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Section 350 (Engine - 5.4L 2V): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All engines 

  1. Record the main bearing code found on the front of the engine block.
    Fig 1: Identifying Main Bearing Code On Front Of Engine Block
    G01548736Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the back of the crankshaft.
    Fig 2: Identifying Main Bearing Code On Back Of Crankshaft
    G01548737Courtesy of FORD MOTOR CO.

    Bearing Select Fit Chart, Standard Bearings 

  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
    G01548738Courtesy of FORD MOTOR CO.

    Bearing Select Fit Chart, Oversize Bearings 

  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 - Oversize Bearings
    G01548739Courtesy of FORD MOTOR CO.

    All engines 

  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.
  6. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
  7. 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 5: Installing Crankshaft Onto Upper Crankshaft Main Bearings
    G01548740Courtesy of FORD MOTOR CO.
  8. Install the crankshaft onto the upper crankshaft main bearings.
  9. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
    Fig 6: Installing Rear Crankshaft Upper Thrust Washer At Back Of No. 5 Main Boss
    G01548741Courtesy of FORD MOTOR CO.
  10. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
  11. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
    Fig 7: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss
    G01548742Courtesy of FORD MOTOR CO.
  12. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
  13. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
    NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
    Fig 8: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap
    G01548743Courtesy of FORD MOTOR CO.
  14. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
  15. 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 tap into place using a plastic or dead-blow hammer.
    Fig 9: Taping Main Bearing Cap
    G01548744Courtesy of FORD MOTOR CO.
  16. Install the dowel pins so the flat sides face the crankshaft.
    Fig 10: view of Installation Dowel Pins
    G01548745Courtesy of FORD MOTOR CO.
  17. 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 11: Identifying Vertical Main Bearing Cap Fasteners And Tightening Sequence
    G01548746Courtesy of FORD MOTOR CO.
  18. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 30 Nm (22 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 12: Identifying Side Bolts Tightening Sequence
    G01548747Courtesy of FORD MOTOR CO.
  19. 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 13: Installing Piston And Connecting Rod With Upper Connecting Rod Bearing In Place
    G01548748Courtesy of FORD MOTOR CO.
  20. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
  21. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 14: Removing Connecting Rod Installer
    G01548749Courtesy of FORD MOTOR CO.
  22. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
  23. 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.
  24. Position the lower bearing and connecting rod, and install the new bolts loosely.
  25. NOTE: Main bearing caps are removed for clarity.
    Fig 15: Identifying Main Bearing Caps bolts Tightening sequence
    G01548750Courtesy of FORD MOTOR CO.
  26. 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.
  27. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    Fig 16: Tightening Oil Pump Bolts In Sequence
    G01548751Courtesy of FORD MOTOR CO.
  28. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
    CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
    Fig 17: Positioning Head Gasket Over Dowel Pins
    G01548752Courtesy of FORD MOTOR CO.
  29. Position the head gasket over the dowel pins.
    • RH is shown; LH is similar.
  30. Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).
    Fig 18: Identifying Crankshaft Keyway Points Position
    G01548753Courtesy of FORD MOTOR CO.
  31. CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    NOTE: Do not turn the crankshaft until instructed to do so.
    Fig 19: Positioning Cylinder Head Over Dowels And Head Gasket
    G01548754Courtesy of FORD MOTOR CO.
  32. Position the cylinder head over the dowels and head gasket and install the cylinder head bolts loosely.
    • RH is shown; LH is similar.
  33. Tighten the bolts in three stages, in the sequence shown.

    RH is shown; LH is similar.

