How to replace ford engine 4.6L?

Engine

Removal & Installation

4.6L Engine
VIN W Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Release the fuel system pressure as follows:
   1. Remove the fuel pump relay (located in the battery junction box).
   2. Start the engine and allow it to idle until it stalls.
   3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released.
   4. Turn the ignition switch to the OFF position.
3. Disconnect the fuel tube spring coupling.
4. Disconnect the electrical connector and detach the wiring harness pin-type retainers.
   
   
   

   

   Fig. Disconnect the electrical connector and detach the wiring harness pin-type retainers-4.6L (VIN W) engine
5. Lift the power distribution box cover, remove the nut and disconnect the wiring harness terminals.
6. Drain the cooling system.
7. Properly discharge and recover the A/C system.
8. Remove or disconnect the following:
   
   CAUTION

   Immediately cap all A/C system openings to prevent contamination.
   
   
   
   NOTE

   Some vehicles are equipped with only one retaining screw.
   
   
   
   
   Hood

   Air cleaner outlet tube

   Mass Air Flow (MAF) sensor electrical connector
   
   

   

   

   Fig. Disconnect the electrical connector from the MAF sensor-4.6L (VIN W) engine

   Air cleaner assembly

   Upper radiator appearance cover

   Upper radiator hose and heater hose from engine connections

   Upper radiator hose and degas bottle vent hose

   Heater hoses from the bulkhead connections

   A/C pressure switch electrical connector

   A/C manifold and tube assembly from the condenser

   A/C tube from the retainers on top of the condenser and position the tube aside
   
   
   
   
   Manifold tube from the accumulator

   Auxiliary A/C tube (if equipped)
   
   

   

   

   Fig. Disconnect the manifold tube from the accumulator and the auxiliary A/C tube (if equipped)-4.6L (VIN W) engine

   Evaporator tube from the condenser

   2 bolts and the screw(s) retaining the fan shroud (from both sides)
   
   
   
   
   

   

   Fig. Remove the 2 bolts and screw(s) from the fan shroud-4.6L (VIN W) engine
   
   
   
   Upper fan shroud

   Engine cooling fan

   Heater control valve bracket bolt

   Heater control vacuum supply hose
   
   

   

   

   Fig. Remove the heater control vacuum supply hose-4.6L (VIN W) engine

   Brake booster vacuum hose from the vacuum booster

   Hoses from the evaporative emissions (EVAP) canister purge valve
   
   

   

   

   Fig. Remove the hoses from the evaporative emissions (EVAP) canister purge valve-4.6L (VIN W) engine

   Position aside the throttle cable bracket
9. Install the lifting eye tool to the engine as shown.
   
   
   

   

   Fig. Install the lifting eye tool to the engine as shown-4.6L (VIN W) engine
10. Drain the engine oil. Reinstall the drain plug when finished. Torque the plug to 10 ft. lbs. (14 Nm).
11. Remove or disconnect the following:
    
    
    Upper radiator hose from the radiator; remove the hose from the retainer

    Lower radiator hose from the coolant pump

    Lower fan shroud

    Lower air deflector (pin-type retainers)

    Tubes from the transmission cooler (drain the coolant into a suitable container)

    LH and RH radiator support brackets

    Radiator and condenser, as an assembly
12. On 4WD models, position a jack under the transfer case.
13. On 2WD models, support the transmission with a transmission jack. Secure the transmission to the jack with a safety chain.
14. On all models, remove or disconnect the following:
    
    
    RH catalytic converter heat shield

    Both HO2S sensor electrical connectors

    Both catalyst monitor sensor electrical connectors

    RH exhaust heat shield

    LH exhaust heat shield bolt

    2 nuts and the plastic shield on the RH side of the crossmember

    Crossmember 4 upper bolts and 4 lower bolts
15. On 2WD models, remove the bolts and bracket, as shown.
    
