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Engine - 4.6L: Material

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MATERIAL SPECIFICATION

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket and Sealant TA-30 or equivalent WSE-M4G323-A4
Instant Gel Adhesive TA-19 or equivalent WSK-M2G402-A4
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California and Oregon VC-7-B, in Canada VC-7-C) or equivalent (yellow in color) WSS-M97B51-A1
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA -
  1. Record the main bearing code found on the front of the engine block.
    Fig 1: Identifying Main Bearing Code Label Location (Engine Block)
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    Fig 2: Identifying Main Bearing Code - Found On Back Of Crankshaft
    G03886015Courtesy 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 3: Bearing Select Fit Chart (Standard Bearings)
      G03886016Courtesy 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 4: Bearing Select Fit Chart
    G04583822Courtesy of FORD MOTOR CO.
    5. 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.
  6. Install the crankshaft onto the upper crankshaft main bearings.
    Fig 5: Installing Crankshaft Onto Upper Crankshaft Main Bearings
    G03885910Courtesy of FORD MOTOR CO.
    7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
    Fig 6: Installing Crankshaft Upper Thrust Washer
    G03962777Courtesy of FORD MOTOR CO.
  7. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
    8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.
    Fig 7: Installing Rear Main Bearing Cap
    G03885912Courtesy of FORD MOTOR CO.
  8. Install the rear main bearing cap.
  9. 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.
  10. Install the vertical main bearing cap fasteners and tighten in two stages, in the sequence shown in Fig 8.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 8: Identifying Tightening Sequence Of Vertical Main Bearing Cap Fasteners
      G03885913Courtesy of FORD MOTOR CO.
  11. Tighten the jack screws against the cylinder block in two stages, in the sequence shown in Fig 9.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 9: Identifying Tightening Sequence Of Jack Screws Against Cylinder Block
      G03885914Courtesy of FORD MOTOR CO.
  12. Install the side bolts and tighten them in the sequence shown in Fig 10.
    Fig 10: Identifying Tightening Sequence Of Side Bolts
    G03885915Courtesy of FORD MOTOR CO.
    13. 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 11: Installing Piston And Connecting Rod
    G03885916Courtesy of FORD MOTOR CO.
  13. Using the special tools, install the piston and connecting rod with the upper connecting rod bearing in place.
    14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 12: Removing Special Tool
    G03905880Courtesy of FORD MOTOR CO.
  14. Once the connecting rod is seated on the crankshaft journal, remove the special tool.
    15. 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.
  15. Position the lower bearing and connecting rod, and install the new bolts loosely.
    16. 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.
  16. Tighten the bolts in two stages, using the sequence shown in Fig 13.
    • Stage 1: Tighten to 43 Nm (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
      Fig 13: Identifying Tightening Sequence Of Main Bearing Cap Bolts
      G03885918Courtesy of FORD MOTOR CO.
  17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown in Fig 14.
    Fig 14: Identifying Tightening Sequence Of Oil Pump Bolts
    G03885919Courtesy of FORD MOTOR CO.
    18. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS - 4.6L .
    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: RH head gasket shown; LH head gasket similar.
    Fig 15: Installing Head Gasket Over Dowel Pins
    G03881930Courtesy of FORD MOTOR CO.
  18. Install the head gasket over the dowel pins.
    19. 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. For additional information, refer to CYLINDER HEADS - 4.6L .
    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: RH cylinder head shown; LH cylinder head similar.
    Fig 16: Installing Cylinder Head On Dowels
    G03886030Courtesy of FORD MOTOR CO.
  19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
    20. NOTE: Make sure to tighten the bolts in sequence in three stages.
  20. 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 17: Identifying Tightening Sequence Of Cylinder Head Bolts (LH)
      G03885922Courtesy of FORD MOTOR CO.
    21. NOTE: Make sure to tighten the bolts in the following three stages.
  21. Tighten the RH bolts in the sequence shown in Fig 18.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
      Fig 18: Identifying Tightening Sequence Of Cylinder Head Bolts (RH)
      G03885923Courtesy of FORD MOTOR CO.
  22. Remove the special tools from both ends of the cylinder head.
    Fig 19: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    23. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 20: Identifying Hydraulic Lash Adjusters
    G04583838Courtesy of FORD MOTOR CO.
  23. Install the hydraulic lash adjusters in their original locations.
  24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown in Fig 21.
    Fig 21: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
    G03885396Courtesy of FORD MOTOR CO.
    25. NOTE: Lubricate the O-ring seal with clean engine oil.
  25. 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 22: Installing Oil Level Indicator Tube
      G03885927Courtesy of FORD MOTOR CO.
