SECTION 303-01B:

Engine — 4.6L (2V)

SPECIFICATIONS
DESCRIPTION AND OPERATION
Engine
DIAGNOSIS AND TESTING
Engine
IN-VEHICLE REPAIR
Intake Manifold
Valve Cover — LH
Valve Cover — RH
Crankshaft Pulley
Crankshaft Front Seal
Engine Front Cover
Timing Drive Components
Valve Train Components — Exploded View
Camshaft
Camshaft Roller Follower
Valve Springs
Valve Seals
Hydraulic Lash Adjuster
Exhaust Manifold — RH
Exhaust Manifold — LH
Engine Lubrication Components — Exploded View
Oil Pan
Oil Pump
Oil Pump Screen and Pickup Tube
Oil Filter Adapter
Oil Level Indicator and Tube
Engine Oil Pressure (EOP) Switch
Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View
Flexplate
Crankshaft Rear Seal
Crankshaft Rear Seal with Retainer Plate
Engine Support Insulators
REMOVAL
Engine
Cylinder Head
DISASSEMBLY
Engine
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head
Piston
Intake Manifold Assembly
ASSEMBLY
Engine
INSTALLATION
Engine
Cylinder Head
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
SPECIFICATIONS Procedure revision date: 06/20/2008

Material
Item Specification Fill
Capacity
Gasket Maker WSK- —
TA-16 M2G348-A5
Instant Gel Adhesive WSK- —
TA-19 M2G402-A4
Motorcraft Metal Surface Prep — —
ZC-31-A
Motorcraft Premium Gold Engine WSS- —
Coolant with Bittering Agent M97B51-A1
(bittered in US only)
VC-7-B (US); CVC-7-A
(Canada); or equivalent (yellow
color)
Motorcraft SAE 5W-20 Premium WSS- 5.7L (6.0
Synthetic Blend Motor Oil M2C930-A qt) with
XO-5W20-QSP (US); Motorcraft filter
SAE 5W-20 Super Premium
Motor Oil CXO-5W20-LSP12
(Canada); or equivalent
Silicone Gasket Remover — —
ZC-30
Silicone Gasket and Sealant WSE- —
TA-30 M4G323-A4
Threadlock 262 WSK- —
TA-26 M2G351-A6

General Specifications

Item Specification
Engine
Displacement 4.6L (281 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 90.0 mm (3.54 in)
Firing order 1-3-7-2-6-5-4-8
Spark plug A6SF-32N
Oil pressure at 2,000 rpm (engine 275-517 kPa
at normal operating temperature)
 (40-75 psi)
Compression ratio 9.3:1
Engine weight (without accessory 218 kg (481 lb)
drive components and with
flexplate)
Cylinder Head and Valve Train
Combustion chamber volume 51.5-52.5 cc

(3.14-3.20 cu in)
Valve arrangement (front to rear) — E-I-E-I-E-I-E-I
LH
Valve arrangement (front to rear) — I-E-I-E-I-E-I-E
RH
Valve guide bore diameter 7.044-7.015 mm (0.2773-0.2762 in)
Valve stem diameter — intake 6.995-6.975 mm (0.2754-0.2746 in)
Valve stem diameter — exhaust 6.970-6.949 mm (0.2744-0.2736 in)
Valve stem-to-guide clearance — 0.020-0.069 mm (0.0008-0.0027 in)
intake
Valve stem-to-guide clearance — 0.045-0.095 mm (0.0018-0.0037 in)
exhaust
Valve head diameter — intake 44.5 mm (1.751 in)
Valve head diameter — exhaust 34.0 mm (1.338 in)
Valve face runout 0.05 mm (0.0019 in)
Valve face angle 45.25-45.75 degrees
Valve seat width 1.9-2.1 mm (0.0748-0.0827 in)
Valve seat runout (T.I.R.) max. 0.025 mm (0.0010 in)
Valve seat angle 45.50 degrees
Valve spring free length 49.55 mm (1.9508 in)
Valve spring squareness 2 degrees
Valve spring compression pressure 587.14 N @ 28.02 mm (131.994 lb @ 1.1032 in)
Valve spring installed height 39.7-40.3 mm (1.5630-1.5866 in)
Valve spring installed pressure — 587.165 N @ 27.99 mm (132 lb @ 1.102 in)
valve open
Valve spring installed pressure — 244.652 N @ 39.98 mm (55 lb @ 1.574 in)
valve closed
Roller follower ratio 1.75:1
Head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.050
mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.1 mm
(0.004 in) overall
Hydraulic Lash Adjuster
Diameter 16.000-15.9888 mm (0.6299-0.6295 in)
Clearance-to-bore 0.018-0.069 mm (0.0007-0.0027 in)
Service limit 0.016 mm (0.0006 in)
Hydraulic leakdown rate 5-25 seconds a
Collapsed lash adjuster gap 0.085-0.450 mm (0.0033-0.0177 in)
Camshaft
Theoretical valve lift @ 0 lash 12.0 mm (0.472 in)
Lobe lift 6.5 mm (0.2560 in)
Allowable lobe lift loss 0
Journal diameter (all) 26.962-26.936 mm (1.0615-1.0605 in)
Camshaft journal bore inside 27.012-26.987 mm (1.0635-1.0625 in)
diameter (all)
Camshaft journal-to-bearing 0.025-0.076 mm (0.0010-0.0030 in)
clearance
Runout 0.05 mm (0.002 in)
End play 0.09-0.19 mm (0.0035-0.0075 in)
Cylinder Block
Cylinder bore diameter — Grade 1 90.200-90.213 mm (3.5512-3.5517 in)
Cylinder bore diameter — Grade 2 90.213-90.226 mm (3.5517-3.5522 in)
Cylinder bore diameter — Grade 3 90.226-90.239 mm (3.5522-3.5527 in)
Cylinder bore maximum taper 0.006 mm (0.00023 in)
Cylinder bore maximum out-of- 0.020 mm (0.00079 in)
round
Main bearing bore inside diameter 72.402-72.422 mm (2.850-2.851 in)
Cylinder bore diameter-surface 0.2-0.6 microns
finish (RMS)
Head gasket surface flatness 0.03 mm (0.001 in) in any 40 mm (1.5 in) x 40 mm (1.5 in) area;
0.05 mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.15
mm (0.006 in) overall
Crankshaft
Main bearing journal diameter 67.483-67.503 mm

(2.65 in)
Main bearing journal maximum 0.004 mm (0.0002 in)
taper
Main bearing journal maximum out- 0.06 mm (0.002 in)
of-round
Main bearing journal-to-cylinder 0.027-0.065 mm (0.0011-0.0026 in)
block clearance
Connecting rod journal diameter 52.983-53.003 mm (2.0859-2.0867 in)
Connecting rod journal maximum 0.004 mm (0.0002 in)
taper
Connecting rod journal maximum 0.006 mm (0.0002 in)
out-of-round
Crankshaft maximum end play 0.130-0.301 mm (0.0051-0.012 in)
Piston and Connecting Rod
Piston diameter — coded red 1 90.177-90.197 mm (3.550-3.551 in)
Piston diameter — coded blue 2 90.190-90.210 mm (3.5507-3.5515 in)
Piston diameter — coded yellow 3 90.203-90.223 mm (3.513-3.5521 in)
Piston-to-cylinder bore clearance 0.017-0.047 mm (0.0007-0.0019 in)
(at grade size)
Piston ring end gap — compression 0.23-0.49 mm (0.010-0.020 in)
(top and bottom)
Piston ring end gap — oil ring (steel 0.05-0.66 mm (0.006-0.026 in)
rail)
Piston ring groove width — 1.520-1.550 mm (0.002-0.610 in)
compression (top)
Piston ring groove width — 1.520-1.530 mm (0.060-0.0602 in)
compression (bottom)
Piston ring groove width — oil ring 6.996-7.224 mm (0.275-0.2844 in)
Piston ring width — compression 1.49-1.47 mm (0.0587-0.0579 in)
Piston ring width — oil ring rail (2) 0.473-0.447 mm (0.0186-0.0176 in), 0.483 mm (0.0190 in) max. at
ID
Piston ring width — oil ring 2.038-1.960 mm (0.080-0.077 in)
expander
Piston ring-to-groove clearance — 0.030-0.070 mm (0.0012-0.0028 in)
compression
Piston ring-to-groove clearance — 0.046-0.196 mm (0.0018-0.0077 in)
oil ring assembly
Piston pin bore diameter 22.0015-22.004 mm (0.866-0.8663 in)
Piston pin diameter 22.0 mm (0.866 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit 0.005-0.010 mm (0.0002-0.0004 in)
Connecting rod-to-pin clearance 0.015-0.040 mm (0.0006-0.0016 in)
Connecting rod pin bore diameter 21.959-21.979 mm (0.864-0.865 in)
Connecting rod length (center-to- 150.7 mm (5.93 in)
center)
Connecting rod maximum allowed 0.038 mm per 25 mm (0.0015-0.984 in)
bend
Connecting rod maximum allowed 0.050 mm per 25 mm (0.0015-0.984 in)
twist b
Connecting rod bearing bore 56.756-56.876 mm (2.234-2.24 in)
diameter
Connecting rod bearing-to- 0.027-0.069 mm (0.001-0.0027 in)
crankshaft clearance
Connecting rod side clearance 0.015-0.45 mm (0.0006-0.0177 in)
(assembled to crank) — standard
Connecting rod side clearance 0.05 mm (0.002 in) max.
(assembled to crank) — service
limit
Accessory Drive Belt
Drive belt 6 ribs
a
Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leak-down fluid in the
lash adjuster.
b
The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified
total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.

Torque Specifications

Description Nm lb-ft lb-in

Accessory drive belt idler pulley bolt 25 18 —
Accessory drive belt tensioner pulley bolt 25 18 —
A/C manifold and tube assembly support bracket nut 10 — 89
Axle carrier bushing bolt 90 66 —
Camshaft bearing cap bolts a
— — —
Camshaft position (CMP) sensor bolt 10 — 89
Camshaft sprocket bolts a
— — —
Coolant bypass tube bolts 10 — 89
Coolant pump bolts 25 18 —
Coolant pump pulley bolts 25 18 —
Cooling fan shroud bolts 10 — 89
Crankshaft damper pulley bolt a
— — —
Crankshaft main bearing bolts (cross-mounted) a — — —
Crankshaft main bearing bolts (vertical) a
— — —
Crankshaft position (CKP) sensor bolt 10 — 89
Crankshaft rear seal retainer plate bolts 10 — 89
Cylinder block drain plug 24 18 —
Cylinder head bolts a — — —
Engine front cover bolts a
— — —
Engine oil pressure (EOP) switch 18 13 —
Engine support insulator bracket bolts 63 46 —
Engine support insulator bracket-to-engine support insulator bolts 72 53 —
Engine support insulator nuts 250 184 —
Engine support insulator through bolt 350 258 —
EGR system module-to-intake manifold bolts 25 18 —
EGR system module-to-exhaust manifold tube fittings 40 30 —
Exhaust manifold-to-cylinder head stud 12 9 —
Exhaust manifold nuts a
— — —
Exhaust Y-pipe flange nuts 40 30 —
Flexplate bolts a
— — —
Flexplate inspection cover bolts 34 25 —
Frame crossmember 115 85 —
Front driveshaft flange-to-front axle pinion flange bolts 111 82 —
Front stabilizer bar nuts 30 22 —
Fuel rail stud bolts 10 — 89
Generator lower bolts 25 18 —
Generator support bracket bolts 10 — 89
Heater outlet tube studs 25 18 —
Hood bolts 30 22 —
Intake manifold bolts a — — —
Oil filter adapter bolt 25 18 —
Oil level indicator tube bolt 10 — 89
Oil pan bolts a
— — —
Oil pan drain plug 14 10 —
Oil pump bolts a — — —
Oil pump screen cover and tube bolts 10 — 89
Oil pump screen cover and tube spacer 25 18 —
Oil pump screen cover and tube spacer bolt 25 18 —
Power steering pump bolts 25 18 —
Power steering reservoir bracket-to-cylinder head bolts 25 18 —
Power steering reservoir bracket-to-thermostat housing bolt 11 8 —
Power steering reservoir support bracket-to-intake manifold support bracket bolts 17 13 —
Power steering reservoir support bracket lower bolts 25 18 —
Power steering pressure tube nut 65 48 —
Power steering pressure tube support bracket nut 12 9 —
Radiator upper hose support bracket nut 10 — 89
Radio ignition interference capacitor nut 25 18 —
Shift cable bracket bolts 25 18 —
Skid plate bolt 25 18 —
Spark plugs 18 13 —
Suction accumulator nuts 6 — 53
Thermostat housing bolts 25 18 —
Throttle body (TB) bolts a
— — —
Timing chain guide bolts 10 — 89
Timing chain hydraulic tensioner bolts 25 18 —
Torque converter-to-flexplate nuts 35 26 —
Transmission cooler tubes support bracket nut 10 — 89
Transmission crossmember bolts 90 66 —
Transmission fluid level indicator tube bolt 10 — 89
Transmission mount nuts 103 76 —
Transmission-to-engine bolts 60 44 —
Valve cover bolts 10 — 89
a
Refer to the procedure in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DESCRIPTION AND OPERATION Procedure revision date: 07/14/2006

Engine

WARNING: Do not operate the engine with the hood open until the fan blade has been
examined for possible cracks and separation. A damaged fan can separate during operation.
Failure to follow this instruction may result in serious personal injury.

The 4.6L (281 CID) is a V-8 engine with the following features:

 Single overhead camshaft

 Two valves per cylinder
 Sequential multi-port fuel injection (SFI)
 Aluminum cylinder heads
 Cast iron, 90-degree V-cylinder block
 Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
 Electronic ignition system with 8 ignition coils
 Electronic returnless fuel system

Engine Cylinder Identification

Identification

Always refer to these labels when installation of new parts is necessary, or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
make sure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of
the codes and their application.

