ford explorer cylinder head installation?

Cylinder Head 3

Removal & Installation

4.6L Engine
DOHC Engine
VIN H

1. Before servicing the vehicle, refer to the -Precautions- section.
2. Remove the engine.
3. Remove the flexplate and the spacer plate.
4. Mount the engine on a suitable engine stand.
5. Remove the two bolts and the pin-type retainer from the power steering reservoir bracket.
6. Remove the power steering reservoir and bracket.
7. Disconnect the battery cable harness ground.
8. Disconnect the electrical connector and the battery cable from the alternator.
9. Disconnect the two retainers from the engine front cover studs.
10. Disconnect the two retainers from the A/C compressor.
11. Remove the bolt and the battery cable harness from the right engine mount.
12. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.
13. Disconnect the vacuum harness from the intake manifold and remove the harness.
14. Remove the left and right coil covers.
15. Disconnect the right and left ignition coil electrical connectors.
16. Disconnect the radio interference capacitor electrical connector.
17. Disconnect the eight fuel injector electrical connectors.
18. Separate the fuel charging wiring harness retainers from the fuel injection supply manifold.
19. Disconnect the camshaft position (CMP) sensor electrical connector and the two retainers from the valve cover.
20. Disconnect the oil pressure sensor electrical connector.
21. Disconnect the pin-type retainers from the back of the engine in the locations shown.
22. Disconnect the knock sensor (KS) electrical connector and the pin-type retainer.
23. Disconnect the wiring harness retainer from the stud on the cylinder head.
24. Disconnect the intake manifold runner control (IMRC) electrical connector.
25. Disconnect the exhaust gas recirculation (EGR) system module tube nut from the exhaust manifold.
26. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the two pin-type retainers.
    
    
    

    

    Fig. These tools, or their equivalents, are necessary for cylinder head removal and installation on the 4.6L DOHC engine (1 of 2)

    
    
    
    

    

    Fig. These tools, or their equivalents, are necessary for cylinder head removal and installation on the 4.6L DOHC engine (2 of 2)

27. Disconnect the positive crankcase ventilation (PCV) electrical connector.
28. Remove the PCV tube.
29. Disconnect the right radio interference capacitor electrical connector and the pin-type retainer.
30. Disconnect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
31. Disconnect the two retainers from the right valve cover studs.
32. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
33. Disconnect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.
34. Remove the upper radiator hose.
35. Remove the coolant bypass-to-thermostat housing hose.
36. Remove the accessory drive belt.
37. Remove the bolts and the alternator support bracket.
38. Remove the bolts and the alternator.
39. Remove the crossover tube.
40. Remove the eight ignition coils.
41. Remove the nut and the bolt from the oil level indicator tube and position the tube aside.
42. Remove the engine lifting eyes.
43. Remove the bolts and the left valve cover.
44. Remove the coolant hose retainers from the right valve cover.
45. Remove the bolts and the right valve cover.
46. Remove the retainers and the upper-to-lower intake bracket.
47. Remove the bolts in the sequence shown and remove the upper and lower intake.
    
    
    

    

    Fig. Intake manifold bolt removal sequence-4.6L DOHC engine

48. Remove the bolt and the coolant bypass tube.
49. Remove the exhaust manifolds.
50. Clean and inspect the exhaust manifolds.
51. Remove the oil level indicator tube.
52. Remove the three remaining bolts and the power steering pump.
53. Install the special tool.
54. Remove the coolant pump pulley.
55. To remove the crankshaft pulley bolt, remove the upper fan shroud and electric fan.
56. Remove the pulley bolt.
57. Remove the crankshaft vibration damper.
58. Remove the crankshaft front seal.
59. Remove the bolt and the belt idler pulley.
60. Remove the four front oil pan-to-timing cover bolts.
61. Remove the engine front cover fasteners in the sequence shown.
    
    
    

    

    Fig. Front cover bolt removal sequence-4.6L DOHC engine

62. Remove the crankshaft position sensor pulse wheel.
    
    NOTE

    Mark the roller follower locations. Reused roller followers must be installed in their original locations.
    
