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Oil Pan: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL ENGINES 

    CAUTION: 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 the O-ring with clean engine oil.
    Fig 1: Installing Oil Pump Screen
    G01536500Courtesy of FORD MOTOR CO.
  1. Install the oil pump screen and pickup tube.
    2. NOTE: If not secured within four 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.
    Fig 2: Applying Bead Of Silicone Gasket And Sealant
    G01536501Courtesy of FORD MOTOR CO.
  2. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
    3. NOTE: If not secured within four 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.
    Fig 3: Applying Bead Of Silicone Gasket And Sealant
    G01536502Courtesy of FORD MOTOR CO.
  3. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
  4. Tighten the bolts in three 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 90 degrees.
    Fig 4: Identifying Bolts Tightening Sequence
    G01536503Courtesy of FORD MOTOR CO.
  5. Install a new oil filter.
    Fig 5: Installing Oil Filter
    G01536504Courtesy of FORD MOTOR CO.
  6. Lower the vehicle.
  7. Lower the engine and remove the special tools.
  8. Raise the vehicle.
    9. NOTE: RH is shown; LH is similar.
    Fig 6: Installing Engine Mount Nuts
    G01536505Courtesy of FORD MOTOR CO.
  9. Install the four engine mount nuts.
  10. Install the flexplate inspection plate.
    Fig 7: Installing Flexplate Inspection Plate
    G01536506Courtesy of FORD MOTOR CO.
  11. Lower the vehicle.
  12. Install the transmission-to-engine bolts.
    Fig 8: Installing Transmission-To-Engine Bolts
    G01536507Courtesy of FORD MOTOR CO.
    13. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.
  13. Insert the heater outlet tube over the new seals.

    14. ROMEO ENGINES (4.6L) 

    Fig 9: Inserting Heater Outlet Tube
    G01536508Courtesy of FORD MOTOR CO.
  14. Install the heater outlet tube studs.
    Fig 10: Installing Heater Outlet Tube Studs
    G01536509Courtesy of FORD MOTOR CO.
  15. Position the transmission fluid filler tube and install the nut.
    Fig 11: Installing Transmission Fluid Filler Tube
    G01536510Courtesy of FORD MOTOR CO.

    16. WINDSOR ENGINE (5.4L) 

  16. Install the heater outlet tube studs.
    Fig 12: Installing Heater Outlet Tube Studs
    G01536511Courtesy of FORD MOTOR CO.
  17. Position the transmission fluid filler tube and install the nut.
    Fig 13: Installing Transmission Fluid Filler Tube
    G01536512Courtesy of FORD MOTOR CO.

    ALL ENGINES 

  18. Connect the hose to the heater outlet tube.
    Fig 14: Connecting Hose To Heater Outlet Tube
    G01536513Courtesy of FORD MOTOR CO.
  19. Install the wiring retainers in the heater outlet tube bracket.
    1. Install the knock sensor electrical connector retainer.
    2. Install the engine harness routing clip retainer.
    Fig 15: Installing Engine Harness Routing Clip Retainer
    G01536514Courtesy of FORD MOTOR CO.
  20. Install the retainers and the shield.
    Fig 16: Installing Retainers And Shield
    G01536515Courtesy of FORD MOTOR CO.
  21. Install the fan shroud and the engine cooling fan. For additional information, refer to ENGINE COOLING .
  22. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD - 4.6L  or INTAKE MANIFOLD - 5.4L .
    23. CAUTION: The oil pump must be primed prior to starting the engine.
  23. Fill the engine with clean engine oil.
  24. Start the engine and check for leaks.
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