How to replace 4.6L engine on 2005 ford explorer?

4.6L DOHC And SOHC Engines

Fig. Engine mounting-4.6L SOHC engines

Fig. Engine mounting-4.6L DOHC engines

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Drain the engine oil.
5. Properly discharge the A/C system.
6. Remove or disconnect the following:
   
   NOTE

   Access the heater control valve bracket through the wheel well.
   
   
   
   
   Battery ground cable

   Hood

   Accelerator cable from the throttle body and all clips

   Speed control cable from the throttle body and all clips

   Air cleaner and the air cleaner outlet pipe

   Radiator and transmission cooler

   A/C condenser core
   
   
   
   
   Heater control valve bracket bolt

   Coolant hoses

   All vacuum hoses. Position the heater control valve assembly aside.

   A/C tubes from the A/C compressor

   Fuel charging wiring harness connections

   Fuel charging wiring harness from the clips on the bulkhead. Release the fuel charging wiring harness pin-type retainer.

   All connections from the evaporative emissions (EVAP) canister purge solenoid

   Brake booster vacuum hose

   Fuel tube

   Alternator connections and the wiring anchors

   Wiring harness side of the left and right heated exhaust gas oxygen (HEGO) sensor connectors

   Power steering return hose. Plug the power steering reservoir.

   Power steering pressure tube from the power steering pump

   Brackets

   Oil pressure sender electrical connector

   CKP sensor electrical connector and the wiring anchor

   A/C compressor electrical connector and the wiring anchor

   Wiring harness routing clip and wiring anchor

   Starter

   On 4x4 vehicles, the bolt from the right side axle housing bushing bolt

   Right side and the left side stabilizer bar bracket nuts

   Left side lower axle housing bushing bolt

   Left side upper axle housing bushing bolt

   Right lower mount nut and washer

   Left lower mount nut and washer

   Transmission inspection cover, torque converter bolts and the transmission-to-engine block bolts
7. Install the right side Lifting Eye.
8. Install the left side Lifting Eye.
9. Install the Spreader Bar to the Lifting Eyes.
10. Attach a floor crane to the Spreader Bar and remove the engine.
    
    NOTE

    If engine disassembly is to be carried out, remove the rear crankshaft oil seal slinger and the crankshaft rear oil seal.
11. Installation is the reverse of removal. Observe the following torques:
    
    
    Lower mount nuts: 59 ft. lbs. (81 Nm) for DOHC engines; 66 ft. lbs. (90 Nm) for SOHC engines

    Left side upper axle housing bushing bolt: 49 ft. lbs. (66 Nm)

    Left side axle housing bushing bolt: 49 ft. lbs. (66 Nm)

    Stabilizer bar bracket nuts: 30 ft. lbs. (40 Nm)

    Right side axle housing bushing bolt: 49 ft. lbs. (66 Nm)

4.6L Engine

Removal & Installation

4.6L Engine
VIN H Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove the transmission.
3. Remove the hood (mark the hinge locations for reinstallation).
4. Properly discharge and recover the A/C system.
5. Remove the air cleaner assembly.
6. Remove the engine cooling fan and cooling module.
7. Properly relieve the fuel system pressure as follows:
   1. Remove the fuel line service valve cap.
   2. Install a special tool (pressure gauge with an in-line petcock) and slowly open the petcock to relieve the fuel system pressure into a suitable container.
   3. Remove the special tool.
   4. Immediately cap all fuel system openings to prevent contamination.
      
      
      

      

      Fig. Showing the fuel line service valve (1, 2) location-4.6L (VIN H) engine
8. Drain the engine oil.
9. Disconnect the accelerator cable, the speed control cable and the throttle return spring.
10. Release the speed control cable from the pin-type retainer.
11. Remove the 2 bolts and position the bracket and cables aside.
    
    
    

    

    Fig. Disconnect the accelerator cable, the speed control cable and the throttle return spring-4.6L (VIN H) engine
    
    
    
    

    

    Fig. Release the speed control cable from the pin-type retainer-4.6L (VIN H) engine
12. Remove or disconnect the following:
    
    
    Heater hoses from the coolant pump and block

    2 vacuum hose connections as shown.
    
