Oil Pan: Installation

LHD AWD/LHD RWD 

1. NOTE: If the oil pan is not secured within 10 minutes of silicone sealant application, the silicone sealant must be removed and the sealing area cleaned. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

   Apply a 5 mm bead of silicone sealant on the chamfer, as shown.

   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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2. Install the oil pan and the bolts finger-tight.

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3. Tighten the bolts in sequence shown.

   Torque: 18 lb.ft (25 Nm)

   Fig 1: Oil Pan Tightening Sequence

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4. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.
   • Apply a 3 mm (0.12 in) bead of silicone sealant on the 3 upper bosses, as shown.

     Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   • Apply a 4 mm (0.16 in) bead of silicone sealant on the chamfer on the 2 lower bosses, as shown.

     Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   • Apply a 5 mm (0.19 in) bead of silicone sealant on the chamfer, as shown.

     Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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5. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Apply a 15 mm (0.59 in) drop of silicone sealant at the cylinder head-to-cylinder block and cylinder block-to-oil pan joint areas.

   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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6. Install the engine front cover and the fasteners and tighten in the sequence shown.

   Torque: Bolts 1 - 3: 35 lb.ft (48 Nm) Bolt 4: 18 lb.ft (25 Nm) Bolts 5 - 22: 97 lb.in (11 Nm)

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7. • Lubricate the crankshaft front seal with clean engine oil.
   • NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

     Using the special tools, install the crankshaft front seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

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8. Lubricate the crankshaft pulley with clean engine oil.

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9. Position the crankshaft pulley onto the crankshaft with the access hole at the 6 o'clock position.

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10. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    Install an M6 bolt.

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11. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crank Damper Holding Tool and the bolt should be installed using hand tools only.

    Using the special tool, install the new crankshaft bolt and washer and tighten. Use Special Service Tool: 303-1689 Holding Tool, Crank Damper.

    Torque: Stage 1: 74 lb.ft (100 Nm) - - Stage 2: 90°

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12. Remove the M6 bolt.

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13. NOTE: Do not tighten the CKP sensor bolts at this time.

    Install the CKP sensor and the bolts finger tight.

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14. Install the special tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

    Torque: 97 lb.in (11 Nm)

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15. Remove Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

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16. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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17. Install the engine plug bolt.

    Torque: 177 lb.in (20 Nm)

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18. Remove Special Service Tool: 303-1685 Alignment Tool, Camshaft.

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19. Install the high-pressure fuel pump drive unit and the bolts.

    Torque: 97 lb.in (11 Nm)

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20. NOTE: Installation of new seals is only required if damaged seals were removed during removal.

    If removed, using the special tools, install the VCT oil control solenoid seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1687 Installer, VCT Solenoid Seal.

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21. Install the new valve cover gaskets.

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22. Apply a 5.5 mm (0.22 in) bead of silicone sealant in the 4 places shown.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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23. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Install the valve cover and tighten the fasteners in sequence shown.

    Torque: 97 lb.in (11 Nm)

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24. Inspect and replace any ignition coil-on-plug rubber boots with cracks, rips or tears.

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25. Install the ignition coil-on-plugs and the fasteners.

    Torque: 97 lb.in (11 Nm)

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26. NOTE: The high-pressure fuel pump tappet cam lobe must be positioned at zero lift before installing the high-pressure fuel pump drive unit.

    Rotate the crankshaft to position the camshaft at zero lift.

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27. Inspect the high-pressure fuel pump tappet for flat spots or scoring, especially in the indicated areas. If any damage is found, inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as necessary.

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28. Lubricate the bore and the high-pressure fuel pump tappet with clean engine oil and install.

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29. • Inspect the mounting plate gasket, clean and replace the mounting plate gasket as needed.
    • Make sure that the mating faces are clean and free of foreign material.

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30. Install a new high-pressure fuel pump O-ring seal.

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31. NOTE: Install new bolts.

    Install the high-pressure fuel pump, mounting plate and alternately tighten each new bolt one complete revolution until seated in 2 stages.

    Torque: Stage 1: 115 lb.in (13 Nm) - - Stage 2: 45°

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32. NOTE: Install a new fuel tube.
    • Install the new fuel tube and the bolts finger-tight.
    • Install the flare nuts finger-tight.

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33. Tighten the flare nuts in 2 stages.

    Torque: Stage 1: 89 lb.in (10 Nm) - - Stage 2: 38°

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34. Tighten the bolts.

    Torque: 97 lb.in (11 Nm)

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35. Install the new engine mount stud.

    Torque: 35 lb.ft (48 Nm)

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    LHD AWD 

36. Install a new front axle assembly seal and lubricate.

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37. Install the front axle assembly and the bolts.

    Torque: Stage 1: 66 lb.ft (90 Nm) - - Stage 2: 90°

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38. Install a new axle connector seal and lubricate.

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39. Install the LH axle connector and the bolts.

    Torque: 26 lb.ft (35 Nm)

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    LHD AWD/LHD RWD 

40. Clean the RH engine mount-to-engine block mating surfaces of any dirt or foreign material prior to installation.

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41. Install the RH engine mount and tighten the new bolts and nuts in sequence shown.

    Torque: Stage 1: 66 lb.ft (90 Nm) - - Stage 2: 90°

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42. Install the accessory drive belt tensioner and the bolts.

    Torque: 18 lb.ft (25 Nm)

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43. Install the coolant pump pulley and the bolts finger tight.

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44. Install the air cleaner bracket and the bolts.

    Torque: 59 lb.ft (80 Nm)

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45. Lubricate the coolant tube O-ring seal with clean engine coolant.

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46. NOTE: The coolant tube must be fully seated prior to tighten the bolt.

    Install the coolant tube and the bolts.

    Torque: 97 lb.in (11 Nm)

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47. 1. Install the EGR valve bracket and nut.

       Torque: 97 lb.in (11 Nm)

    2. Install the EGR valve bracket bolt.

       Torque: 97 lb.in (11 Nm)

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48. 1. Install the coolant tube support bracket and the bolt.

       Torque: 97 lb.in (11 Nm)

    2. Install the coolant tube support bracket bolt.

       Torque: 97 lb.in (11 Nm)

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49. • Attach the wiring harness retainers.
    • Connect the wiring harness electrical connectors.

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50. Install the oil level indicator.

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51. • Attach the wiring harness retainers.
    • Connect the wiring harness electrical connectors.

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52. • Attach the wiring harness retainers.
    • Connect the wiring harness electrical connectors.

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53. 1. Install tool and release the tension on the accessory drive belt tensioner.
    2. Install the accessory drive belt.
    3. Release the tool and remove.

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54. Tighten the coolant pump pulley bolts.

    Torque: 18 lb.ft (25 Nm)

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55. Position the A/C compressor belt onto the A/C compressor pulley and around the Stretchy Belt Installer Tool on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C compressor belt. Use Special Service Tool: 303-1252 Stretchy Belt Remover/ Installer Tool.

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56. Install the engine lift equipment.

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57. Remove engine from the mounting stand. Use the General Equipment: Mounting Stand

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58. • NOTE: Special bolts are used for installation. Do not use standard bolts.

      Install the flexplate and the new bolts finger-tight.

    • Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
    • Tighten the bolts in sequence shown in 3 stages.

      Torque: Stage 1: 37 lb.ft (50 Nm) - - Stage 2: 59 lb.ft (80 Nm) - - Stage 3: 83 lb.ft (112 Nm)

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59. Install the engine. Refer to: Engine .