FixVault
Home › Ford › 2004 › Excursion 5.4 L, 4WD › Repair and Diagnosis › External Pages › Different car › Section 1848 (Engine - 4.6L And 5.4L) › Assembly › Engine - 4.6L

Engine - 4.6L

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000362
 Alignment Pins, Cylinder Head 303-1040 (SR-015486)
GF0000361
 Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
GF0000262
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
GF0000434
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
GF0000400
 Holding Tool, Crankshaft 303-448 (T93P-6303-A)
GF0000351
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000313
 Installer, Crankshaft Front Oil Seal 303-635
GF0000318
 Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
GF0000316
 Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
GF0000320
 Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
GF0000290
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GF0000314
 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
GF0000339
 Lifting Bracket, Engine 303-F047 (014-00073) or equivalent
GF0011693
 Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A)
GF0000345
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
GF0000246
 Strap Wrench 303-D055 (D85L-6000-A)
Material

Item Specification
Gasket Maker
TA-16		 WSK-M2G348-A5
Hydraulic Chain Tensioner Retaining Clip
1L3Z-6P250-AA		 -
Instant Gel Adhesive
TA-19		 WSK-M2G402-A4
Motorcraft Metal Surface Prep
ZC-31-A		 -
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)		 WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Silicone Gasket Remover
ZC-30		 -
Fig 1: Exploded View Of Upper End Engine - 4.6L
GF0011711Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6766 Oil filler cap
2 6K817 Crankcase ventilation hose
3 6A666 PCV valve
4 6582 Valve cover - RH
5 6B280 Camshaft bearing cap
6 N811085 Camshaft sprocket bolt - RH
7 N806164 Camshaft sprocket bolt washer - RH
8 6256 Camshaft sprocket - RH
9 6265 Camshaft sprocket spacer - RH
10 6250 Camshaft - RH
11 18465 Coolant hose
12 W704925 Heater outlet tube stud
13 18663 Heater outlet tube
14 12405 Spark plug (8 required)
15 9430 Exhaust manifold - RH
16 9Y431 Exhaust manifold gasket - RH
17 6051 Cylinder head gasket - RH
18 6049 Cylinder head - RH
19 6758 Crankcase vent tube
20 N806183 Valve cover bolt (8 required)
21 N807441 Valve cover bolt
22 W705644 Valve cover stud (13 required)
23 6A505 Valve cover - LH
24 N807352 Camshaft bearing cap bolt (26 required)
25 6B280 Camshaft bearing cap
26 6C501 Hydraulic lash adjuster (16 required)
27 6529 Roller follower (16 required)
28 6518 Valve spring retainer key (32 required)
29 6514 Valve spring retainer (16 required)
30 6513 Valve spring (16 required)
31 6A517 Valve stem seal (16 required)
32 N811085 Camshaft sprocket bolt - LH
33 N806164 Camshaft sprocket bolt washer - LH
34 6256 Camshaft sprocket - LH
35 6265 Camshaft sprocket spacer - LH
36 6A274 Camshaft - LH
37 14B102 Cylinder head temperature (CHT) sensor jumper harness
38 6G004 CHT sensor
39 6507 Intake valve (8 required)
40 6505 Exhaust valve (8 required)
41 W707747 Exhaust manifold stud (16 required)
42 9Y431 Exhaust manifold gasket (2 required)
43 9431 Exhaust manifold - LH
44 W701706 Exhaust manifold nut (16 required)
45 W704594 Cylinder head positioning dowel (4 required)
46 6083 Cylinder head gasket - LH
47 6050 Cylinder head - LH
48 6010 Cylinder block
Fig 2: Exploded View Of Engine Induction System
GF0002706Courtesy of FORD MOTOR CO.
