Section 653 (Engine - 5.4L (2V) - Excursion & F250-F350 Super Duty): Assembly: Engine

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 Back Of 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: 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
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
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 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.
    Fig 11: Installing Crankshaft Lower Main Bearings Into Main Bearing Caps

    Courtesy of FORD MOTOR CO.
11. Install the dowel pins so the flat sides face the crankshaft.
    Fig 12: 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 13: Installing Vertical Main Bearing Cap Fasteners

      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 14: Tightening Side Bolts In Sequence

      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 15: Installing Piston And Connecting Rod With Upper Connecting Rod Bearing In Place Using Special Tool
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 16: Removing Connecting Rod Installer Using Special Tool
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.
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.
      Fig 17: Positioning Lower Bearing And Connecting Rod

      Courtesy of FORD MOTOR CO.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    Fig 18: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. Refer to CYLINDER HEADS .
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.
NOTE: The RH head gasket is shown; the LH head gasket is similar.
Fig 19: 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 0.0254 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. Refer to CYLINDER HEADS .
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 20: 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.
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.
      Fig 21: Tightening LH Bolts In Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Make sure to tighten the bolts in the following three stages.
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.
      Fig 22: Tightening RH Bolts In Sequence

      Courtesy of FORD MOTOR CO.
23. Remove the special tools from both ends of the cylinder head.
    Fig 23: Removing Special Tools From Both Ends Of Cylinder Head

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
Fig 24: Installing Hydraulic Lash Adjusters In Locations
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 25: Installing RH Exhaust Manifold Gaskets And Exhaust Manifold

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil.
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.
      Fig 26: Installing Oil Level Indicator Tube

      Courtesy of FORD MOTOR CO.
27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
    Fig 27: Installing LH Exhaust Manifold And Exhaust Manifold Gaskets

    Courtesy of FORD MOTOR CO.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
Fig 28: 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 29: Installing 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 30: Removing Tensioner From Vise

    Courtesy of FORD MOTOR CO.
32. Install the timing chain guides.
    Fig 31: Installing Timing Chain Guides

    Courtesy of FORD MOTOR CO.
33. Pre-position the camshafts.
    1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
    2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
       Fig 32: Identifying 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 33: Identifying Crankshaft Position
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 34: Identifying Flange Facing Position

    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 35: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper (Marked) Link On Chain

    Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Fig 36: 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 37: 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 38: 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 39: Aligning Timing Mark On Sprocket With Single Copper (Marked) Chain Link

    Courtesy of FORD MOTOR CO.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
Fig 40: Positioning RH Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
42. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 41: Installing RH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
44. Remove the retaining clip from the RH timing chain tensioner.
    Fig 42: 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 43: Identifying Timing Marks Alignment

    Courtesy of FORD MOTOR CO.
46. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 44: 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.
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.
       Fig 45: Installing Camshaft Roller Followers

       Courtesy of FORD MOTOR CO.
48. Remove the special tool.
    Fig 46: Removing Special Tool

    Courtesy of FORD MOTOR CO.
CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
49. Install the eight spark plugs.
    • Tighten the spark plugs to 18 Nm (13 lb-ft).
50. Install the crankshaft sensor ring on the crankshaft.
    Fig 47: 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 48: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
51. 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.
52. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 49: Installing Engine Front Cover Gasket On Engine Front Cover

    Courtesy of FORD MOTOR CO.
53. Tighten the engine front cover fasteners in sequence in three stages.
    1. Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).
    2. Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
    3. Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
       Fig 50: Tightening Engine Front Cover Fasteners In Sequence

       Courtesy of FORD MOTOR CO.
54. Position the belt idler pulley and install the bolt.
    Fig 51: Positioning Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
55. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 52: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip

    Courtesy of FORD MOTOR CO.
56. Use the special tools to install the crankshaft front seal into the engine front cover.
    Fig 53: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool

    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 54: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
57. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
58. Use the special tool to install the crankshaft pulley.
    Fig 55: Installing Crankshaft Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
59. 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.
      Fig 56: Tightening Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
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 57: 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 58: 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 59: Positioning LH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
63. Tighten the bolts in the sequence shown.
    Fig 60: Tightening Bolts In 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 61: Applying Instant Adhesive Around Gasket Groove In RH Valve 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 62: 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 63: Positioning RH Valve Cover And Gasket On Cylinder Head