Code Information

The engine code information label, located on the side of the valve cover and the front side of the valve
cover, contains the following:

 Engine build date

 Engine plant code
 Engine code

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

Induction System

The sequential multi-port fuel injection (SFI) provides the fuel/air mixture needed for combustion in the
cylinders. The 8 solenoid-operated fuel injectors:

 are mounted in the intake manifold.

 meter fuel into the air intake stream in accordance with engine demand.
 are positioned so that their tips direct fuel just ahead of the engine intake valves.
 are connected in series with the fuel rail pressure and temperature sensor.
 supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel
pressure sensor is positioned upstream from the fuel injectors on the fuel rail.

Valve Train

The valve train operates as follows:

 Ball-tip hydraulic lash adjusters provide automatic lash adjustment.

 Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts
to the valves in the cylinder heads.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper
intake manifold.

Lubrication System

The engine lubrication system operates as follows:

  Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
 Oil is pumped through the oil filter on the left front side of the cylinder block.
 Oil enters the main gallery where it is distributed to the crankshaft main journals and to both
cylinder heads.
 From the main journals, the oil is routed through cross-drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main
bearings and connecting rod bearings is slung radially outward to cool and lubricate the
cylinder walls as well as the entire connecting rod, piston and piston ring assembly.
 The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the
front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the main
gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed
serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure
in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash adjusters
and the primary and secondary timing chain tensioners.
 The camshaft lobe and roller followers are lubricated by splash created through valve train
operation.

Oil Pump

The lubrication system of the 4.6L (2V) engine is designed to provide optimum oil flow to critical
components of the engine through its entire operating range. The heart of the system is a positive
displacement internal gear oil pump using top seal rotors. Generically, this design is known as a gerotor
pump, which operates as follows:

 The oil pump is mounted on the front face of the cylinder block.
 The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
 System pressure is limited by an integral, internally-vented relief valve which directs the bypassed
oil back to the inlet side of the oil pump.
 Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure, both at hot idle and maximum speed.
 The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
 The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high-speed conditions.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 07/14/2006

Engine

For basic engine mechanical concerns, refer to Section 303-00 . For driveability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 12/12/2008

Intake Manifold

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Silicone Gasket Remover —
ZC-30

EGR System Module Tube, PCV Tube, Electrical and Vacuum Connections
 Part
Item Number Description
1 9D477 EGR system module tube
2 9J274 Fuel tube spring lock coupling
3 — EGR system module electrical connector (part of
12B637)
4 — Electronic throttle control electrical connector (part of
12B637)
5 — Fuel rail pressure and temperature sensor vacuum
connector (part of 9E498)
6 — Fuel rail pressure and temperature sensor electrical
connector (part of 12B637)
7 6K817 PCV tube

Intake Manifold and Gaskets

Item Part Number Description

1 N806178 Thermostat housing bolt (2 required)
2 8594 Thermostat housing
3 8575 Thermostat
4 N806156 Intake manifold bolt (9 required)
5 9S455 Intake manifold
6 9441 LH intake manifold gasket
7 9439 RH intake manifold gasket

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when
working on or near any fuel-related component. Highly flammable mixtures are always present
and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the
fuel system remains under high pressure, even when the engine is not running. Failure to follow
this instruction may result in serious personal injury.

1. Disconnect the fuel hose spring lock coupling. Release the fuel system pressure. For
additional information, refer to Section 310-00 .

2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

3. Drain the cooling system. For additional information, refer to Section 303-03 .

4. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

5. Remove the ignition coils. For additional information, refer to Section 303-07B .

6. Remove the generator. For additional information, refer to Section 414-02 .

7. Remove the EGR system module tube.

8. Disconnect the EGR system module electrical connector.

9. Disconnect the quick connect couplings and remove the PCV tube. For additional information,
refer to Section 310-00 .

10. Disconnect the electronic throttle control electrical connector.

11. Disconnect the fuel rail pressure and temperature sensor electrical connector.

12. Disconnect the fuel rail pressure and temperature sensor vacuum connector.

13. Disconnect the 8 fuel injector electrical connectors.

14. Disconnect the vacuum and coolant hose and plug the coolant hose.
15. Disconnect the brake booster vacuum hose and the evaporative emissions (EVAP) hose quick
connect coupling. For additional information, refer to Section 310-00 .

16. Disconnect the upper radiator coolant hose and position aside.

17. Disconnect the heater coolant hose and position aside.

18. Remove the 3 power steering reservoir support bracket bolts and the power steering reservoir
support bracket.

19. Disconnect the vacuum hose.

20. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring
seal.

21. Remove the thermostat.

 22. Remove the 9 intake manifold bolts.

23. Remove the intake manifold and discard the RH and LH intake manifold gaskets.

Installation

1. NOTICE: 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.

Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep
and silicone gasket remover. Follow the directions on the packaging.

2. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal
debris is found, install a new intake manifold. Failure to follow these instructions can
result in engine damage.

Install the intake manifold in the following sequence.

1. Position the new intake manifold gaskets.

2. Position the intake manifold.

3. Loosely install the 9 intake manifold bolts.

3. Tighten the intake manifold bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).
4. Install the thermostat.

5. Install the thermostat housing and a new thermostat housing O-ring seal.

6. Install the 2 thermostat housing bolts.

 Tighten to 25 Nm (18 lb-ft).

7. Connect the fuel hose spring lock coupling. Release the fuel system pressure. For additional
information, refer to Section 310-00 .

8. Connect the vacuum hose.

9. Install the power steering reservoir support bracket and the 3 bolts.
 Tighten the 2 bracket-to-power steering reservoir bolts to 17 Nm (13 lb-ft).
 Tighten the power steering reservoir bracket-to-thermostat housing bolt to 11 Nm (8 lb-ft).

10. Connect the heater coolant hose.

11. Connect the upper radiator coolant hose.

12. Connect the electronic throttle control electrical connector.

13. Connect the fuel rail pressure and temperature sensor electrical connector.

14. Connect the fuel rail pressure and temperature sensor vacuum connector.

15. Connect the 8 fuel injector electrical connectors.

16. Connect the vacuum and coolant hose.

17. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. For
additional information, refer to Section 310-00 .
18. Install the EGR system module tube.
 Tighten to 40 Nm (30 lb-ft).

19. Connect the EGR system module electrical connector.

20. Position the PCV tube and connect the quick connect couplings. For additional information,
refer to Section 310-00 .

21. Install the ignition coils. For additional information, refer to Section 303-07B .

22. Install the generator. For additional information, refer to Section 414-02 .

23. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

24. Connect the battery ground cable. For additional information, refer to Section 414-01 .

25. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Cover — LH

Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
Motorcraft Metal Surface Prep —
ZC-31-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30

Power Steering Reservoir, EGR and Crankcase Tube Connections

Item Part Description

 Number
1 N606676 Power steering reservoir support bracket-to-
thermostat housing bolt
2 N606713 Power steering reservoir support bracket-to-cylinder
head bolt (2 required)
3 — Power steering reservoir and support bracket
assembly
4 6758 Crankcase ventilation tube
5 9D477 EGR system module-to-exhaust manifold tube fittings

LH Valve Cover and Gasket

 Part
Item Number Description
1 — Engine wiring harness retainer (3 required) (part of
12B637)
2 N806155 Oil level indicator tube bracket bolt
3 6754 Oil level indicator tube bracket
4 6A505 LH valve cover
5 6A559 LH valve cover gasket

Removal
 1. Remove the air cleaner outlet pipe and the air cleaner assembly. For additional information,
refer to Section 303-12 .

2. Remove the power steering reservoir support bracket-to-thermostat housing bolt.

3. Remove the 2 power steering reservoir support bracket-to-cylinder head bolts and position the
power steering reservoir and support bracket assembly aside.

4. Remove the bolt and position the oil level indicator aside.

5. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For
additional information, refer to Section 310-00 .

6. Remove the EGR system module-to-exhaust manifold tube.

7. Disconnect the 3 engine wiring harness retainers.

8. Remove the 5 LH valve cover studs.

9. Remove the 6 LH valve cover bolts.

10. Remove the LH valve cover bolt.

11. NOTICE: 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.

Remove the LH 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.
 Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water
or a suitable solvent.

Installation

1. Apply instant gel adhesive completely around the gasket groove in the valve cover and install
the new valve cover gasket.

2. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
3. Position the valve cover and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705782 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
7 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

4.
4. Connect the 3 engine wiring harness retainers.

5. Position the oil level indicator and install the bolt.

 Tighten to 10 Nm (89 lb-in).

6. Install the EGR system module-to-exhaust manifold tube.

 Tighten to 40 Nm (30 lb-ft).

7. Position the crankcase ventilation tube and connect the quick connect coupling. For additional
information, refer to Section 310-00 .

8. Position the power steering reservoir and support bracket assembly and install the 2 power
steering reservoir support bracket-to-cylinder head bolts.
 Tighten to 25 Nm (18 lb-ft).

9. Install the power steering reservoir support bracket-to-thermostat housing bolt.

 Tighten to 11 Nm (8 lb-ft).

10. Install the air cleaner outlet pipe and the air cleaner assembly. For additional information, refer
to Section 303-12 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 03/27/2007

Valve Cover — RH

Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
Motorcraft Metal Surface Prep —
ZC-31-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30

Part
Item Number Description
1 6K817 PCV tube
2 — Engine wiring harness retainer (4 required) (part of
 12B637)
3 6584 RH valve cover gasket
4 6582 RH valve cover

Removal

1. Remove the suction accumulator. For additional information, refer to Section 412-01 .

2. Disconnect the quick connect couplings and remove the PCV tube. For additional information,
refer to Section 310-00 .

3. Disconnect the PCV valve electrical connector.

4. Disconnect the vacuum tube connector.

5. Remove the bolt and position the transmission fluid level indicator tube aside.
 6. Disconnect the engine wiring harness retainers from the valve cover stud bolts.

7. NOTICE: 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.

Remove the 11 fasteners and remove the RH 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.
 Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water
or a suitable solvent.

Installation

1. Apply instant gel adhesive completely around the gasket groove in the valve cover and install
the new valve cover gasket.

2. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
 Apply the silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.

3. Position the valve cover and install the fasteners in the sequence shown to 10 Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
7 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

4.
4. Attach the engine wiring harness retainers to the valve cover stud bolts.

5. Connect the vacuum tube connector.

6. Connect the PCV valve electrical connector.

7. Position the transmission fluid level indicator tube and install the bolt.
 Tighten to 10 Nm (89 lb-in).

8. Position the PCV tube and connect the quick connect couplings. For additional information,
refer to Section 310-00 .

9. Install the suction accumulator. For additional information, refer to Section 412-01 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Pulley

Special Tool(s)
Installer, Crankshaft Vibration
Damper
303-102 (T74P-6316-B)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30
 Item Part Number Description
1 8620 Accessory drive belt
2 N806139 Crankshaft pulley bolt
3 N806165 Washer
4 6316 Crankshaft pulley

Removal

1. Remove the cooling fan shroud. For additional information, refer to Section 303-03 .

2. Rotate the tensioner clockwise and remove the drive belt.

 3. NOTICE: This bolt is torque-to-yield and cannot be reused. Failure to follow these
instructions may result in engine damage.

Using the special tool, remove the bolt and washer and discard the bolt.

4. Using the special tool, remove the crankshaft pulley.

Installation
1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

2. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

3. Using the special tool, install the crankshaft pulley.

4. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the
special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
 Stage 1: Tighten to 90 Nm (66 lb-ft).
 Stage 2: Loosen one full turn.
 Stage 3: Tighten to 50 Nm (37 lb-ft).
 Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft).

5. Rotate the tensioner clockwise and install the drive belt.

6. Install the cooling fan shroud. For additional information, refer to Section 303-03 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Front Seal

Special Tool(s)
Installer, Crankshaft Front Oil
Seal
303-635

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
 Item Part Number Description
1 8620 Accessory drive belt
2 N806139 Crankshaft pulley bolt
3 N806165 Washer
4 6316 Crankshaft pulley
5 6700 Crankshaft front seal

Removal

1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.

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

1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

2. Using the special tools, install a new crankshaft front seal.

3. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Engine Front Cover

Special Tool(s)
Installer, Crankshaft Front Oil
Seal
303-635

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Installer, Power Steering Pump

Pulley
211-185 (T91P-3A733-A)

Installer Set, Teflon® Seal

211-D027 (D90P-3517-A) or
equivalent

Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)
 Remover, Crankshaft Vibration
Damper
303-009 (T58P-6316-D)

Remover, Power Steering Pump

Pulley
211-016 (T69L-10300-B)

Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30

Accessory Drive Belt, Idler Pullies and Crankshaft Pulley

Item Part Number Description
1 8620 Accessory drive belt
2 N806139 Crankshaft pulley bolt
3 N806165 Washer
4 6316 Crankshaft pulley
5 6700 Crankshaft front seal
6 N808102 Accessory drive belt idler pulley bolt
7 19A216 Accessory drive belt idler pulley
8 N808102 Accessory drive belt idler pulley bolt
9 19A216 Accessory drive belt idler pulley
10 N808104 Accessory drive belt idler pulley bolt
11 19A216 Accessory drive belt idler pulley

Power Steering Pump, Coolant Pump Pulley and Electrical Connections

 Part
Item Number Description
1 N806155 Camshaft position (CMP) sensor bolt
2 6B288 CMP sensor
3 3A696 Power steering pump
4 W500315 Power steering pump bolt (3 required)
5 W701605 Oil pan bolt (4 required)
6 — Crankshaft position (CKP) sensor electrical connector
(part of 12B637)
7 — A/C compressor electrical connector (part of 12B637)
8 N806282 Coolant pump pulley bolt (4 required)
9 8A528 Coolant pump pulley
10 N804758 RH radio ignition interference capacitor nut
11 18801 RH radio ignition interference capacitor
12 N804758 LH radio ignition interference capacitor nut
13 N804758 LH radio ignition interference capacitor

Engine Front Cover and Gaskets

Item Part Number Description

1 6D081 Engine front cover gasket (3 required)
2 6C086 Engine front cover
3 N806300 Engine front cover upper stud bolt (4 required)
4 N808294 Engine front cover bolt
5 N806177 Engine front cover bolt (8 required)
6 W706508 Engine front cover lower stud bolt
7 N808586 Engine front cover lower stud bolt
8 6C315 Crankshaft position sensor (CKP) sensor
9 N806155 CKP sensor bolt

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Drain the engine oil.

