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1 Page 1 of 14 Oil Pan Removal & Installation 4.2L Engine 4WD Vehicles To Remove: 1. Before servicing the vehicle refer to the precautions at the beginning of this section. 2. Raise and support the vehicle. 3. Remove or disconnect the following: The oil pan plug The engine oil into an appropriate container The front differential The front differential support The three oil pan to transmission bolts The 15 oil pan to cylinder block bolts and the oil pan To Install: 1. Temporarily install two locator dowels if needed NOTE: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M A. Use Silicone Gasket and Sealant F7AZ EA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Thoroughly clean the oil pan 3. Install or connect the following: Sealant to the oil pan sealing areas indicated The oil pan rear seal NOTE: If the oil pan is not installed within 15 minutes the sealant must be removed and reapplied.
2 Page 2 of 14 Sealant to the rear main bearing cap (A) The oil pan rear seal (B) Sealant to the oil pan mating surface (C) The oil pan The oil pan bolts (finger tight) 4. Tighten the bolts in two stages the sequence indicated: Torque to: 44 inch lbs. (5 Nm) Torque to: 89 inch lbs. (10 Nm) 5. Install or connect the following: The oil pan-to-transmission bolts A. Torque to 33 ft-lbs (45 Nm) The oil pan drain plug The front differential support
3 Page 3 of 14 The front differential 6. Safely lower the vehicle 7. Install or connect the following: The negative battery cable Engine oil into the crankcase 2WD Vehicles To Remove: 1. Before servicing the vehicle refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: The engine The oil dip stick tube The oil dip stick tube O-ring seal (discard) The oil bypass filter The oil pan The bolts To Install: NOTE: If the oil pan is not installed within four minutes, remove the sealer and reapply. Clean and apply the sealant to the oil pan sealing areas indicated and install the oil pan rear seal. To Install: 1. Install or connect the following:
4 Page 4 of 14 The sealant to the rear main bearing cap The oil pan rear seal The sealant to the oil pan mating surface The oil pan Tighten the bolts in two stages in the sequence shown: A. Torque to: 44 inch lbs. (5 Nm) B. Torque to: 89 inch lbs. (10 Nm) 2. Install or connect the following: The oil bypass filter A new O-ring seal to the dipstick tube The oil dip stick and tube The bolt A. Torque to: 89 inch-lbs (10 Nm) The engine into the vehicle 4.6L/5.4L Engines 4WD Vehicles To Remove: 1. Before servicing the vehicle refer to the precautions at the beginning of this section. 2. Raise and support the vehicle. 3. Drain the engine oil 4. Support the front axle housing using a jack stand 5. Remove or disconnect the following: The front axle mount bolt
5 Page 5 of 14 The axle support bolts The axle support CAUTION When lowering the front axle housing, use care to ensure the vacuum lines to the axle solenoid do not become disconnected or damaged. The right and front axle housing mount bolts 6. Lower the axle to allow clearance for the oil pan to be removed 7. Remove the oil pan CAUTION Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting In leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil pan gasket. Clean the sealing surfaces with metal surface-cleaner. NOTE: Allow the surfaces to dry for four minutes or until there is no sign of wetness, Failure to do so can cause future oil leaks. To Install: NOTE: If the oil pan and gasket are not secured within four minutes of sealer application, the sealant must be removed and the sealing surfaces cleaned with metal surface cleaner.
6 Page 6 of Install or connect the following: Silicone gasket and sealant in two places The new oil pan gasket and the oil pan The bolts (finger tight) 2. Tighten the bolts in three stages in the sequence shown: Torque to: 18 inch lbs. (2 Nm) Torque to: 15 ft. lbs. (20 Nm)
7 Page 7 of 14 Torque an additional Install or connect the following: The drain plug A. Torque to: ft-lbs. (8-11Nm) The front axle housing The bolts (finger tight) A. Torque to: 66 ft-lbs (90 Nm) 4. Remove the jack stand. 5. Safely lower the vehicle. CAUTION The oil pump must be primed prior to starting the engine. 6. Fill the engine with clean engine oil. 7. Start the engine and inspect for leaks. 2WD Vehicles To Remove: Special Service Tools (SST) needed: 3-Bar Engine Support 303-F Before servicing the vehicle refer to the precautions at the beginning of this section.
