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Oil Pan

Special Tools

Illustration Tool Name Tool Number
GF0000311
 3-Jaw Puller 303-D121
GF0000811
 Handle 205-153 (T80T-4000-W)
GF0029086
 Seal Remover 303-1247/1
GF0000249
 Remover, Oil Seal 303-409 (T92C-6700CH)
GF0000246
 Strap Wrench 303-D055 (D85L-6000-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION: 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, can cause engine failure.

All vehicles 

  1. Remove the engine from the vehicle. For additional information, refer to Engine .
  2. Remove the 8 bolts and the flexplate.
    3. Fig 1: Identifying Flexplate & Bolts
    GF0031416Courtesy of FORD MOTOR CO.
  3. Remove the crankshaft sensor ring.
    4. Fig 2: Identifying Crankshaft Sensor Ring
    GF0029263Courtesy of FORD MOTOR CO.
    CAUTION: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
  4. Mount the engine on a suitable engine stand.
  5. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    • Detach all of the engine block heater harness retainers and remove the harness.
    6. Fig 3: Identifying Block Heater Wiring Harness
    GF0029221Courtesy of FORD MOTOR CO.
  6. Disconnect the positive crankcase ventilation (PCV) fitting electrical connector.
    7. Fig 4: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
    GF0029167Courtesy of FORD MOTOR CO.
  7. Disconnect the PCV hose from the PCV valve.
    8. Fig 5: Identifying PCV Hose From PCV Valve
    GF0029168Courtesy of FORD MOTOR CO.
  8. Disconnect the throttle body electrical connector.
    9. Fig 6: Locating Throttle Body Electrical Connector
    GF0029169Courtesy of FORD MOTOR CO.
  9. Detach the wiring harness retainers from the upper intake manifold.
    10. Fig 7: Locating Wiring Harness Retainers From Upper Intake Manifold
    GF0029170Courtesy of FORD MOTOR CO.
  10. Remove the upper intake manifold support bracket bolt.
    11. Fig 8: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029171Courtesy of FORD MOTOR CO.
  11. Remove the upper intake manifold support bracket bolt.
    12. Fig 9: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029172Courtesy of FORD MOTOR CO.
  12. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
    13. Fig 10: Identifying Upper Intake Manifold Bolts
    GF0029173Courtesy of FORD MOTOR CO.
  13. Disconnect the power steering pressure (PSP) switch electrical connector.
    14. Fig 11: Locating PSP Switch Electrical Connector
    GF0029174Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  14. Disconnect the RH catalyst monitor sensor electrical connector.
    15. Fig 12: Locating RH Catalyst Monitor Electrical Connector
    GF0029150Courtesy of FORD MOTOR CO.

    All vehicles 

  15. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    16. Fig 13: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    GF0029175Courtesy of FORD MOTOR CO.
  16. Disconnect the 3 RH coil-on-plug electrical connectors.
    17. Fig 14: Locating RH Coil-On-Plug Electrical Connectors
    GF0029176Courtesy of FORD MOTOR CO.
  17. Disconnect the heated PCV valve electrical connector.
    18. Fig 15: Locating Heated PCV Valve Electrical Connector
    GF0029177Courtesy of FORD MOTOR CO.
  18. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  19. Disconnect the LH catalyst monitor sensor electrical connector.
    20. Fig 16: Locating LH Catalyst Monitor Sensor Electrical Connector
    GF0029228Courtesy of FORD MOTOR CO.
  20. Disconnect the LH VCT solenoid electrical connector.
    21. Fig 17: Locating LH VCT Solenoid Electrical Connector
    GF0029178Courtesy of FORD MOTOR CO.
  21. Disconnect the 3 LH coil-on-plug electrical connectors.
    22. Fig 18: Locating LH Coil-On-Plug Electrical Connectors
    GF0029179Courtesy of FORD MOTOR CO.
  22. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
    23. NOTE: The A/C compressor must remain bolted to the engine block prior to installing the oil pan.
  23. Remove the A/C compressor nut and stud.
    24. Fig 19: Locating A/C Compressor Nut & Stud
    GF0031417Courtesy of FORD MOTOR CO.
  24. Remove the 3 bolts and the power steering pump.
    25. Fig 20: Locating Power Steering Pump Bolts
    GF0031411Courtesy of FORD MOTOR CO.
  25. Remove the 3 bolts and the accessory drive belt tensioner.
    26. Fig 21: Locating Accessory Drive Belt Tensioner Bolts
    GF0029185Courtesy of FORD MOTOR CO.
  26. Remove the 4 nuts (3 shown) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    27. Fig 22: Locating LH Catalytic Converter Nuts
    GF0029230Courtesy of FORD MOTOR CO.