3. Remove the cooling fan. For additional information, refer to Section 303-03 .

4. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this
section.

5. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this
section.

6. Rotate the tensioner clockwise and remove the drive belt.

7. NOTICE: This bolt is torque-to-yield and cannot be reused. Failure to follow these
instructions may result in engine damage.

Using the special tool, remove the bolt and washer and discard the bolt.
8. Using the special tool, remove the crankshaft pulley.

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

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

11. Remove the 3 bolts and the 3 accessory drive belt idler pulleys.

12. Using the special tool, remove the power steering pump pulley.
13. Disconnect the power steering pressure tube.
 Drain the power steering fluid into a suitable container.

14. Remove the nut and position aside the power steering pressure tube.

15. Remove the bolts and position the power steering pump assembly aside.
16. Disconnect the camshaft position (CMP) sensor electrical connector.

17. Remove the CMP sensor bolt and the CMP sensor.

18. Remove the nut and position the LH radio interference capacitor aside.

19. Remove the nut and the upper radiator hose bracket.

20. Remove the nut and position the RH radio interference capacitor aside.

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

22. Remove the 4 oil pan bolts.

23. Remove the nut and the A/C manifold and tube assembly support bracket.
24. If equipped, remove the nut and the transmission cooler tube support bracket.

25. Remove the bolts and the studs.

26. NOTICE: 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.

Remove the engine front cover from the front cover-to-cylinder block dowel.
  Remove the engine front cover gaskets.
 Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow
the directions on the packaging.
 Inspect the mating surfaces.

27. Remove the CKP sensor bolt and the CKP sensor.

Installation

1. Install the CKP sensor and the CKP sensor bolt.

 Tighten to 10 Nm (89 lb-in).

2. NOTICE: 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: If the engine front cover is not secured within 4 minutes, the sealant must be removed
and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover
before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface
and the oil pan-to-cylinder block surface, at the locations shown.
3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder
block dowel and loosely install the bolts.

4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 53
6 W706508 Stud Hex Shoulder Pilot, M8 x 1.25 x 50— M6 x 1 x 10
7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 — M6 x 1 x 86.35
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53
12 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
13 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
14 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
15 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1

5.

5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
 Stage 1: Tighten to 20 Nm (15 lb-ft).
 Stage 2: Tighten an additional 60 degrees.
6. If equipped, install the transmission cooler tube support bracket and nut.
 Tighten to 10 Nm (89 lb-in).

7. Install the A/C manifold and tube assembly support bracket and nut.
 Tighten to 10 Nm (89 lb-in).

8. Connect the CKP sensor electrical connector.

9. Position the RH radio interference capacitor and install the nut.

 Tighten to 25 Nm (18 lb-ft).
10. Position the upper radiator hose bracket and install the nut.
 Tighten to 10 Nm (89 lb-in).

11. Position the LH radio interference capacitor and install the nut.
 Tighten to 25 Nm (18 lb-ft).

12. Install the CMP sensor and the bolt.

 Tighten to 10 Nm (89 lb-in).

13. Connect the CMP sensor electrical connector.

14. Position the power steering pump and install the bolts.
 Tighten to 25 Nm (18 lb-ft).

15. Using the special tool, install a new O-ring seal on the pressure line fitting.
16. Connect the power steering pressure tube.
 Tighten to 65 Nm (48 lb-ft).

17. Position the power steering pressure tube support bracket and install the nut.
 Tighten to 12 Nm (9 lb-ft).

18. NOTE: If the pulley has been removed and installed twice, install a new power steering pump
pulley.

Using the special tool, install the power steering pump pulley.
  Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint
marks, install a new pulley. If there is one paint mark or none at all, use a pencil to
mark the web area of the pulley near the hub.

19. Install the 3 accessory drive belt idler pulleys and the 3 bolts.
 Tighten to 25 Nm (18 lb-ft).

20. Install the coolant pump pulley and the 4 bolts.

 Tighten to 25 Nm (18 lb-ft).

21. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

22. Using the special tools, install a new crankshaft front seal.
23. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

24. Using the special tool, install the crankshaft pulley.

25. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the
special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
 Stage 1: Tighten to 90 Nm (66 lb-ft).
 Stage 2: Loosen one full turn.
 Stage 3: Tighten to 50 Nm (37 lb-ft).
 Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft).

26. Rotate the tensioner clockwise and install the drive belt.

27. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.

28. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this
section.

29. Install the cooling fan. For additional information, refer to Section 303-03 .

30. Fill the engine with clean engine oil.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Timing Drive Components

Special Tool(s)
Aligner, Camshaft
303-380 (T91P-6256-A)

Aligner, Camshaft Pulley

303-413 (T92P-6256-A)

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

General Equipment
Hydraulic Chain Tensioner Retaining Clip 1L3Z-
6P250-AA

Removal

NOTICE: Since the engine is not free-wheeling, the timing procedures must be followed exactly or
piston and valve damage can occur.

1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.

2. Remove the crankshaft sensor ring from the crankshaft.

3. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at
the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at
the 12 o'clock position.

4. Install the Camshaft Aligner and Camshaft Pulley Aligner on the camshaft.
5. NOTICE: If one or both of the tensioner mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for seat integrity. If cracks, tears or
separation from the tensioner body or permanent compression of the seal bead is
observed, install a new tensioner or engine damage may occur.

Remove the timing chain tensioning system from both timing chains.

1. Remove the 4 bolts.

2. Remove the 2 timing chain tensioners.

3. Remove the 2 timing chain tensioner arms.

6. Remove the 2 timing chains and the crankshaft sprocket.

7. Remove the timing chain guides.
1. Remove the 2 bolts.

2. Remove the LH timing chain guide.

3. Remove the 2 bolts.

4. Remove the RH timing chain guide.

Installation

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

NOTICE: If one or both of the tensioner mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for seat integrity. If cracks, tears or
separation from the tensioner body or permanent compression of the seal bead is
observed, install a new tensioner or engine damage may occur.

Compress the tensioner plunger, using a vise.

2. Install a retaining clip on the tensioner to hold the plunger in during installation.

3. 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. Install the crankshaft sprocket, making sure the flange faces forward.

5. Install the timing chain guides.

1. Position the LH timing chain guide.
 2. Install the 2 LH bolts.
 Tighten to 10 Nm (89 lb-in).

3. Position the RH timing chain guide.

4. Install the 2 RH bolts.

 Tighten to 10 Nm (89 lb-in).

6. NOTICE: Unless otherwise instructed, do not rotate either the crankshaft or the
camshafts, when the timing chains are removed and the cylinder heads are installed.
Severe piston and valve damage will occur.

NOTE: The No. 1 cylinder is at Top Dead Center (TDC) when the stud on the engine block fits
into the slot in the handle of the special tool.

Using the Crankshaft Holding Tool, position the crankshaft so the No. 1 cylinder is at TDC .
7. Remove the Crankshaft Holding Tool.

8. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.

9. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

10. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
 Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain
tensioner and the 2 bolts.

 Tighten to 25 Nm (18 lb-ft).

11. Remove the retaining clip from the LH timing chain tensioner.

12. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.
13. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

14. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain
tensioner and the 2 bolts.
 Tighten to 25 Nm (18 lb-ft).

15. Remove the retaining clip from the RH timing chain tensioner.
16. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft
sprockets and the camshaft sprocket.

17. Remove the Camshaft Aligner and Camshaft Pulley Aligner from the camshaft.

18. Install the crankshaft sensor ring on the crankshaft.

19. Install the engine front cover. For additional information, refer to Engine Front Cover in this
section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Train Components — Exploded View

NOTE: LH shown, RH similar.

Item Part Number Description

1 6529 Camshaft roller follower (8 required)
2 6518 Valve spring retainer key (16 required)
3 6514 Valve spring retainer (8 required)
4 6513 Valve spring (8 required)
5 6A517 Valve stem seal (8 required)
6 N811085 Camshaft sprocket bolt
7 N806164 Camshaft sprocket bolt washer
8 6C255 Camshaft sprocket
9 6265 Camshaft gear spacer
10 N807834 Camshaft bearing cap assembly bolt (13 required)
11 6B280 Camshaft bearing cap
12 6B280 Camshaft bearing cap
13 6C255 Camshaft
14 6C501 Hydraulic lash adjuster (8 required)

1. For additional information, refer to the procedures in this section.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Camshaft

Special Tool(s)
Compressor, Valve Spring
303-452 (T93P-6565-AR)

Compressor, Valve Spring

303-567 (T91P-6571-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Aligner, Camshaft
303-380 (T91P-6256-A)

Aligner, Camshaft Pulley

303-413 (T92P-6256-A)

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Removal

1. Remove the timing drive components. For additional information, refer to Timing Drive
Components in this section.

2. Install the special tool between the valve spring coils to protect the valve stem seal from
damage.

3. NOTE: The camshaft roller followers must be installed in their original locations. Record the
camshaft roller follower locations.

NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567
in the same manner as is shown in the illustration.

Using the special tool, compress the valve spring and remove the camshaft roller follower.

 Remove all of the camshaft roller followers from the camshaft being serviced.

4. Remove the bolt, camshaft sprocket and camshaft sprocket spacer from the camshaft being
serviced.

5. Remove the special tools from the camshaft being serviced.

 6. Remove the bolts, camshaft bearing caps and the camshaft.

7. Clean and inspect the camshaft bearing caps.

 One of the bearing caps contains an oil flow restriction groove. Make sure the groove is
free of foreign material.

Installation

1. Install the camshaft and the camshaft bearing caps in their original locations.
 Lubricate the camshaft with clean engine oil.
 Position the camshaft.
 Lubricate the camshaft bearing caps with clean engine oil.
 Position the camshaft bearing caps.
 Install the bolts loosely.
2. NOTE: LH shown, RH similar.

Tighten the bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).

3. Install the special tools on the camshaft being serviced.

4. Install the camshaft sprocket spacer, camshaft sprocket, washer and bolt onto the camshaft
being serviced. Tighten the camshaft sprocket bolt in 2 stages:
 Stage 1: Tighten to 40 Nm (30 lb-ft).
 Stage 2: Tighten an additional 90 degrees.

5. Install the special tool between the valve spring coils to protect the valve stem seal from
damage.

6. NOTE: The camshaft roller followers must be installed in their original locations.

NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567
in the same manner as is shown in the illustration.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Using the special tool, compress the valve spring and install the camshaft roller follower.

 Install all of the camshaft roller followers onto the camshaft being serviced.
7. Install the timing drive components. For additional information, refer to Timing Drive
Components in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Camshaft Roller Follower

Special Tool(s)
Compressor, Valve Spring
303-452 (T93P-6565-AR)

Compressor, Valve Spring

303-567 (T91P-6571-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. If servicing the RH cylinder valve train components, remove the RH valve cover. For additional
information, refer to Valve Cover — RH in this section.

2. If servicing the LH cylinder valve train components, remove the LH valve cover. For additional
information, refer to Valve Cover — LH in this section.

3. Position the piston of the cylinder being repaired at the bottom of the stroke.
4. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve
stem seal from damage.

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

NOTE: The 3 rearmost camshaft roller followers on the RH side must use Valve Spring
Compressor 303-567 in the same manner as is shown in the illustration.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, compress the valve spring and remove the camshaft
roller follower.
 6. Repeat the previous 2 steps for each of the camshaft roller followers being serviced.

Installation

1. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve
stem seal from damage.

2. NOTICE: The camshaft roller followers must be installed in their original locations.
Failure to follow this instruction may result in engine damage.

NOTE: The 3 rearmost camshaft roller followers on the RH side must use Valve Spring
Compressor 303-567 in the same manner as is shown in the illustration.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Using the Valve Spring Compressor, compress the valve springs and install the camshaft roller
follower.
3. Repeat the previous 2 steps for each camshaft roller follower being serviced.

4. If servicing the RH cylinder valve train components, install the RH valve cover. For additional
information, refer to Valve Cover — RH in this section.

5. If servicing the LH cylinder valve train components, install the LH valve cover. For additional
information, refer to Valve Cover — LH in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Springs

Special Tool(s)
Compressor, Valve Spring
303-452 (T93P-6565-AR)

Compressor, Valve Spring

303-567 (T91P-6571-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal and Installation

1. If servicing the RH cylinder valve train components, remove the RH valve cover. For additional
information, refer to Valve Cover — RH in this section.

2. If servicing the LH cylinder valve train components, remove the LH valve cover. For additional
information, refer to Valve Cover — LH in this section.

3. Position the piston of the cylinder being serviced at the bottom of the stroke.

4. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve
stem seal from damage.
5. NOTICE: The camshaft roller followers must be installed in their original locations.
Record the camshaft roller follower locations. Failure to follow these instructions may
result in engine damage.

