Oil Pump: Installation

4x2/4x4 

1. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.

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2. Install the oil pump and the bolts.

   Torque: 89 lb.in (10 Nm)

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3. Install a new oil pump screen and pickup tube O-ring seal.

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4. Install the oil pump screen and pickup tube and the bolts.

   Torque: 89 lb.in (10 Nm)

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5. NOTE: The oil pan and the specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

   Apply a 5 mm (0.20 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

   Material

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

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6. Apply a 9 mm (0.35 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

   Material

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

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7. NOTE: The oil pan and the specified bolts must be installed within 4 minutes of the start of sealant application.
   NOTE: Keep the oil pan as close as possible to the transmission while installing, then slide forward towards the engine front cover to prevent wiping off of the sealant.

   Install the bolts finger tight.

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8. NOTE: Do not torque at this time.

   Install the bolts finger tight.

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9. NOTE: Do not torque at this time.

   Install the bolt finger tight.

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10. Tighten the oil pan bolts in sequence.

    Torque: 27 lb.in (3 Nm)

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11. Install the remaining oil pan bolts and tighten in sequence.

    Torque: Stage 1: Tighten bolts 1-9 and 11-14 to : 177 lb.in (20 Nm); Stage 2: Tighten bolt 1-9 and 11-14 additional : 45°; Stage 3: Tighten bolt 10 to : 177 lb.in (20 Nm); Stage 4: Tighten bolt 10 an additional : 45°; Stage 5: Tighten bolts 15 and 16 to : 89 lb.in (10 Nm); Stage 6: Tighten bolts 15 and 16 an additional : 90°

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12. Tighten the oil pan bolts.

    Torque: 35 lb.ft (48 Nm)

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13. Tighten the oil pan bolt.

    Torque: 35 lb.ft (48 Nm)

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14. Attach the generator wiring harness retainer to the engine block.

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    4x4 

15. NOTE: Use care when positioning the front axle housing or the vacuum lines to the axle solenoid may become disconnected or damaged.

    Using an adjustable stand, raise the front axle carrier into position. Use the General Equipment: Vehicle/Axle Stands

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16. NOTE: It may be necessary to reposition the axle assembly to prevent interference with the steering components when installing the bolt.

    Install the new upper front axle carrier mounting bushing nut and the bolt finger tight.

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17. Install the new axle shaft housing carrier bushing nut and the bolt finger tight.

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18. Install the new lower front axle carrier mounting bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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19. Tighten the axle shaft housing carrier bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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20. Tighten the upper front axle carrier mounting bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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21. Remove the adjustable stand. Use the General Equipment: Vehicle/Axle Stands

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22. Install the steering gear boot.

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23. 1. Position back the steering column shaft U-joint to the steering gear.
    2. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

       Install a new steering column shaft bolt.

       Torque: 22 lb.ft (30 Nm)

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24. Remove the holding device from the steering wheel.

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    4x2/4x4 

25. Position the cooler tubes to the oil pan and install the pin-type retainer.

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26. Position the cooler tubes back and install the nut.

    Torque: 124 lb.in (14 Nm)

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27. Position the sway bar back and install the nuts.

    Torque: 41 lb.ft (55 Nm)

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28. Position the crossmember, install the nuts and bolts.

    Torque: 66 lb.ft (90 Nm)

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29. Install the timing chain sprocket.

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30. NOTE: The crankshaft sprocket is reversible with a timing mark on each face. For installation of each timing chain, utilize the timing mark on the front face of the crankshaft sprocket for chain alignment.
    1. Install the LH timing chain with the single colored links aligned with the timing marks on the VCT units.
    2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

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31. Install the LH timing chain tensioner arm.

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32. Position the tensioner in a soft-jawed vise.

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33. NOTE: Use of a commercially available tools with a curved radius in the range of 10mm - 15mm is suggested for use in resetting the ratchet clip. Examples are a 8mm closed end wrench, 12x12mm piece of bar stock, T40 to T50 Torx screwdriver or 3/8 wobble style socket extender.

    Using a commercially available wrench, push down on the ratchet clip so the ratchet clip pushes outward.

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34. 1. Using the soft-jawed vise, compress the piston to the reset position.
    2. Install a locking pin in the 2 holes of the tensioner body to hold the piston in place.
    3. Remove the commercially available tool and the tensioner.

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35. Position the LH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm and install the fasteners.

    Torque: 89 lb.in (10 Nm)

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36. Install the LH timing chain guide and bolts.

    Torque: Stage 1: 89 lb.in (10 Nm); Stage 2: 30°

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37. Remove the tensioner pins.

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38. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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39. Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

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40. NOTE: The crankshaft sprocket is reversible with a timing mark on each face. For installation of each timing chain, utilize the timing mark on the front face of the crankshaft sprocket for chain alignment.
    1. Install the RH timing chain with the single colored links aligned with the timing marks on the VCT units.
    2. Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

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41. Install the RH timing chain tensioner arm.

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42. Position the tensioner in a soft-jawed vise.

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43. NOTE: Use of a commercially available tools with a curved radius in the range of 10mm - 15mm is suggested for use in resetting the ratchet clip. Examples are a 8mm closed end wrench, 12x12mm piece of bar stock, T40 to T50 Torx screwdriver or 3/8 wobble style socket extender.

    Using a commercially available wrench, push down on the ratchet clip so the ratchet clip pushes outward.

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44. 1. Using the soft-jawed vise, compress the piston to the reset position.
    2. Install a locking pin in the 2 holes of the tensioner body to hold the piston in place.
    3. Remove the commercially available tool and the tensioner.

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45. Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm and install the fasteners.

    Torque: 89 lb.in (10 Nm)

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46. Install the RH timing chain guide and bolts.

    Torque: 89 lb.in (10 Nm)

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47. Remove the tensioner pins.

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48. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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49. Install the engine front cover. Refer to: Engine Front Cover .