Installation

1. Clean oil pan. Inspect for damage and replace as required.
2. Clean sealing surfaces of engine front cover (6019), crankshaft rear oil seal and retainer (6K301) and cylinder blocks (6010).
3. Inspect oil pump screen cover and tube and replace if necessary.
4. If removed, position oil pump screen cover and tube on oil pump and hand start two bolts.
5. Install bolt retaining oil pump screen cover and tube to main bearing stud spacer hand-tight.





6. Tighten oil pump screen cover and tube-to-oil pump bolts to 8-12 Nm (71-106 inch lbs.). Tighten oil pump screen cover and tube-to-main bearing stud spacer bolt to 20-30 Nm (15-22 ft. lbs.).
7. Position new oil pan gasket (6710) on oil pan.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residue that may interfere with the sealer's ability to adhere.





8. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 where engine front cover meets cylinder blocks and crankshaft rear oil seal retainer meets cylinder blocks. Position oil pan on engine and install retaining bolts. Tighten bolts in sequence shown to 20 Nm (14 ft. lbs.) then an additional 60 degrees) in no more than four minutes after applying sealer.
9. Position screw-type jackstand and block of wood under oil pan, rearward of oil pan drain hole.





10. Raise engine enough to remove wood blocks.
11. Lower engine onto front engine support insulator and remove jack.
12. Install front engine support insulator through bolts and tighten to 20-30 Nm (15-22 ft. lbs.).

NOTE: Two through bolts required on LH front engine support insulator and one through bolt required on RH front engine support insulator.

13. Position EGR valve to exhaust manifold tube in vehicle and connect to exhaust manifold. Tighten line nut to 35-45 Nm (26-33 ft. lbs.).

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

14. Remove wire and position exhaust system to both exhaust manifolds. Install four nuts and tighten to 27-41 Nm (20-30 ft. lbs.).

NOTE: Make sure exhaust system clears No.3 crossmember. Adjust as necessary.

15. Replace oil bypass filter (6714).
16. Lower vehicle.
17. Install bolt retaining RH front engine support insulator to front sub-frame. Tighten to 20-30 Nm (15-22 ft. lbs.).
18. Install a new EGR valve gasket (9D476) on EGR valve and position on throttle body adapter.
19. Install two bolts retaining EGR valve to intake manifold (9424) and tighten to 20-30 Nm (15-22 ft. lbs.).





20. Tighten EGR valve-to-exhaust manifold tube nut at EGR valve to 35-45 Nm (26-33 ft. lbs.).
21. Install heater blower motor switch resistor with two retaining screws.
22. Install EGR backpressure transducer bracket and heater water hose. Install upper bolt and lower stud bolt. Tighten to 20-30 Nm (15-22 ft. lbs.).
23. Connect vacuum hoses to EGR valve and EGR backpressure transducer hoses to EGR valve to exhaust manifold tube.
24. Connect heater water hose.
25. Connect 42-pin connector and 8-pin connector.
26. Connect A/C compressor to condenser discharge line (19972) to A/C compressor and install bolt retaining hose to RH ignition coil bracket.
27. Install upper radiator hose.
28. Connect fuel lines. See Powertrain Management.
29. Install windshield wiper governor and retaining bracket.
30. Fill crankcase to specified level on oil level dipstick (6750) with engine oil meeting Ford specification WSS-M2C153-F.
31. Evacuate and recharge air conditioning. See Heating and Air Conditioning.
32. Install cooling fan motor/fan blade and fan shroud assembly and fill engine cooling system.
33. Connect battery ground cable.
34. Install air cleaner outlet tube.
35. Start engine and check for leaks.