Oil Pan: Service and Repair

Oil Pan





Removal









NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

All Vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Remove the Air Cleaner (ACL) assembly.

3. Remove the battery tray.

4. Remove the oil level indicator.





5. Detach the wiring harness retainer from the starter stud bolt.
- Remove the starter stud bolt.






6. Loosen the 3 upper bellhousing-to-engine bolts 5 mm (0.19 in).





7. Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).


8. Remove and discard the engine oil filter.

9. Remove the exhaust Y-pipe.

10. Remove the engine roll restrictor.

All-Wheel Drive (AWD) vehicles

11. Remove the RH catalytic converter.

12. Remove the RH wheel and tire.

13. Remove the 2 intermediate shaft support bolts, the 5 Power Transfer Unit (PTU) support bracket bolts and the PTU (Power Transfer Unit) support bracket.





All vehicles

14. NOTE: It may be necessary to roll the bottom of the engine back for the Air Conditioning (A/C) compressor stud to clear the subframe.
Remove the A/C (Air Conditioning) compressor nut and stud.






15. Loosen the 3 LH bellhousing-to-engine bolts 5 mm (0.19 in).





16. NOTE: All-Wheel Drive (AWD) vehicle shown, Front Wheel Drive (FWD) similar. Parts removed from graphic for clarity.
Loosen the RH engine-to-bellhousing bolt 5 mm (0.19 in).






17. Remove the 2 fasteners and the inspection cover.





18. Remove the 4 oil pan-to-bellhousing bolts.





19. Separate the engine and transaxle 5 mm (0.19 in).





20. Remove the 4 lower engine front cover bolts.





21. Remove the 16 oil pan bolts.





22. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.





23. NOTICE: Only use a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.

Clean the engine oil pan using a 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.


24. NOTICE: Do not use wire brushes, power abrasive discs or 3M(TM) Roloc(R) Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder block and engine front cover in the following sequence.
1. Remove any large deposits of silicone or gasket material.

2. Apply silicone gasket remover and allow to set for several minutes.

3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep to remove any remaining traces of oil and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.


Installation

All vehicles

1. Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the 2 engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.





2. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The oil pan and the 4 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 3 mm (0.11 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the sealing surface of the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.






3. Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) 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.





4. NOTE: The oil pan and the 4 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 oil pan and bolts 10, 11, 13 and 14 finger tight.






5. Draw the bellhousing up to the engine by tightening the LH bellhousing-to-engine bolt.
- Do not torque at this time.






6. NOTE: All-Wheel Drive (AWD) vehicle shown, Front Wheel Drive (FWD) similar. Parts removed from graphic for clarity.
Draw the bellhousing up to the engine by tightening the RH engine-to-bellhousing bolt.

- Do not torque at this time.






7. Install the 4 oil pan-to-bellhousing bolts.
- Do not torque at this time.






8. NOTE: It may be necessary to roll the bottom of the engine back for the Air Conditioning (A/C) compressor stud to clear the subframe.
Install the A/C (Air Conditioning) compressor nut and stud.

- Tighten the stud to 9 Nm (80 lb-in).

- Hand tighten the nut.






9. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).





10. Install the 4 lower engine front cover bolts.
- Do not torque at this time.






11. Install the remaining oil pan bolts and tighten in the sequence shown.
- Tighten bolts 1 through 9 and 11 through 14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees.

- Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.

- Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.






12. Tighten the 4 lower engine front cover bolts to 24 Nm (18 lb-ft).





13. Tighten the A/C (Air Conditioning) compressor nut to 25 Nm (18 lb-ft).





14. Tighten the 4 oil pan-to-bellhousing bolts to 48 Nm (35 lb-ft).





15. NOTE: All-Wheel Drive (AWD) vehicle shown, Front Wheel Drive (FWD) similar. Parts removed from graphic for clarity.
Tighten the RH engine-to-bellhousing bolt to 48 Nm (35 lb-ft).






16. Tighten the 3 LH bellhousing-to-engine bolts to 48 Nm (35 lb-ft).





17. Install the inspection cover and the 2 fasteners.





All-Wheel Drive (AWD) vehicles

18. Install the Power Transfer Unit (PTU) support bracket, the 5 PTU (Power Transfer Unit) support bracket bolts the 2 intermediate shaft support bolts.
- Tighten the Power Transfer Unit (PTU) support bracket bolts to 70 Nm (52 lb-ft).

- Tighten the 2 intermediate shaft support bolts to 40 Nm (30 lb-ft).






19. Install the RH catalytic converter.

20. Install the RH wheel and tire.

All vehicles

21. Tighten the 3 upper bellhousing-to-engine bolts to 48 Nm (35 lb-ft).





22. NOTE: Do not lubricate the engine oil filter gasket.
Install a new engine oil filter.

- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.


23. Install the engine roll restrictor.

24. Install the starter stud bolt.
- Tighten to 27 Nm (20 lb-in).

- Attach the wiring harness retainer to the starter stud bolt.






25. Install the oil level indicator.





26. Install the battery tray.

27. Install the Air Cleaner (ACL) assembly.

28. Fill the engine with clean engine oil.