Oil Pan

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

All vehicles 

1. Remove the engine from the vehicle. For additional information, refer to Engine .
2. Remove the 8 bolts and the flywheel.
Fig 1: Identifying Flexplate & Bolts
Courtesy of FORD MOTOR CO.
3. Remove the crankshaft sensor ring.
Fig 2: Identifying Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
NOTE: 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.
Fig 3: Identifying Block Heater Wiring Harness
Courtesy of FORD MOTOR CO.
6. If equipped, disconnect the heated PCV electrical connector.
Fig 4: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
Courtesy of FORD MOTOR CO.
7. Disconnect the PCV hose from the PCV valve.
Fig 5: Identifying PCV Hose From PCV Valve
Courtesy of FORD MOTOR CO.
8. Disconnect the throttle body (TB) electrical connector.
Fig 6: Locating Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
9. Detach the wiring harness retainers from the upper intake manifold.
Fig 7: Locating Wiring Harness Retainers From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
10. If equipped, remove the upper intake manifold long support bracket bolt.
Fig 8: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.
11. Remove the upper intake manifold short support bracket bolt.
Fig 9: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.
12. Remove the fuel tube bracket bolt from the upper intake manifold.
Fig 10: Identifying Bolt
Courtesy of FORD MOTOR CO.
13. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
Fig 11: Identifying Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
14. Disconnect the fuel efficient power steering system solenoid electrical connector.
Fig 12: Identifying Connector
Courtesy of FORD MOTOR CO.
15. Disconnect the power steering pressure (PSP) switch electrical connector.
Fig 13: Identifying PSP Connector
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

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

All vehicles 

17. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
Fig 15: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
18. Disconnect the 3 RH coil-on-plug electrical connectors.
Fig 16: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
19. If equipped, disconnect the heated PCV valve electrical connector.
Fig 17: Locating Heated PCV Valve Electrical Connector
Courtesy of FORD MOTOR CO.
20. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
Fig 18: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
22. Disconnect the LH catalyst monitor sensor electrical connector.
Fig 19: Identifying LH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
23. Disconnect the LH VCT solenoid electrical connector.
Fig 20: Locating LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
24. Disconnect the 3 LH coil-on-plug electrical connectors.
Fig 21: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
25. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
NOTE: LH shown, RH similar.
26. Remove the 6 bolts and the 6 coil-on-plugs.
Fig 22: Locating Coil-On-Plugs & Bolts
Courtesy of FORD MOTOR CO.
NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan.
27. Remove the A/C compressor nut and stud.
Fig 23: Locating A/C Compressor Nut & Stud
Courtesy of FORD MOTOR CO.
28. Remove the PSP tube bracket-to-power steering pump bolt.
Fig 24: Identifying Bracket-To-Power Steering Pump Bolt
Courtesy of FORD MOTOR CO.
29. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
Fig 25: Identifying Nut And PSP Tube Bracket
Courtesy of FORD MOTOR CO.
30. Remove the 3 bolts and position aside the power steering pump.
Fig 26: Identifying Bolts
Courtesy of FORD MOTOR CO.
31. Remove the 3 bolts and the accessory drive belt tensioner.
Fig 27: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
32. Remove the 4 nuts (3 shown) and the LH catalytic converter.
    • Discard the nuts and the gasket.
Fig 28: Locating LH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.

FWD vehicles 

33. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
Fig 29: Identifying Nuts
Courtesy of FORD MOTOR CO.

All vehicles 

34. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
Fig 30: Locating RH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
35. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
Fig 31: Locating LH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
36. Remove the 11 stud bolts and the LH valve cover.
    • Discard the gasket.
Fig 32: Locating LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
37. Remove the bolt, the 10 stud bolts and the RH valve cover.
    • Discard the gasket.
Fig 33: Locating RH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
38. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the special tools, remove the seal(s).
Fig 34: Removing Seals Using Special Tools (205-153) & (303-1247/1)
Courtesy of FORD MOTOR CO.
39. Using the special tool, remove the crankshaft bolt and washer.
    • Discard the bolt.
Fig 35: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
Courtesy of FORD MOTOR CO.
40. Using the special tool, remove the crankshaft pulley.
Fig 36: Identifying Special Tools (303-D121) And Crankshaft Pulley
Courtesy of FORD MOTOR CO.
41. Using the special tool, remove and discard the crankshaft front seal.
Fig 37: Removing Crankshaft Front Seal Using Special Tool (303-409)
Courtesy of FORD MOTOR CO.
42. Remove the 2 bolts and the engine mount bracket.
Fig 38: Locating Engine Mount Bracket & Bolts
Courtesy of FORD MOTOR CO.
43. Remove the 2 engine mount studs.
Fig 39: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
44. Remove the 3 bolts and the engine mount bracket.
Fig 40: Locating Engine Mount Bracket & Bolts
Courtesy of FORD MOTOR CO.
45. Remove the 22 engine front cover bolts.
Fig 41: Identifying Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
46. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
    • Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
      • Remove the engine front cover.
Fig 42: Identifying Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
47. Remove the 16 oil pan bolts.
Fig 43: Identifying Oil Pan Bolts
Courtesy of FORD MOTOR CO.
48. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan.
    • Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
      • Remove the oil pan.
Fig 44: Installing 2 Of Oil Pan Bolts (Finger Tight) Into 2 Threaded Holes In Oil Pan
Courtesy of FORD MOTOR CO.
CAUTION: Only use a 3M Roloc® Bristle Disk (2-in 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 engine front cover. These tools cause scratches and gouges that make leak paths.
49. Clean the engine front cover and 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 engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
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, may cause engine failure.
CAUTION: 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 will cause premature engine failure. Remove all traces of the gasket.
50. Clean the sealing surfaces of the cylinder block 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 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.