Installation

Engine - Pickup Chassis

Special Service Tool(s):

Special Service Tool(s)

Installation
1. Attach the Modular Lifting Bar.
2. Remove the engine from the engine stand.

3. 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.

Clean and inspect the mating surfaces of the cylinder block and the retainer plate.

4. Note: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.





Apply a bead of silicone around the rear oil seal retainer sealing surface.
^ Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





5. Install the retainer plate. Tighten the bolts to 8-12 Nm (71-107 inch lbs.).





6. Use the Rear Crankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal.
7. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer to install the crankshaft oil slinger.





8. Install the flexplate.
9. Position the engine in the vehicle and remove the Modular Lifting Bar and the jack supporting the transmission.
10. Raise and support the vehicle.





11. Install and tighten the nuts.





12. Install the lower transmission to engine bolts.





13. Install the access plug.





14. Install and tighten the four new nuts retaining the torque converter.
15. Install the flywheel inspection cover.





16. Install the wiring bracket.
17. Install the starter motor.





18. Install and tighten the nuts.





19. Install the ground strap.





20. Install the transmission cooler line bracket.





21. Install the oil cooler to the oil filter adapter and install the oil bypass filter.
22. Lower the vehicle.





23. Install the remaining transmission-to-engine bolts and fuel line bracket.





24. Connect the transmission wiring harness and the LH and RH heated exhaust gas oxygen sensor connectors.





25. Connect the heater hose.





26. Install the suction line to the accumulator.





27. Connect the A/C cycling switch.





28. Install the bolt.





29. Connect the connector and position the harness aside.





30. Install the power steering pump.
31. Install the intake manifold.





32. Install the harness mounting bracket and connect the 42-pin and 16-pin connector.
33. Install the upper and lower radiator supports, grille opening panel, front stone shield and grille.
34. Install the A/C condenser core.
35. Install the radiator.
36. Install the engine Air Cleaner (ACL) and the air cleaner outlet tube.
37. Fill all fluids to the correct levels.
38. Connect the battery ground cable.
39. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
40. Evacuate and recharge the A/C system.