ENGINE-4.6L 2V: Overhaul Ford Explorer III

Item 8: Crankshaft Rear Oil Seal Retainer Plate Disassembly Note

1. After retainer plate removal, mount the engine on an engine stand.

Items 19 and 20: Engine Lifting Bracket and Bolts Disassembly Note

1. Remove the right side bolts and bracket (not shown).

Scheme 631

1. Using the special tool, remove the crankshaft vibration damper.

Scheme 632

1. Using the special tool, remove the crankshaft front seal.

Scheme 633

Scheme 634

Scheme 635

Scheme 636

1. Disconnect the generator electrical connectors.
2. Remove the bolt and position aside the radio interference capacitor.
3. Disconnect the wiring harness retainers.
4. Remove the upper radiator hose bracket and the radio capacitor.

Scheme 637

Scheme 638

1. Disconnect the oil pressure switch electrical connector.
2. Remove the power steering hose support bracket.

Scheme 639

1. Using the special tool, remove the power steering pump pulley.

Item 50: Power Steering Pressure Hose Disassembly Note

1. Drain the power steering pump fluid into a suitable container.

Scheme 640

Scheme 641

Scheme 642

1. Disconnect the brake booster vacuum hose.
2. Disconnect the vacuum hoses from the throttle body adapter and the fuel pressure regulator.
3. Disconnect the vacuum hoses from the EGR valve and the EVAP canister purge solenoid.
4. Remove the vacuum hose harness.

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

1. Remove the bolt and the ground wire.
2. Disconnect the eight fuel injector and ignition coil electrical connectors.
3. Disconnect the CKP sensor electrical connector.
4. Disconnect the A/C compressor electrical connector.
5. Disconnect the camshaft position (CMP) sensor electrical connector.
6. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
7. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
8. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
9. Disconnect the EGR vacuum regulator solenoid electrical connector.
10. Remove the engine wiring harness.

Item 76: Intake Manifold Disassembly Note

1. Clean the intake manifold sealing surfaces.

Scheme 652

1. Remove the bolt and the transmission bracket.
2. Remove the RH and LH cylinder block drain plugs. Reinstall the plugs after draining the coolant.

Items 105 and 109: RH and LH Valve Cover Disassembly Note

Note. There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.

Scheme 653

Scheme 654

1. Loosen the bolts and remove the left valve cover. Clean and inspect the mating surfaces, and if necessary, install new gaskets.
2. Loosen the bolts and remove the right valve cover. Clean and inspect the mating surfaces, and if necessary, install new gaskets.
3. Remove the spark plugs.

Scheme 655

1. Remove the engine front cover fasteners in the sequence shown in illustration.

Item 125: Camshaft Roller Followers Disassembly Note

Note. The roller followers are positional. Mark the followers for installation in their original locations.

Scheme 656

1. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
2. Using the special tool, compress the valve spring and remove the roller follower.
3. Repeat the above steps to remove all the roller followers.

Scheme 657

1. Remove the bolts and the oil pump screen cover and tube.
2. Remove the oil pump screen cover and tube spacer.

Scheme 658

Scheme 659

1. Install the Lifting Handles on both ends of the cylinder head.
2. Remove the bolts and discard. Remove the cylinder heads.
3. Discard the head gasket.
4. Clean and inspect the sealing surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .

Item 157: Connecting Rod Caps Disassembly Note

1. Install the connecting rod caps in their correct locations.

Scheme 660

1. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer. Follow the manufacturer instructions.
2. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.

Scheme 661

Scheme 662

Scheme 663

1. Clean and inspect the sealing surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
2. Remove the components in the order indicated in the following illustration and table.
3. To assemble, reverse the disassembly procedure.

Scheme 664

1. Using the special tool, compress the valve spring.
2. Remove the valve spring retainer keys, the valve spring retainer, the valve spring and the valve stem seal.
3. Repeat the above steps and remove all of the valve spring retainer keys, the valve spring retainer, the valve spring and the valve stem seal.

