Part 2

Engine - 4.6L











Disassembly (Steps 34-66)
34. Remove the crankshaft sensor ring from the crankshaft.





35. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder.

NOTE: Refer to specifications for correct spark plug identification.

Remove the 8 spark plugs.

36. NOTE: Camshaft roller follower is removed for clarity.

Install the special tool between the valve spring coils to prevent valve stem seal damage.





37. CAUTION: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage.

NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.

Use the special tool to compress the valve springs and remove all of the camshaft roller followers.





38. Position the crankshaft with the keyway at the 12 o'clock position.





39. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.

Remove the timing chain tensioning system from both timing chains.
1 Remove the bolts.
2 Remove the timing chain tensioners.
3 Remove the timing chain tensioner arms.





40. Remove the timing chains and crankshaft sprocket.





41. Remove the timing chain guides.
1 Remove the bolts.
2 Remove the LH timing chain guide.
3 Remove the bolts.
4 Remove the RH timing chain guide.





42. Remove the RH exhaust manifold.
1 Remove and discard the nuts.
2 Remove the RH exhaust manifold.
3 Remove and discard the RH exhaust manifold gasket.





43. Remove the LH exhaust manifold.
1 Remove and discard the nuts.
2 Remove the LH exhaust manifold.
3 Remove and discard the LH exhaust manifold gasket.





44. Remove and discard the 16 exhaust manifold-to-cylinder head studs.
45. Clean and inspect the exhaust manifolds.
46. Install the special tools on both ends of the cylinder head.





47. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.

Remove the hydraulic lash adjusters.





48. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Failure to follow these instructions may result in engine damage.

CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.

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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: RH shown, LH similar.

Remove the bolts and the cylinder heads.
^ Discard the cylinder head gaskets.
^ Discard the cylinder head bolts.





49. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3 Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4 Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

50. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length, such as Snap-On(R) GA438A or equivalent. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat within 0.010 mm (0.0004 in) from end to end.

NOTE: LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).





51. Remove the fasteners, the oil filter adapter and discard the oil filter adapter gasket.





52. Clean the oil filter adapter gasket surface at the cylinder block.





53. Remove the 4 coolant pump bolts.





54. Remove the coolant pump from the cylinder block.





55. Remove the bolts and the A/C compressor.





56. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
57. Remove the bolts, the oil pan and the oil pan gasket.
^ Clean and inspect the sealing surfaces.





58. Remove the 3 bolts and the oil pump screen and pickup tube.





59. Remove the oil pump screen and pickup tube spacer.





60. Remove the 3 bolts and the oil pump.





61. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation. Failure to follow these instructions may result in engine damage.

Remove the bolts and the connecting rod cap. Discard the bolts.





62. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.

Use the special tool to push the piston through the top of the cylinder block.





63. Disassemble the 8 pistons.

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

Remove the crankshaft bearing cap fasteners.
1 Remove and discard the cross-mounted main cap bolts.
2 Loosen the jack screws.
3 Remove and discard the main cap bolts.





65. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.





66. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.