303-01B-i

Engine 4.6L (3V)

303-01B-i

SECTION 303-01B Engine 4.6L (3V)

CONTENTS IN-VEHICLE REPAIR Engine Front Cover PAGE

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303-01B-2

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-2
IN-VEHICLE REPAIR

Engine 4.6L (3V)

303-01B-2

Engine Front Cover

Special Tool(s)
3 Jaw Puller 303-D121

Installer, Crankshaft Front Seal 303-335 (T88T-6701-A)

Installer, Crankshaft Front Seal 303-635

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

Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)

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

WSE-M4G323-A4

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-3
IN-VEHICLE REPAIR (Continued)

Engine 4.6L (3V)

303-01B-3

Accessory Drive Components and Wiring Harness Brackets

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part Number W701512 N806165 8316 6700 7R081 BK0001728 N805320 81396 W520101 10A779 N805403 10W652 14A163 W707225

Description Crankshaft pulley bolt Crankshaft pulley washer Crankshaft pulley Crankshaft front seal Transmission cooler tube bracket nut Transmission cooler tube bracket (part of 7H420) Power Steering Pressure (PSP) hose bracket nut PSP hose bracket (part of 3A719) Battery cable bracket nut Battery cable bracket (part of 14A280) Battery cable bracket nuts (2 required) Battery cable bracket (part of 14A280) Wiring harness retainer (part of 12B637) Power steering pump bolt (3 required) 2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-4
IN-VEHICLE REPAIR (Continued)
Item 15 16 17 Engine Front Cover Part Number 3A696 N806282 8A528

Engine 4.6L (3V)

303-01B-4

Description Power steering pump Coolant pump pulley bolt (4 required) Coolant pump pulley

Item 1 2 3 4 5 6 7 8

Part Number 14A464 N804758 14W163 N804758 18801 14A464 N804758 18801

Description LH Camshaft Position (CMP) sensor electrical connector (part of 12B637) Cooling fan wiring harness bracket nut Cooling fan wiring harness bracket LH radio interference capacitor nut LH radio interference capacitor RH CMP sensor electrical connector (part of 12B637) RH radio interference capacitor nut RH radio interference capacitor

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-5
IN-VEHICLE REPAIR (Continued)
Item 9 10 11 12 13 14 15 16 Part Number 14A464 W701605 W706508 N806177 N808294 N806300 6D080 6D081

Engine 4.6L (3V)

303-01B-5

Description Crankshaft Position (CKP) sensor electrical connector (part of 12B637) Oil pan-to-engine front cover bolts (4 required) Engine front cover stud bolt Engine front cover bolt (8 required) Engine front cover bolt Engine front cover stud bolt (5 required) Engine front cover Engine front cover gasket (3 required)

Removal
1. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. Remove the drain plug and drain the engine oil. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. To install, tighten to 23 Nm (17 lb-ft).

Remove the cooling fan shroud. For additional information, refer to Section 303-03. Remove the RH side idler pulley. For additional information, refer to Section 303-05. Remove the RH valve cover. For additional information, refer to Valve Cover RH in this section. Remove the LH valve cover. For additional information, refer to Valve Cover LH in this section. Remove the nut and position the RH radio interference capacitor aside. Disconnect the RH Camshaft Position (CMP) sensor electrical connector. Remove the nut and the cooling fan wiring harness bracket. Remove the nut and position the LH radio interference capacitor aside. Disconnect the LH CMP sensor electrical connector. Remove the 4 bolts and the coolant pump pulley. Remove the 2 nuts and detach the battery cable bracket from the power steering pump stud bolts. Detach the wiring harness retainer from the power steering pump stud bolt. Remove the 3 stud bolts and position the power steering pump aside. Support the power steering pump with a length of mechanic's wire.

16. 17. 18. 19. 20.

Remove the nut and detach the Power Steering Pressure (PSP) hose bracket from the battery cable bracket. Remove the nut and detach the battery cable bracket from the engine front cover. Remove the nut and detach the transmission cooler tube bracket from the engine front cover. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.

21.

Using the 3 Jaw Puller, remove the crankshaft pulley.

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-6
IN-VEHICLE REPAIR (Continued)
22.

Engine 4.6L (3V)

303-01B-6

Using the Crankshaft Front Seal Remover, remove the crankshaft front seal. Discard the crankshaft front seal.

23. 24. 25.

Remove the 4 oil pan-to-engine front cover bolts. Remove the 15 engine front cover bolts and stud bolts. Remove the engine front cover from the engine front cover-to-cylinder block dowel. Remove and discard the engine front cover 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 with silicone gasket remover, metal surface prep and a plastic scraping tool. Follow the directions on the packaging. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block mating surface and the oil pan-to-cylinder block mating surface at the locations shown.

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-7
IN-VEHICLE REPAIR (Continued)

Engine 4.6L (3V)

303-01B-7

3.

Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.

4.

Tighten the 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-8
IN-VEHICLE REPAIR (Continued)

Engine 4.6L (3V)

303-01B-8

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5.

Part Number N806177 N806177 N806177 N806177 N806177 W706508 N806300 N806177 N806177 N806177 N808294 N806300 N806300 N806300 N806300

Description Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Stud, Hex Shoulder Pilot, M8 x 1.25 x 50 - M6 x 1 x 10 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 Bolt, Hex Head Pilot, M8 x 1.25 x 53 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1 Stud, Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1

Loosely install the 4 oil pan-to-engine front cover bolts, then tighten the bolts in 2 stages in the sequence shown. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-9
IN-VEHICLE REPAIR (Continued)

Engine 4.6L (3V)

303-01B-9

6.

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

7.

Using the 2 Crankshaft Front Seal Installers and the Crankshaft Vibration Damper Installer, install the crankshaft front seal.

8.

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. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket sealant to the Woodruff key slot in the crankshaft pulley.

9.

Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009

303-01B-10
IN-VEHICLE REPAIR (Continued)

Engine 4.6L (3V)

303-01B-10

10.

Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.

11. 12.

Connect the CKP sensor electrical connector. Attach the transmission cooler tube bracket to the engine front cover and install the nut. Tighten to 12 Nm (106 lb-in).

13.

Attach the battery cable bracket to the front cover and install the nut. Tighten to 10 Nm (89 lb-in).

14.

Attach the PSP hose bracket to the battery cable bracket and install the nut. Tighten to 10 Nm (89 lb-in).

15.

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

16. 17.

Attach the wiring harness retainer to the power steering pump stud bolt. Position the battery cable bracket on the power steering pump stud bolts and install the nuts. Tighten to 10 Nm (89 lb-in).

18.

Position the coolant pump pulley and install the bolts. Tighten the bolts to 25 Nm (18 lb-ft).

19. 20.

Connect the LH CMP sensor electrical connector. Position the LH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).

21. 22. 23.

Position the cooling fan wiring harness bracket and install the nut. Connect the RH CMP sensor electrical connector. Position the RH radio interference capacitor and install the nut. Tighten to 25 Nm (18 lb-ft).

24. 25. 26. 27. 28.

Install the LH valve cover. For additional information, refer to Valve Cover LH in this section. Install the RH valve cover. For additional information, refer to Valve Cover RH in this section. Install the RH side idler pulley. For additional information, refer to Section 303-05. Install the cooling fan shroud. For additional information, refer to Section 303-03. Fill the engine with clean engine oil.

2010 Explorer, Mountaineer, Explorer Sport Trac, 11/2009