    Courtesy of FORD MOTOR CO.
67. Tighten the bolts in the sequence shown.
    Fig 64: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
68. Install the crankcase ventilation tube on the LH valve cover.
    Fig 65: Installing Crankcase Ventilation Tube On LH Valve Cover

    Courtesy of FORD MOTOR CO.
69. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
    Fig 66: Installing Positive Crankcase Ventilation (PCV) Valve And Hose In RH Valve Cover

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 67: Installing Radio Frequency Interference Capacitors
Courtesy of FORD MOTOR CO.
70. Install the radio frequency interference capacitors.
71. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
72. Install the bracket.
    Fig 68: Installing Bracket

    Courtesy of FORD MOTOR CO.
73. Connect the CKP sensor electrical connector.
    Fig 69: Connecting CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
74. Connect the oil pressure switch electrical connector.
    Fig 70: Connecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
75. Connect the knock sensor electrical connector.
    Fig 71: Connecting Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
76. Connect the RH radio frequency interference capacitor electrical connector.
    Fig 72: Connecting RH Radio Frequency Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
77. Connect the CMP sensor electrical connector.
    Fig 73: Connecting CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
78. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
    Fig 74: Connecting LH Radio Frequency Interference Capacitor And CHT Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 75: Installing Cylinder Block Drain Plugs
Courtesy of FORD MOTOR CO.
79. Install the cylinder block drain plugs.
NOTE: Clean and inspect the mating surfaces, and install new gaskets.
Fig 76: Positioning Oil Filter Adapter
Courtesy of FORD MOTOR CO.
80. Position the oil filter adapter and install the four bolts.
81. Install the rear nut.
    Fig 77: Installing Rear Nut

    Courtesy of FORD MOTOR CO.
82. Position the engine mounts to the cylinder block and install the six bolts.
    Fig 78: Positioning Engine Mounts To Cylinder Block

    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.
83. 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.
       Fig 79: Installing Bolts

       Courtesy of FORD MOTOR CO.
84. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 80: Positioning Coolant Pump Pulley On Coolant Pump

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, 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.
85. 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, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 81: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
86. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
87. Install the crankshaft rear seal retainer plate and loosely install the six bolts.
    Fig 82: Installing Crankshaft Rear Seal Retainer Plate

    Courtesy of FORD MOTOR CO.
88. Tighten the bolts in the sequence shown.
    Fig 83: Tightening Bolts In Sequence

    Courtesy of FORD MOTOR CO.
89. Install the oil drain plug.
    Fig 84: Installing Oil Drain Plug

    Courtesy of FORD MOTOR CO.
90. Install the oil pump screen and pickup tube spacer.
    Fig 85: 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 86: Positioning Oil Pump Screen And Pickup Tube
Courtesy of FORD MOTOR CO.
91. 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.
92. 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, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 87: Applying Silicone Gasket And Sealant At Crankshaft Rear Seal Retainer-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
93. Apply silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block sealing surface.
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, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
Fig 88: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
94. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
95. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 89: Installing Oil Pan Gasket And Oil Pan

    Courtesy of FORD MOTOR CO.
96. Tighten the bolts in three stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 90: Tightening Bolts In Sequence

      Courtesy of FORD MOTOR CO.
97. Remove the special tool.
    Fig 91: Removing Special Tool

    Courtesy of FORD MOTOR CO.
98. Install the special tool.
    Fig 92: Installing Special Tool

    Courtesy of FORD MOTOR CO.
99. Install the special tool and remove the engine from the work stand.
    Fig 93: Removing Engine From Work Stand

    Courtesy of FORD MOTOR CO.
100. Lower the engine onto wooden blocks.
101. Remove the special tool.
     Fig 94: Removing Special Tool

     Courtesy of FORD MOTOR CO.
102. Remove the special tool.
     Fig 95: Removing Special Tool

     Courtesy of FORD MOTOR CO.
103. Install the special tool and raise the engine.
     Fig 96: Installing Special Tool And Raising Engine

     Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.
Fig 97: Installing Crankshaft Rear Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
104. Using the special tools, install a new crankshaft rear oil seal.
105. Using the special tools, install the crankshaft rear oil slinger.
     Fig 98: Installing Crankshaft Rear Oil Slinger Using Special Tool

     Courtesy of FORD MOTOR CO.
106. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
     Fig 99: Installing Flexplate And Bolts

     Courtesy of FORD MOTOR CO.
107. Install the engine. Refer to ENGINE .