Item Part Number Description
1 9E498 Vacuum harness
2 N811425 Fuel rail bolt (4 required)
3 9F792 Fuel rail
4 W704693 Thermostat housing bolt (2 required)
5 8594 Thermostat housing
6 N806807 Thermostat O-ring seal
7 8575 Thermostat
8 W711062 Ignition coil bolt (8 required)
9 9F593 Fuel injector (8 required)
10 12A366 Ignition coil (8 required)
11 9Y456 EGR system module
12 9S455 Intake manifold
13 W503301 Intake manifold bolt (9 required)
14 9E930 Throttle body (TB) gasket
15 9F991 TB assembly
16 W701592 TB bolt (4 required)
17 9439 Intake manifold gasket (2 required)
18 9D477 EGR system module-to-exhaust manifold tube
Fig 3: Exploded View Of Lower End Engine - 4.6L
GF0011712Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W500110 Knock sensor (KS) bolt
2 12A699 KS
3 6152 Lower compression ring (8 required)
4 6161 Inner oil control ring (8 required)
5 6150 Upper compression ring (8 required)
6 6159 Outer oil control rings (16 required)
7 6135 Piston pin (8 required)
8 6110 Piston (8 required)
9 6140 Piston pin retainer (16 required)
10 6200 Connecting rod assembly (8 required)
11 6211 Connecting rod bearings (16 required)
12 6A341 Crankshaft thrust washer - Upper
13 6333 Crankshaft bearing - upper (5 required)
14 6303 Crankshaft
15 6A339 Crankshaft thrust washer - Lower
16 6A338 Crankshaft bearing - lower (4 required)
17 6325 Crankshaft main bearing cap (5 required)
18 6345 Crankshaft main bearing cap bolt (9 required)
19 6C357 Crankshaft main bearing cap bolt (10 required)
20 N806155 Oil pump screen and pickup tube bolt (2 required)
21 6622 Oil pump screen and pickup tube
22 6K258 Crankshaft main bearing cap stud
23 N806180 Oil pump screen and pickup tube spacer
24 N605904 Oil pump screen and pickup tube bolt
25 N811342 Oil filter adapter stud (2 required)
26 6A636 Oil filter adapter gasket
27 N804178 Oil filter adapter nut (2 required)
28 W705128 Oil filter adapter bolt (2 required)
29 6881 Oil filter adapter
30 N808713 Oil filter adapter bolt (2 required)
31 6710 Oil pan gasket
32 6675 Oil pan
33 W701605 Oil pan bolt (16 required)
34 N806183 Oil pump bolt (3 required)
35 6621 Oil pump
36 N806168 Flexplate bolt (6 required)
37 6375 Flexplate
38 6310 Crankshaft oil slinger
39 6701 Crankshaft rear seal
40 N806155 Crankshaft rear oil seal retainer bolt (6 required)
41 6K318 Crankshaft rear oil seal retainer
42 6010 Cylinder block
43 N806821 Key
Fig 4: Exploded View Of Front End Engine - 4.6L
GF0011713Courtesy of FORD MOTOR CO.
Item Part Number Description
1 N806282 Coolant pump pulley bolt (4 required)
2 8A528 Coolant pump pulley
3 N806177 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 N808102 Accessory drive idler pulley bolt
6 19A216 Accessory drive idler pulley
7 N804178 Radio ignition interference capacitor nut (2 required)
8 18801 Radio ignition interference capacitor (2 required)