    
63. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
64. Compress the intake valve spring and remove the roller follower.
    
    
    

    

    Fig. Compressing the intake valve spring-4.6L DOHC engine

    
    
    
    

    

    Fig. Compressing the exhaust valve spring-4.6L DOHC engine

65. Compress the exhaust valve spring and remove the roller follower.
66. Repeat the above steps to remove all the roller followers.
67. Remove the bolts and the right and left timing chain tensioners.
68. Remove the right and left timing chain tensioner arms.
69. Remove the right and the left timing chains and the crankshaft sprocket.
70. Remove the right and left timing chain guides.
71. Remove the right and left cylinder heads. Discard the cylinder head bolts. Discard the cylinder head gaskets.
72. Clean and inspect the cylinder heads.

To install:

NOTE

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

All vehicles

1. Install new cylinder head gaskets.
   
   NOTE

   Lubricate the new bolt heads and threads. Use clean engine oil.
   
   
   
   
   

   

   Fig. Cylinder head bolt torque sequence-4.6L DOHC engine

2. Install the left and right cylinder heads and tighten the bolts in six stages in the sequence shown.
   
   
   Stage 1: Tighten to 30 ft. lbs. (40 Nm).

   Stage 2: Tighten an additional 90 degrees.

   Stage 3: Loosen the bolts a minimum of one full turn.

   Stage 4: Tighten to 30 ft. lbs. (40 Nm).

   Stage 5: Tighten an additional 90 degrees.

   Stage 6: Tighten an additional 90 degrees.
   
   

Engine with ratcheting timing chain tensioners

WARNING

Timing chain procedures must be followed exactly or damage to valves and pistons will result.

WARNING

Do not compress the ratchet assembly. This will damage the ratchet assembly.

1. Compress each tensioner plunger, using an edge of a vise.
2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
4. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.

Engine with non-ratcheting timing chain tensioners

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

All engine

1. 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.
   
   
   

   

   Fig. 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-4.6L DOHC engine

2. Install the timing chain guides.
3. Rotate the left camshaft timing sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the right camshaft timing sprocket until the timing mark is at approximately the 11 o'clock position.
   
   WARNING

   Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
   
   
   
   
   

   

   Fig. 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-4.6L DOHC engine

4. Using the special tool, position the crankshaft.
   
   
   

   

   Fig. Using the special tool, position the crankshaft-4.6L DOHC engine

5. Install the crankshaft sprocket with the flange facing forward.
6. Install the left and right timing chains onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
   
   NOTE

   If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
   
   
7. Position the left and right timing chains on the camshaft sprockets. Make sure the copper-colored links align with the camshaft sprocket timing marks.
8. Position the left and right timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.

Engine with ratcheting timing chain tensioners

1. Remove the retaining clip from the timing chain tensioners.

Engine with non-ratcheting timing chain tensioners

1. Remove the retaining clips from the timing chain tensioners.

All engine

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

   If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
   
   
3. Apply silicone gasket and sealant in the locations shown.
4. Install the engine front cover and tighten the bolts in the sequence shown.
   
   
   

   

   Fig. Verify timing mark alignment-4.6L DOHC engine

   
   
   
   

   

   Fig. Apply silicone gasket and sealant in the locations shown-4.6L DOHC engine

   
   
   
   

   

   Fig. Front cover bolt torque sequence-4.6L DOHC engine

   
   
   
   

   

   Fig. Install the four oil pan bolts and tighten in the sequence shown-4.6L DOHC engine

5. Install the four oil pan bolts and tighten in the sequence shown.
   
   WARNING

   If reusing the roller followers, install them in their original locations.
   
   
   
   
   Stage 1: Tighten to 18 inch lbs. (2 Nm).

   Stage 2: Tighten to 15 ft. lbs. (20 Nm).

   Stage 3: Tighten an additional 60 degrees.
   
   
6. Position the piston of the cylinder in which the roller followers are being installed at the bottom of the stroke and the camshaft lobe at the base circle.
7. Compress the intake valve spring and install the roller follower.
8. Compress the exhaust valve spring and install the roller follower.
9. Repeat the above steps to install all of the roller followers.
   
