level indicator tube and install the bolt. Tighten to 10 Nm (89 lb-in).
60. Install the 8 ignition coils and the 8 bolts. Tighten to 6 Nm (53 lb-in).
61. Install a new oil filter. Tighten the oil filter until the gasket makes contact, then use an oil filter strap wrench to tighten the filter an additional 270 degrees.
62. Connect the PCV hose to the LH valve cover.
63. Connect the breather tube to the RH valve cover.
64. Position the engine wiring harness and attach the electrical connectors to the heater supply tube bracket.
65. Connect the cylinder head temperature (CHT) sensor electrical connector.
66. Attach the wiring harness retainers to the RH valve cover studs.
67. Connect the RH and LH ignition coil electrical connectors.
68. Attach the wiring harness retainers to the LH valve cover studs.
69. Position the LH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
70. Position the cooling fan wiring harness and install the nut. Tighten to 25 Nm (18 lb-ft).
71. Connect the LH camshaft position sensor and attach the wiring harness retainers.
72. Connect the oil pressure sensor electrical connector.
73. Position the RH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).
74. Attach the wiring harness retainers.
75. Connect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
76. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
77. Connect the crankshaft position sensor electrical connector and attach the wiring harness retainer.
78. Install the special tool.
79. Using a suitable floor crane, remove the engine from the engine stand.
80. Install the engine. For additional information, refer to «Engine»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-46l-3v) .

See also:
• ENGINE SYSTEM - GENERAL INFORMATION
• Introduction - Gasoline Engines
• FUEL SYSTEM - GENERAL INFORMATION
• INTAKE AIR DISTRIBUTION AND FILTERING
• FUEL CHARGING AND CONTROLS - 4.6L (3V)
• ENGINE IGNITION - 4.6L (3V)
• JACKING AND LIFTING
• ENGINE COOLING
• ACCESSORY DRIVE
• AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60
• SUPPLEMENTAL RESTRAINT SYSTEM
• FRONT DRIVE AXLE/DIFFERENTIAL - DANA 30
• FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)
• GENERATOR AND REGULATOR
• Crankshaft Pulley
• Flexplate
• Oil Pan
• Valve Cover - RH
• Valve Cover - LH
• Engine Front Cover
• Cylinder Head
• Timing Drive Components
• Camshaft Phaser and Sprocket
• Camshaft - RH
• Camshaft - LH
• Valve Train Components - Exploded View
• Intake Manifold
• Piston