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Oil Pan: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    All engines 

    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.
  1. 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.
  2. Position the oil pump screen and pickup tube in the oil pan and position the oil pan into the vehicle.
    3. 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 And Pickup Tube
    G03885461Courtesy of FORD MOTOR CO.
  3. Install the oil pump screen and pickup tube.
    4. 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: Area For Applying Bead Of Silicone Gasket And Sealant
    G04583522Courtesy of FORD MOTOR CO.
  4. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown in Fig 2.
    5. 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 Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
    G03885463Courtesy of FORD MOTOR CO.
  5. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown in Fig 3.
  6. Tighten the bolts in three stages, in the sequence shown in Fig 4.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
      Fig 4: Tightening Bolts In Sequence
      G03885464Courtesy of FORD MOTOR CO.
    • Stage 3: Tighten an additional 90 degrees.
  7. Install a new oil filter.
    Fig 5: Oil Filter With Torque Specification
    G03885415Courtesy of FORD MOTOR CO.
  8. Lower the engine and remove the special tools.
    9. NOTE: RH shown; LH similar.
    Fig 6: Installing Engine Mount Nuts
    G03886117Courtesy of FORD MOTOR CO.
  9. Install the four engine mount nuts.
  10. Install the flexplate inspection plate.
    Fig 7: Flywheel Inspection Plate With Torque Specification
    G03885467Courtesy of FORD MOTOR CO.

    11. Romeo engine (4.6L) 

  11. Position the transmission fluid cooler tubes and support bracket and install the nut.
    Fig 8: Positioning Transmission Fluid Cooler Tubes
    G03886125Courtesy of FORD MOTOR CO.

    12. Windsor engine (5.4L) 

  12. Position the transmission fluid cooler tubes and support bracket and install the nut.
    Fig 9: Positioning Transmission Fluid Cooler Tubes And Support Bracket
    G03886126Courtesy of FORD MOTOR CO.

    13. All engines 

  13. Install the transmission-to-engine bolts.
    Fig 10: Installing Transmission-To-Engine Bolts
    G03885532Courtesy of FORD MOTOR CO.
    14. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.
    Fig 11: Installing Heater Outlet Tube Over New Seals
    G03885471Courtesy of FORD MOTOR CO.
  14. Insert the heater outlet tube over the new seals.

    15. Romeo engines (4.6L) 

  15. Install the heater outlet tube studs.
    Fig 12: Installing Heater Outlet Tube Studs - Romeo Engines (4.6L)
    G03885534Courtesy of FORD MOTOR CO.

    16. Windsor engine (5.4L) 

  16. Install the heater outlet tube studs.
    Fig 13: Installing Heater Outlet Tube Studs - Windsor Engine (5.4L)
    G03886135Courtesy of FORD MOTOR CO.

    17. All engines 

  17. Connect the hose to the heater outlet tube.
    Fig 14: Connecting Hose To Heater Outlet Tube
    G03886137Courtesy of FORD MOTOR CO.
  18. 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
      G03886138Courtesy of FORD MOTOR CO.
  19. Install the retainers and the shield.
    Fig 16: Installing Retainers And Shield
    G03885447Courtesy of FORD MOTOR CO.
  20. Position the generator and tighten the bolts.
    Fig 17: Positioning Generator Bolts
    G03885539Courtesy 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. Fill the engine with clean engine oil.
  24. Start the engine and check for leaks.
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