Engine - 5.4L

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool(s) (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tool(s) (2 Of 2)

Courtesy of FORD MOTOR CO.

MATERIAL 

1. Record the main bearing code found on the front of the engine block.
   Fig 3: Identifying Main Bearing Code On Front Of Engine Block

   Courtesy of FORD MOTOR CO.
2. Record the main bearing code found on the back of the crankshaft.
   Fig 4: Identifying Main Bearing Code On Crankshaft

   Courtesy of FORD MOTOR CO.
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 two 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 four main bearings.
   Fig 5: Bearing Select Fit Chart (1 Of 2)

   Courtesy of FORD MOTOR CO.
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.
   Fig 6: Bearing Select Fit Chart (2 Of 2)

   Courtesy of FORD MOTOR CO.
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.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
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 two steps.
Fig 7: Installing Crankshaft Onto Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
6. Install the crankshaft onto the upper crankshaft main bearings.
NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
Fig 8: Installing Rear Crankshaft Upper Thrust Washer At Back Of No. 5 Main Boss
Courtesy of FORD MOTOR CO.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
NOTE: If equipped, the oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
Fig 9: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss
Courtesy of FORD MOTOR CO.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE: If equipped, the oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
Fig 10: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap
Courtesy of FORD MOTOR CO.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. 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.
11. Install the dowel pins so the flat sides face the crankshaft.
    Fig 11: Installing Dowel Pins

    Courtesy of FORD MOTOR CO.
12. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
    • Tighten to 40 Nm (30 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 12: Main Bearing Cap Fastener Tightening Sequence

    Courtesy of FORD MOTOR CO.
13. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 30 Nm (22 lb-ft)
    • Tighten an additional 90 degrees.
    Fig 13: Installing Side Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The next three steps are for all eight 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.
Fig 14: Installing Piston And Connecting Rod With Upper Connecting Rod Bearing In Place
Courtesy of FORD MOTOR CO.
14. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 15: Removing Connecting Rod Installer
Courtesy of FORD MOTOR CO.
15. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
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.
16. Position the lower bearing and connecting rod, and install the new bolts loosely.
NOTE: Main bearing caps are removed for clarity.
NOTE: Rotate the crankshaft after each connecting rod is installed and tightened to check for assembly binding.
Fig 16: Connecting Rod Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
17. Tighten the bolts in two stages, using the sequence shown.
    • Stage 1: Tighten to 43 Nm (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    Fig 17: Oil Pump Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS - 5.4L .
CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
Fig 18: Installing Head Gasket Over Dowel Pins
Courtesy of FORD MOTOR CO.
19. Install the head gasket over the dowel pins.
CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS - 5.4L .
CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.
NOTE: The RH cylinder head is shown; the LH cylinder head is similar.
Fig 19: Installing Cylinder Head On Dowels And Head Gasket
Courtesy of FORD MOTOR CO.
20. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
NOTE: Make sure to tighten the bolts in sequence in three stages.
Fig 20: Left Cylinder Head Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
21. 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.
NOTE: Make sure to tighten the bolts in the following three stages.
Fig 21: Right Cylinder Head Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
22. 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.
23. Remove the special tools both ends of the cylinder head.
    Fig 22: Removing Special Tools Both Ends Of Cylinder Head

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Fig 23: Installing Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
24. Install the hydraulic lash adjusters in their original locations.
25. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
    Fig 24: Right Exhaust Manifold Nut Tightening Sequence

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil.
Fig 25: Installing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
26. 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.
27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
    Fig 26: Left Exhaust Manifold Nut Tightening Sequence

    Courtesy of FORD MOTOR CO.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Fig 27: Compressing Tensioner Plunger, Using Vise
Courtesy of FORD MOTOR CO.
28. Compress the tensioner plunger, using a vise.
29. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 28: Installing A Retaining Clip On Tensioner

    Courtesy of FORD MOTOR CO.
30. Remove the tensioner from the vise.
31. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
    Fig 29: Removing Tensioner From Vise