    FWD vehicles 

  27. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
    28. Fig 23: Locating RH Catalytic Converter Nuts
    GF0029151Courtesy of FORD MOTOR CO.

    All vehicles 

  28. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
    29. Fig 24: Locating RH Cylinder Block Drain Plug
    GF0029232Courtesy of FORD MOTOR CO.
  29. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    30. Fig 25: Locating LH Cylinder Block Drain Plug
    GF0029231Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  30. Remove the 6 bolts and the 6 coil-on-plugs.
    31. Fig 26: Locating Coil-On-Plugs & Bolts
    GF0029180Courtesy of FORD MOTOR CO.
  31. Remove the 11 stud bolts and the LH valve cover.
    • Discard the gasket.
    32. Fig 27: Locating LH Valve Cover Stud Bolts
    GF0029182Courtesy of FORD MOTOR CO.
  32. Remove the bolt, the 10 stud bolts and the RH valve cover.
    • Discard the gasket.
    33. Fig 28: Locating RH Valve Cover Stud Bolts
    GF0029183Courtesy of FORD MOTOR CO.
    NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
  33. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the special tools, remove the seal(s).
    34. Fig 29: Removing Seals Using Special Tools (205-153) & (303-1247/1)
    GF0029092Courtesy of FORD MOTOR CO.
  34. Using the special tool, remove the crankshaft bolt and washer.
    • Discard the bolt.
    35. Fig 30: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
    GF0029103Courtesy of FORD MOTOR CO.
  35. Using the special tool, remove the crankshaft pulley.
    36. Fig 31: Removing Crankshaft Pulley Using Special Tool (303-D121)
    GF0017017Courtesy of FORD MOTOR CO.
  36. Using the special tool, remove and discard the crankshaft front seal.
    37. Fig 32: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0029106Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and the engine mount bracket.
    38. Fig 33: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  38. Remove the 2 engine mount studs.
    39. Fig 34: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  39. Remove the 3 bolts and the engine mount bracket.
    40. Fig 35: Locating Engine Mount Bracket & Bolts
    GF0029188Courtesy of FORD MOTOR CO.
  40. Remove the 22 engine front cover bolts.
    41. Fig 36: Identifying Engine Front Cover Bolts
    GF0029189Courtesy of FORD MOTOR CO.
  41. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
    1. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.
    42. Fig 37: Identifying Engine Front Cover Bolts
    GF0029190Courtesy of FORD MOTOR CO.
  42. Remove the 16 oil pan bolts.
    43. Fig 38: Identifying Oil Pan Bolts
    GF0029265Courtesy of FORD MOTOR CO.
  43. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan.
    1. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
    2. Remove the oil pan.
    44. Fig 39: Installing 2 Of Oil Pan Bolts (Finger Tight) Into 2 Threaded Holes In Oil Pan
    GF0029266Courtesy of FORD MOTOR CO.
    CAUTION: Only use a 3M Roloc® Bristle Disk, (2 inch, white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
  44. Clean the engine front cover and oil pan using a 3M Roloc® Bristle Disk, (2 inch, white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
    • Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
    45. CAUTION: Place clean, lint free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, can cause engine failure.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of sealant.
    CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
  45. Clean the sealing surfaces of the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
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