9 N806300 Engine front cover stud (4 required)
10 W701512 Crankshaft pulley bolt
11 N806165 Crankshaft pulley washer
12 6316 Crankshaft pulley
13 N806155 Crankshaft position (CKP) sensor bolt
14 6C315 CKP sensor
15 6700 Crankshaft front seal
16 N806177 Engine front cover bolt (8 required)
17 N808586 Engine front cover stud
18 W706508 Engine front cover stud
19 N808294 Engine front cover bolt
20 W500315 Power steering pump bolt (3 required)
21 3A696 Power steering pump
22 6C086 Engine front cover
23 N806155 Camshaft position (CMP) sensor bolt
24 6B288 CMP sensor
25 N806177 Timing chain tensioner bolt (4 required)
26 W503279 Timing chain guide bolt - RH
27 6L266 Timing chain tensioner - RH
28 6L253 Tensioner arm - RH
29 12A227 Ignition pulse wheel
30 6306 Crankshaft sprocket
31 6268 Timing chain - RH
32 6268 Timing chain - LH
33 6M256 Timing chain guide - RH
34 6M269 Timing chain tensioner - LH
35 6L253 Tensioner arm - LH
36 N804958 Timing chain guide bolt - LH
37 6B274 Timing chain guide - LH
38 N606527 Timing chain guide bolt - LH
39 6010 Cylinder block
  1. Record the main bearing code found on the front of the engine block.
    2. Fig 5: Identifying Main Bearing Code Found On Front Of Engine Block
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    3. Fig 6: Identifying Main Bearing Code - Found On Back Of Crankshaft
    G03886015Courtesy of FORD MOTOR CO.
    NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
  3. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
  4. Install the crankshaft onto the upper crankshaft main bearings.
    5. Fig 7: Locating Crankshaft Onto Upper Crankshaft Main Bearings
    GF0002710Courtesy of FORD MOTOR CO.
    NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
  5. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
    6. Fig 8: Locating Crankshaft Upper Thrust Washer At Back Of Upper Main Bearing
    GF0002711Courtesy of FORD MOTOR CO.
    NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.
  6. Install the rear main bearing cap.
    7. Fig 9: Locating Rear Main Bearing Cap
    GF0002712Courtesy of FORD MOTOR CO.
  7. 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.
  8. 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.
    9. Fig 10: Identifying Main Bearing Cap Fasteners Tightening Sequence
    GF0002713Courtesy of FORD MOTOR CO.
  9. Tighten the jack screws against the cylinder block in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    10. Fig 11: Identifying Jack Screws Tightening Sequence
    GF0002714Courtesy of FORD MOTOR CO.
  10. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 21 Nm (15 lb-ft).
    11. Fig 12: Identifying Side Bolts Tightening Sequence
    GF0002715Courtesy of FORD MOTOR CO.
  11. Assemble the 8 pistons. For additional information, refer to Piston .
  12. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
    13. Fig 13: Identifying Piston Ring Gap Positioning
    G03920387Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.
    NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
    NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.
  13. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
    14. Fig 14: Using Special Tools To Install Piston And Connecting Rod Assembly
    G03920388Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.
  14. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
    15. Fig 15: Identifying Special Tool (303-442)
    G03920389Courtesy of FORD MOTOR CO.
    CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. Failure to follow these instructions may result in engine damage.
    NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
  15. Position the lower bearing and connecting rod and install the new bolts loosely.
    16. NOTE: Main bearing caps are removed for clarity.
  16. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 105 degrees.
    17. Fig 16: Rod Cap Bolt Torque Sequence
    GF0011714Courtesy of FORD MOTOR CO.
  17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    18. Fig 17: Identifying Oil Pump Bolts Tightening Sequence
    G03962526Courtesy of FORD MOTOR CO.
    CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
    NOTE: Do not turn the crankshaft until instructed to do so.
    NOTE: LH shown, RH similar.
  18. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
    19. Fig 18: Locating Cylinder Head And Gaskets Using Special Tool (303-1040)
    G03920395Courtesy of FORD MOTOR CO.
  19. Tighten the LH cylinder head bolts in 6 stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Loosen all 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.
    20. Fig 19: Left Cylinder Head Bolt Torque Sequence
    GF0011715Courtesy of FORD MOTOR CO.
  20. Tighten the RH cylinder head bolts in 6 stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Loosen all 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.
    21. Fig 20: Right Cylinder Head Bolt Torque Sequence
    GF0011716Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  21. Install the hydraulic lash adjusters in their original locations.