NOTE: The 3 rearmost camshaft roller followers on the RH side must use Valve Spring
Compressor 303-567 in the same manner as is shown in the illustration.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

Use the Valve Spring Compressor to compress the valve spring and remove the camshaft
roller follower.

6. Remove the spark plug. For additional information, refer to Section 303-07B .

7. Use compressed air in the cylinder to hold both valves in position.

 Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.

8. NOTICE: The camshaft roller followers must be installed in their original locations.
Failure to follow these instructions may result in engine damage.
 NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Cylinder Head in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, compress the valve spring and remove the valve spring
retainer keys.

9. Remove the valve spring retainer and the valve spring.

10. Repeat the previous 7 steps for each valve spring being serviced.

11. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

To install, reverse the removal procedure.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Valve Seals

Special Tool(s)
Compressor, Valve Spring
303-452 (T93P-6565-AR)

Compressor, Valve Spring

303-567 (T91P-6571-AH)

Installer, Valve Stem Oil Seal

303-383 (T91P-6571-A)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the valve spring for the valve seal being serviced. For additional information, refer to
Valve Springs in this section.

2. Remove and discard the valve stem seal.

Installation

1. NOTE: The 3 rearmost valve seals on the RH side must use Valve Spring Compressor 303-
567 in the same manner as is shown in the illustration.
 NOTE: Lubricate the valve seal with clean engine oil prior to installation.

Using the Valve Stem Oil Seal Installer and Valve Spring Compressor, install the new valve
stem seal.

2. Install the valve spring. For additional information, refer to Valve Springs in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Hydraulic Lash Adjuster

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the camshaft roller follower for the hydraulic lash adjuster being serviced. For
additional information, refer to Camshaft Roller Follower in this section.

2. NOTICE: The hydraulic lash adjusters must be installed in their original locations.
Record the hydraulic lash adjuster locations. Failure to follow these instructions may
result in engine damage.

Remove the hydraulic lash adjuster.

Installation

1. NOTICE: The hydraulic lash adjusters must be installed in their original locations.
Failure to follow this instruction may result in engine damage.

NOTE: Lubricate the hydraulic lash adjuster with clean engine oil prior to installation.

Install the hydraulic lash adjuster in its original location.

2. Install the camshaft roller follower. For additional information, refer to Camshaft Roller Follower
in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 12/12/2007

Exhaust Manifold — RH

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A

Item Part Number Description

1 W705443 Exhaust Y-pipe flange nut (2 required)
2 5F250 Exhaust Y-pipe flange
3 W701706 Exhaust manifold nut (8 required)
4 9430 Exhaust manifold
5 W707747 Exhaust manifold-to-cylinder head stud (8 required)
6 9448 Exhaust manifold gasket

Removal
 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the starter. For additional information, refer to Section 303-06 .

3. Remove the RH inner fenderwell. For additional information, refer to Section 501-02 .

4. Remove and discard the 2 exhaust Y-pipe flange nuts and position the exhaust Y-pipe flange
aside.

5. Remove and discard the 8 exhaust manifold nuts.

6. Remove and discard the 4 rear exhaust manifold-to-cylinder head studs.

7. Remove the RH exhaust manifold and discard the gasket.

8. Remove and discard the 4 remaining exhaust manifold-to-cylinder head studs.

9. Inspect the exhaust manifold for flatness. For additional information, refer to Section 303-00 .

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other
abrasive means to clean the sealing surfaces. These may cause scratches and gouges
resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the sealing surfaces with metal surface prep.

2. Install 4 new front exhaust manifold-to-cylinder head studs.

 Tighten to 12 Nm (106 lb-in).

3. Using a new exhaust manifold gasket, position the gasket and exhaust manifold onto the
cylinder head.

4. Install 4 new rear exhaust manifold-to-cylinder head studs.

 Tighten to 12 Nm (106 lb-in).

5. Using new exhaust manifold nuts, tighten in the sequence shown.

 Tighten to 25 Nm (18 lb-ft).
6. Position the Y-pipe flange and install 2 new nuts.
 Tighten to 40 Nm (30 lb-ft).

7. Install the RH inner fenderwell. For additional information, refer to Section 501-02 .

8. Install the starter. For additional information, refer to Section 303-06 .

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Exhaust Manifold — LH

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A

Part
Item Number Description
1 W705443 Exhaust Y-pipe flange nut (2 required)
2 5F250 Exhaust Y-pipe flange
3 9D477 EGR system module-to-exhaust manifold tube
fittings
4 W701706 Exhaust manifold nut (8 required)
5 9431 Exhaust manifold
6 W707747 Exhaust manifold-to-cylinder head stud (8 required)
7 9Y431 Exhaust manifold gaskets

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the LH inner fenderwell. For additional information, refer to Section 501-02 .

3. Remove the 2 exhaust Y-pipe flange nuts and position the exhaust Y-pipe flange aside.

4. Remove the EGR system module-to-exhaust manifold tube.

5. Remove and discard the 8 exhaust manifold nuts.

6. Remove the LH exhaust manifold and discard the gasket.

7. Remove and discard the 8 exhaust manifold-to-cylinder head studs.

8. Inspect the exhaust manifold for flatness. For additional information, refer to Section 303-00 .

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These may cause scratches and gouges
resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the sealing surfaces with metal surface prep.

2. Install 8 new exhaust manifold-to-cylinder head studs.

 Tighten to 12 Nm (9 lb-ft).

3. NOTE: Install a new exhaust manifold gasket and new nuts.

Position the gaskets and the LH exhaust manifold and tighten the nuts in the sequence shown.

 Tighten to 25 Nm (18 lb-ft).

4. Install the EGR system module-to-exhaust manifold tube.
 Tighten to 40 Nm (30 lb-ft).

5. Position the Y-pipe flange and install the 2 nuts.

 Tighten to 40 Nm (30 lb-ft).

6. Install the LH inner fenderwell. For additional information, refer to Section 501-02 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Engine Lubrication Components — Exploded View

Skid Plate and Fasteners

Item Part Number Description

1 W707472-S Skid plate bolt (4 required) (if equipped)
2 — Skid plate (if equipped)

Oil Pan, Oil Pump and Oil Pump Screen and Pickup Tube
Item Part Number Description
1 W701605 Oil pan bolt (16 required)
2 6675 Oil pan
3 6710 Oil pan gasket
4 N605904 Oil pump screen and pickup tube bolt
5 N806155 Oil pump screen and pickup tube bolts (2 required)
6 6622 Oil pump screen and pickup tube
7 N806183 Oil pump bolt (3 required)
8 6621 Oil pump

1. For additional information, refer to the procedures in this section.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Pan

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30

Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Drain the engine oil.

3. If equipped, remove the 4 skid plate bolts and the skid plate.

4. Remove the bolts and the crossmember.

Four wheel drive (4WD) vehicles

5. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle.

6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows
clearance for the isolator bolt.

Remove the upper front axle carrier mounting bushing bolt.

7. Remove the axle shaft housing carrier bushing bolt.

 8. Remove the lower front axle carrier mounting bushing bolt.

9. Partially lower the front axle assembly.

All vehicles

10. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These may cause scratches and gouges
resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Remove the 16 oil pan bolts, the oil pan and discard the oil pan gasket. Clean the sealing
surfaces with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Inspect the mating surfaces.

Installation

All vehicles

1. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply the silicone gasket and sealant at the engine front cover-to-cylinder block mating
surface.
2. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in the locations shown.

3. Position the new oil pan gasket and the oil pan and loosely install the 16 bolts.
 4. Tighten the bolts in 3 stages in the sequence shown.
 Stage 1: Tighten to 2 Nm (18 lb-in).
 Stage 2: Tighten to 20 Nm (15 lb-ft).
 Stage 3: Tighten an additional 60 degrees.

4WD vehicles

5. Position the front axle.

6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows
clearance for the isolator bolt.

Install the upper front axle carrier mounting bushing bolt.

 Tighten to 90 Nm (66 lb-ft).

7. Install the axle shaft housing carrier bushing nut and bolt.
 Tighten to 90 Nm (66 lb-ft).
 8. Install the lower front axle carrier mounting bushing bolt.
 Tighten to 90 Nm (66 lb-ft).

All vehicles

9. Install the crossmember and the 4 bolts.

 Tighten to 115 Nm (85 lb-ft).

10. If equipped, install the skid plate and the 4 bolts.

 Tighten to 25 Nm (18 lb-ft).

11. Install the engine oil pan drain plug and fill the engine with clean engine oil.
 Tighten to 14 Nm (10 lb-ft).
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Pump

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the timing drive components. For additional information, refer to Timing Drive
Components in this section.

3. Remove the oil pan. For additional information, refer to Oil Pan in this section.

4. Remove the 3 bolts and the oil pump screen and pickup tube.
 Discard the O-ring seal.

5. Remove the 3 bolts and the oil pump.

Installation

1. NOTICE: 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.

Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

2. Install the oil pump and the 3 bolts.

 Tighten to 10 Nm (89 lb-in).

3. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-
ring can cause foam in the lubrication system, low oil pressure and severe engine
damage.

NOTE: Install a new O-ring seal and lubricate with clean engine oil.

Install the oil pump screen and pickup tube and the 3 bolts.

1. Tighten to 25 Nm (18 lb-ft).

2. Tighten to 10 Nm (89 lb-in).

4. Install the oil pan. For additional information, refer to Oil Pan in this section.

5. Install the timing drive components. For additional information, refer to Timing Drive
Components in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Pump Screen and Pickup Tube

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the oil pan. For additional information, refer to Oil Pan in this section.

2. Remove the 3 bolts and the oil pump screen and pickup tube.
 Discard the O-ring seal.

Installation

1. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-
ring can cause foam in the lubrication system, low oil pressure and severe engine
damage.

NOTE: Install a new O-ring and lubricate with clean engine oil.

Install the oil pump screen and pickup tube and the 3 bolts.

1. Tighten to 25 Nm (18 lb-ft).

2. Tighten to 10 Nm (89 lb-in).

2. Install the oil pan. For additional information, refer to Oil Pan in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Filter Adapter

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
Silicone Gasket Remover —
ZC-30

Part
Item Number Description
1 6714 Oil filter
2 15161 Lower radiator hose clamp
3 8B273 Lower radiator hose
4 — Coolant reservoir hose clamp
5 8C351 Coolant reservoir hose
6 — Engine oil pressure (EOP) switch electrical connector
(part of 12B637)
7 W701605 Oil filter adapter bolt (4 required)
8 6884 Oil filter adapter
9 6A636 Oil filter adapter gasket

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Drain the coolant. For additional information, refer to Section 303-03 .

3. Remove and discard the engine oil filter.

 To install, lubricate the oil filter gasket with clean engine oil.

4. Release the lower radiator hose clamp and position the lower radiator hose aside.

5. Release the coolant reservoir hose clamp and position the coolant reservoir hose aside.

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

7. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These may cause scratches and gouges
resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Remove the 4 oil filter adapter bolts, the oil filter adapter and discard the gasket. Clean the
sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on
the packaging. Inspect the mating surfaces.

 To install, tighten to 25 Nm (18 lb-ft).

8. To install, reverse the removal procedure.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Oil Level Indicator and Tube

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Item Part Number Description

1 N806155 Oil level indicator tube bolt
2 6750 Oil level indicator and tube
3 — Oil level indicator tube O-ring seal

Removal and Installation

1. Remove the LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH
in this section.

2. Remove the oil level indicator tube bolt.

 To install, tighten to 10 Nm (89 lb-in).

3. Remove the oil level indicator tube and discard the O-ring seal.

4. NOTE: Install a new O-ring seal. Lubricate the O-ring seal with clean engine oil prior to
installation.

To install, reverse the removal procedure.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Engine Oil Pressure (EOP) Switch

Part
Item Number Description
1 — Engine oil pressure (EOP) switch electrical connector
(part 12B637)
2 9278 EOP switch

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the engine oil pressure (EOP) switch.

 To install, tighten to 18 Nm (13 lb-ft).

3. To install, reverse the removal procedure.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View

Item Part Number Description

1 N806168 Flexplate bolt (6 required)
2 6375 Flexplate
3 6A373 Rear cover plate
4 6310 Crankshaft oil slinger
5 6701 Crankshaft rear seal
6 N806155 Crankshaft rear seal retainer plate bolt (6 required)
7 6K318 Crankshaft rear seal retainer plate

1. For additional information, refer to the procedures in this section.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Flexplate

Removal

1. Remove the transmission. For additional information, refer to Section 307-01 .

2. Remove the 6 flexplate bolts and the flexplate.

Installation

1. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
 Stage 1: Tighten to 20 Nm (15 lb-ft).
 Stage 2: Tighten to 80 Nm (59 lb-ft).

2. Install the transmission. For additional information, refer to Section 307-01 .

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 08/09/2006

Crankshaft Rear Seal

Special Tool(s)
Installer, Crankshaft Rear Oil
Seal
303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil

Seal
303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil

Slinger
303-517 (T95P-6701-CH)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Remover, Crankshaft Rear Oil

Slinger
303-514 (T95P-6701-AH)

Slide Hammer
100-001 (T50T-100-A)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Removal

1. Remove the flexplate. For additional information, refer to Flexplate in this section.

2. Remove the engine rear cover plate.

3. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove and discard the
crankshaft oil slinger.

4. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear seal.

Installation

1. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
 Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

2. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers and Crankshaft Rear Oil Slinger Installer, install a
new crankshaft oil slinger.

