Engine - 4.6L (3V): Other Ford Explorer IV

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.

Positive Crankcase Ventilation System

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

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

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

Intake Manifold

Material

Scheme 65

Valve Cover - LH

Material

Scheme 66

Scheme 67

Valve Cover - RH

Material

Scheme 68

Crankshaft Pulley

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

Scheme 69

Scheme 70

Material

Crankshaft Front Seal

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

Material

Crankshaft Rear Seal

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

Scheme 71

Scheme 72

Material

Crankshaft Rear Seal with Retainer Plate

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

Material

Engine Front Cover

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

Scheme 73

Material

Scheme 74

Scheme 75

Timing Drive Components

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

Scheme 76

Material

Valve Train Components - Exploded View

Note. LH shown, RH similar.

Scheme 77

1. For additional information, refer to the appropriate procedures.

Camshaft - LH

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

Material

Camshaft Phase and Sprocket

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

Camshaft Roller Follower

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

Material

Valve Springs

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

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 78

Material

Hydraulic Lash Adjuster

Material

Oil Pan

Material

Oil Pump Screen and Pickup Tube

Material

Material

Oil Filter Adapter

Material

Scheme 79

Oil Level Indicator and Tube

Material

Scheme 80

Engine Support Insulators

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

Scheme 81

Cylinder Head

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

Material

All cylinder heads

1. Remove the engine. For additional information, refer to «Engine»(ref-270890-S39284596062007110700000) .
2. Mount the engine on a suitable work stand.
3. Remove the special tool.
4. Detach the wiring harness retainers from the RH oil pan bolts.
5. Disconnect the crankshaft position sensor electrical connector and detach the wiring harness retainer.
6. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
7. Disconnect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
8. Detach the wiring harness retainers.
9. Remove the nut and the RH radio ignition interference capacitor.
10. Disconnect the oil pressure sensor electrical connector.
11. Disconnect the LH CMP sensor electrical connector and detach the wiring harness retainers.
12. Remove the nut and the cooling fan wiring harness bracket.
13. Remove the nut and detach the LH radio interference capacitor.
14. Detach the wiring harness retainers from the LH valve cover studs.
15. Disconnect the 4 RH and 4 LH ignition coil electrical connectors.
16. Detach the wiring harness retainers from the RH valve cover studs.
17. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
18. Detach the electrical connector retainers and remove the engine wiring harness.
19. 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.
20. Remove the positive crankcase ventilation (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.
21. Remove and discard the oil filter.
22. Remove the 8 bolts and the 8 ignition coils.
23. Remove the bolt and position the oil level indicator aside.
24. Loosen the 15 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.
25. Loosen the 14 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.
26. Remove the 5 bolts, the coolant pump pulley and the RH side accessory drive belt idler pulley.
27. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
28. Using the special tool, remove the crankshaft seal.
29. Remove the 4 oil pan-to-engine front cover bolts.
30. Remove the engine front cover fasteners.
31. Remove the engine front cover from the cylinder block.
32. Remove the crankshaft sensor ring from the crankshaft.
33. Position the crankshaft keyway at the 12 o'clock position.
34. 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.
35. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
36. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
37. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
38. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
39. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
40. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
41. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
42. 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.
43. Remove the LH and RH timing chain guides. Remove the 2 bolts. Remove both timing chain guides.
44. Using the special tool, remove the bolt and the RH camshaft phase sprocket assembly. Discard the camshaft phase sprocket bolt.
45. Using the special tool, remove the bolt and the LH camshaft phase sprocket assembly. Discard the camshaft phase sprocket bolt.
46. Remove the bolts in the sequence shown. Remove the RH cylinder head front camshaft bearing cap, then the remaining bearing caps.
47. 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.
48. Remove the RH camshaft.
49. Remove the bolts in the sequence shown. Remove the LH cylinder head front camshaft bearing cap, then the remaining bearing caps.
50. 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.
51. Remove the LH camshaft.
52. Remove all of the remaining roller followers from the cylinder heads.
53. Remove the hydraulic lash adjusters from the LH cylinder head.
54. Install the special tool onto the LH cylinder head.
55. Remove the bolts and the LH exhaust manifold heat shield.
56. Remove the nuts, the LH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
57. Remove and discard the 8 LH exhaust manifold studs.
58. Remove the hydraulic lash adjusters from the RH cylinder heads.
59. Install the special tool onto the RH cylinder head.
60. Remove the bolts and the RH exhaust manifold heat shield.
61. Remove the nuts, the RH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
62. Remove and discard the 8 RH exhaust manifold studs.
63. Remove the nut and the ground strap.
64. Remove the stud bolt and the heater supply tube and hoses as an assembly. Discard the O-ring seals.
65. Remove the 20 bolts and the cylinder heads. Discard the cylinder head gaskets. Discard the cylinder head bolts.
66. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
67. Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches longer than 0.0254 mm (0.001 in).

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

Material

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 .