    22. Fig 21: Locating Hydraulic Lash Adjusters
    GF0002630Courtesy of FORD MOTOR CO.
  22. Install 16 new exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (9 lb-ft).
  23. Position the new gaskets and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
    • Tighten to 20 Nm (15 lb-ft).
    24. Fig 22: Right Exhaust Manifold Torque Sequence - 4.6L
    GF0011656Courtesy of FORD MOTOR CO.
  24. Position the new gaskets and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
    • Tighten to 20 Nm (15 lb-ft).
    25. Fig 23: Left Exhaust Manifold Torque Sequence - 4.6L
    GF0011659Courtesy of FORD MOTOR CO.
    CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.
  25. Compress the tensioner plunger, using a vise.
    26. Fig 24: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  26. Install a retaining clip on the tensioner to hold the plunger in during installation.
    27. Fig 25: Identifying Retaining Clip on Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  27. Remove the tensioner from the vise.
  28. If the copper links are not visible, mark 1 link on one end and 1 link on the other end and use as timing marks.
    29. Fig 26: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  29. Install the crankshaft sprocket, making sure the flange faces forward.
    30. Fig 27: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  30. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
    5. Tighten to 10 Nm (89 lb-in).
    31. Fig 28: Identifying Timing Chain Guides
    G03962457Courtesy of FORD MOTOR CO.
  31. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
    32. Fig 29: Identifying LH And RH Camshaft Timing Mark Position
    G04583473Courtesy of FORD MOTOR CO.
    NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
  32. Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
    33. Fig 30: Positioning Crankshaft With Special Tool (303-448)
    G03919963Courtesy of FORD MOTOR CO.
  33. Remove the special tool.
    34. Fig 31: Positioning Crankshaft With Special Tool (303-448)
    G03919963Courtesy of FORD MOTOR CO.
  34. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    35. Fig 32: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  35. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    36. Fig 33: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  36. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    37. Fig 34: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
    GF0002719Courtesy of FORD MOTOR CO.
  37. Remove the retaining clip from the LH timing chain tensioner.
    38. Fig 35: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  38. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    39. Fig 36: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  39. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    40. Fig 37: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  40. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    41. Fig 38: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
    GF0002720Courtesy of FORD MOTOR CO.
  41. Remove the retaining clip from the RH timing chain tensioner.
    42. Fig 39: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  42. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    43. Fig 40: Identifying Copper (Marked) Chain Links And Dots On Crankshaft Sprockets And Camshaft Sprockets
    G03962922Courtesy of FORD MOTOR CO.
  43. Install the crankshaft sensor ring on the crankshaft.
    44. Fig 41: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    NOTE: Camshaft roller follower is shown removed for clarity.
  44. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    45. Fig 42: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
    NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Engine .
    NOTE: It may be necessary to push the valve down while compressing the spring.
    NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
  45. Use the special tool to compress the valve springs and install the camshaft roller follower.
    46. Fig 43: Compressing Valve Springs Using Special Tool (303-567)
    G04612479Courtesy of FORD MOTOR CO.
  46. Repeat the previous 3 steps for each camshaft roller follower.
    47. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
    NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder.
    NOTE: Refer to SPECIFICATIONS  for correct spark plug identification.
  47. Install the 8 spark plugs.
    • Tighten to 18 Nm (13 lb-ft).
    48. 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.
    NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
  48. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
    49. Fig 44: Applying Sealant To Cylinder Head-To-Cylinder Block Seam
    GF0011717Courtesy of FORD MOTOR CO.
  49. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    50. Fig 45: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  50. Tighten the 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 Shldr Pilot, M8 x 1.25 x 50 - M6 x 1 x 10
    7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 50 - M6 x 1 x 24
    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 Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x26
    15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    51. Fig 46: Front Cover Fastener Torque Sequence - 4.6L
    GF0011641Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  51. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  52. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    53. Fig 47: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    NOTE: If not secured within 4 minutes, the sealant must be removed and cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  53. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    54. Fig 48: Applying Sealant Where Engine Front Cover Meets Cylinder Head
    G03947580Courtesy of FORD MOTOR CO.