Scheme 665

Scheme 666

1. Use a plastic scraper and metal surface cleaner to clean the cylinder head.
2. Lubricate the camshaft journals with clean engine oil.
3. Lubricate the camshaft bearing caps with clean engine oil.
4. Install the camshaft and the camshaft bearing caps in their original locations. Install the bolts loosely.
5. Tighten the bolts in the sequence shown in illustration.

Item 8: Camshaft Sprocket Bolt Assembly Note

1. Tighten the camshaft sprocket bolt to 40 Nm (30 lb-ft) then rotate 85°-95°.

Scheme 667

Scheme 668

1. Using the special tools, install new valve seals.
2. Install the special tool between the valve spring coils to protect the valve stem seal from damage.
3. Using the special tool, install the valve spring, the spring retainer and the valve spring retainer keys.
4. Repeat the above steps and install all of the remaining valves, valve stem seals, valve spring, spring retainer and the valve spring retainer keys.

Item 1: Hydraulic Lash Adjuster Assembly Note

1. Install the hydraulic lash adjusters in their original location.

Scheme 669

Scheme 670

Scheme 671

1. Remove the components in the order indicated in the following illustration and table.
2. To assemble, reverse the disassembly procedure.

Scheme 672

1. Using the special tool, press the piston pin out of the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.

Scheme 673

Scheme 674

1. Lubricate the piston pin and piston pin bore with clean engine oil.
2. Position the connecting rod in the piston.
3. Using the special tool, press the piston pin into the piston and rod assembly.

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Assembly

Note. Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

Note. During engine assembly, it may become necessary to check bearing clearances and end play. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

Scheme 680

Scheme 681

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Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

1. Read the first character code information on the cylinder block face (1) and record the information.
2. Read the first character on the No. 7 crankshaft counterweight and note it.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2". Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and (Scheme 719) and (Scheme 720) to determine the required bearing grade for each main bearing.
5. Illustration 1 of 19. Install the components in the order indicated in the following illustration and table.
6. Illustration 2 of 19. Install the components in the order indicated in the following illustration and table.
7. Illustration 3 of 19. Install the components in the order indicated in the following illustration and table.
8. Illustration 4 of 19. Install the components in the order indicated in the following illustration and table.
9. Illustration 5 of 19. Install the components in the order indicated in the following illustration and table.
10. Illustration 6 of 19. Install the components in the order indicated in the following illustration and table.
11. Illustration 7 of 19. Install the components in the order indicated in the following illustration and table.
12. Illustration 8 of 19. Install the components in the order indicated in the following illustration and table.
13. Illustration 9 of 19. Install the components in the order indicated in the following illustration and table.
14. Illustration 10 of 19. Install the components in the order indicated in the following illustration and table.
15. Illustration 11 of 19. Install the components in the order indicated in the following illustration and table.
16. Illustration 12 of 19. Install the components in the order indicated in the following illustration and table.
17. Illustration 13 of 19. Install the components in the order indicated in the following illustration and table.
18. Illustration 14 of 19. Install the components in the order indicated in the following illustration and table.
19. Illustration 15 of 19. Install the components in the order indicated in the following illustration and table.
20. Illustration 16 of 19. Install the components in the order indicated in the following illustration and table.
21. Illustration 17 of 19. Install the components in the order indicated in the following illustration and table.
22. Illustration 18 of 19. Install the components in the order indicated in the following illustration and table.
23. Illustration 19 of 19. Install the components in the order and table. the order indicated in the following illustration and table.

Item 6: Crankshaft Main Lower Bearing Thrust Washer Assembly Note

1. Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5 main boss.

Scheme 703

Scheme 704

Scheme 705

1. Loosely install the main bearing caps and bolts.
2. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
3. Tighten the bolts in the sequence shown in four stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten bolts 1-10 to 25 Nm (18 Ib-ft). Stage 3: Tighten bolts 11-20 to 40 Nm (30 lb-ft). Stage 4: Tighten an additional 90 degrees.