  26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown in Fig 23.
    Fig 23: Identifying Tightening Sequence Of LH Exhaust Manifold Bolts
    G03885405Courtesy of FORD MOTOR CO.
    27. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 24: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  27. Using a vise, compress the tensioner plunger.
  28. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 25: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  29. Remove the tensioner from the vise.
  30. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    Fig 26: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  31. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
      Fig 27: Installing Timing Chain Guides
      G03885348Courtesy of FORD MOTOR CO.
  32. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    Fig 28: Identifying Timing Mark
    G04583473Courtesy of FORD MOTOR CO.
    33. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and valve damage can occur. See Fig 29.
    NOTE: The number one cylinder 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 29: Positioning Crankshaft
    G03885349Courtesy of FORD MOTOR CO.
  33. Using the special tool, position the crankshaft so the number one cylinder is at TDC.
  34. Remove the special tool.
  35. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 30: Identifying Crankshaft Sprocket Flange
    G03881584Courtesy of FORD MOTOR CO.
  36. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 31: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  37. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 32: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    38. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 33: LH Timing Chain Tensioner And Guide - With Torque Specification
    G03885938Courtesy of FORD MOTOR CO.
  38. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
  39. Remove the retaining clip from the LH timing chain tensioner.
    Fig 34: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  40. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 35: Aligning Copper (Marked) Link With Timing Mark On Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  41. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 36: Aligning Copper (Marked) Link With Timing Marks On Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  42. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 37: View Of RH Timing Chain Tensioner - With Torque Specification
    G03886280Courtesy of FORD MOTOR CO.
  43. Remove the retaining clip from the RH timing chain tensioner.
    Fig 38: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  44. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 39: Identifying Camshaft & Crankshaft Alignment Links/Marks
    G03962922Courtesy of FORD MOTOR CO.
  45. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 40: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    46. 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.
  46. 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 41: Installing Camshaft Roller Followers
      G03905495Courtesy of FORD MOTOR CO.
    47. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
  47. Install the eight spark plugs.
    • Tighten to 18 Nm (13 lb-ft).
  48. Install the crankshaft sensor ring on the crankshaft.
    Fig 42: Installing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
    49. 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 43: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
    G03886213Courtesy of FORD MOTOR CO.
  49. 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 in Fig 43.
  50. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 44: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  51. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 45: Identifying Tightening Sequence Of Engine Front Cover Bolts
    G03885950Courtesy of FORD MOTOR CO.
  52. Position the belt idler pulley and install the bolt.
    Fig 46: View Of Belt Idler Pulley Bolt With Torque Specification
    G03885300Courtesy of FORD MOTOR CO.
  53. Lubricate the engine front cover and the front seal inner lip with clean engine oil.
    Fig 47: Installing Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  54. Using the special tools, install the crankshaft front seal into the engine front cover.
    Fig 48: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
    G03885953Courtesy of FORD MOTOR CO.
    55. 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 49: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03886063Courtesy of FORD MOTOR CO.
  55. Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
  56. Using the special tool, install the crankshaft pulley.
    Fig 50: Installing Crankshaft Pulley Using Special Tool
    G03886064Courtesy of FORD MOTOR CO.
    57. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
  57. 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 51: Installing Crankshaft Pulley Bolt & Washer
      G04672695Courtesy of FORD MOTOR CO.
    58. NOTE: The front lower hole in the power steering pump is not used.
    Fig 52: Identifying Tightening Torque Of Power Steering Pump Bolts
    G03885304Courtesy of FORD MOTOR CO.
  58. Position the power steering pump and install the bolts.
  59. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    Fig 53: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    60. 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 Engine Front Cover
    G03885959Courtesy of FORD MOTOR CO.
  60. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  61. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 55: Installing LH Valve Cover And Gasket On Cylinder Head
    G03885960Courtesy of FORD MOTOR CO.
  62. Tighten the bolts in the sequence shown in Fig 56.
    Fig 56: Identifying Tightening Sequence Of LH Valve Cover Bolts
    G03885216Courtesy of FORD MOTOR CO.
  63. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    Fig 57: Applying Instant Adhesive Around Gasket Groove In Valve Cover
    G03905398Courtesy of FORD MOTOR CO.
    64. 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: Identifying Area For Applying Silicone Gasket And Sealant
    G03885963Courtesy of FORD MOTOR CO.
  64. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  65. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
    Fig 59: Identifying RH Valve Cover
    G03905400Courtesy of FORD MOTOR CO.
  66. Tighten the bolts in the sequence shown in Fig 60.
    Fig 60: Identifying Tightening Sequence Of RH Valve Cover Bolts
    G03885240Courtesy of FORD MOTOR CO.
