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

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»(ref-270909) .
9. Remove the bolts and the front camshaft bearing cap and then the remaining bearing caps.
10. Remove the camshaft.
11. Check the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .

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 bolts and the front camshaft bearing cap and then the remaining bearing caps.
9. Remove the camshaft.
10. Install a new gasket, the variable camshaft timing (VCT) housing and the bolts. Tighten to 10 N.m (89 lb-in).

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the piston pin retainers and the piston pin.
3. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .

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 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Compressor, Valve Spring 303-1039 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Crankshaft Front Seal 303-635 Installer, Front Cover Seal 303-335 (T88T-6701-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH) Impact Slide Hammer 100-001 (T50T-100-A) Alignment Pins, Cylinder Head 303-1040 (SR-015486) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Locking Tool, Camshaft Phase Sprocket 303-1046

Material

Scheme 63

Scheme 64

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»(ref-270909) .
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»(ref-270909) .
13. Assemble the pistons. For additional information, refer to «Piston»(ref-270890-S25070276172007110700000) .
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 phase sprockets and install new camshaft phase bolts finger-tight.
31. 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.
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 14 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 15 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»(ref-270909) .
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»(ref-270909) .
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 positive crankcase ventilation (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. Attach the wiring harness retainers to the RH oil pan bolts.
105. Install the special tool.
106. Using a suitable floor crane, remove the engine from the engine stand.
107. 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.
108. Apply a bead of gasket maker to the crankshaft rear seal retainer mating surface on the engine block.
109. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
110. Tighten the 6 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
111. 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.
112. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
113. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
114. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
115. 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.
116. Using the special tools, install a new crankshaft rear seal.
117. Using the special tools, install the crankshaft rear oil slinger.
118. Install the spacer plate.
119. 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»(ref-270910) .
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 powertrain control module (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 positive crankcase ventilation (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»(ref-270902) .
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»(ref-270890-S16274743342007110700000) .
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»(ref-270902) .
40. Carry out the fluid level check for the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R60»(ref-270910) .