Oil Pan Gasket - Oil Leaks
91ford20
Article No.
91-13-7
06/26/91
^ LEAKS - OIL - 2.3L/2.5L - AVAILABILITY OF NEW RTV SEALANT
^ LEAKS - OIL - 2.3L/2.5L - FROM OIL PAN GASKET AND FRONT COVER BOLTS
^ LEAKS - OIL - 2.3L/2.5L - MISDIAGNOSIS LEADS TO REPEAT REPAIRS
FORD: 1984-91 TEMPO 1986-91 TAURUS
LINCOLN-MERCURY: 1984-91 TOPAZ
ISSUE: A new RTV sealant with better sealing characteristics is now available for service use. Current RTV is not as oil resistant in its wet state as the new grade of RTV material (F1AZ-19562-A).
Sometimes oil leaks from other sources have been misdiagnosed as being oil pan gasket and seal leaks. This misdiagnosis often results in repeat repairs.
ACTION: If service is required, use the following procedure to correct or prevent repeat repairs and ensure proper use of RTV for adequate sealing.
1. Perform a pressure leak check as described in the appropriate 1990/91 Car Shop Manual, Engine Diagnosis Test Procedure Section.
^ The engine must be cool. A cool engine is required because a warm engine may not show any leakage with this test procedure.
^ The air pressure should be 2-3 PSI (14 to 21 KPa).
^ Use a solution of liquid detergent and water with a suitable squirt bottle applicator to check the oil pan rails, oil pan front half-round and the entire front cover area.
^ If the area of the soap bubbles (leakage) is too large to isolate the source, reduce the air pressure to pinpoint the location.
2. If no leakage is determined by the pressure leak check, perform an engine black light test as described in the Engine Diagnosis Test Procedure Section of the Shop Manual. (Since it is difficult to shine the black light on certain sections of the oil pan joint and the entire front cover, the pressure leak check in Step # 1 is usually preferred and will produce better results.)
3. If no leakage is determined from either the pressure leak or the black light test, check for leakage from other sources above the oil pan joint. Check the front cover, rocker cover gasket and cylinder head gasket. Repair as necessary.
4. If the oil leakage is coming from the front cover, proceed to Step # 5. If the oil leakage is coming from the oil pan, proceed to Step # 6.
5. Seal the front cover bolts.
a. Remove the front cover and oil pan.
b. Blow out any fluid in the front cover bolt holes in the block.
c. Install a new cover gasket (F13Z-6020-A).
d. Use Gasket Maker (E2AZ-19562-B) on the bolts prior to tightening. Gasket Maker is used instead of a threadlock because it is a thicker material. It will help displace any residual oil in the tapped bolt holes.
e. Tighten the bolts to 6-9 lb.ft. (8-12 N-m).
f. Install the oil pan as described in Step # 8.
6. Remove the oil pan.
7. Prevent the front cover gasket from leaking at a future date by proceeding as follows:
a. Remove the bottom two (2) front cover bolts on the spark plug and manifold side of the engine.
b. Blow out any oil in the bolt holes in the block.
c. Use Gasket Maker (E2AZ-19562-B) on the bolts prior to tightening.
d. Tighten the bolts to 6-9 lb.ft. (8-12 N-m).
e. Tighten the remainder of the lower front cover bolts to 6-9 lb.ft. (8-12 N-m).
8. Before reinstalling the oil pan, use a putty knife, scraper, or wire brush to completely remove all traces of RTV sealant from the front cover, block, rear seal retainer and oil pan sealing surface grooves.
9. Clean any oil residue on the cylinder block rails, front cover, rear seal retainer and oil pan thoroughly with brake cleaner.
CAUTION: DO NOT USE CARBURETOR CLEANER OR ANY OTHER SOLVENT THAT WILL LEAVE A HYDROCARBON RESIDUE ON THE PARTS WHICH WILL PREVENT THE RTV FROM BONDING TO THE ENGINE/OIL PAN. FAILURE TO COMPLETELY CLEAN THE SURFACE PRIOR TO THE USE OF THE BRAKE CLEANER OR USE OF THE INCORRECT SOLVENT COULD RESULT IN A REPEAT REPAIR.
10. Remove and clean the oil pick-up tube and screen assembly. After cleaning, install the pick-up tube and screen assembly.
11. Obtain a tube of the new grade RTV (F1AZ-19562-A) and check the expiration date before using.
WARNING: USE ADEQUATE VENTILATION WHEN APPLYING RTV SEALER.
Figure 1:
12. Apply enough RTV (F1AZ-19562-A) in the oil pan to completely fill the oil pan groove, regardless of the groove size or configuration, Figure 1.
^ Have a bead approximately 0.2" (5 mm) wide by 0.25" (6 mm) high, above the pan surfaces, in both front and rear half-rounds.
^ Have a bead approximately 0.2" (5 mm) wide by .15" (4 mm) high, above the oil pan surfaces, along the rails.
13. Be sure that the groove is completely filled with RTV. Make certain that no air is trapped in the groove because a blow out of the RTV may occur when the engine is heated up during normal engine operations.
^ Have the nozzle of the RTV tube slightly above the oil pan groove.
^ Apply enough RTV to build up the bead above the oil pan surface before moving the nozzle along the groove.
^ Do not lay the RTV nozzle on top of the groove because this may leave air pockets, especially in oil pans with deep grooves, Figure 2.
Figure 2:
CAUTION: APPLYING RTV IN EXCESS OF THE SPECIFIED AMOUNT WILL NOT IMPROVE THE SEALING OF THE OIL PAN. IT COULD CAUSE THE OIL PICK-UP SCREEN TO BECOME PLUGGED WITH PIECES OF RTV.
14. Immediately, within 5 minutes of applying the RTV to the oil pan, install the oil pan against the cylinder block to prevent the RTV from skinning over. Tighten the oil pan bolts as follows:
a. Tighten the oil pan to transaxle bolts to 30-39 lb.ft. (40-54 N-m).
b. Loosen the oil pan to Transaxle bolts one half turn.
c. Tighten the oil pan flange bolts to 15-22 lb.ft. (20-30 N-m). Start in the center of the oil pan and work to the rear of the engine. Then, tighten the bolts from the center working to the front of the engine.
d. Tighten the oil pan to transaxle bolts to 30-39 lb.ft. (40-64 N-m).
CAUTION: DO NOT ADD ENGINE OIL UNTIL ONE HOUR AFTER THE OIL PAN BOLTS HAVE BEEN TIGHTENED. THIS ALLOWS THE OUTSIDE LAYER OF THE RTV TO SKIN OVER PRIOR TO COMING IN CONTACT WITH THE ENGINE OIL.
PART NUMBER PART NAME CLASS
E2AZ-19562-B Ford Gasket Maker AM
F1AZ-19562-A RTV B
F13Z-6020-A Gasket B
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
911307A Perform Engine Oil Leak 0.7 Hr.
Diagnosis.
911307B Perform Front Cover And 6.6 Hr.
Oil Pan Oil Leak Repair -
2.3L Tempo /Topaz.
911307C Perform Front Cover And 5.0 Hr.
Oil Pan Oil Leak Repair -
2.5L Taurus.
911307D Perform Oil Pan Leak 1.3 Hr.
Repair - 2.3L Tempo/Topaz.
911307E Perform Oil Pan Leak 1.9 Hr.
Repair - 2.5L Taurus.
DEALER CODING
BASIC PART NO. CONDITION CODE
6781 77
OASIS CODES: 401000, 499000