4.6L Engine
  1. Disconnect the negative battery cable.
  2. Remove the valve covers, timing chain cover, and oil pan. Refer to the procedures in this Section.
  3. Remove the timing chains according to the procedure in this Section.
  4. Remove the 4 bolts retaining the oil pump to the cylinder block and remove the pump.
  5. Remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the oil pickup tube to the main bearing stud spacer. Remove the pickup tube.

To install:

  1. Clean the oil pickup tube and replace the O-ring.
  2. Position the tube on the oil pump and hand-start the 2 bolts. Install the bolt retaining the pickup tube to the main bearing stud spacer hand tight.
  3. Tighten the pickup tube-to-oil pump bolts to 6.0–8.8 ft. lbs. (8–12 Nm). Tighten the pickup tube to main bearing stud spacer bolt to 15–22 ft. lbs. (20–30 Nm).
  4. Rotate the inner rotor of the oil pump to align with the flats on the crankshaft and install the oil pump flush with the cylinder block. Install the 4 retaining bolts and tighten to 6.0–8.8 ft. lbs. (8–12 Nm).
  5. Install a new oil filter. Install the timing chains.
  6. Install the oil pan, front cover and camshaft covers.
  7. Fill the crankcase with the proper type and quantity of engine oil. Connect the negative battery cable, start the engine, and check for leaks.

Fig. 1: Oil pump installation— 4.6L engine

valve covers,

4.6L Engine
  1. Disconnect the negative battery cable.
  2. Remove the right valve cover as follows:
  3. Disconnect the positive battery cable at the battery and at the power distribution box. Remove the retaining bolt from the positive battery cable bracket located on the side of the right cylinder head.
  4. Disconnect the crankshaft position sensor, air conditioning compressor clutch and canister purge solenoid connectors. Position the harness out of the way.
  5. Disconnect the vent hose from the purge solenoid and position the positive battery cable out of the way.
  6. Disconnect the spark plug wires from the spark plugs. Remove the spark plug wire brackets from the camshaft cover studs and position the wires out of the way.
  7. Remove the PCV valve from the valve cover grommet and position out of the way.
  8. Remove the bolts and stud bolts (note their positions for reassembly) and remove the valve cover.
  9. Remove the left valve cover as follows:
  10. Remove the air inlet tube. Relieve the fuel system pressure and disconnect the fuel lines; refer to Section 5.
  11. Raise and safely support the vehicle.
  12. Disconnect the Electronic Variable Orifice (EVO) sensor and oil pressure-sending unit and position the harness out of the way. Lower the vehicle.
  13. Remove the 42-pin engine harness connector from the retaining bracket on the brake vacuum booster. Disconnect and position out of the way.
  14. Remove the windshield wiper module.
  15. Disconnect the spark plug wires from the spark plugs. Remove the spark plug wire brackets from the studs and position the wires out of the way.
  16. Remove the bolts and stud bolts (noting their position for reassembly) and remove the valve cover.

To install:

  1. Clean the sealing surfaces of the valve covers and cylinder heads. Apply silicone sealer to the places where the front engine cover meets the cylinder head.
  2. Attach new gaskets to the valve covers, using suitable sealant. Install the covers with the bolts and stud bolts and tighten to 6.0–8.8 ft. lbs. (8–12 Nm).
  3. When installing the right valve cover, proceed as follows:
  4. Install the PCV into the valve cover grommet.
  5. Install the spark plug wire brackets on the studs and connect the wires to the spark plugs.
  6. Position the harness and connect the canister purge solenoid, air conditioning compressor clutch and crankshaft position sensor.
  7. Position the positive battery cable harness on the right cylinder head. Install the bolt retaining the cable bracket to the cylinder head.
  8. Connect the positive battery cable at the power distribution box and the battery.
  9. When installing the left valve cover, proceed as follows:
  10. Install the spark plug wire brackets on the studs and connect the wires to the spark plugs.
  11. Install the windshield wiper module.
  12. Connect the 42-pin connector and transmission harness connector. Install the connector on the retaining bracket.
  13. Raise and safely support the vehicle. Position and connect the EVO sensor and oil pressure sending unit harness.
  14. Lower the vehicle. Connect the fuel lines.
  15. Connect the negative battery cable. Start the engine and check for leaks.