  67. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
    Fig 61: Installing Positive Crankcase Ventilation Valve And Hose In RH Valve Cover
    G03885966Courtesy of FORD MOTOR CO.
  68. Install the crankcase ventilation tube on the LH valve cover.
    Fig 62: Locating Crankcase Ventilation Tube On LH Valve Cover
    G03885676Courtesy of FORD MOTOR CO.
    69. NOTE: RH shown; LH similar.
    Fig 63: Installing Radio Frequency Interference Capacitor
    G03885968Courtesy 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 64: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  72. Connect the oil pressure switch electrical connector.
    Fig 65: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  73. Connect the KS electrical connector.
    Fig 66: Locating KS Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  74. Connect the RH radio frequency interference capacitor electrical connector.
    Fig 67: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  75. Connect the CMP sensor electrical connector.
    Fig 68: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
    Fig 69: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
    77. NOTE: LH shown; RH similar.
    Fig 70: Installing Cylinder Block Drain Plugs
    G03885975Courtesy 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 71: Installing New Gasket And Oil Filter Adapter
    G03885429Courtesy of FORD MOTOR CO.
  79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.
    Fig 72: Installing LH And RH Engine Mounts To Cylinder Block
    G03885977Courtesy of FORD MOTOR CO.
  80. If equipped, install the A/C compressor and the bolts.
    Fig 73: Installing A/C Compressor Bolts
    G03885978Courtesy of FORD MOTOR CO.
    81. 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.
  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.
      Fig 74: Installing Coolant Pump Retaining Bolts
      G03885979Courtesy of FORD MOTOR CO.
  82. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 75: Installing Coolant Pump Pulley On Coolant Pump With Torque Specification
    G03885980Courtesy of FORD MOTOR CO.
    83. 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 clean sealing surfaces.
  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.
    84. 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 76: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
    G03881975Courtesy 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 77: Identifying Crankshaft Rear Oil Seal Retainer
    G04583880Courtesy of FORD MOTOR CO.
  86. Tighten the bolts in the sequence shown in Fig 78.
    Fig 78: Identifying Tightening Sequence Of Rear Oil Seal Retainer Bolts
    G03885983Courtesy of FORD MOTOR CO.
  87. Install the oil drain plug before installing the oil pan.
    Fig 79: Installing Oil Drain Plug With Torque Specification
    G03885305Courtesy of FORD MOTOR CO.
  88. Install the oil pump screen and pickup tube spacer.
    Fig 80: Installing Oil Pump Screen And Pickup Tube Spacer
    G03885985Courtesy of FORD MOTOR CO.
    89. 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 81: Installing Oil Pump Screen And Pickup Tube
    G03885986Courtesy of FORD MOTOR CO.
  89. Position the oil pump screen and pickup tube and install the bolts.
    90. 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 clean sealing surfaces.
  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.
    91. 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 82: Applying Bead Of Silicone Gasket And Sealant To Rear Oil Seal Retainer-To-Cylinder Block Sealing Surface
    G04583522Courtesy 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 83: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
    G03885463Courtesy of FORD MOTOR CO.
  93. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 84: Identifying Oil Pan And Gasket
    G03885989Courtesy of FORD MOTOR CO.
  94. Tighten the bolts in two stages, in the sequence shown in Fig 85.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 85: Identifying Tightening Sequence Of Oil Pan Bolts
      G03886098Courtesy of FORD MOTOR CO.
  95. Install the special tool.
    Fig 86: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
    96. NOTE: The oil level indicator and tube are removed for clarity.
    Fig 87: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  96. Install the special tool.
  97. Install the special tool and remove the engine from the work stand.
    Fig 88: Installing Special Tool
    G03885993Courtesy of FORD MOTOR CO.
  98. Lower the engine onto wooden blocks.
  99. Install the special tool and raise the engine.
    Fig 89: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  100. Install the oil level indicator tube nut and insert the oil level indicator.
    Fig 90: Installing Oil Level Indicator Tube Nut
    G03885225Courtesy of FORD MOTOR CO.
    101. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
    Fig 91: Installing Crankshaft Rear Seal Using Special Tool
    G04002055Courtesy 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 92: Installing Crankshaft Rear Oil Slinger Using Special Tool
    G03905624Courtesy of FORD MOTOR CO.
  103. Install the flexplate and bolts. Tighten the bolts in the sequence shown in Fig 93.
    Fig 93: Identifying Tightening Sequence Of Flexplate Bolts
    G03886247Courtesy of FORD MOTOR CO.
  104. Install the engine. For additional information, refer to ENGINE .
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