    
    

    

    Fig. On 2WD models, remove the bolts and bracket, as shown-4.6L (VIN W) engine
16. On all models, remove the 2 nuts in the center of the crossmember. Remove the crossmember.
17. Support the dual-converter Y-pipe with a jack stand, then disconnect the muffler from the Y-pipe.
18. Remove the transmission rear mount.
19. Remove the Y-pipe from the exhaust manifold. Remove the jack stand.
20. Disconnect the shift cable and remove the bolts and the bracket.
    
    
    

    

    Fig. Disconnect the shift cable and remove the bolts and the bracket-4.6L (VIN W) engine
21. Position the manual shift lever out of the park position by moving it forward.
22. On 4WD models, mark the flanges for installation reference, then remove the front driveshaft.
23. On all models, mark the flanges for installation reference, then remove the rear driveshaft.
24. Disconnect the Turbine Shaft Speed (TSS) sensor, the Output Shaft Speed (OSS) sensor and the Intermediate Shaft Speed (ISS) sensor electrical connectors.
    
    
    

    

    Fig. Disconnect the Turbine Shaft Speed (TSS) sensor, the Output Shaft Speed (OSS) sensor and the Intermediate Shaft Speed (ISS) sensor electrical connectors-4.6L (VIN W) engine
25. Remove or disconnect the following:
    
    
    Solenoid body electrical connector

    Transmission range sensor electrical connector (move rubber boot back for access)
    
    

    

    

    Fig. Disconnect the transmission range sensor electrical connector (move rubber boot back for access)-4.6L (VIN W) engine

    Wiring harness retainers from the side of the transmission

    Both heated oxygen sensor (HO2S) electrical connector retainers from the transmission
    
    

    

    

    Fig. Disconnect both heated oxygen sensor (HO2S) electrical connector retainers from the transmission-4.6L (VIN W) engine (RH shown; LH similar)

    LH catalyst monitor sensor electrical retainer from the transmission
    
    

    

    

    Fig. Disconnect the LH catalyst monitor sensor electrical retainer from the transmission-4.6L (VIN W) engine

    RH catalyst monitor sensor electrical connector retainer and the fuel tubes from the bracket
    
    

    

    

    Fig. Disconnect the RH catalyst monitor sensor electrical connector retainer and the fuel tubes from the bracket-4.6L (VIN W) engine
26. On 4WD models, perform the following:
    1. If equipped, disconnect the shift motor electrical connector and detach the harness pin-type retainer(s).
    2. Support the transmission with a transmission jack, and secure the transmission to the jack with a safety chain.
    3. Remove the jack stand from the transfer case.
27. On all models, remove or disconnect the following:
    
    
    4 bolts and the front crossmember

    Starter

    2 rear bolts and the flexplate cover

    Torque converter access cover

    4 torque converter nuts (mark one stud and the flexplate for assembly reference)

    Transmission cooler tube fittings

    7 transmission-to-engine bolts
28. Support the engine with a wood block for stability.
29. Lower the transmission and, if equipped, the transfer case.
30. Remove or disconnect the following:
    
    
    LH HO2S wiring harness from the retainer

    Nut and the cooler tube bracket (near the flexplate)

    Power steering return hose from the PS cooler (drain the fluid)

    Power steering pressure (PSP) hose

    Nut and washer from the RH engine mount

    Bolt from the LH engine mount

    Fuel charging wiring harness electrical connectors
    
    

    

    

    Fig. Disconnect the fuel charging wiring harness electrical connectors-4.6L (VIN W) engine

    Fuel charging wiring harness pin-type retainer

    Harness retaining clip from the ground stud bolt

    Stud bolt and disconnect the ground strap
31. Install the lifting eye to the RH side of the engine as shown.
    
    
    

    

    Fig. Install the lifting eye to the engine as shown-4.6L (VIN W) engine
32. Support the fuel hose with mechanic-s wire.
33. Attach a lifting crane and carefully remove the engine.