Fig. 6: Valve cover installation— 4.6L engine

timing chain cover,

4.6L Engine

NOTE: To replace the seal in the front cover (timing chain cover), it will be necessary to obtain special tools. A power steering plump pulley remover and replacer will be necessary; it is also necessary to use a crankshaft damper remover and replacer to effectively complete this job

  1. Disconnect the negative battery cable.
  2. Remove the windshield wiper module assembly, if necessary.
  3. Remove the engine appearance cover, if applicable.
  4. Remove the air cleaner outlet tube and the engine air intake resonator, where necessary..
  5. Remove the cooling fan and shroud. Loosen the water pump pulley bolts, remove the accessory drive belt, and remove the water pump pulley.
  6. Raise and safely support the vehicle.
  7. Remove the bolts retaining the power steering pump to the engine block and cylinder front cover. The lower front bolt on the power steering pump will not come all the way out. Wire the power steering pump out of the way.
  8. Remove the four bolts retaining the oil pan to the front cover. Remove the crankshaft damper retaining bolt and washer. Remove the damper using a puller.
  9. Lower the vehicle. Remove the bolt retaining the air conditioner high-pressure line to the right coil bracket.
  10. Remove the front bolts and loosen the remaining bolts on the valve covers. Using plastic wedges or similar tools, prop up both valve covers. Disconnect both ignition coils and Camshaft Identification (CID) sensor.
  11. Remove the nuts retaining the right coil bracket to the front cover. Position the power steering hose out of the way.
  12. Remove the nuts retaining the left coil bracket to the front cover. Slide both coil brackets and spark plug wires off the mounting studs and lay the assembly on top of the engine.
  13. Disconnect the crankshaft position sensor. Remove the seven stud bolts and four bolts retaining the front cover to the engine and remove the front cover.

To install:

  1. Inspect and replace the front cover seal as necessary and clean the sealing surfaces of the cylinder block. Apply silicone sealer to the oil pan where it meets the cylinder block and to the points where the cylinder head meets the cylinder block.
  2. Install the front cover and the attaching studs and bolts. Tighten to 15–22 ft. lbs. (20–30 Nm). Connect the crankshaft position sensor.
  3. Position the coil brackets and spark plug wires as an assembly onto the mounting studs. Position the power steering hose and install the nuts retaining the coil brackets to the front cover. Tighten the nuts to 15–22 ft. lbs. (20–30 Nm). Connect both ignition coils and CID sensor.
  4. Remove the plastic wedges holding up the valve covers. Apply silicone sealer where the front cover meets the cylinder head and make sure the valve cover gaskets are properly positioned. Install the front retaining bolts into the valve cover and tighten the bolts to 6.0–8.8 ft. lbs. (8–12 Nm).
  5. Position the air conditioner high-pressure line on the right coil bracket and install the bolt. Raise and safely support the vehicle.
  6. Apply a small amount of silicone sealer in the rear of the keyway in the damper. Position the damper on the crankshaft and install, using a suitable installation tool. Install the damper bolt and washer and tighten to 114–121 ft. lbs. (155–165 Nm).
  7. Install the four bolts retaining the oil pan to the front cover. Tighten to 15–22 ft. lbs. (20–30 Nm).
  8. Position the power steering pump on the engine and install the 4 retaining bolts. Tighten to 15–22 ft. lbs. (20–30 Nm). Lower the vehicle.
  9. Install the water pump pulley with the four bolts. Tighten to 15–22 ft. lbs. (20–30 Nm). Install the accessory drive belt and the cooling fan and shroud.
  10. Connect the negative battery cable, start the engine and check for leaks.

Fig. 1: Timing chain cover installation— 4.6L engine

and oil pan

4.6L Engine
  1. Disconnect the battery cables, negative cable first, and remove the air inlet tube.
  2. Relieve the fuel system pressure and disconnect the fuel lines; refer to Section 5. Drain the cooling system and remove the cooling fan and shroud.

CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. In addition, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the upper radiator hose. Remove the wiper module and support bracket.
  2. Discharge the air conditioning system. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
  3. Remove the 42-pin engine harness connector from the retaining bracket on the brake vacuum booster and disconnect the connector and transmission harness connector.
  4. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
  5. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
  6. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
  7. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
  8. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
  9. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
  10. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
  11. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1⁄2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
  12. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.

NOTE: It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.

  1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.