Scheme 706

1. Install and tighten the cross-mounted bolts in two stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
2. Check the crankshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .

Scheme 707

1. Check the piston to cylinder block and piston ring clearances. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
2. Position the piston rings as illustrated.
3. Using the special tools, install the connecting rod and piston with upper connecting rod bearing (6211) in place. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil.

Item 15: Connecting Rod Caps Assembly Note

1. Position the lower bearing and connecting rod cap, and install the new bolts loosely.

Item 16: Connecting Rod Cap Bolts Assembly Note

1. Install the connecting rod bearing caps and bolts and tighten in three stages: Stage 1: Tighten to 25 Nm (18 Ib-ft). Stage 2: Tighten to 45 Nm (33 lb-ft). Stage 3: Tighten an additional 90 degrees.
2. Check the connecting rod bearing clearance. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .

Items 20 and 23: RH and LH Cylinder Head Bolts Assembly Note

1. Tighten the cylinder head bolts in six stages in the sequence shown: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Loosen the bolts a minimum of one full turn. Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees. Stage 6: Tighten an additional 90 degrees.

Scheme 708

Scheme 709

Scheme 710

Scheme 711

1. Install the crankshaft sprocket with the flange facing forward.
2. Using the special tool, position the crankshaft. Remove the special tool.
3. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH timing sprocket until the timing mark is at approximately the 11 o'clock position.
4. 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.
5. Install the LH and RH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
6. Position the RH timing chain on the camshaft sprocket. Make sure the two copper- colored links align with the camshaft sprocket timing mark.

Scheme 712

1. Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation. Remove the retaining clip after installation.

Scheme 713

Scheme 714

1. As a post-check, verify correct alignment of all timing marks.
2. Position the crankshaft sensor ring on the crankshaft.

Item 48: Camshaft Roller Followers Assembly Note

Note. Be sure to install the roller followers in their original locations.

Scheme 715

1. Position the piston of the cylinder in which the roller followers are being installed at the bottom of the stroke and camshaft lobe at the base circle.
2. Using the special tool, compress the valve spring and install the roller follower.
3. Repeat the above steps to install all the roller followers.

Scheme 716

1. Apply silicone gasket and sealant in the locations shown in illustration.
2. Install the engine front cover.

Item 61: Oil Pan Assembly Note

Note. If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

Scheme 717

1. Apply silicone gasket and sealant in two places.
2. Apply silicone gasket and sealant in two places.

Scheme 718

1. Tighten the bolts in the sequence shown. Tighten to 20 Nm (15 lb-ft). Rotate an additional 60 degrees.

Scheme 719

1. Apply silicone gasket and sealant in the locations shown in illustration.
2. Install the valve rocker arm covers and tighten the bolts in the sequence shown in illustration.
3. Install the spark plugs.

Scheme 720

1. Install the bracket and the bolt.

Scheme 721

1. Install the LH exhaust manifold and tighten the nuts in the sequence shown in illustration.

Scheme 722

1. Install the RH exhaust manifold and tighten the nuts in the sequence shown in illustration.

Scheme 723

1. Hand-start all fasteners.
2. Tighten all fasteners in the sequence shown in illustration.

Item 112: Water Pump Assembly Note

1. Lubricate the o-ring seal before installing the water pump.

Item 114: Ignition Coil Assembly Note

1. Apply dielectric compound to the inside of the ignition coil boots.

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

1. Install the ground wire and bolt.
2. Position the engine wiring harness onto the engine and connect the harness locators.
3. Connect the eight fuel injector and ignition coil electrical connectors.
4. Connect the CKP sensor electrical connector.
5. Connect the a/c compressor electrical connector.
6. Connect the CMP sensor electrical connector.
7. Connect the cylinder head temperature (CHT) sensor electrical connector.
8. Connect the KS electrical connector and the wiring harness pin-type retainer.
9. Connect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
10. Connect the EGR vacuum regulator solenoid electrical connector.