To install:

1. With the lifting crane, carefully position the engine into the vehicle.
2. Remove the lifting crane and sling.
3. Remove the mechanic-s wire from the fuel hose.
4. Remove the lifting eye from the RH side of the engine.
5. Install or connect the following:
   
   
   Ground strap and install the stud bolt

   Fuel charging wiring harness electrical connectors

   Harness retaining clip to the ground stud bolt

   Fuel charging wiring harness push pins

   LH engine support insulator through-bolt; torque to 76 ft. lbs. (103 Nm)

   Washer and nut on the RH engine support insulator; torque to 66 ft. lbs. (90 Nm)

   New seal on the power steering pressure hose fitting

   Power steering pressure hose; tighten the fitting to 48 ft. lbs. (66 Nm)

   Power steering return hose and clamp

   Power steering cooler tubes and install the nut; torque to 89 inch lbs. (10 Nm)

   LH heated oxygen sensor (HO2S) wiring harness
6. Make sure the stud and the flexplate marks made during removal line up.
7. Install the transmission and transfer case as follows:
   1. Position the transmission and, if equipped, the transfer case.
   2. Install the 7 engine-to-transmission bolts. Tighten the bolts to 35 ft. lbs. (48 Nm).
   3. Remove the wooden support from the front of the engine.
   4. Install the 4 torque converter nuts. Tighten the nuts to 28 ft. lbs. (38 Nm).
   5. Install the torque converter access cover.
   6. Install the flexplate cover and tighten the bolts to 19 ft. lbs. (26 Nm).
8. Install or connect the following:
   
   
   Starter

   Transmission fluid cooler tubes; tighten the fittings to 26 ft. lbs. (35 Nm)

   Front crossmember; tighten the bolts to 52 ft. lbs. (70 Nm)
9. Support the transfer case with a suitable jack stand (4WD).
10. Disconnect the safety chain and remove the transmission jack (4WD).
11. If equipped, connect the shift motor electrical connector and wiring harness pin-type retainer(s).
    
    
    

    

    Fig. If equipped, connect the shift motor electrical connector and wiring harness pin-type retainer(s)-4.6L (VIN W) engine
12. Attach the RH catalyst monitor sensor electrical connector and the fuel tubes to the bracket.
13. Attach the LH catalyst monitor sensor electrical connector to the transmission.
14. Attach the RH and LH HO2S wiring harness retainers to the transmission.
15. Connect the wiring harness retainers to the side of the transmission.
16. Connect the Transmission Range (TR) sensor electrical connector. Reposition the rubber boot.
17. Install and lubricate new O-ring seals on the transmission body electrical connector, connect the electrical connector and tighten the screw. Tighten to not more than 44 inch lbs. (5 Nm).
18. Connect the Turbine Shaft Speed (TSS) sensor, the Output Shaft Speed (OSS) sensor and the Intermediate Shaft Speed (ISS) sensor electrical connectors, on the side of the transmission.
    
    CAUTION

    The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown.
19. Align the marks made on the flange and driveshaft during removal.
20. Remove the plug placed in the transmission (2WD).
21. Position the driveshaft and install the driveshaft-to-pinion flange bolts. Tighten, in sequence, to 83 ft. lbs. (112 Nm).
    
    
    

    

    Fig. Showing the driveshaft-to-pinion flange bolt tightening sequence-4.6L (VIN W) engine
22. Verify the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration, top box. Install a new driveshaft if the can flange is not housed correctly.
    
    CAUTION

    The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housing shown in the cut-away illustration, bottom box. Install a new driveshaft.
    
    
    
    CAUTION

    Always connect the front driveshaft to the axle first. The weight of the driveshaft can pinch the boot, causing the boot to tear.
    
    
    
    
    

    

    Fig. Verify the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration, top box-4.6L (VIN W) engine
23. Align the marks made on the front axle flange and the driveshaft during removal.
24. Install new bolts and washers, in sequence, to 22 ft. lbs. (30 Nm).
    
