Installation

Oil Pan

Special Tool(s)








Material





CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

All vehicles

1. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

Apply a 3 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the sealing surface of the oil pan.
^ Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.





2. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

Install the oil pan and bolts 10, 11, 13 and 14.
^ Tighten in the sequence shown to 3 Nm (27 lb-in).
^ Loosen the bolts 180 degrees.





3. Align the oil pan to the cylinder block and A/C compressor.
^ Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.





4. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).





5. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
^ Tighten the large bolts (1-14) to 20 Nm (15 lb-ft).
^ Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).





6. Install the A/C compressor mounting stud and nut.
^ Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).





7. Install the special tools.





8. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.





9. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 17, 18, 19 and 20.
^ Tighten in sequence shown to 3 Nm (27 lb-in).





10. Remove the special tools (alignment pins).

11. NOTE: Do not tighten the bolts at this time.

Install the engine mount bracket and the 3 bolts.





12. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
^ Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).





13. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).





14. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).





15. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

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





16. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the special tools, install the crankshaft pulley.





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





18. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, variable camshaft timing (VCT) seal installation similar.

Using the special tools, install new VCT solenoid and/or spark plug tube seals.





19. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.





20. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





21. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened 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. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.





22. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





23. NOTE: LH shown, RH similar.

Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-in).





24. Install the LH cylinder block drain plug.
^ Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.





25. Install the RH cylinder block drain plug or, if equipped, the block heater.
^ Tighten to 40 Nm (30 lb-ft).





Front wheel drive (FWD) vehicles
26. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).





27. Using a new gasket, install the RH catalytic converter and 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).





All vehicles
28. Install the 4 new LH catalytic converter-to-exhaust manifold studs.
^ Tighten to 25 Nm (18 lb-ft).





29. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
^ Tighten to 40 Nm (30 lb-ft).





30. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).





31. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).





32. Install the power steering pressure (PSP) tube bracket bolt.
^ Tighten to 10 Nm (89 lb-in).





33. Install the PSP bracket and nut to the RH valve cover stud bolt.
^ Tighten to 7 Nm (62 lb-in).





34. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
35. Connect the 3 LH coil-on-plug electrical connectors.





36. Connect the LH camshaft VCT solenoid electrical connector.





37. Connect the LH catalyst monitor sensor electrical connector.





38. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
39. Connect the RH heated oxygen sensor (HO2S) electrical connector.





40. If equipped, connect the heated PCV valve electrical connector.





41. Connect the 3 RH coil-on-plug electrical connectors.





42. Connect the RH VCT solenoid electrical connector.





FWD vehicles
43. Connect the RH catalyst monitor sensor electrical connector.





All vehicles
44. Connect the PSP switch electrical connector.





45. Connect the fuel efficient power steering system solenoid electrical connector.





46. Using new gaskets, install the upper intake manifold and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).





47. Install the fuel tube bracket bolt to the upper intake manifold.
^ Tighten to 6 Nm (53 lb-in).





48. Install the upper intake manifold short support bracket bolt.
^ Tighten to 10 Nm (89 lb-in).





49. If equipped, install the upper intake manifold long support bracket bolt.
^ Tighten to 10 Nm (89 lb-in).





50. Attach the wiring harness retainers to the upper intake manifold.





51. Connect the throttle body (TB) electrical connector.





52. Connect the PCV hose to the PCV valve.





53. If equipped, connect the heated PCV electrical connector.





54. If equipped, connect the block heater electrical connector and install the heat shield.
^ Attach all the engine block heater wiring harness retainer.





55. Using the special tools, remove the engine from the stand.





56. Install the crankshaft sensor ring.





57. Install the flexplate and the 8 bolts.
^ Tighten to 80 Nm (59 lb-ft).





58. Install the engine in the vehicle.