Scheme 734

Scheme 735

Scheme 736

Scheme 737

1. Position the vacuum hose harness in place.
2. Connect the brake booster vacuum hose and install the bolt.
3. Connect the vacuum hoses to the throttle body adapter and the fuel pressure regulator.
4. Connect the vacuum hoses to the EGR valve and the EVAP canister purge solenoid.
5. Install the positive crankcase ventilation (PCV) valve and tube.

Scheme 738

1. Using the appropriate special tool, install a new O-ring seal on the power steering pressure hose fitting.

Scheme 739

1. Using the special tool, install the power steering pump pulley.

Scheme 740

Scheme 741

Scheme 742

Scheme 743

1. Connect the generator electrical connectors.
2. Install the upper radiator hose bracket and the radio capacitor.
3. Position the harness and connect the retainers.
4. Install the oil pressure switch electrical connector.

Scheme 744

Scheme 745

1. Lubricate the front oil seal and the engine front cover with clean engine oil.
2. Using the special tools, install the front oil seal.

Scheme 746

Scheme 747

Scheme 748

1. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install the crankshaft pulley and tighten the bolt in four stages: Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen the bolt one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

Items 153 and 154: Engine Lifting Bracket and Bolts Assembly Note

1. Install right side engine lifting bracket and bolts (not shown).

Scheme 749

1. Install the power steering bracket and the radio interference capacitor and nut.

Scheme 750

1. Install the power steering hose support bracket.

Scheme 751

Scheme 752

1. Using the special tool and a floor crane, remove the engine from the engine stand.
2. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface. Also apply a bead of silicone gasket and sealant at the junction where the cylinder block, oil pan and rear oil seal retainer plate meet.
3. Install the rear oil seal retainer plate. Tighten the bolts in the sequence shown. Tighten bolts 1-6 to 10 Nm (89 lb-in). Hand-tighten bolts 7 and 8. Tighten bolts 7 and 8 to 20 Nm (15 lb-ft). Tighten bolts 7 and 8 an additional 60 degrees.

Scheme 753

1. Using the special tools, install the crankshaft rear main seal.

Scheme 754

1. Using the special tool, install the crankshaft oil slinger.

Scheme 755

1. Install the flywheel bolts in the sequence see scheme 376

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

1. Illustration 1 of 3. Install the components in the order table. order indicated in the following illustration and table.
2. Illustration 2 of 3. Install the components in the order indicated in the following illustration and table.
3. Illustration 3 of 3. Install the components in the order indicated in the following illustration and table.
4. Connect the fuel hose spring lock coupling. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
5. Fill the engine with engine oil.
6. Install the starter motor. For additional information, refer to «STARTERS»(ref-168028) .
7. Install the evaporative emissions canister purge valve. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
8. Install the air cleaner assembly. For additional information, refer to «REMOVAL & INSTALLATION»(ref-156578) .
9. Install the hood.
10. Install the cooling fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-194047) .
11. Connect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
12. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-194054) .
13. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM»(ref-194037) .

Scheme 762

Scheme 763

1. Install the engine into the vehicle.
2. Remove the special tool.
3. Install the special tools.

Scheme 764

1. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049) .
2. Remove the special tools.

Scheme 765

Scheme 766

Scheme 767

Scheme 768

1. Using the special tool, install a new seal on the power steering pressure hose fitting.
2. Position the cooler tubes and install the nut.
3. Connect the cooler hoses.
4. Attach the LH heated oxygen sensor (HO2S) wiring harness.

Scheme 769

1. Connect the accelerator cable and the speed control cable from the throttle cam.

Scheme 770

Scheme 771

Scheme 772

Scheme 773

1. Position the engine wiring harness and install the engine wiring harness retainers. Install the transmission wiring harness to the retainers.
2. Connect the heater control vacuum supply hose.
3. Position the heater control valve bracket and install the bolt.
4. Connect the fuel charging wiring harness pushpins.