    
    

    

    Fig. Install the front axle flange new bolts and washers, in sequence-4.6L (VIN W) engine
25. Install new universal joint retainers and bolts. Tighten the bolts to 13 ft. lbs. (18 Nm).
26. Place the manual shift lever in the park position by moving it to the rear.
27. Position the shift cable and bracket, install the bolts and connect the cable to the manual shift lever. Tighten the bolts to 30 ft. lbs. (40 Nm).
28. Position the dual converter Y-pipe with the heat shields on a jack stand and loosely install the 4 nuts.
29. Install the transmission rear mount and loosely install the bolts.
30. Using a new gasket, connect the dual converter Y-pipe to the muffler and install the bolts, springs and flag nuts. Tighten the nuts to 30 ft. lbs. (40 Nm).
31. Tighten the 4 dual converter Y-pipe-to-exhaust manifold nuts to 30 ft. lbs. (40 Nm).
32. Tighten the transmission rear mount bolts to 66 ft. lbs. (90 Nm).
33. Remove the jack stand from the dual converter Y-pipe.
34. Connect the LH and RH HO2S electrical connectors.
35. Position the crossmember and loosely install the 2 nuts.
36. Install the 4 crossmember lower bolts and the 4 upper bolts. Tighten to 52 ft. lbs. (70 Nm).
37. On 2WD, position the cable bracket and install the bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
38. Disconnect the safety chain and remove the transmission jack (2WD).
39. Remove the jack stand from the transfer case (4WD).
40. Tighten the 2 crossmember nuts, near the center, to 66 ft. lbs. (90 Nm).
41. Position the plastic shield on the right side of the crossmember and install the nuts.
42. Position the RH and LH heat shields and install the bolts to 15 ft. lbs. (20 Nm).
43. Install or connect the following:
    
    
    Radiator and A/C condenser assembly

    Radiator support brackets and bolts to 9 ft. lbs. (12 Nm).

    Power steering cooler hoses

    Lower air deflector (pin retainers)

    lower fan shroud and install the bolts to 62 inch lbs. (7 Nm)

    Lower radiator hose to coolant pump and into hose retainer
44. Remove the engine lifting brackets.
45. Position the bracket and install the bolts to 15 ft. lbs. (20 Nm).
    
    
    

    

    Fig. Position the bracket and install the bolts-2005 Explorer And Mountaineer 4.6L
46. Install or connect the following:
    
    NOTE

    Do not install the assembly screw holding the upper and lower shrouds together.
    
    
    
    
    Evaporative emissions (EVAP) canister purge valve hoses

    Brake booster vacuum hose

    Heater control vacuum supply hose

    Heater control valve bracket and install the bolt to 89 inch lbs. (10 Nm)

    Cooling fan; tighten the bolts to 41 ft. lbs. (55 Nm)

    Upper fan shroud
    
    
    
    
    2 bolts on each side of the fan shroud

    Tube and install the nut
    
    

    

    

    Fig. Install the tube and nut to the radiator-2005 Explorer And Mountaineer 4.6L

    A/C tubes to the condenser and install the nuts; if equipped, position the auxiliary A/C tube and install the nuts to 71 inch lbs. (8 Nm)

    A/C pressure switch electrical connector

    Heater hose

    Upper radiator and degas vent hoses

    Upper radiator and heater hoses to engine

    Radiator appearance cover

    Air cleaner assembly

    MAF sensor connector

    Air cleaner outlet tube

    Spring-lock coupling on fuel hose

    Wiring terminals at power distribution center

    Wiring harness connectors and retaining clips

    Battery cables

    Hood

    Windshield washer hose to hood
47. Refill engine with clean oil and new oil filter.
48. Fill and bleed the cooling system.
49. Fill the power steering system.
50. Evacuate and recharge the A/C system.
51. Start the engine and check for leaks. Stop the engine and recheck all fluid levels.
52. Perform an A/C system leak check.

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