Part 1

Engine - 4.6L











Disassembly (Steps 1-33)

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: The crankshaft rear seal, the rear oil seal slinger and the crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.

1. Remove the engine.
2. Remove the 6 bolts and the flexplate.
3. Remove the engine rear cover plate.
4. Using the special tools, remove and discard the crankshaft oil slinger.





5. Using the special tools, remove and discard the crankshaft rear seal.





6. Remove the 2 rear oil pan bolts, the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.





7. CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.

Lower the engine onto wooden blocks.
8. Remove the special tool.





9. Install the special tool.





10. Install the special tool.





11. Mount the engine on a suitable work stand.

12. NOTE: RH shown, LH similar.

Remove the 6 bolts and the RH and LH engine support insulators.





13. NOTE: LH shown, RH similar.

Remove the cylinder block drain plugs and drain the coolant in a suitable container.





14. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.





15. Disconnect the camshaft position (CMP) sensor electrical connector.





16. Disconnect the RH radio frequency interference capacitor electrical connector.





17. Disconnect the knock sensor (KS) electrical connector.





18. Disconnect the crankshaft position (CKP) sensor electrical connector.





19. Disconnect the engine oil pressure (EOP) switch electrical connector.





20. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.

21. NOTE: RH shown, LH similar.

Remove the 2 nuts and the 2 radio interference capacitors.





22. Remove the oil level indicator tube support bracket nut.





23. Remove the bolt and the oil level indicator tube.
^ Discard the O-ring seal.





24. 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: The fasteners are part of the valve cover and should not be removed.

NOTE: LH shown, RH similar.

Remove the LH and RH valve covers.
^ Fully loosen the fasteners and remove the valve cover.
^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.





25. Remove the bolt and the accessory drive belt idler pulley.





26. Remove the 4 bolts and the coolant pump pulley.





27. Remove the crankshaft pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
28. Using the special tool, remove the crankshaft pulley.





29. Using the special tool, remove and discard the crankshaft front seal.





30. Remove the 3 bolts and the power steering pump.





31. Remove the 4 front oil pan bolts.





32. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.

Remove the fasteners.





33. Remove the engine front cover from the cylinder block.