  54. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.
    55. Fig 49: View Of LH Valve Cover And Gasket At Cylinder Head
    G03885960Courtesy of FORD MOTOR CO.
  55. Tighten the valve cover fasteners in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    56. Fig 50: Valve Cover Torque Sequence - 4.6L
    GF0011620Courtesy of FORD MOTOR CO.
  56. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    57. Fig 51: Valve Cover Gasket
    GF0011626Courtesy of FORD MOTOR CO.
    NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  57. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    58. Fig 52: Applying Sealant At Engine Front Cover & Cylinder Head Seam
    G03947588Courtesy of FORD MOTOR CO.
  58. Position the RH valve cover and gasket on the cylinder head and install the fasteners loosely.
    59. Fig 53: Positioning RH Valve Cover And Gasket On Cylinder Head
    GF0002727Courtesy of FORD MOTOR CO.
  59. Tighten the valve cover fasteners in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    60. Fig 54: Valve Cover Fastener Torque Sequence
    GF0011627Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  60. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    61. Fig 55: Locating LH CMP Sensor Bolt
    G03919989Courtesy of FORD MOTOR CO.
    CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
  61. Install the coolant pump.
    1. Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
    2. Position the coolant pump into the engine block.
    3. Install the bolts.
      • Tighten to 25 Nm (18 lb-ft).
    62. Fig 56: Installing Coolant Pump
    GF0002722Courtesy of FORD MOTOR CO.
  62. Position the accessory drive belt idler pulley and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    63. Fig 57: Accessory Drive Belt Idler Pulley And Retaining Bolt
    G04613548Courtesy of FORD MOTOR CO.
  63. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    64. Fig 58: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  64. Using the special tools, install a new crankshaft front seal.
    65. Fig 59: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  65. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    66. Fig 60: Identifying Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  66. Using the special tool, install the crankshaft pulley.
    67. Fig 61: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
    NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
  67. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    68. Fig 62: Identifying Crankshaft Pulley Bolt Tightening Sequence
    GF0002723Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  68. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    69. Fig 63: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
    NOTE: The front lower hole in the power steering pump is not used.
  69. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    70. Fig 64: Power Steering Pump Bolts
    GF0011694Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  70. Install the radio frequency interference capacitors and the nuts.
    • Tighten to 25 Nm (18 lb-ft).
    71. Fig 65: Radio Interference Capacitor And Retaining Nut
    G04612142Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  71. Using a new O-ring seal, install the oil level indicator tube and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    72. Fig 66: Oil Level Indicator Tube & Bolt
    GF0011718Courtesy of FORD MOTOR CO.
  72. Install the oil level indicator and tube support bracket nut.
    • Tighten to 10 Nm (89 lb-in).
    73. Fig 67: Oil Level Indicator Tube Support Bracket Nut
    GF0011613Courtesy of FORD MOTOR CO.
  73. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
  74. Connect the CKP sensor electrical connector.
    75. Fig 68: Locating CKP Sensor Electrical Connector And Harness Retainer
    GF0002667Courtesy of FORD MOTOR CO.
  75. Connect the engine oil pressure (EOP) switch electrical connector.
    76. Fig 69: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  76. Connect the knock sensor (KS) electrical connector.
    77. Fig 70: Knock Sensor (KS) Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  77. Connect the RH radio frequency interference capacitor electrical connector.
    78. Fig 71: Locating RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  78. Connect the CMP sensor electrical connector.
    79. Fig 72: Locating Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  79. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    80. Fig 73: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  80. Install the cylinder block drain plugs.
    • Tighten to 20 Nm (15 lb-ft).
