Oil Pan
Oil Pan
Removal
All engines
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the intake manifold. For additional information, refer to Intake Manifold - 4.6L (2V) Removal and Replacement or Intake Manifold - 5.4L (2V) Removal and Replacement.
3. Remove the fan shroud and the engine cooling fan.
4. Disconnect the generator electrical connections.
1. Remove the B+ terminal nut and disconnect the terminal.
2. Disconnect the S electrical connector.
3. Disconnect the ASI electrical connector.
5. Loosen the 2 bolts and position the generator aside.
6. Remove the retainers and the shield.
4.6L (2V) engine
7. Disconnect the coolant hose from the heater outlet tube and remove the heater outlet tube stud.
5.4L (2V) engine
8. Disconnect the Knock Sensor (KS) electrical connector and engine wiring harness retainers.
9. Disconnect the heater coolant hose from the heater outlet tube.
10. Remove the 2 heater outlet tube studs.
All engines
11. Remove the heater outlet tube.
- Discard the O-ring seals.
12. Remove the 2 upper transmission-to-engine bolts.
13. Assemble the Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
14. Install the Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
15. Install the Engine Support Bar and support the engine.
16. Drain the engine oil, remove and discard the oil filter.
17. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.
18. NOTE: RH shown, LH similar.
Remove the 4 engine support insulator-to-crossmember nuts.
19. Remove the 2 bolts and the flexplate inspection plate.
20. Using the Engine Support Bar, raise the engine 260.35 mm (10.25 in) from the crankshaft pulley to the lower edge of the No. 1 crossmember.
21. Remove the 16 oil pan bolts and partially lower the oil pan.
22. Remove the 3 bolts retaining the oil pump screen and pickup tube. Position the bolts and the oil pump screen and pickup tube in the oil pan.
23. Remove the oil pan from the rear of the engine. Discard the oil pan gasket.
24. NOTICE: 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.
Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
Installation
All engines
1. Position the oil pump screen and pickup tube and the 3 bolts into the oil pan and position the oil pan and new oil pan gasket onto the crossmember.
2. Position the oil pump screen and pickup tube and install the 3 bolts.
- Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
- Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
3. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 the silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
4. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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 silicone gasket and sealant in the locations shown.
5. Position the new oil pan gasket and the oil pan and loosely install the 16 bolts.
4.6L (2V) engine
6. Tighten the bolts in 3 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
5.4L (2V) engine
7. Tighten the bolts in 3 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.
All engines
8. Install a new oil filter.
9. Lower the engine and remove the Engine Support Bar, Engine Lifting Bracket and the Modular Engine Lift Bar Adapter.
10. NOTE: RH shown, LH similar.
Install the 4 engine support insulator-to-crossmember nuts.
- Tighten to 90 Nm (66 lb-ft).
11. Position the flexplate inspection cover and install the 2 bolts.
- Tighten to 34 Nm (25 lb-ft).
4.6L (2V) engines
12. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).
5.4L (2V) engines
13. Position the transmission fluid cooler tubes and support bracket and install the nut.
- Tighten to 28 Nm (21 lb-ft).
All engines
14. Install the 2 upper transmission-to-engine bolts.
- Tighten to 60 Nm (44 lb-ft).
15. NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.
Install the heater outlet tube.
4.6L (2V) engine
16. Connect the coolant hose to the heater outlet tube and install the heater outlet tube stud.
- Tighten to 25 Nm (18 lb-ft).
5.4L (2V) engine
17. Install the 2 heater outlet tube studs.
- Tighten to 40 Nm (30 lb-ft).
18. Connect the coolant hose to the heater outlet tube.
19. Connect the KS electrical connector and engine wiring harness retainers.
All engines
20. Install the retainers and the shield.
21. Position the generator and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
22. Connect the generator electrical connections.
1. Tighten the B+ terminal nut to 8 Nm (71 lb-in).
2. Connect the S electrical connector.
3. Connect the ASI electrical connector.
23. Install the fan shroud and the engine cooling fan.
24. Install the intake manifold. For additional information, refer to Intake Manifold - 4.6L (2V) Removal and Replacement or Intake Manifold - 5.4L (2V) Removal and Replacement.
25. Fill the engine with clean engine oil.
26. Start the engine and check for leaks.