   NOTE

   If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.
   
   
   
   
   

   

   Fig. Valve cover bolt torque sequence-4.6L DOHC engine

   
   
   
   

   

   Fig. Apply silicone gasket and sealant in the locations shown-4.6L DOHC engine

10. Apply silicone gasket and sealant in the locations shown.
11. Install the valve covers and tighten the bolts in the sequence shown.
12. Install the belt idler pulley.
13. Lubricate the front oil seal and the engine front cover with clean engine oil.
14. Install the front oil seal.
15. Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
16. Install the crankshaft pulley.
17. Install the crankshaft pulley bolt and tighten the bolt in four stages.
    
    
    Stage 1: Tighten to 66 ft. lbs. (90 Nm).

    Stage 2: Loosen the bolt one full turn.

    Stage 3: Tighten to 37 ft. lbs. (50 Nm).

    Stage 4: Tighten an additional 90 degrees.
    
    
18. Install the coolant pump pulley.
19. Install the power steering pump and the three bolts.
    
    NOTE

    Install a new O-ring and lubricate with clean engine oil.
    
    
20. Install the oil level indicator tube in the engine block.
21. Install the fasteners and tighten to 89 inch lbs. (10 Nm).
22. Install new exhaust manifold gaskets.
23. Install the exhaust manifolds.
24. Install the 16 nuts.
25. Install the bolt and the coolant bypass tube.
26. Install the upper and lower intake. Tighten all fasteners in the sequence shown to 89 inch lbs. (10 Nm).
    
    
    

    

    Fig. Intake manifold bolt torque sequence-4.6L DOHC engine

27. Install the upper-to-lower intake bracket and the nuts.
28. Install the coolant hose retainers on the right valve cover.
29. Install the engine lifting eyes.
30. Install the eight ignition coils.
31. Install the crossover tube and the nuts. Connect the coolant hose.
32. Install the alternator and the bolts.
33. Install the alternator support bracket and the bolts.
34. Install the accessory drive belt.
35. Install the coolant bypass-to-thermostat housing hose.
36. Install the upper radiator hose.
37. Position the engine wiring harness on the engine.
38. Connect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.
39. Connect the engine coolant temperature (ECT) sensor electrical connector.
40. Connect the two harness retainers to the right valve cover studs.
41. Connect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
42. Connect the right radio interference capacitor electrical connector and the pin-type retainer.
43. Install the positive crankcase ventilation (PCV) tube.
44. Connect the PCV electrical connector.
45. Connect the Cylinder Head Temperature (CHT) sensor electrical connector and the two pin-type retainers.
46. Connect the exhaust gas recirculation (EGR) system module tube to the exhaust manifold.
47. Connect the intake manifold runner control (IMRC) electrical connector.
48. Connect the wiring harness retainer to the stud on the cylinder head.
49. Connect the KS electrical connector and the pin-type retainer.
50. Connect the pin-type retainers to the back of the engine in the locations shown.
51. Connect the oil pressure sensor electrical connector.
52. Connect the camshaft position (CMP) sensor electrical connector and the two retainers to the valve cover.
53. Install the fuel charging wiring harness retainers to the fuel injection supply manifold.
54. Connect the eight fuel injector electrical connectors.
55. Connect the radio interference capacitor electrical connector.
56. Connect the eight ignition coil electrical connectors.
57. Install the right and left coil covers.
58. Position the vacuum harness and connect it to the intake manifold.
59. Connect the electrical connector and the vacuum hose to the fuel pressure sensor.
60. Install the battery cable harness and the bolt to the right engine mount.
61. Connect the two retainers to the A/C compressor.
62. Connect the two retainers to the engine front cover studs.
63. Connect the electrical connector and the battery cable to the alternator.
64. Connect the battery cable harness ground.
65. Position the power steering reservoir and install the two bolts and the pin-type retainer.
66. Install the remaining bolt and the hose to the power steering reservoir.
67. Remove the engine from the stand.
    
    
    

    

    Fig. Flexplate bolt torque sequence-4.6L DOHC engine

68. Install the spacer plate and the flexplate.
69. Install the engine.

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