    81. Fig 74: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  81. Position the oil filter adapter gasket and the oil filter adapter. Install the nuts and bolts.
    • Tighten the front nuts and bolts to 25 Nm (18 lb-ft).
    • Tighten the rear bolt to 48 Nm (35 lb-ft).
    82. Fig 75: Identifying Oil Filter Adapter Nuts And Bolts
    G03885425Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  82. Position the RH and LH engine support insulators and install the 6 bolts.
    • Tighten to 80 Nm (59 lb-ft).
    83. Fig 76: RH Engine Support Insulator Bolts
    G04612459Courtesy of FORD MOTOR CO.
  83. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    84. Fig 77: Identifying Coolant Pump Pulley Bolts
    G04612515Courtesy of FORD MOTOR CO.
  84. Install the pickup tube spacer.
    • Tighten to 25 Nm (18 lb-ft).
    85. Fig 78: Locating Pickup Tube Spacer
    GF0002716Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil.
  85. Position the oil pump screen and pickup tube and install the bolts.
    1. Tighten to 25 Nm (18 lb-ft).
    2. Tighten to 10 Nm (89 lb-in).
    86. Fig 79: Locating Oil Pump Screen And Pickup Tube
    G03962527Courtesy of FORD MOTOR CO.
  86. Install the special tool.
    87. Fig 80: Special Tool (303-D087)
    G04612457Courtesy of FORD MOTOR CO.
  87. Install the special tool.
    88. Fig 81: Special Tool (303-D088)
    G04612458Courtesy of FORD MOTOR CO.
  88. Install the special tool and remove the engine from the work stand.
    89. Fig 82: Special Tool
    GF0011719Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  89. 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.
    90. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer plate mating surface on the engine block.
  90. Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block.
    91. Fig 83: Applying Bead Of Gasket Maker To Rear Crankshaft Seal Retainer
    GF0002646Courtesy of FORD MOTOR CO.
  91. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
    92. Fig 84: Locating Crankshaft Rear Seal Retainer Plate Bolts
    GF0000369Courtesy of FORD MOTOR CO.
  92. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    93. Fig 85: Crankshaft Rear Seal Retainer Plate Bolt Tightening Sequence
    GF0002724Courtesy of FORD MOTOR CO.
    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 clean sealing surfaces.
  93. 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.
    94. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  94. Apply silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block sealing surface.
    95. Fig 86: Applying Silicone Gasket And Sealant
    GF0000322Courtesy of FORD MOTOR CO.
    NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  95. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
    96. Fig 87: Applying Sealant At Engine Front Cover-To-Cylinder Block Mating Surface
    G03920465Courtesy of FORD MOTOR CO.
  96. Install the oil pan gasket and the oil pan and loosely install the bolts.
    97. Fig 88: Positioning New Oil Pan Gasket And Oil Pan
    GF0000323Courtesy of FORD MOTOR CO.
  97. Tighten the bolts 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.
    98. Fig 89: Oil Pan Bolt Torque Sequence - 4.6L
    GF0011665Courtesy of FORD MOTOR CO.
  98. Lower the engine onto wooden blocks.
  99. Install the special tool and raise the engine.
    100. Fig 90: Identifying Special Tool (303-F047)
    G03962845Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
  100. Using the special tools, install a new crankshaft rear seal.
    101. Fig 91: Using Special Tools To Install New Crankshaft Rear Seal
    G04583928Courtesy of FORD MOTOR CO.
  101. Using the special tools, install a new crankshaft rear oil slinger.
    102. Fig 92: Installing Crankshaft Rear Oil Slinger Using Special Tools
    G03920154Courtesy of FORD MOTOR CO.
  102. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    103. Fig 93: Flexplate Bolt Torque Sequence 4.6L
    GF0011673Courtesy of FORD MOTOR CO.
  103. Install the engine. For additional information, refer to Engine .
About FixVault