To install:

  1. Clean the oil pan and inspect for damage. Clean the sealing surfaces of the front cover and engine block. Clean and inspect the oil pickup tube and replace the O-ring.
  2. If removed, position the oil pickup tube on the oil pump and hand start the 2 bolts. Install the bolt retaining the pickup tube to the main bearing stud spacer hand tight.
  3. Tighten the pickup tube-to-oil pump bolts to 6.0–8.8 ft. lbs. (8–12 Nm), then tighten the pickup tube-to-main bearing stud spacer bolt to 15–22 ft. lbs. (20–30 Nm).
  4. Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and rear seal retainer meets the cylinder block. Position the oil pan on the engine and install the bolts. Tighten the bolts, in sequence, to 15–22 ft. lbs. (20–30 Nm).
  5. Position the jack and wood block under the oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack.
  6. Install the engine mount through bolts and tighten to 15–22 ft. lbs. (20–30 Nm).
  7. Position the EGR valve and tube assembly in the vehicle and connect to the exhaust manifold. Tighten the line nut to 26–33 ft. lbs. (35–45 Nm).

NOTE: Loosen the line nut at the EGR valve prior to installing the assembly into the vehicle. This will allow enough movement to align the EGR valve retaining bolts.

  1. Cut the wire and position the exhaust system to the manifolds. Install the 4 nuts and tighten to 20–30 ft. lbs. (27–41 Nm). Make sure the exhaust system clears the crossmember. Adjust as necessary.
  2. Install a new oil filter and lower the vehicle.
  3. Install the bolt retaining the right engine mount to the lower engine bracket. Tighten to 15–22 ft. lbs. (20–30 Nm).
  4. Install a new gasket on the EGR valve and position on the intake manifold. Install the 2 bolts retaining the EGR valve to the intake manifold and tighten to 15–22 ft. lbs. (20–30 Nm). Tighten the EGR tube line nut at the EGR valve to 26–33 ft. lbs. (35–45 Nm). Connect the vacuum hoses to the EGR valve and tube.
  5. Install the blower motor resistor. Position the heater outlet hose, install the upper stud and tighten the upper and lower bolts to 15–22 ft. lbs. (20–30 Nm). Install the ground strap on the stud and tighten to 15–22 ft. lbs. (20–30 Nm).
  6. Connect the heater outlet hose and the throttle valve cable. If necessary, adjust the throttle valve cable.
  7. Connect the 42-pin connector and transmission harness connector. Install the harness connector on the brake vacuum booster.
  8. Connect the air conditioning compressor outlet hose to the compressor and install the bolt retaining the hose to the right coil bracket.
  9. Install the upper radiator hose and connect the fuel lines. Install the wiper module and retaining bracket.
  10. Install the cooling fan and shroud and fill the cooling system. Fill the crankcase with the proper type and quantity of engine oil.
  11. Connect the negative battery cable and install the air inlet tube. Start the engine and check for leaks.
  12. Have a MVAC certified evacuate and recharge the air conditioning system.

Fig. 2: Position of wood blocks under the engine mounts— 4.6L engine

Fig. 3: Oil pump pickup tube— 4.6L engine

Fig. 4: Oil pan bolt torque sequence— 4.6L engine

timing chains

4.6L Engine

NOTE: This is not a free wheeling engine. If it has "jumped time," there will be damage to the valves and/or pistons and will require the removal of the cylinder heads.

WARNING
The camshafts and/or crankshaft must never be rotated when the cylinder heads are installed and the timing chain is removed. Failure to heed this warning will result in valve and/or piston damage.

  1. Disconnect the negative battery cable.
  2. Remove the valve covers and the timing chain front cover.
  3. Remove the crankshaft position sensor tooth wheel.
  4. Rotate the engine to set the No. 1 piston at TDC on the compression stroke.
  5. Install cam positioning, on the flats of the camshaft. This will prevent accidental rotation of the camshafts.
  6. Remove the 2 bolts retaining the right tensioner to the cylinder head and remove the tensioner. Remove the right tensioner arm.
  7. Remove the 2 bolts retaining the right chain guide to the cylinder head and remove the chain guide. Remove the right chain and right crankshaft sprocket. If necessary, remove the right camshaft sprocket retaining bolt, washer, sprocket, and spacer.

NOTE: Cam positioning tools must be installed on the camshaft to prevent the camshaft from rotating.

  1. Remove the 2 bolts retaining the left tensioner to the cylinder head and remove the tensioner. Remove the left tensioner arm.
  2. Remove the 2 bolts retaining the left chain guide to the cylinder head and remove the chain guide. Remove the left chain and left crankshaft sprocket. If necessary, remove the left camshaft sprocket retaining bolt, washer, sprocket, and spacer.

NOTE: Cam positioning tools, must be installed on the camshaft to prevent the camshaft from rotating.