3. Install the engine rear cover plate.

4. Install the flexplate. For additional information, refer to Flexplate in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 07/14/2006

Crankshaft Rear Seal with Retainer Plate

Special Tool(s)
Installer, Crankshaft Rear Oil
Seal
303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil

Seal
303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil

Slinger
303-517 (T95P-6701-CH)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Remover, Crankshaft Rear Oil

Slinger
303-514 (T95P-6701-AH)

Slide Hammer
100-001 (T50T-100-A)

Material
Item Specification
Gasket Maker WSK-
TA-16 M2G348-A5
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket Remover —
ZC-30

Removal

1. Remove the flexplate. For additional information, refer to Flexplate in this section.

2. Remove the engine rear cover plate.

3. Remove the oil pan. For additional information, refer to Oil Pan in this section.

4. Using the Slide Hammer and Crankshaft Rear Oil Slinger Remover, remove and discard the
crankshaft oil slinger.

5. Using the Slide Hammer and Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear seal.
 6. Remove the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer
plate.

7. NOTICE: 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: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Clean and inspect the mating surface.

Installation

1. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker
must be applied to the rear crankshaft seal retainer plate mating surface on the engine block.

Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the
engine block.

2. Position the crankshaft seal retainer plate and tighten the 6 bolts in the sequence shown.
 Tighten to 10 Nm (89 lb-in).
3. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

4. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers and Crankshaft Rear Oil Slinger Installer, install a
new crankshaft oil slinger.

5. Install the oil pan. For additional information, refer to Oil Pan in section.
6. Install the engine rear cover plate.

7. Install the flexplate. For additional information, refer to Flexplate in this section.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 02/15/2007

Engine Support Insulators

Special Tool(s)
Support Bar, Engine
303-F070

Support Bracket, Engine

303-639

Support Hook
303-F071

Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
 Part
Item Number Description
1 W710384 RH engine support insulator nut (2 required)
2 6D047 RH engine insulator nut washer
3 W706698 RH engine support insulator bracket bolt (3 required)
4 6038 RH engine support insulator and bracket
5 — RH engine support insulator bracket-to-engine
support insulator bolt
6 — RH engine support insulator-to-cylinder block bracket
(part of 6038)
7 — RH engine support insulator (part of 6038)
8 W711403 LH engine support insulator bolt
9 W706698 LH engine support insulator bracket bolt (3 required)
10 6B032 LH engine support insulator and bracket
11 — LH engine support insulator bracket-to-engine
support insulator bolt
12 — LH engine support insulator-to-cylinder block bracket
(part of 6B032)
13 — LH engine support insulator (part of 6B032)

Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

3. Remove the air cleaner and the air cleaner outlet pipe and resonator. For additional
information, refer to Section 303-12 .

4. Remove the generator. For additional information, refer to Section 414-02 .

5. Remove the bolts and position the cooling fan shroud away from the radiator.

6. Remove the oil level indicator and the oil level indicator tube bolt.
7. Install the special tools.

8. Remove the 4 exhaust manifold-to-catalytic converter nuts.

9. Remove the exhaust system support bracket bolts from the crossmember.
 10. Remove the transmission mount nuts.

Four wheel drive (4WD) vehicles

11. Remove the 4 nuts and lower the front stabilizer bar.

RH engine support insulator

12. Remove the starter. For additional information, refer to Section 303-06 .
LH engine support insulator

13. If removing the LH engine support insulator in a four wheel drive (4WD) vehicle, index-mark
the front driveshaft flange to the front axle pinion flange.

14. NOTE: Do not let the driveshaft hang unsupported.

If removing the LH engine support insulator in a 4WD vehicle, disconnect and support the front
driveshaft.

 Remove the 4 bolts.

 Support the front driveshaft.

All vehicles

15. Remove the RH engine support insulator nuts and washer.

 16. Remove the LH engine support insulator bolt.

17. Using the special tools, raise the engine.

RH engine support insulator

18. Remove the 3 RH engine support insulator bracket bolts.

19. Remove the 2 RH engine support insulator bracket-to-engine support insulator bolts.
 20. Remove the RH engine support insulator bracket and the RH engine support insulator.

LH engine support insulator

21. Remove the 3 LH engine support insulator bracket bolts.

22. Remove the oil level indicator tube from the cylinder block and position aside.
 Discard the O-ring seal.

23. Remove the 2 LH engine support insulator bracket-to-engine support insulator bolts.

24. Remove the LH engine support insulator bracket and the LH engine support insulator.

Installation

LH engine support insulator

1. NOTE: Clean the engine support insulator-to-bracket mating surfaces of any dirt or foreign
material prior to installation.

Install the LH engine support insulator bracket and the LH engine support insulator.

2. Install the 2 LH engine support insulator bracket-to-engine support insulator bolts.

 Apply threadlock to the bolt threads prior to installation.
 Tighten to 72 Nm (53 lb-ft).

3. Using a new O-ring seal, install the oil level indicator into the cylinder block.
 4. NOTE: Clean the engine support insulator bracket-to-cylinder block mating surfaces of any dirt
or foreign material prior to installation.

Install the 3 LH engine support insulator bracket bolts.

 Apply threadlock to the bolt threads prior to installation.

 Tighten to 63 Nm (46 lb-ft).

RH engine support insulator

5. NOTE: Clean the engine support insulator-to-bracket mating surfaces of any dirt or foreign
material prior to installation.

Install the RH engine support insulator bracket and the RH engine support insulator.

6. Install the 2 RH engine support insulator bracket-to-engine support insulator bolts.

 Apply threadlock to the bolts threads prior to installation.
 Tighten to 72 Nm (53 lb-ft).

7. NOTE: Clean the engine support insulator bracket-to-cylinder block mating surfaces of any dirt
or foreign material prior to installation.

Install the 3 RH engine support insulator bracket bolts.

 Apply threadlock to the bolts threads prior to installation.

 Tighten to 63 Nm (46 lb-ft).

All vehicles

8. Lower the engine.

9. NOTE: Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign
material prior to installation.

Apply threadlock to the threads and install the LH engine support insulator bolt.

 Tighten to 350 Nm (258 lb-ft).

 10. NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating
surface are free of foreign material and corrosion before installation. Install a new washer.

Apply threadlock to the stud threads and install the RH engine support insulator washer and
nuts.

 Tighten to 250 Nm (184 lb-ft).

LH engine support insulator

11. If installing the LH engine support insulator in a 4WD vehicle, align the front driveshaft flange-
to-front axle pinion flange at the index mark and install the bolts.
 Tighten to 111 Nm (82 lb-ft).
RH engine support insulator

12. Install the starter. For additional information, refer to Section 303-06 .

4WD vehicles

13. Install the front stabilizer bar and the 4 nuts.

 Tighten to 30 Nm (22 lb-ft).

All vehicles

14. Install the transmission mount nuts.

 Tighten to 103 Nm (76 lb-ft).
15. Install the exhaust system support bracket bolts from the crossmember.
 Tighten to 40 Nm (30 lb-ft).

16. Install the 4 exhaust manifold-to-catalytic converter nuts.

 Tighten to 40 Nm (30 lb-ft).

17. Position the cooling fan shroud and install the bolts.
 Tighten to 10 Nm (89 lb-in).
18. Position the oil level indicator tube and install the bolt and oil level indicator.
 Tighten to 10 Nm (89 lb-in).

19. Install the generator. For additional information, refer to Section 414-02 .

20. Install the air cleaner and the air cleaner outlet pipe and resonator. For additional information,
refer to Section 303-12 .

21. Connect the battery ground cable. For additional information, refer to Section 414-01 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
REMOVAL Procedure revision date: 12/12/2008

Engine

Special Tool(s)
Lifting Bracket, Engine
303-F047 (014-00073)

Remover, Power Steering Pump

Pulley
211-016 (T69L-10300-B)

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .

2. Remove the hood.

3. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal
debris is found, install a new intake manifold. Failure to follow these instructions can
result in engine damage.

Remove the intake manifold. For additional information, refer to Intake Manifold in this section.

4. Remove the radiator. For additional information, refer to Section 303-03 .

5. Remove the PCM and the support bracket. For additional information, refer to Section 303-14 .

6. Remove the cowl panel grille. For additional information, refer to Section 501-02 .

7. Detach the wiring harness and the windshield washer hose from the cowl panel extension.
8. Remove the bolts and the cowl panel extension.

9. Disconnect the electrical connector and remove the bolt and the ground strap.

10. Disconnect the heater hose.

11. Remove the nut and the A/C manifold and tube assembly support bracket.

12. Disconnect the A/C compressor electrical connector.

13. Disconnect the degas bottle coolant hose.

14. Remove the bolts and position the power steering reservoir assembly aside.

15. Using the special tool, remove the power steering pump pulley.

16. Disconnect the power steering pressure tube.

 Drain the power steering fluid into a suitable container.
17. Remove the nut and position aside the power steering pressure tube.

18. Remove the power steering pump bolts and position the power steering pump assembly aside.

19. Remove the starter. For additional information, refer to Section 303-06 .

20. Disconnect the crankshaft position (CKP) sensor electrical connector and harness retainer.
21. If equipped, remove the nut and the transmission cooler tube support bracket.

22. Remove the bolts and position the A/C compressor aside.

23. If equipped, disconnect the block heater electrical connector.

24. Detach the starter electrical harness support from the cylinder block.

25. Remove the drain plug and drain the engine oil.

26. Remove the oil filter.

27. Remove the bolts and the flexplate inspection cover.

28. Remove the cylinder block opening cover.

29. Remove the torque converter-to-flexplate nuts.

 Discard the nuts.
30. Disconnect the LH heated exhaust gas oxygen sensor (HO2S) electrical connector and detach
the electrical connector retainer.

31. Disconnect the shift cable and remove the shift cable bracket.

32. NOTE: The left upper transmission-to-engine bolt will be removed later.

Remove the 6 transmission-to-engine bolts.

33. Remove the bolt and position the transmission fluid filler tube aside.

34. Remove the 4 exhaust manifold flange nuts.

35. Remove the RH motor mount nuts.

36. Remove the LH motor mount bolt.

37. Support the transmission.

38. NOTE: On four wheel drive (4WD) vehicles, it may be necessary to reposition the transfer
case vent hose to access the bolt.

Remove the left upper transmission-to-engine bolt.

39. Install the special tool.

40. NOTE: Raise the engine and position forward to disconnect the transmission wiring harness
retainer at the rear of the RH cylinder head, disconnect the RH HO2S electrical connector and
detach the electrical connector retainer.

Using a suitable floor crane, remove the engine assembly from the vehicle.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
REMOVAL Procedure revision date: 09/08/2008

Cylinder Head

Special Tool(s)
Compressor, Valve Spring
303-452 (T97P-6565-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Silicone Gasket Remover —
ZC-30
All cylinder heads

1. Remove the engine. For additional information, refer to Engine in this section.

2. Remove the 6 bolts and the flexplate.

3. Remove the spacer plate.

4. Install the engine onto a suitable engine stand.

5. If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support
insulator.
6. NOTE: LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable
container.

7. NOTE: LH shown, RH similar.

If equipped, install the cylinder block drain plugs.

 Tighten to 24 Nm (18 lb-ft).

8. Disconnect the engine oil pressure (EOP) sensor electrical connector.

9. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type
retainer.

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

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

12. Remove the nut and the upper radiator hose bracket.

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

14. Disconnect the RH radio ignition interference capacitor electrical connector.

15. Disconnect the engine wiring harness retainers from the valve cover studs and remove the
electrical harness from the engine assembly.

16. NOTE: RH shown, LH similar.

Remove the nuts and the 2 radio interference capacitors.

17. Remove the bolt and the CMP sensor.

18. Remove the bolt and the CKP sensor.

19. NOTICE: 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 bolts are part of the valve cover and should not be removed.

NOTE: LH shown, RH similar.

Remove the valve covers.

 Fully loosen the bolts and remove the valve covers.

 Clean the valve cover mating surface of the cylinder heads with silicone gasket remover
and metal surface prep. Follow the directions on the packaging.

20. Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.
21. Remove the bolts and the accessory drive belt tensioner.

22. Remove the crankshaft pulley bolt and washer.

 Discard the crankshaft pulley bolt.

23. Using the special tool, remove the crankshaft pulley.

24. Using the special tool, remove and discard the crankshaft front seal.
25. Remove the 4 front oil pan bolts.

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

Remove the fasteners.

27. NOTICE: 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.

Remove the engine front cover from the front cover-to-cylinder block dowel.

 Remove the engine front cover gaskets.

 Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow
the directions on the packaging.
 Inspect the mating surfaces.

28. NOTICE: Only use hand tools when removing or installing the spark plugs or damage
may 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.

Remove the 8 spark plugs.

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

Install the special tool between the valve spring coils to prevent valve stem seal damage.
30. NOTICE: The camshaft roller followers must be installed in their original locations.
Record the camshaft roller follower locations. Failure to follow these instructions may
result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

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

Using the special tool, compress the valve springs and remove the camshaft roller followers.

31. Repeat the previous 3 steps for each of the roller followers.

32. Remove the crankshaft sensor ring from the crankshaft.

33. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at
the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at
the 12 o'clock position.

34. NOTICE: 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.

35. Remove the timing chains and crankshaft sprocket.

36. 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.

LH cylinder head

37. 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.

 Inspect the exhaust manifold. For additional information, refer to Section 303-00 .

38. Remove and discard the 8 LH exhaust manifold-to-cylinder head studs.

39. Remove the bolt and the oil level indicator tube.

40. Remove the cylinder head insert from the LH cylinder head.
RH cylinder head

41. 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.

 Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
42. Remove and discard the 8 RH exhaust manifold-to-cylinder head studs.

43. Disconnect the coolant hoses from the heater outlet tube.

44. Remove the heater outlet tube studs.

45. Remove the heater outlet tube and discard the O-ring seal.
All cylinder heads

46. Install the special tools on both ends of the cylinder head being serviced.

47. NOTICE: 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.

NOTICE: 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.