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
    Fig 20: Identifying Bolts Tightening Sequence
    G01548755Courtesy of FORD MOTOR CO.
  34. NOTE: Lubricate the O-ring seal with clean engine oil.
    Fig 21: Installing Oil Level Indicator Tube
    G01548756Courtesy of FORD MOTOR CO.
  35. 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.
  36. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
    Fig 22: Installing RH Exhaust Manifold Gaskets And Exhaust Manifold
    G01548757Courtesy of FORD MOTOR CO.
  37. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
    Fig 23: Installing LH Exhaust Manifold And Exhaust Manifold Gaskets
    G01548758Courtesy of FORD MOTOR CO.
  38. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    Fig 24: Compressing Tensioner Plunger, Using Vise
    G01548759Courtesy of FORD MOTOR CO.
  39. Compress the tensioner plunger, using a vise.
  40. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 25: Installing Retaining Clip On Tensioner
    G01548760Courtesy of FORD MOTOR CO.
  41. Remove the tensioner from the vise.
  42. 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 26: Locating Timing Marks On Chain
    G01548761Courtesy of FORD MOTOR CO.
  43. Install the timing chain guides.
    Fig 27: Installing Timing Chain Guides
    G01548762Courtesy of FORD MOTOR CO.
  44. CAUTION: Do not turn the engine over with the special tool or damage to the camshaft sprocket or the bolt can occur.
    Fig 28: Installing Special Tool
    G01548763Courtesy of FORD MOTOR CO.
  45. Install the special tool.
  46. 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 29: Identifying LH And RH Camshaft Timing Mark Position
    G01548764Courtesy of FORD MOTOR CO.
  47. 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 30: Removing Crankshaft Holding Tool
    G01548765Courtesy of FORD MOTOR CO.
  48. Position the crankshaft so the number one cylinder is at TDC with the special tool.
  49. Remove the Crankshaft Holding Tool.
  50. Install the crankshaft sprocket and make sure the flange faces forward.
    Fig 31: Identifying Crankshaft Sprocket Flange Facing Position
    G01548766Courtesy of FORD MOTOR CO.
  51. 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 32: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper (Marked) Link On Chain
    G01548767Courtesy of FORD MOTOR CO.
  52. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
    NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
    Fig 33: Positioning Timing Chain On Camshaft Sprocket With Camshaft Sprocket Timing Mark
    G01548768Courtesy of FORD MOTOR CO.
  53. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
  54. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
    Fig 34: Installing LH Timing Chain Tensioner
    G01548769Courtesy of FORD MOTOR CO.
  55. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
  56. Remove the retaining clip from the LH timing chain tensioner.
    Fig 35: Removing Retaining Clip From LH Timing Chain Tensioner
    G01548770Courtesy of FORD MOTOR CO.
  57. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
    Fig 36: Aligning Timing Mark On Sprocket With Single Copper (Marked) Chain Link
    G01548771Courtesy of FORD MOTOR CO.
  58. 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.
  59. NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.
    Fig 37: Positioning RH Timing Chain On Camshaft Sprocket
    G01548772Courtesy of FORD MOTOR CO.
  60. 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.
  61. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    Fig 38: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
    G01548773Courtesy of FORD MOTOR CO.
  62. Remove the retaining clip from the RH timing chain tensioner.
    Fig 39: Removing Retaining Clip From RH Timing Chain Tensioner
    G01548774Courtesy of FORD MOTOR CO.
  63. As a post-check, verify correct alignment of all timing marks.
    Fig 40: Identifying Alignment Timing Marks
    G01548775Courtesy of FORD MOTOR CO.
  64. Remove the special tool.
    Fig 41: Removing Special Tool
    G01548776Courtesy of FORD MOTOR CO.
  65. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 42: Installing Special Tool Between Valve Spring Coils
    G01548777Courtesy of FORD MOTOR CO.
  66. NOTE: Lubricate the camshaft roller followers with clean engine oil.
    Fig 43: Installing Camshaft Roller In Original Locations
    G01548778Courtesy of FORD MOTOR CO.
  67. Install the camshaft roller followers.
    1. Install the special tool.
    2. Compress the valve springs.
    3. Install the camshaft roller followers in their original locations.
  68. Remove the special tool.
    Fig 44: Removing Special Tool
    G01548779Courtesy of FORD MOTOR CO.
  69. Install the crankshaft sensor ring on the crankshaft.
    Fig 45: Installing Crankshaft Sensor Ring On Crankshaft
    G01548780Courtesy of FORD MOTOR CO.
  70. 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, 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 46: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Sealing Surfaces
    G01548781Courtesy of FORD MOTOR CO.
  71. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block sealing surfaces, at the locations shown.
  72. 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
    G01548782Courtesy of FORD MOTOR CO.
  73. Tighten the engine front cover fasteners in sequence in three stages.