    

    

    

    Fig. Disconnect the 2 vacuum hose connections shown-4.6L (VIN H) engine

    Coolant hose from the retaining clips on the RH valve cover and position aside

    Coolant hose from the intake manifold

    Engine wiring harness and the electrical connector from the Powertrain Control Module (PCM)
    
    

    

    

    Fig. Disconnect the wiring harness and the electrical connector from the Powertrain Control Module (PCM)-4.6L (VIN H) engine

    Engine wiring harness from the 3 retaining clips and position aside

    Wiring harness and remove the wiring harness retaining clip

    Ground strap bolt

    Electrical connector and the vacuum hose from the exhaust gas recirculation (EGR) system module

    EGR system module
    
    

    

    

    Fig. Disconnect the connector and the vacuum hose from the exhaust gas recirculation (EGR) system module-4.6L (VIN H) engine

    Vacuum harness from the retainer clip

    Brake booster hose from the intake manifold

    Fuel tube

    2 vacuum hoses from the vapor management (VMV) valve-to-intake manifold
    
    

    

    

    Fig. Disconnect the 2 vacuum hoses from the vapor management (VMV) valve-to-intake manifold-4.6L (VIN H) engine

    Power distribution supply electrical connector (from inside the box cover)

    Positive and negative battery cables

    Battery cable harness pin-type retainers and position the harness aside
    
    

    

    

    Fig. Disconnect the battery cable harness pin-type retainers and position the harness-4.6L (VIN H) engine

    Power steering reservoir hose from the power steering cooler

    Power steering pressure (PSP) switch electrical connector
    
    

    

    

    Fig. Disconnect the Power steering pressure (PSP) switch electrical connector-4.6L (VIN H) engine

    Power steering pressure tube from the power steering pump

    Power steering pressure hose bracket from the front cover

    Power steering pressure hose support bracket and position aside

    Position the A/C compressor manifold assembly aside
    
    

    

    

    Fig. Remove the bolt and position the A/C compressor manifold assembly aside-4.6L (VIN H) engine

    LH engine mount through-bolt

    2 nuts from the RH engine mount (through the wheel well)
13. Install engine lifting eyes on each side of the block.
14. Using a lifting crane, carefully lift the engine from the vehicle.

To install:

1. Using the lifting crane, carefully position the engine into the vehicle.
2. Install the 2 nuts to the RH engine mount (through the wheel well). Tighten the nuts to 66 ft. lbs. (90 Nm).
3. Install the LH engine mount through-bolt. Tighten the bolt to 59 ft. lbs. (80 Nm).
4. Remove the crane and the lifting eyes from the engine.
5. Install or connect the following:
   
   CAUTION

   Do not connect the negative battery cable at this time.
   
   
   
   
   A/C compressor manifold assembly; tighten the bolt to 15 ft. lbs. (20 Nm)

   New O-ring seal on the power steering pressure (PSP) tube fitting

   PSP tube to the power steering pump; tighten the fitting to 48 ft. lbs. (65 Nm)

   PS hose support bracket; tighten the bolt to 89 inch lbs. (10 Nm)
   
   

   

   

   Fig. Install the PS hose support bracket as shown-4.6L (VIN H) engine

   PSP hose bracket to the front cover

   PSP switch electrical connector

   Power steering reservoir hose to the power steering cooler

   Battery cable harness and install the pin-type retainers
   
   
   
   
   Positive battery cable to the battery

   Power distribution power supply electrical connector; tighten the fastener to 89 inch lbs. (10 Nm)

   Power distribution box cover

   2 vacuum hoses
   
   

   

   

   Fig. Connect the 2 vacuum hoses to the vapor management (VMV) valve-to-intake manifold-4.6L (VIN H) engine

   Fuel tube

   Brake booster hose to the intake manifold

   Vacuum harness and install it in the retainer

   2 bolts and the exhaust gas recirculation (EGR) system module; tighten the bolts to 15 ft. lbs. (20 Nm)

   EGR system module tube nut to the EGR system module

   Electrical connector and the vacuum hose to the EGR system module

   Ground strap to the body; tighten the nut to 89 inch lbs. (10 Nm)

   Wiring harness retaining clip and the wiring harness

   Engine wiring harness into the 3 retaining clips

   Engine wiring harness and the electrical connector to the Powertrain Control Module (PCM)

   Coolant hose to the intake manifold

   Coolant hose into the retaining clips on the RH valve cover

   Vacuum harness and install the 2 vacuum hoses
   
   

   

   

   Fig. Connect the 2 vacuum hose connections shown-4.6L (VIN H) engine

   Coolant hoses to the coolant pump and engine

   Accelerator bracket and cables and install the 2 bolts; tighten the bolts to 89 inch lbs. (10 Nm)
   
   

   

   

   Fig. Connect the accelerator bracket and cables and install the 2 bolts-4.6L (VIN H) engine

   Speed control cable into the pin-type retainer
   
   

   

   

   Fig. Connect the speed control cable into the pin-type retainer-4.6L (VIN H) engine
6. Install the transmission.
7. Install the cooling fan and shroud module.
8. Install the air cleaner assembly.
9. Install a new oil filter and refill the engine with clean engine oil
10. Connect the negative battery cable.
11. Fill and bleed the engine cooling system.
12. Evacuate and recharge the A/C system.
13. Start the engine and check for leaks. Stop the engine and recheck all fluid levels.
14. Perform an A/C system leak check.
15. Perform a transmission fluid level check.
16. Install the hood.