NOTICE: 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.

NOTICE: 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.

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

NOTE: LH shown, RH similar.

 Remove the bolts and the cylinder head.

 Discard the cylinder head gasket.

 Discard the cylinder head bolts.

48. NOTICE: 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 in the following sequence.

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.

49. NOTE: LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion, paying particular attention to the oil pressure feed
area. For additional information, refer to Section 303-00 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY Procedure revision date: 09/08/2008

Engine

Special Tool(s)
Compressor, Valve Spring
303-452 (T97P-6565-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Installer, Connecting Rod

303-442 (T93P-6136-A)

Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-DH)

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)
 Remover, Crankshaft Rear Oil
Slinger
303-514 (T95P-6701-AH)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Slide Hammer
100-001 (T50T-100-A)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31-A
Silicone Gasket Remover —
ZC-30

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

NOTE: For additional information, refer to the exploded views under Engine in the Assembly portion of
this section.

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 bolts and the flexplate.

2. Remove the spacer plate.

3. Using the special tools, remove and discard the crankshaft rear oil slinger.

4. Using the special tools, remove and discard the crankshaft rear seal.
5. Remove the bolts, oil pan and oil pan gasket.
 Clean and inspect the sealing surfaces.

6. Remove the bolts and the crankshaft rear seal retainer plate.
 Clean and inspect the sealing surfaces.

7. Mount the engine on a suitable workstand.

8. Remove the 3 bolts and the RH engine support insulator.

9. NOTE: LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable
container.

10. NOTE: LH shown, RH similar.

If equipped, install the cylinder block drain plugs.

 Tighten to 24 Nm (18 lb-ft).

11. Disconnect the engine oil pressure (EOP) sensor electrical connector.

12. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type
retainer.

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

14. Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT)
sensor electrical connectors.
15. Disconnect the RH radio ignition interference capacitor electrical connector.

16. Disconnect the engine wiring harness retainers from the valve cover studs and remove the
electrical harness from the engine assembly.

17. Remove the nut and the upper radiator hose bracket.

18. NOTE: RH shown, LH similar.

Remove the nuts and the 2 radio interference capacitors.

19. Remove the bolt and the CMP sensor.

20. Remove the bolt and the crankshaft position (CKP) sensor.

21. NOTICE: 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 valve covers.

 Fully loosen the fasteners and remove the valve covers.

 Clean the valve cover mating surface of the cylinder heads with silicone gasket remover
and metal surface prep. Follow the directions on the packaging.

22. Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.

23. Remove the bolts and the accessory drive belt tensioner.
24. Remove the bolts.

25. Remove the coolant pump from the cylinder block.

26. Remove and discard the crankshaft pulley bolt.

Use the special tool to remove the crankshaft pulley.
27. Use the special tool to remove and discard the crankshaft front seal.

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

Remove the fasteners.

29. Remove the engine front cover from the cylinder block.
30. NOTE: Camshaft roller follower is removed for clarity.

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

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

NOTE: It may be necessary to push the valve down while compressing the spring.

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

Using the special tool, compress the valve springs and remove the camshaft roller follower.
32. Repeat the previous 2 steps for each camshaft roller follower.

33. Remove the crankshaft sensor ring from the crankshaft.

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

35. NOTICE: 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 or
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.

36. Remove the timing chains and crankshaft sprocket.

37. 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.

38. 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.

39. 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.

40. NOTE: RH shown, LH similar.

Remove and discard the 16 exhaust manifold-to-cylinder head studs.

41. Clean and inspect the exhaust manifolds. For additional information, refer to Section 303-00 .

42. Remove the bolt and the oil level indicator tube.
43. Install the special tools on both ends of the cylinder head.

44. NOTICE: 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.

NOTICE: 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.

NOTICE: 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.

NOTICE: 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.

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

NOTE: LH shown, RH similar.

Remove the bolts and the cylinder heads.

 Discard the cylinder head gasket.

 Discard the cylinder head bolts.
45. NOTICE: 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 in the following sequence.

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.
46. NOTE: LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion, paying particular attention to the oil pressure feed
area. For additional information, refer to Section 303-00 .

47. Remove the bolts and the LH engine support insulator.

48. Remove the bolts and the oil filter adapter.

 Discard the gasket.
49. Clean the gasket surfaces at the cylinder block and the oil filter adapter.

50. Remove the bolts, the oil pump screen and pickup tube and the spacer.
51. Remove the 3 bolts and the oil pump.

52. 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 instructions.

53. NOTICE: 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 caps. Discard the bolts.
54. NOTICE: 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.
55. Disassemble the 8 pistons. For additional information, refer to Piston in this section.

56. NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to follow
these instructions may 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.

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

58. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers
from the cylinder block.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 07/14/2006

Cylinder Head

Special Tool(s)
Aligner, Camshaft
303-380 (T91P-6256-A)

Aligner, Camshaft Pulley

303-413 (T92P-6256-A)

Compressor, Valve Spring

303-452 (T93P-6565-AR)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Installer, Valve Stem Oil Seal

303-383 (T91T-6571-A)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
NOTE: LH shown, RH similar.

Item Part Number Description

1 6518 Valve spring retainer key (16 required)
2 6514 Valve spring retainer (8 required)
3 6513 Valve spring (8 required)
4 6A517 Valve stem seal (8 required)
5 6505 Intake valve (4 required)
6 6507 Exhaust valve (4 required)
7 N811085 Camshaft sprocket bolt
8 N806164 Camshaft sprocket bolt washer
9 6256 Camshaft sprocket
10 6265 Camshaft sprocket spacer
11 N807834 Camshaft bearing cap bolt (13 required)
12 W705438 Camshaft bearing cap
13 6B277 Camshaft bearing cap
14 6A271 Camshaft
15 6C501 Hydraulic lash adjuster (8 required)

Disassembly

1. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring
retainer keys.

2. Remove the valve spring retainer, valve spring, valve stem seal and the valve.
 Discard the valve seal.

3. Repeat the above steps and remove all of the valve springs, valve stem seals and valves.
 Discard the valve stem seals.

4. Install the Camshaft Aligner and Camshaft Pulley Aligners on the camshaft.
5. Remove the camshaft sprocket bolt, washer and the camshaft sprocket.

6. Remove the Camshaft Aligner and Camshaft Pulley Aligners from the camshaft.

7. Remove the camshaft sprocket spacer.

8. Remove the 13 camshaft bearing cap bolts, 2 camshaft bearing caps and the camshaft.

9. Clean and inspect the camshaft bearing caps.

 One of the bearing caps contains an oil flow restriction groove. Make sure the groove is
free of foreign material.

10. NOTICE: The hydraulic lash adjusters must be installed in their original locations.
Record the hydraulic lash adjuster locations. Failure to follow these instructions may
result in engine damage.

Remove the hydraulic lash adjusters.

Assembly

1. NOTICE: The hydraulic lash adjusters must be installed in their original locations.
Failure to follow this instruction may result in engine damage.

NOTE: Lubricate the hydraulic lash adjuster with clean engine oil prior to installation.

Install the hydraulic lash adjusters in their original locations.

 Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

2. Lubricate the camshaft journals with clean engine oil.

3. Install the camshaft and the camshaft bearing caps in their original locations.
 Lubricate the camshaft bearing caps with clean engine oil.
 Lubricate the camshaft journals and lobes with clean engine oil.
 Position the camshaft bearing caps.
 Install the 13 bolts loosely.

4. Tighten the 13 bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).
5. Install the sprocket spacer, sprocket, washer and bolt.
1. Position the spacer, sprocket, washer and bolt.

2. Tighten the bolt in 2 stages:

 Stage 1: Tighten to 40 Nm (30 lb-ft).
 Stage 2: Tighten an additional 90 degrees.

6. Using the Valve Spring Compressor and Valve Stem Oil Seal Installer, install new valve seals.
7. Install the Valve Spring Compressor Spacer between the valve spring coils to protect the valve
stem seal from damage.

8. Using the Valve Spring Compressor, install the valve spring, the spring retainer and the valve
spring retainer keys.

9. Repeat the above steps and install the valve spring, the spring retainer and the valve spring
retainer keys.
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 07/14/2006

Piston

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Item Part Number Description

1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 6110 Piston

Disassembly

1. Remove the upper piston compression ring.

2. Remove the lower piston compression ring.

3. Remove the upper piston oil control segment ring.

4. Remove the piston oil control spacer.

5. Remove the lower piston oil control segment ring.

6. Remove the 2 piston pin retainers.

7. Remove the piston pin and remove the connecting rod from the piston.

Assembly

1. NOTE: The connecting rod must be installed into the piston with identification markings toward
the front.

Position the connecting rod in the piston.

2. NOTE: Lubricate the piston pin and retainers with clean engine oil.

Install the piston pin and the 2 piston pin retainers.

3. NOTE: Lubricate all the piston rings and the piston oil control spacer with clean engine oil.

Install the lower piston oil control segment ring.

4. Install the piston oil control spacer.

5. Install the upper piston oil control segment ring.

6. Install the lower piston compression ring.

7. Install the upper piston compression ring.

SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 12/12/2008

Intake Manifold Assembly

Material
Item Specification
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent

Fuel Rail and Fuel Injectors

Part
Item Number Description
1 N804394 Fuel rail stud bolt (4 required)
2 9F792 Fuel rail
3 — Fuel injector-to-fuel rail O-ring seal (8 required)
4 9F593 Fuel injector (8 required)
5 — Fuel injector-to-intake manifold O-ring seal (8
required)

EGR System Module and Throttle Body (TB)

Item Part Number Description

1 9D475 EGR system module vacuum connector
2 W701232 EGR system module bolt (2 required)
3 9D475 EGR system module
4 18465 PCV coolant hose
5 9E930 Throttle body (TB) gasket
6 9F991 TB
7 W500302 TB bolt (4 required)

Coolant Bypass Tube and Intake Manifold

Item Part Number Description
1 9J447 Coolant bypass tube
2 9461 Coolant bypass tube gaskets (2 required)
3 N807071 Coolant bypass tube bolt (6 required)
4 9424 Intake manifold

Disassembly

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when
working on or near any fuel-related component. Highly flammable mixtures are always present
and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Remove the 4 fuel rail stud bolts.

2. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will
make removal of the fuel rail easier.

Separate the fuel rail from the fuel injectors and remove the fuel rail.

3. Remove fuel injectors.

 Discard the O-ring seals.

4. Disconnect and remove the PCV coolant hose.

 5. Remove the 4 throttle body (TB) bolts and the TB.
 Discard the TB gasket.

6. Remove the EGR system module bolts and the EGR system module.
 Discard the EGR system module gasket.

7. Remove the 6 coolant bypass tube bolts.

8. Remove the coolant bypass tube.

 Discard the gaskets.

Assembly

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal
debris is found, install a new intake manifold. Failure to follow these instructions can
result in engine damage.

Position new coolant bypass tube gaskets, the coolant bypass tube and install the 6 bolts.

 Tighten to 10 Nm (89 lb-in).

2. Install a new EGR gasket (with the raised gasket surface facing the throttle body spacer) and
the EGR system module and the bolts.
 Tighten to 25 Nm (18 lb-ft).

3. Install a new TB gasket and the TB and tighten the 4 TB bolts in 2 stages.
 Stage 1: Tighten to 9 Nm (80 lb-in).
 Stage 2: Tighten an additional 90 degrees (1/4 turn).

4. Install the PCV coolant hose.

5. NOTE: Install new fuel injector O-ring seals on the fuel injectors.
 NOTE: Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation.

Using new O-ring seals, install the fuel injectors.

6. Install the fuel rail and the 4 fuel rail stud bolts.
 Tighten to 10 Nm (89 lb-in).
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
ASSEMBLY Procedure revision date: 09/08/2008

Engine

Special Tool(s)
Alignment Pins, Cylinder Head
303-1040

Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent

Compressor, Valve Spring

303-452 (T91P-6571-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Installer, Connecting Rod

303-442 (T93P-6136-A)
 Installer, Crankshaft Front Oil
Seal
303-635

Installer, Crankshaft Rear Oil

Seal
303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil

Seal
303-516 (T95P-6701-EH)

Installer, Crankshaft Rear Oil

Slinger
303-517 (T95P-6701-CH)

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Lifting Bracket, Engine

303-F047 (014-00073) or
equivalent

Material
Item Specification
Gasket Maker WSK-
TA-16 M2G348-A5
Hydraulic Chain Tensioner —
Retaining Clip
1L3Z-6P250-AA
Instant Gel Adhesive WSK-
TA-19 M2G402-A4
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent M97B51-A1
(bittered in US only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30
Threadlock 262 WSK-
TA-26 M2G351-A6