    Stage 1: Tighten fasteners 1 through 5 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: Identifying Bolts Tightening Sequence Of Engine Front Cover
    G01548783Courtesy of FORD MOTOR CO.
    Fig 49: Bolts Tightening Specifications
    G01548784Courtesy of FORD MOTOR CO.
  74. Install the oil pump screen and pickup tube spacer.
    Fig 50: Installing Oil Pump Screen
    G01548785Courtesy of FORD MOTOR CO.
  75. 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 the O-ring with clean engine oil.
    Fig 51: Positioning Oil Pump Screen
    G01548786Courtesy of FORD MOTOR CO.
  76. Position the oil pump screen and pickup tube and install the bolts.
  77. NOTE: Clean and inspect the mating surfaces, and install new gaskets.
    Fig 52: Installing Bolts
    G01548787Courtesy of FORD MOTOR CO.
  78. Position the oil filter adapter and install the four bolts.
  79. Install the rear nut.
    Fig 53: Installing Rear Nut
    G01548788Courtesy of FORD MOTOR CO.
  80. Position the engine mounts to the cylinder block and install the six bolts.
    Fig 54: Positioning Engine Mounts To Cylinder Block
    G01548789Courtesy of FORD MOTOR CO.
  81. Position the belt idler pulley and install the bolt.
    Fig 55: Positioning Belt Idler Pulley And Installing Bolt
    G01548790Courtesy of FORD MOTOR CO.
  82. 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 56: Positioning Coolant Pump Into Engine Block
    G01548791Courtesy of FORD MOTOR CO.
  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.
  84. Lubricate the engine front cover and the front seal inner lip with clean engine oil.
    Fig 57: Lubricating Engine Front Cover And Front Seal Inner Lip With Clean Engine Oil
    G01548792Courtesy of FORD MOTOR CO.
  85. Use the special tools to install the crankshaft front seal into the engine front cover.
    Fig 58: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
    G01548793Courtesy of FORD MOTOR CO.
  86. 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 59: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G01548794Courtesy of FORD MOTOR CO.
  87. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  88. Use the special tool to install the crankshaft pulley.
    Fig 60: Installing Crankshaft Pulley Using Special Tool
    G01548795Courtesy of FORD MOTOR CO.
  89. Install a new crankshaft pulley bolt and tighten the 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 61: Installing Crankshaft Pulley Bolt
    G01548796Courtesy of FORD MOTOR CO.
  90. Position the coolant pump pulley on the coolant pump and install the bolts.
    Fig 62: Positioning Coolant Pump Pulley On Coolant Pump
    G01548797Courtesy of FORD MOTOR CO.
  91. Install the oil drain plug.
    Fig 63: Installing Oil Drain Plug
    G01548798Courtesy of FORD MOTOR CO.
  92. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new LH valve cover gasket.
    Fig 64: Installing LH Valve Cover Gasket
    G01548799Courtesy of FORD MOTOR CO.
  93. NOTE: If not secured within four minutes, 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 65: Applying Silicone Gasket And Sealant In Engine Front Cover Meets Cylinder Head
    G01548800Courtesy of FORD MOTOR CO.
  94. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  95. Position the LH valve cover and the valve cover gasket on the cylinder head and install the bolts loosely.
    Fig 66: Positioning LH Valve Cover And Valve Cover Gasket On Cylinder Head
    G01548801Courtesy of FORD MOTOR CO.
  96. Tighten the bolts in the sequence shown.
    Fig 67: Identifying Bolts Tightening Sequence
    G01548802Courtesy of FORD MOTOR CO.
  97. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new RH valve cover gasket.
    Fig 68: Installing RH Valve Cover Gasket
    G01548803Courtesy of FORD MOTOR CO.
  98. 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 69: Applying Silicone Gasket And Sealant In Two Places Engine Front Cover Meets Cylinder Head
    G01548804Courtesy of FORD MOTOR CO.