    Courtesy of FORD MOTOR CO.
32. Install the timing chain guides.
    Fig 30: Installing Timing Chain Guides

    Courtesy of FORD MOTOR CO.
33. Pre-position the camshaft.
    1. Rotate the LH camshaft until mark is approximately at 12 o'clock.
    2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
    Fig 31: Identifying Camshaft Timing Mark Position

    Courtesy of FORD MOTOR CO.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Fig 32: Positioning Crankshaft On One Cylinder
Courtesy of FORD MOTOR CO.
34. Position the crankshaft so the number one cylinder is at TDC with the special tool.
35. Remove the Crankshaft Holding Tool.
36. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 33: Installing Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
37. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    Fig 34: Positioning Lower End Of LH (Inner) Timing Chain On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Fig 35: Positioning Timing Chain On Camshaft Sprocket With Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
38. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Fig 36: Installing LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
39. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
40. Remove the retaining clip from the LH timing chain tensioner.
    Fig 37: Removing Retaining Clip From LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
41. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    Fig 38: Positioning Lower End Of RH (Outer) Timing Chain On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
42. Install the RH timing chain on the camshaft sprocket, Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
    Fig 39: Installing RH Timing Chain On Camshaft Sprocket

    Courtesy of FORD MOTOR CO.
43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 40: Installing RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
44. Remove the retaining clip from the RH timing chain tensioner.
    Fig 41: Removing Retaining Clip From RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
45. As a post-check, verify correct alignment of all timing marks.
    Fig 42: Identifying Timing Mark Alignment

    Courtesy of FORD MOTOR CO.
46. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 43: Installing Special Tool Between Valve Spring Coils

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
Fig 44: Installing Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
47. Install the camshaft roller followers.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
48. Install the eight spark plugs.
    • Tighten the spark plugs to 18 Nm (13 lb-ft).
49. Install the crankshaft sensor ring on the crankshaft.
    Fig 45: Installing Crankshaft Sensor Ring On Crankshaft

    Courtesy of FORD MOTOR CO.
NOTE: If the front cover is 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 46: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
50. 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.
51. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 47: Installing Engine Front Cover Gasket On Engine Front Cover

    Courtesy of FORD MOTOR CO.
52. Tighten the engine front cover fasteners in sequence in three stages.

    Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

    Fig 48: Engine Front Cover Fastener Tightening Sequence

    Courtesy of FORD MOTOR CO.
53. Position the belt idler pulley and install the bolt.
    Fig 49: Positioning Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 50: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip

    Courtesy of FORD MOTOR CO.
55. Use the special tools to install the crankshaft front seal into the engine front cover.
    Fig 51: Installing Crankshaft Front Seal Into Engine Front Cover

    Courtesy of FORD MOTOR CO.
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 52: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
56. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
57. Use the special tool to install the crankshaft pulley.
    Fig 53: Installing Crankshaft Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Use a suitable strap wrench (303-D055) to hold pulley while tightening the bolt.
Fig 54: Tightening Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
58. Tighten the new crankshaft pulley bolt in four 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.
NOTE: The front lower hole in the power steering pump is not used.
Fig 55: Installing Power Steering Pump
Courtesy of FORD MOTOR CO.
59. Position the power steering pump and install the bolts.
60. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 56: Installing Valve Cover Gasket

    Courtesy of FORD MOTOR CO.
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 57: Applying Silicone Gasket And Sealant In Engine Front Cover
Courtesy of FORD MOTOR CO.
61. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
62. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 58: Positioning LH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
63. Tighten the bolts in the sequence shown.
    Fig 59: Left Valve Cover Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
64. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 60: Installing Valve Cover Gasket

