Oil Pan - Automated Equipment: Installation

All vehicles 

NOTE: The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.
1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
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 with clean engine oil.
2. Install the oil pump screen and pickup tube.
   • Position the oil pump screen and pickup tube on the engine.
   • Install the bolts.
     Fig 1: Installing Bolts

     Courtesy of FORD MOTOR CO.
NOTE: If not secure 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 2: Applying Bead Of Silicone Gasket And Sealant At Crankshaft Rear Seal Retainer-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
3. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
NOTE: If not secure 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 3: Applying Bead Of Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Surface
Courtesy of FORD MOTOR CO.
4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
NOTE: Be sure to tighten the bolts in two stages.
5. Tighten the bolts in the sequence shown.
   • Stage 1: Tighten to 20 Nm (15 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
     Fig 4: Tightening Bolts In Sequence

     Courtesy of FORD MOTOR CO.
6. Lower the transmission.
7. Remove the High Lift Transmission Jack.
8. Install the flywheel inspection plate.
   Fig 5: Installing Flywheel Inspection Plate

   Courtesy of FORD MOTOR CO.
9. Install the oil bypass filter.
10. Lower the vehicle.
11. Align the engine mount studs and lower the engine, using the Heavy Duty Engine Support.
    Fig 6: Aligning Engine Mount Studs And Lower Engine

    Courtesy of FORD MOTOR CO.
12. Remove the Heavy Duty Engine Support.
13. Raise and support the vehicle.
14. Install the engine mount nuts.
    Fig 7: Installing Engine Mount Nuts

    Courtesy of FORD MOTOR CO.
15. Install a suitable transmission jack and support the transmission.

    Excursion vehicles 

16. Remove the crossmember bolts.
    Fig 8: Removing Crossmember Bolts

    Courtesy of FORD MOTOR CO.
17. Remove the crossmember bolts.
    Fig 9: Removing Crossmember Bolts

    Courtesy of FORD MOTOR CO.
18. Remove the transmission mount nuts and the crossmember.
    Fig 10: Removing Transmission Mount Nuts And Crossmember

    Courtesy of FORD MOTOR CO.

    F-SuperDuty vehicles 

19. Remove the RH crossmember nuts.
    Fig 11: Removing RH Crossmember Nuts

    Courtesy of FORD MOTOR CO.
20. Remove the LH crossmember nuts.
    Fig 12: Removing LH Crossmember Nuts

    Courtesy of FORD MOTOR CO.
21. Remove the nuts and the crossmember.
    Fig 13: Removing Nuts And Crossmember

    Courtesy of FORD MOTOR CO.

    All vehicles 

22. If the vehicle is equipped with TSS and turbine/OSS, remove the plugs and install the sensors in the transmission. Refer to AUTOMATIC TRANSMISSION - 4R100 or AUTOMATIC TRANSMISSION - TORQSHIFT
23. Position the exhaust Y-pipe and install the nuts on the exhaust manifold studs.
    Fig 14: Installing Nuts On Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
24. Install the exhaust Y-pipe flange nuts.
    Fig 15: Installing Exhaust Y-Pipe Flange Nuts

    Courtesy of FORD MOTOR CO.
25. Connect the heated oxygen sensor electrical connectors.
    Fig 16: Connecting Heated Oxygen Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
26. Lower the vehicle.
27. Remove the modular engine support bracket from the engine.
    Fig 17: Removing Modular Engine Support Bracket From Engine

    Courtesy of FORD MOTOR CO.
CAUTION: The large clutch assembly nut has a right-handed thread and must be rotated counterclockwise to remove it.
Fig 18: Installing Fan And Fan Clutch To Coolant Pump Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
28. Using the special tool, install the fan and fan clutch to the coolant pump pulley.
29. Install the generator. Refer to GENERATORS & REGULATORS .
30. Install the throttle body adapter.
    • Position a new throttle body adapter gasket.
    • Position the throttle body adapter.
    • Install the four bolts.
      Fig 19: Installing Bolts

      Courtesy of FORD MOTOR CO.
31. If equipped, connect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 20: Connecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections

    Courtesy of FORD MOTOR CO.
32. If equipped, connect the EGR valve vacuum hose.
    Fig 21: Connecting EGR Valve Vacuum Hose

    Courtesy of FORD MOTOR CO.
33. If equipped, install the differential pressure feedback EGR system bracket.
    • Position the bracket.
    • Install the bolts.
      Fig 22: Installing Bolts

      Courtesy of FORD MOTOR CO.
34. If equipped, install the exhaust manifold to EGR valve tube.
    • Hand-tighten the fittings.
    • Tighten the upper fitting to 40-60 Nm (30-44 lb-ft).
    • Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).
      Fig 23: Installing Exhaust Manifold To EGR Valve Tube

      Courtesy of FORD MOTOR CO.
35. If equipped, connect the differential pressure feedback EGR system vacuum lines.
    Fig 24: Connecting Differential Pressure Feedback EGR System Vacuum Lines

    Courtesy of FORD MOTOR CO.
36. If equipped, connect the differential pressure feedback EGR system electrical connector.
    Fig 25: Connecting Differential Pressure Feedback EGR System Electrical Connector

    Courtesy of FORD MOTOR CO.
37. Connect the TP sensor electrical connector.
    Fig 26: Connecting TP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
38. Connect the IAC electrical connector.
    Fig 27: Connecting IAC Electrical Connector

    Courtesy of FORD MOTOR CO.
39. Install the IAC fresh air tube and insert it in the routing clip.
    Fig 28: Installing IAC Fresh Air Tube

    Courtesy of FORD MOTOR CO.
40. Install the accelerator cable bracket.
    • Position the bracket and cables.
    • Install the bolts.
      Fig 29: Installing Accelerator Cable Bracket

      Courtesy of FORD MOTOR CO.
41. Connect the throttle body cam.
    • Connect the accelerator cable.
    • If equipped, connect the speed control cable.
    • Install the throttle return spring.
      Fig 30: Installing Throttle Return Spring

      Courtesy of FORD MOTOR CO.
42. Install the accelerator cable snow shield.
    Fig 31: Installing Accelerator Cable Snow Shield

    Courtesy of FORD MOTOR CO.
43. Install the air cleaner outlet pipe. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
44. Connect the battery cable.
CAUTION: The oil pump must be primed prior to starting the engine.
45. Fill the engine with clean engine oil.