Engine — Upper End

 Part
Item Number Description
1 6766 Oil filler cap
2 6K817 Crankcase ventilation hose
3 6A666 PCV valve
4 6582 Valve cover — RH
5 6B280 Camshaft bearing cap
6 N811085 Camshaft sprocket bolt — RH
7 N806164 Camshaft sprocket bolt washer — RH
8 6256 Camshaft sprocket — RH
9 6265 Camshaft sprocket spacer — RH
10 6250 Camshaft — RH
11 14465 Coolant hose
12 W704925 Heater outlet tube stud
13 18663 Heater outlet tube
14 12405 Spark plug (8 required)
15 9430 Exhaust manifold — RH
16 9448 Exhaust manifold gasket — RH
17 6051 Cylinder head gasket — RH
18 6049 Cylinder head — RH
19 6758 Crankcase vent tube
20 N806183 Valve cover bolt (8 required)
21 W705782 Valve cover bolt
22 W705644 Valve cover stud (13 required)
23 6A505 Valve cover — LH
24 N807352 Camshaft bearing cap bolt (26 required)
25 6B280 Camshaft bearing cap
26 6C501 Hydraulic lash adjuster (16 required)
27 6529 Roller follower (16 required)
28 5618 Valve spring retainer key (32 required)
29 6514 Valve spring retainer (16 required)
30 6513 Valve spring (16 required)
31 6A517 Valve stem seal (16 required)
32 N811085 Camshaft sprocket bolt — LH
33 N806164 Camshaft sprocket bolt washer — LH
34 6256 Camshaft sprocket — LH
35 6265 Camshaft sprocket spacer — LH
36 6A274 Camshaft — LH
37 14B102 Cylinder head temperature (CHT) sensor jumper
harness
38 6G004 CHT sensor
39 6507 Intake valve (8 required)
40 6505 Exhaust valve (8 required)
41 W707747 Exhaust manifold stud (16 required)
42 9Y431 Exhaust manifold gasket (2 required)
43 9431 Exhaust manifold — LH
44 W701706 Exhaust manifold nut (16 required)
45 W704594 Cylinder head positioning dowel (4 required)
46 6083 Cylinder head gasket — LH
47 6050 Cylinder head — LH
48 6010 Cylinder block

Engine Induction System

Item Part Number Description
1 9E498 Vacuum harness
2 N811425 Fuel rail bolt (4 required)
3 9F792 Fuel rail
4 W704693 Thermostat housing bolt (2 required)
5 8594 Thermostat housing
6 N806807 Thermostat O-ring seal
7 8575 Thermostat
8 W711062 Ignition coil bolt (8 required)
9 9F593 Fuel injector (8 required)
10 12A366 Ignition coil (8 required)
11 9Y456 EGR system module
12 9S455 Intake manifold
13 W503301 Intake manifold bolt (9 required)
14 9E930 Throttle body (TB) gasket
15 9F991 TB assembly
16 W701592 TB bolt (4 required)
17 9439 Intake manifold gasket (2 required)
18 9D477 EGR system module-to-exhaust manifold tube

Engine — Lower End

Item Part Number Description
1 W500225 Knock sensor (KS) bolt
2 12A699 KS
3 6152 Lower compression ring (8 required)
4 6161 Inner oil control ring (8 required)
5 6150 Upper compression ring (8 required)
6 6159 Outer oil control rings (16 required)
7 6135 Piston pin (8 required)
8 6110 Piston (8 required)
9 6140 Piston pin retainer (16 required)
10 6200 Connecting rod assembly (8 required)
11 6211 Connecting rod bearing (16 required)
12 6A341 Crankshaft thrust washer — upper
13 6333 Crankshaft bearing — upper (5 required)
14 6303 Crankshaft
15 6K302 Crankshaft thrust washer — lower
16 6A338 Crankshaft bearing — lower (4 required)
17 6325 Crankshaft main bearing cap (5 required)
18 6325 Crankshaft main bearing cap bolt (9 required)
19 6325 Crankshaft main bearing cap side bolt (10 required)
20 N806201 Crankshaft key
21 N806155 Oil pump screen and pickup tube bolt (2 required)
22 6622 Oil pump screen and pickup tube
23 6K258 Crankshaft main bearing cap stud
24 N806180 Oil pump screen and pickup tube spacer
25 N605904 Oil pump screen and pickup tube bolt
26 6A636 Oil filter adapter gasket
27 6881 Oil filter adapter
28 6A636 Oil filter adapter bolt (4 required)
29 6A636 Oil filter
30 6710 Oil pan gasket
31 6675 Oil pan
32 W701605 Oil pan bolt (16 required)
33 6621 Oil pump bolt (3 required)
34 6621 Oil pump
35 N806168 Flexplate bolt (6 required)
36 6375 Flexplate
37 6310 Crankshaft oil slinger
38 6701 Crankshaft rear seal
39 N806155 Crankshaft rear oil seal retainer bolt (6 required)
40 6K318 Crankshaft rear oil seal retainer
41 6010 Cylinder block

Engine — Front End

Item Part Number Description
1 N806282 Coolant pump pulley bolt (4 required)
2 8A528 Coolant pump pulley
3 N806177 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 N808102 Accessory drive idler pulley bolt
6 19A216 Accessory drive idler pulley
7 N804178 Radio ignition interference capacitor nut
8 18801 Radio ignition interference capacitor
9 N806300 Engine front cover stud (5 required)
10 W701512 Crankshaft pulley bolt
11 N806165 Crankshaft pulley washer
12 6316 Crankshaft pulley
13 6700 Crankshaft front seal
14 N806177 Engine front cover bolt
15 N808586 Engine front cover stud
16 W706508 Engine front cover stud
17 W706447 Power steering pump bolts (2 required)
18 W710927 Power steering pump bolt
19 3A696 Power steering pump
20 N806155 Camshaft position (CMP) sensor bolt
21 6B288 CMP sensor
22 6C088 Engine front cover
23 12A227 Ignition pulse wheel
24 N806177 Timing chain tensioner bolt (4 required)
25 6L266 Timing chain tensioner — RH
26 6L253 Tensioner arm — RH
27 6268 Timing chain — RH
28 6M256 Timing chain guide — RH
29 6M269 Timing chain tensioner — LH
30 6L253 Tensioner arm — LH
31 N804958 Timing chain guide bolt
32 6B274 Timing chain guide — LH
33 N606527 Timing chain guide bolt
34 6268 Timing chain — LH
35 6306 Crankshaft sprocket
36 6010 Cylinder block

1. Record the main bearing code found on the front of the engine block.

2. Record the main bearing code found on the crankshaft counterweight.

3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings,
determine the required bearing grade for each main bearing.
 Read the first letter of the engine block main bearing code and the first letter of the
crankshaft main bearing code.
 Read down the column below the engine block main bearing code letter, and across the
row next to the crankshaft main bearing code letter, until the 2 intersect. This is the
required bearing grade for the number one crankshaft main bearing.
 As an example, if the engine block code letter is "F" and the crankshaft code letter is "D",
the correct bearing grade for this main bearing is a "2".
 Repeat this process for the remaining 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main
bearing.

5. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt,
paint and foreign material. Also, make sure the coolant and oil passages are clear.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean
engine oil.

6. NOTE: The upper thrust washers are shown for location purposes only. Do not install the
upper thrust washers until the crankshaft is installed. refer to the following 2 steps.

Install the crankshaft onto the upper crankshaft main bearings.

7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against
the crankshaft thrust surface).

Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the
No. 5 upper main bearing.

8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the
cylinder block prior to installing the bearing caps.

Install the rear main bearing cap.

9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with
clean engine oil. Locate the main bearing cap on the cylinder block, and keeping the cap as
square as possible, alternately draw the cap down evenly using the cap fasteners.

10. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages:
 Stage 1: Tighten to 40 Nm (30 lb-ft).
 Stage 2: Tighten an additional 90 degrees.

11. Tighten the jack screws against the cylinder block in the sequence shown, in 2 stages:
 Stage 1: Tighten to 5 Nm (44 lb-in).
  Stage 2: Tighten to 10 Nm (89 lb-in).

12. Install the side bolts and tighten them in the sequence shown.
 Tighten to 21 Nm (15 lb-ft).
13. Assemble the 8 pistons. For additional information, refer to Piston in this section.

14. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced
around the circumference of the piston.
15. Make sure the dimple in the piston faces the front of the engine.

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

NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one
connecting rod, rod cap and piston is shown.

NOTE: Make sure the identification marks on the piston and connecting rod face toward the
front of the engine.
 Use the special tools to install the piston and connecting rod with the upper connecting rod
bearing in place.

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

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod
Installer.

18. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly. Failure to follow these instructions may result in engine damage.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the
connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod, and install the new bolts loosely.

19. NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.

 Stage 1: Tighten to 43 Nm (32 lb-ft).

 Stage 2: Tighten an additional 105 degrees.
20. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
 Tighten to 10 Nm (89 lb-in).

21. Install the pickup tube spacer.

 Tighten to 25 Nm (18 lb-ft).
22. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-
ring can cause foam in the lubrication system, low oil pressure and severe engine
damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-
ring with clean engine oil.

Position the oil pump screen and pickup tube and install the bolts.

1. Tighten to 25 Nm (18 lb-ft).

2. Tighten to 10 Nm (89 lb-in).

23. NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts.

 Tighten to 25 Nm (18 lb-ft).

24. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block
surface and cylinder bore. Failure to follow these instructions may result in engine
damage.

NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry. Failure to follow these instructions may
result in engine damage.

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

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels
and install the cylinder head bolts loosely.
25. NOTE: RH shown, LH similar.

Tighten the bolts in 3 stages, in the sequence shown.

 Stage 1: Tighten to 40 Nm (30 lb-ft).

 Stage 2: Tighten an additional 90 degrees.
 Stage 3: Tighten an additional 90 degrees.
26. Install 8 new RH exhaust manifold-to-cylinder head studs.
 Tighten to 12 Nm (9 lb-ft).

27. Install the new RH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in
the sequence shown.
 Tighten to 25 Nm (18 lb-ft).
28. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or
foreign material prior to installation.

Position the RH engine support insulator and install the bolts.

 Apply threadlock to the bolt threads prior to installation.

 Tighten to 63 Nm (46 lb-ft).

29. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or
foreign material prior to installation.

Position the LH engine support insulator and install the bolts.

 Apply threadlock to the bolt threads prior to installation.

 Tighten to 63 Nm (46 lb-ft).
30. NOTICE: Timing chain procedures must be followed exactly or damage to valves and
pistons will result.

NOTICE: Prior to installation, inspect the tensioner-sealing bead 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.

Compress the tensioner plunger, using a vise.

31. Install a retaining clip on the tensioner to hold the plunger in during installation.
32. Remove the tensioner from the vise.

33. 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.

34. Install the crankshaft sprocket, making sure the flange faces forward.

35. Install the timing chain guides.

1. Position the LH timing chain guide.
 2. Install and tighten the LH bolts.

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts.

 Tighten to 10 Nm (89 lb-in).

36. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock
position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12
o'clock position.
37. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits
into the slot in the handle of the special tool.

Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.

38. Remove the Crankshaft Holding Tool.

39. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.
40. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

41. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain
tensioner.

 Tighten to 25 Nm (18 lb-ft).

42. Remove the retaining clip from the LH timing chain tensioner.

43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.

44. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain
tensioner.
  Tighten to 25 Nm (18 lb-ft).

46. Remove the retaining clip from the RH timing chain tensioner.

47. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft
sprockets and the camshaft sprocket.

48. Install the crankshaft sensor ring on the crankshaft.

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

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

50. NOTICE: The camshaft roller followers must be installed in their original locations.
Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller
follower.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Use the special tool to compress the valve springs and install the camshaft roller follower.
51. Repeat the previous 2 steps for each camshaft roller follower.

52. NOTICE: 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: If the engine front cover is not secured within 4 minutes, the sealant must be removed
and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover
before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface
and the oil pan-to-cylinder block surface, at the locations shown.
53. Install a new engine front cover gasket on the engine front cover. Position the engine front
cover onto the dowels. Install the fasteners finger-tight.

54. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 53
6 W706508 Stud Hex Shoulder Pilot, M8 x 1.25 x 50— M6 x 1 x 10
7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 — M6 x 1 x 86.35
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53
12 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
13 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
14 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
15 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1

55.

55. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the camshaft position (CMP) sensor and the bolt.

  Tighten to 10 Nm (89 lb-in).

56. NOTICE: Do not rotate the coolant pump housing once the coolant pump has been
positioned in the cylinder block. Damage to the O-ring seal will occur.

Install the coolant pump.

1. Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal
onto the coolant pump.

2. Position the coolant pump into the engine block.

3. Install the bolts.

 Tighten to 25 Nm (18 lb-ft).

57. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
58. Using the special tools, install a new crankshaft front seal into the engine front cover.

59. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

60. Use the special tool to install the crankshaft pulley.

61. Tighten the new crankshaft pulley bolt in 4 stages.
 Stage 1: Tighten to 90 Nm (66 lb-ft).
 Stage 2: Loosen 360 degrees.
 Stage 3: Tighten to 50 Nm (37 lb-ft).
 Stage 4: Tighten an additional 90 degrees.

62. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
 Tighten to 25 Nm (18 lb-ft).

63. Position the accessory drive belt tensioner and install the 3 bolts.
  Tighten to 25 Nm (18 lb-ft).

64. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools cause scratches and gouges
which make leak paths.

Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.

65. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the
new valve cover gasket.

66. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder
head.
67. Position the LH valve cover and gasket and tighten the fasteners in the sequence shown to 10
Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705782 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
7 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

68.
68. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the
new valve cover gasket.

69. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder
head.
70. Position the RH valve cover and gasket and tighten the fasteners in the sequence shown to 10
Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
7 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

71.
71. NOTE: Lubricate the O-ring seal with clean engine oil.

Install the oil level indicator tube.

 Install a new O-ring seal on the oil level indicator tube.

 Install the oil level indicator tube.
 Install the bolt.
 Tighten to 10 Nm (89 lb-in).

72. Install 8 new LH exhaust manifold-to-cylinder head studs.

  Tighten to 12 Nm (9 lb-ft).

73. Install the new LH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in
the sequence shown.
 Tighten to 25 Nm (18 lb-ft).

74. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the nuts.

 Tighten to 25 Nm (18 lb-ft).

75. NOTE: Do not reuse the O-ring seal.

NOTE: Lubricate the O-ring seal with clean engine coolant.

Slide the heater outlet tube forward with the new O-ring seal into the cylinder block.

76. Install the heater outlet tube studs.

 Tighten to 25 Nm (18 lb-ft).

77. Connect the coolant hoses to the heater outlet tube.

78. Position the electrical harness on the engine assembly and connect the engine wiring harness
retainers to the valve cover studs.