    Courtesy of FORD MOTOR CO.
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 61: Applying Silicone Gasket And Sealant In Engine Front Cover
Courtesy of FORD MOTOR CO.
65. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
66. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 62: Positioning RH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
67. Tighten the bolts in the sequence shown.
    Fig 63: Right Valve Cover Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
68. Install the crankcase ventilation tube on the LH valve cover.
    Fig 64: Installing Crankcase Ventilation Tube On LH Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 65: Installing Radio Frequency Interference Capacitors
Courtesy of FORD MOTOR CO.
69. Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
71. Connect the CKP sensor electrical connector.
    Fig 66: Connecting CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
72. Connect the oil pressure switch electrical connector.
    Fig 67: Connecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
73. Connect the KS electrical connector.
    Fig 68: Connecting KS Electrical Connector

    Courtesy of FORD MOTOR CO.
74. Connect the RH radio frequency interference capacitor electrical connector.
    Fig 69: Connecting RH Radio Frequency Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
75. Connect the CMP sensor electrical connector.
    Fig 70: Connecting CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
    Fig 71: Connecting LH Radio Frequency Interference Capacitor And CHT Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 72: Installing Cylinder Block Drain Plugs
Courtesy of FORD MOTOR CO.
77. Install the cylinder block drain plugs.
78. Position a new gasket and the oil filter adapter. Install the bolts and nut.
    Fig 73: Installing Bolts And Nut

    Courtesy of FORD MOTOR CO.
79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
    Fig 74: Positioning LH And RH Engine Mounts To Cylinder Block

    Courtesy of FORD MOTOR CO.
80. If equipped, install the A/C compressor end the bolts.
    Fig 75: Installing A/C Compressor End Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: 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.
Fig 76: Positioning Coolant Pump Into Engine Block
Courtesy of FORD MOTOR CO.
81. Install the coolant pump.
    1. Lubricate the new O-ring seal using 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.
82. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 77: Positioning Coolant Pump Pulley On Coolant Pump

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushers, 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.
83. Inspect the 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.
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 78: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
84. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
    Fig 79: Installing Crankshaft Rear Seal Retainer Plate

    Courtesy of FORD MOTOR CO.
86. Tighten the bolts in the sequence shown.
    Fig 80: Crankshaft Rear Seal Retainer Plate Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
87. Install the oil drain plug before installing the oil pan.
    Fig 81: Installing Oil Drain Plug

    Courtesy of FORD MOTOR CO.
88. Install the oil pump screen and pickup tube spacer.
    Fig 82: Installing Oil Pump Screen And Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
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 83: Positioning Oil Pump Screen And Pickup Tube
Courtesy of FORD MOTOR CO.
89. Position the oil pump screen and pickup tube and install the bolts.
CAUTION: 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.
90. 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.
NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas 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 84: Applying Silicone Gasket And Sealant At Rear Oil Seal Retainer-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
91. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
    Fig 85: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface

    Courtesy of FORD MOTOR CO.
93. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 86: Installing Oil Pan Gasket And Oil Pan

    Courtesy of FORD MOTOR CO.
94. Tighten the bolts in two stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 87: Oil Pan bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
95. Install the special tool.
    Fig 88: Installing Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: The oil level indicator and tube are removed for clarity.
Fig 89: Installing Special Tool
Courtesy of FORD MOTOR CO.
96. Install the special tool.
97. Install the special tool and remove the engine from the work stand.
    Fig 90: Removing Engine From Work Stand Using Special Tool

    Courtesy of FORD MOTOR CO.
98. Lower the engine onto wooden blocks.
99. Install the special tool and raise the engine.
    Fig 91: Raising Engine Using Special Tool

    Courtesy of FORD MOTOR CO.
100. Install the oil level indicator tube nut and insert the oil level indicator.
     Fig 92: Installing Oil Level Indicator Tube Nut

     Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Fig 93: Installing Crankshaft Rear Seal Using Special Tool
Courtesy of FORD MOTOR CO.
101. Using the special tools, install a new crankshaft rear seal.
102. Using the special tools, install the crankshaft rear oil slinger.
     Fig 94: Installing Crankshaft Rear Oil Slinger Using Special Tool

     Courtesy of FORD MOTOR CO.
103. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
     Fig 95: Flexplate Bolt Tightening Sequence

     Courtesy of FORD MOTOR CO.