  99. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  100. Position the RH valve cover on the cylinder head and install the bolts loosely.
    Fig 70: Positioning RH Valve Cover On Cylinder Head
    G01548805Courtesy of FORD MOTOR CO.
  101. Tighten the bolts in the sequence shown.
    Fig 71: Identifying Bolts Tightening Sequence
    G01548806Courtesy of FORD MOTOR CO.
  102. Install the crankcase ventilation tube on the LH valve cover.
    Fig 72: Installing Crankcase Ventilation Tube On LH Valve Cover
    G01548807Courtesy of FORD MOTOR CO.
  103. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
    Fig 73: Installing Positive Crankcase Ventilation (PCV) Valve And Hose In RH Valve Cover
    G01548808Courtesy of FORD MOTOR CO.
  104. NOTE: RH shown, LH similar.
    Fig 74: Installing Radio Frequency Interference Capacitors
    G01548809Courtesy of FORD MOTOR CO.
  105. Install the radio frequency interference capacitors.
  106. Install the engine control sensor wiring harness.
  107. Install the special tool.
    Fig 75: Installing Special Tool (1 Of 2)
    G01548810Courtesy of FORD MOTOR CO.
  108. Install the special tool.
    Fig 76: Installing Special Tool (2 Of 2)
    G01548811Courtesy of FORD MOTOR CO.
  109. Install the special tool and remove the engine from the work stand.
    Fig 77: Removing Engine From Work Stand
    G01548812Courtesy of FORD MOTOR CO.
  110. 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.
  111. 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.
  112. 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 78: Applying Bead Of Silicone Gasket And Sealant Around Rear Oil Seal Retainer Sealing Surface
    G01548813Courtesy of FORD MOTOR CO.
  113. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
  114. Install the rear oil seal retainer plate and loosely install the six bolts.
    Fig 79: Installing Rear Oil Seal Retainer Plate
    G01548814Courtesy of FORD MOTOR CO.
  115. Tighten the bolts in the sequence shown.
    Fig 80: Tightening Bolts In Sequence
    G01548815Courtesy of FORD MOTOR CO.
  116. 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.
  117. 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.
  118. 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 81: Applying Silicone Gasket And Sealant At Rear Oil Seal Retainer-To-Cylinder Block Sealing Surface
    G01548816Courtesy of FORD MOTOR CO.
  119. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
  120. 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 82: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
    G01548817Courtesy of FORD MOTOR CO.
  121. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
  122. Install the oil pan gasket and the oil pan and loosely install the bolts.
    Fig 83: Installing Oil Pan Gasket And Oil Pan
    G01548818Courtesy of FORD MOTOR CO.
  123. Tighten the bolts in three stages, in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    Fig 84: Identifying Bolts Tightening Sequence
    G01548819Courtesy of FORD MOTOR CO.
  124. Lower the engine onto wooden blocks.
  125. Remove the special tool.
    Fig 85: Removing Special Tool (1 Of 2)
    G01548820Courtesy of FORD MOTOR CO.
  126. Remove the special tool.
    Fig 86: Removing Special Tool (2 Of 2)
    G01548821Courtesy of FORD MOTOR CO.
  127. Install the special tool and raise the engine.
    Fig 87: Installing Special Tool
    G01548822Courtesy of FORD MOTOR CO.
  128. NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.
    Fig 88: Installing Crankshaft Rear Oil Seal Using Special Tool
    G01548823Courtesy of FORD MOTOR CO.
  129. Using the special tools, install a new crankshaft rear oil seal.
  130. Using the special tools, install the crankshaft rear oil slinger.
    Fig 89: Installing Crankshaft Rear Oil Slinger Using Special Tool
    G01548824Courtesy of FORD MOTOR CO.
  131. Install the flexplate and bolts. Tighten the bolts in the sequence shown.