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. CAUTION: 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. Detach the wiring harness retainers from the RH oil pan bolts.
9. Disconnect the crankshaft position sensor electrical connector and detach the wiring harness retainer.
10. Disconnect the RH and LH camshaft position (CMP) sensor electrical connectors.
11. Disconnect the RH and LH variable camshaft timing (VCT) solenoid electrical connectors.
12. Detach the wiring harness retainers.
13. Remove the nut and the RH radio ignition interference capacitor.
14. Disconnect the oil pressure sensor electrical connector.
15. Disconnect the LH CMP sensor electrical connector and detach the wiring harness retainers.
16. Remove the nut and the cooling fan wiring harness bracket.
17. Remove the nut and detach the LH radio interference capacitor.
18. Detach the wiring harness retainers from the LH valve cover studs.
19. Disconnect the 4 RH and 4 LH ignition coil electrical connectors.
20. Detach the wiring harness retainers from the RH valve cover studs.
21. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
22. Remove the nut and the ground strap.
23. Detach the electrical connector retainers and remove the engine wiring harness.
24. Remove the stud bolt and the heater supply tube and hoses as an assembly. Discard the O-ring seals.
25. 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.
26. Remove the positive crankcase ventilation (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.
27. Remove the 8 bolts and the 8 ignition coils.
28. Remove the bolts and the LH engine support insulator bracket.
29. Remove and discard the oil filter. Remove the bolts and the oil filter adapter.
30. Remove the bolts and the LH exhaust manifold heat shield.
31. Remove the nuts, the LH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
32. Remove and discard the 8 LH exhaust manifold studs.
33. Remove the bolt and the oil level indicator tube.
34. Remove the bolts and the RH engine support insulator bracket.
35. Remove the bolts and the RH exhaust manifold heat shield.
36. Remove the nuts, the RH exhaust manifold and the gaskets. Discard the nuts and the gaskets.
37. Remove and discard the 8 RH exhaust manifold studs.
38. Loosen the 14 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.
39. Loosen the 15 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.
40. Remove the bolt and the RH CMP sensor.
41. Remove the bolt and the LH CMP sensor.
42. Remove the bolt and the CKP sensor.
43. Remove the 7 bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
44. Remove the 3 bolts and the accessory drive belt tensioner.
45. Remove the 4 coolant pump bolts.
46. Remove the coolant pump from the cylinder block. Discard the O-ring seal.
47. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
48. Using the special tool, remove the crankshaft front oil seal.
49. Remove the bolts, oil pan and oil pan gasket. CAUTION: 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.
50. Remove the engine front cover fasteners.
51. Remove the engine front cover from the cylinder block.
52. Remove the crankshaft sensor ring from the crankshaft.
53. Position the crankshaft keyway at the 12 o'clock position.
54. 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.
55. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
56. Using the special tool, remove the 3 roller followers designated in the previous step from the RH cylinder head.
57. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.
58. Using the special tool, remove the 3 roller followers designated in the previous step from the LH cylinder head.
59. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
60. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
61. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
62. 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.
63. Remove the LH and RH timing chain guides. Remove the 2 bolts. Remove both timing chain guides.
64. Using the special tool, remove the bolt and the RH camshaft phase sprocket assembly. Discard the camshaft phase sprocket bolt.
65. Using the special tool, remove the bolt and the LH camshaft phase sprocket assembly. Discard the camshaft phase sprocket bolt.
66. Install the special tool onto the LH cylinder head.
67. Install the special tool onto the RH cylinder head.
68. Remove the bolts in the sequence shown. Remove the RH cylinder head front camshaft bearing cap, then the remaining bearing caps.
69. 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.
70. Remove the RH camshaft.
71. Remove the remaining roller followers from the RH cylinder head.
72. Remove the hydraulic lash adjusters from the RH cylinder head.
73. Remove the bolts in the sequence shown. Remove the LH cylinder head front camshaft bearing cap, then the remaining bearing caps.
74. 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.
75. Remove the LH camshaft.
76. Remove the remaining roller followers from the LH cylinder head.
77. Remove the hydraulic lash adjusters from the LH cylinder head.
78. Remove the 20 bolts and the cylinder heads. Discard the cylinder head gaskets. Discard the cylinder head bolts.
79. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
80. Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches longer than 0.0254 mm (0.001 in).
81. Remove the bolts, the oil pump screen and pickup tube and the spacer.
82. Remove the 3 bolts and the oil pump.
83. 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 instructions.
84. Remove the bolts and the connecting rod caps. Discard the bolts.
85. Use the special tool to push the piston through the top of the cylinder block.
86. Disassemble the 8 pistons. For additional information, refer to «Piston»(ref-270890-S25070276172007110700000) .
87. 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.
88. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
89. 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

Scheme 82

Piston

Material

Scheme 83

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

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»(ref-270909) .
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»(ref-270909) .
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 phase sprockets and new camshaft phase bolts finger tight.
22. Using the special tool, tighten the LH and RH camshaft phase 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 positive crankcase ventilation (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. Attach the wiring harness retainers to the RH oil pan bolts.
79. Install the special tool.
80. Using a suitable floor crane, remove the engine from the engine stand.
81. Install the engine. For additional information, refer to «Engine»(ref-270890-S09100120282007110700000) .