8 Page 8 of Remove or disconnect the following: The negative battery cable The coolant The radiator air deflector The Engine Air Cleaner (ACL) The air cleaner outlet line The accelerator cable snow shield The accelerator cable The speed control actuator cable The accelerator return spring The accelerator cable bracket bolts and position the bracket and cables aside The vapor management valve hose The crankcase ventilation tube and the Idle Air Control (IAC) valve fresh air tube The Exhaust Gas Recirculation (EGR) valve vacuum line The main vacuum harness The throttle position sensor electrical connector The engine vacuum regulator connector The fuel pressure regulator vacuum line The vapor management valve vacuum line The differential pressure feedback EGR The nut The brake booster vacuum line and bracket The fuel lines The idle air control motor electrical connector The EGR valve to exhaust manifold tube aside
9 Page 9 of 14 The four bolts The throttle body adapter The bolts The generator 3. Install the 3-Bar Engine Support Bracket onto the engine using the generator mounting bolts. 4. Raise and support the vehicle. 5. Remove or disconnect the following: The drain plug The engine oil The RH motor mount bolt The LH motor mount bolt 6. Safely lower the vehicle. 7. Raise the engine using the 3-Bar Engine Support. 8. Raise and support the vehicle. NOTE: If undamaged, the oil pan gasket may be reused. 9. Remove the oil pan bolts. 10. Position the oil pan aside to gain access to the oil pump screen cover and tube.
10 Page 10 of Remove or disconnect the following: The bolt securing the rear of the oil pump screen cover and line To Install: The bolts securing the front of the oil pump screen cover and line. 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. Clean and inspect the mating surfaces. 1. Install or connect the following: The oil pan gasket, the oil pan and the oil pump screen cover and line together to the cylinder block
11 Page 11 of 14 The bolts A. Torque to: inch-lbs (8-12 Nm) The bolt A. Torque to: ft-lbs (20-30 Nm) NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure may result in future oil leakage.
12 Page 12 of 14 NOTE: Use Silicone Gasket and Sealant F7AZ EA or equivalent meeting Ford specification WSE-M4G323-A4. The silicone at the engine front cover to cylinder block mating surface The silicone at the rear oil seal retainer to cylinder block sealing surface The oil pan gasket
13 Page 13 of 14 The bolts and tighten in three stages, in the sequence shown. A. Torque to: 18 inch lbs. (2 Nm) B. Torque to: 15 ft. lbs. (20 Nm) C. Torque an additional Safely lower the vehicle. 3. Lower the engine and remove the 3-Bar Engine Support. 4. Raise and support the vehicle. 5. Install or connect the following: The RH motor mount bolt The LH motor mount bolt A. Torque to: ft-lbs (68-92 Nm) The drain plug 6. Safely lower the vehicle. 7. Remove the 3-Bar Engine Support Bracket. 8. Install or connect the following: The generator The fan shroud The bolts The throttle body adapter The four bolts in two stages A. Torque to: 89 inch lbs. (10 Nm) B. Torque an additional 90 The EGR valve to the exhaust manifold line Tighten the fittings (finger tight) Torque the fittings A. Torque to: ft-lbs (40-60 Nm) The two DPF vacuum hoses
14 Page 14 of 14 The idle air control motor The fuel lines The brake booster vacuum line and bracket The nut The differential pressure feedback EGR connections The vapor management valve vacuum line The fuel pressure regulator vacuum line The throttle position sensor connector The engine vacuum regulator connector The EGR valve The main vacuum harness vacuum connections The crankcase ventilation line The IAC fresh air tub The vapor management hose The accelerator cable bracket and the bolts The accelerator cable The speed control actuator cable The throttle return spring The accelerator cable snow shield The bolts The engine air cleaner The air cleaner outlet line The radiator air deflector The negative battery cable Clean engine oil 9. Fill and bleed the cooling system.
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