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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

3. Remove the battery tray. For additional information, refer to Section 414-01 .

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 RH and LH catalytic converters. For additional information, refer to Section 309-00 .

8. Remove the 2 engine roll restrictors. For additional information, refer to Section 307-01 .

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

10. Remove and discard the engine oil filter.

11. Remove the intermediate shaft assembly. For additional information, refer to Section 205-04 .

12. Remove the 3 bolts and the RH turbocharger bracket.

13. Remove the 3 Power Transfer Unit (PTU) support bracket bolts and the PTU support bracket.

14. Detach the wiring harness retainer from the A/C compressor stud.

15. Remove the A/C compressor nut.
    • Remove the stud from the oil pan boss (stud will remain in compressor housing).

16. Remove the 2 bolts and the LH turbocharger oil return tube.
    • Discard the gasket and the 2 O-ring seals.

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

18. Loosen the RH engine-to-bellhousing bolt 5 mm (0.19 in).

19. Remove the 2 fasteners and the inspection cover.

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

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

22. Remove the 4 lower engine front cover bolts.

23. Remove the 16 oil pan bolts.

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

25. NOTICE: Only use a 3M™ Roloc® 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™ Roloc® 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.

26. NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® 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

1. Apply a 5.5 mm (0.21 in) bead of Motorcraft® 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® 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® 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® 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. 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. Install the A/C compressor stud and nut.
   • 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 compressor nut to 25 Nm (18 lb-ft).

14. Attach the wiring harness retainer to the A/C compressor stud.

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

16. Tighten the RH engine-to-bellhousing bolt to 48 Nm (35 lb-ft).

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

18. Install the inspection cover and the 2 fasteners.

19. Install the Power Transfer Unit (PTU) support bracket and the 3 bolts.
    • Tighten to 70 Nm (52 lb-ft).

20. NOTE: Lubricate the oil pan bore with clean engine oil.

    Using new O-ring seals and gasket, install the LH turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).

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

22. Install the RH turbocharger bracket and the 3 bolts.
    1. Tighten the bolt to 19 Nm (168 lb-in).
    2. Tighten the 2 bolts to 48 Nm (35 lb-ft).

23. Install the intermediate shaft assembly. For additional information, refer to Section 205-04 .

24. 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.

25. Install the 2 engine roll restrictors. For additional information, refer to Section 307-01 .

26. Install the RH and LH catalytic converters. For additional information, refer to Section 309-00 .

27. Install the starter stud bolt.
    • Tighten to 27 Nm (20 lb-in).
    • Attach the wiring harness retainer to the starter stud bolt.

28. Install the oil level indicator.

29. Install the battery tray. For additional information, refer to Section 414-01 .

30. Install the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

31. NOTICE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the oil pan. Failure to follow these instructions may cause engine oil leakage.

    Fill the engine with clean engine oil.