79. Connect the RH radio ignition interference capacitor electrical connector.

80. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT)
sensor electrical connectors.

81. Install the insert into the LH cylinder head.

82. Connect the engine oil pressure (EOP) switch electrical connector.

83. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
84. Connect the CMP sensor electrical connectors.

85. Install the special tool.

86. Using a suitable floor crane, remove the engine from the engine stand.

87. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the aluminum retainer plate. These tools cause scratches and
gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old
sealant.
 Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal
retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.

88. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker
must be applied to the rear crankshaft seal retainer plate mating surface on the engine block.

Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the
engine block.

89. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

90. Tighten the bolts in the sequence shown.

 Tighten to 10 Nm (89 lb-in).
91. NOTICE: 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.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.

92. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block
sealing surface.

93. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
94. Install the oil pan gasket and the oil pan and loosely install the bolts.

95. Tighten the bolts in 3 stages, in the sequence shown.

 Stage 1: Tighten to 2 Nm (18 lb-in).
 Stage 2: Tighten to 20 Nm (15 lb-ft).
 Stage 3: Tighten an additional 60 degrees.
96. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the special tools, install a new crankshaft rear seal.

97. Using the special tools, install a new crankshaft rear oil slinger.
98. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
 Stage 1: Tighten to 20 Nm (15 lb-ft).
 Stage 2: Tighten to 80 Nm (59 lb-ft).
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
INSTALLATION Procedure revision date: 12/12/2008

Engine

Special Tool(s)
Installer, Power Steering Pump
Pulley
211-185 (T91P-3A733-A)

Installer Set, Teflon® Seal

211-D027 (D90P-3517-A) or
equivalent

Lifting Bracket, Engine

303-F047 (014-00073)

Material
Item Specification
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent M97B51-A1
(bittered in US only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Threadlock 262 WSK-
TA-26 M2G351-A6

1. NOTE: Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign
material prior to engine installation.
 NOTE: Position the engine assembly forward to connect the RH heated exhaust gas oxygen
sensor (HO2S) electrical connector and the transmission harness retainers at the rear of the
cylinder head.

Using a suitable floor crane, position the engine assembly into the vehicle.

2. Apply threadlock to the bolt threads and install the LH engine support insulator bolt.
 Tighten to 350 Nm (258 lb-ft).

3. NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating
surface are free of foreign material and corrosion before installation. Install a new washer.

Apply threadlock to the bolt threads and install the RH engine support insulator washer and
nuts.

 Tighten to 250 Nm (184 lb-ft).

4. Install the 6 transmission-to-engine bolts.

 Tighten to 60 Nm (44 lb-ft).
5. Connect the shift cable and install the shift cable bracket and the bolts.
 Tighten to 25 Nm (18 lb-ft).

6. Connect the LH HO2S electrical connector and attach the electrical connector retainer.

7. NOTE: Lubricate the O-ring seals with clean transmission fluid.

Position the transmission fluid filler tube and install the bolt.

 Tighten to 10 Nm (89 lb-in).

8. Install the 4 exhaust manifold-to-catalytic converter nuts.
 Tighten to 40 Nm (30 lb-ft).

9. Install the torque converter-to-flexplate nuts.

 Tighten to 35 Nm (26 lb-ft).

10. Install the cylinder block opening cover.

11. Install the flexplate inspection cover.
 Tighten to 34 Nm (25 lb-ft).

12. Install a new oil filter.

13. Install the drain plug.

 Tighten to 14 Nm (10 lb-ft).
14. Attach the starter electrical harness support to the cylinder block.

15. If equipped, connect the block heater electrical connector.

16. Position the A/C compressor and install the bolts.

 Tighten to 25 Nm (18 lb-ft).
17. Install the starter. For additional information, refer to Section 303-06 .

18. Position the power steering reservoir and install the 2 lower bolts.
 Tighten to 25 Nm (18 lb-ft).

19. Position the power steering pump and install the bolts.
 Tighten to 25 Nm (18 lb-ft).

20. Using the special tool, install a new O-ring seal on the pressure line fitting.
21. Connect the power steering pressure tube.
 Tighten to 65 Nm (48 lb-ft).

22. Position the power steering pressure tube support bracket and install the nut.
 Tighten to 12 Nm (9 lb-ft).

23. NOTE: If the pulley has been removed and installed twice, install a new power steering pump
pulley.

Using the special tool, install the power steering pump pulley.
  Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint
marks, install a new pulley. If there is one paint mark or none at all, use a pencil to
mark the web area of the pulley near the hub.

24. If equipped, install the transmission cooler tube support bracket and nut.
 Tighten to 10 Nm (89 lb-in).

25. Connect the degas bottle coolant hose.

26. Connect the A/C compressor electrical connector.

27. Connect the crankshaft position (CKP) sensor electrical connector and the harness retainer.

28. Position the A/C manifold and tube assembly support bracket and install the nut.
 Tighten to 10 Nm (89 lb-in).

29. Remove the special tool.

30. Install the upper transmission-to-engine bolts.
 Tighten to 60 Nm (44 lb-ft).

31. Connect the heater coolant hose.

32. Install the ground strap and the bolt and connect the electrical connector.
 Tighten to 10 Nm (89 lb-in).
33. Install the cowl panel extension.

34. Attach the wiring harness and the windshield washer hose to the cowl panel extension.

35. Install the cowl panel grille. For additional information, refer to Section 501-02 .

36. Install the PCM and the support bracket. For additional information, refer to Section 303-14 .

37. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal
 debris is found, install a new intake manifold. Failure to follow these instructions can
result in engine damage.

Install the intake manifold. For additional information, refer to Intake Manifold in this section.

38. Install the radiator. For additional information, refer to Section 303-03 .

39. Install the hood and the 4 bolts.

 Tighten to 30 Nm (22 lb-ft).

40. Fill the engine with clean engine oil.

41. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
SECTION 303-01B: Engine — 4.6L (2V) 2007 F-150/Mark LT Workshop Manual
INSTALLATION Procedure revision date: 09/08/2008

Cylinder Head

Special Tool(s)
Alignment Pins, Cylinder Head
303-1040

Compressor, Valve Spring

303-452 (T91P-6571-AH)

Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Installer, Crankshaft Front Oil

Seal
303-635

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
 Installer, Front Cover Oil Seal
303-335 (T88T-6701-A)

Lifting Bracket, Engine

303-F047 (014-00073) or
equivalent

Material
Item Specification
Hydraulic Chain Tensioner —
Retaining Clip
1L3Z-6P250-AA
Instant Gel Adhesive WSK-
TA-19 M2G402-A4
Motorcraft Metal Surface Prep —
ZC-31-A
Motorcraft Premium Gold Engine WSS-
Coolant with Bittering Agent M97B51-A1
(bittered in US only)
VC-7-B (US); CVC-7-A (Canada);
or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium WSS-
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Silicone Gasket Remover —
ZC-30
Threadlock 262 WSK-
TA-26 M2G351-A6

All cylinder heads

1. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block
surface and cylinder bore. Failure to follow these instructions may result in engine
damage.
 NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry. Failure to follow these instructions may
result in engine damage.

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

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels
and install the cylinder head bolts loosely.

LH cylinder head

2. NOTE: Make sure to tighten the bolts in sequence in 3 stages.

Tighten the LH bolts in the sequence shown.

 Stage 1: Tighten to 40 Nm (30 lb-ft).

 Stage 2: Tighten an additional 90 degrees.
 Stage 3: Tighten an additional 90 degrees.
RH cylinder head

3. NOTE: Make sure to tighten the bolts in the following 3 stages.

Tighten the RH bolts in the sequence shown.

 Stage 1: Tighten to 40 Nm (30 lb-ft).

 Stage 2: Tighten an additional 90 degrees.
 Stage 3: Tighten an additional 90 degrees.
All cylinder heads

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

NOTICE: Prior to installation, inspect the tensioner-sealing bead 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.

Compress the tensioner plunger, using a vise.

5. Install a retaining clip on the tensioner to hold the plunger in during installation.

6. Remove the tensioner from the vise.

7. 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.

8. Install the crankshaft sprocket, making sure the flange faces forward.
9. Install the timing chain guides.
1. Position the LH timing chain guide.

2. Install and tighten the LH bolts.

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts.

 Tighten to 10 Nm (89 lb-in).

10. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock
position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12
o'clock position.

11. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits
into the slot in the handle of the special tool.

Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.

12. Remove the Crankshaft Holding Tool.

13. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.
14. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

15. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain
tensioner.

 Tighten to 25 Nm (18 lb-ft).

16. Remove the retaining clip from the LH timing chain tensioner.

17. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.

18. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the
timing marks on the sprocket.

19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain
tensioner.
  Tighten to 25 Nm (18 lb-ft).

20. Remove the retaining clip from the RH timing chain tensioner.

21. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft
sprockets and the camshaft sprocket.

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

Install the special tool between the valve spring coils to prevent valve stem seal damage.
23. NOTICE: The camshaft roller followers must be installed in their original locations.
Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Engine in this section.

NOTE: It may be necessary to push the valve down while compressing the spring.

NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller
follower.

NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.

Use the special tool to compress the valve springs, and install the camshaft roller follower.

24. Repeat the previous 2 steps for each of the camshaft roller followers.

25. Install the crankshaft sensor ring on the crankshaft.

26. NOTICE: 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: If the engine front cover is not secured within 4 minutes, the sealant must be removed
and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover
before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface
and the oil pan-to-cylinder block surface, at the locations shown.
27. Install a new engine front cover gasket on the engine front cover. Position the engine front
cover. Install the fasteners finger-tight.

28. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 53
6 W706508 Stud Hex Shoulder Pilot, M8 x 1.25 x 50— M6 x 1 x 10
7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 — M6 x 1 x 86.35
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53
12 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
13 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
14 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
15 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1

29.

29. Install the camshaft position (CMP) sensor and the bolt.
 Lubricate the O-ring seal with clean engine oil prior to installation.
 Tighten to 10 Nm (89 lb-in).
30. Install the crankshaft position (CKP) sensor and the bolt.
 Lubricate the O-ring seal with clean engine oil prior to installation.
 Tighten to 10 Nm (89 lb-in).

31. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

32. Use the special tools to install a new crankshaft front seal into the engine front cover.
33. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

34. Use the special tool to install the crankshaft pulley.

35. Tighten the new crankshaft pulley bolt in 4 stages.

  Stage 1: Tighten to 90 Nm (66 lb-ft).
 Stage 2: Loosen 360 degrees.
 Stage 3: Tighten to 50 Nm (37 lb-ft).
 Stage 4: Tighten an additional 90 degrees.

36. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
 Tighten to 25 Nm (18 lb-ft).

37. Position the accessory drive belt tensioner and install the bolts.
 Tighten to 25 Nm (18 lb-ft).
38. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools cause scratches and gouges
which make leak paths.

Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.

39. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the
new valve cover gasket.

40. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder
head.

41. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
42. Position the RH valve cover and gasket and tighten the fasteners in the sequence shown to 10
Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
7 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

43.
43. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools cause scratches and gouges
which make leak paths.

Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.

44. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the
new valve cover gasket.
45. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder
head.

46. Position the LH valve cover and gasket and tighten the fasteners in the sequence shown to 10
Nm (89 lb-in).

Item Part Number Description

1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
4 W705782 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
6 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
7 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5

47.
 47. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors.

 Tighten to 25 Nm (18 lb-ft).

LH cylinder head

48. NOTE: Lubricate the O-ring seal with clean engine oil.
 Install the oil level indicator tube.

 Install a new O-ring seal on the oil level indicator tube.

 Install the oil level indicator tube.
 Install the bolt.
 Tighten to 10 Nm (89 lb-in).

49. Install 8 new LH exhaust manifold-to-cylinder head studs.

 Tighten to 12 Nm (9 lb-ft).

50. Install the new LH exhaust manifold and the exhaust manifold gasket. Tighten the new nuts in
the sequence shown.
 Tighten to 25 Nm (18 lb-ft).
 51. Install the insert into the LH cylinder head.

RH cylinder head

52. Install 8 new RH exhaust manifold-to-cylinder head studs.

 Tighten to 12 Nm (9 lb-ft).
53. Install the new RH exhaust manifold gaskets and the exhaust manifold. Tighten the new nuts
in the sequence shown.
 Tighten to 25 Nm (18 lb-ft).

54. Slide the heater outlet tube forward with a new O-ring seal into the cylinder block.
 Lubricate the O-ring seal with engine coolant.

55. Install the heater outlet tube studs.

 Tighten to 25 Nm (18 lb-ft).
 56. Connect the coolant hoses to the heater outlet tube.

All cylinder heads

57. Position the electrical harness onto the engine assembly and connect the engine wiring
harness retainers to the valve cover studs.

58. Connect the RH radio ignition interference capacitor electrical connector.

59. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT)
sensor electrical connectors.

60. Position the upper radiator hose bracket and install the nut.
 Tighten to 10 Nm (89 lb-in).

61. Connect the CMP sensor electrical connectors.

62. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
63. Connect the engine oil pressure (EOP) switch electrical connector.

64. Connect the CKP sensor electrical connector.

65. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or
foreign material prior to installation.

Position the RH engine support insulator and install the 3 bolts.

 Apply threadlock to the bolt threads prior to installation.

  Tighten to 63 Nm (46 lb-ft).

66. Install the special tool.

67. Using a suitable floor crane, remove the engine from the engine stand.

68. Install the spacer plate.

69. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
 Stage 1: Tighten to 20 Nm (15 lb-ft).
  Stage 2: Tighten to 80 Nm (59 lb-ft).

70. Install the engine. For additional information, refer to Engine in this section.