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Oil Pan - Manual Transmission: Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.
  1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
    2. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
    Fig 1: Installing Oil Pump Screen And Pickup Tube
    G01548487Courtesy of FORD MOTOR CO.
  2. Install the oil pump screen and pickup tube.
    • Position the oil pump screen and pickup tube on the engine.
    • Install the bolts.
    3. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
  3. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
    4. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 2: Applying Bead Of Silicone Gasket And Sealant At Crankshaft Rear Seal Retainer-To-Cylinder Block Surface
    G01548488Courtesy of FORD MOTOR CO.
    Fig 3: Applying Bead Of Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Surface
    G01548489Courtesy of FORD MOTOR CO.
  4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
    5. NOTE: Be sure to tighten the bolts in three stages.
    Fig 4: Identifying Bolts Tightening Sequence
    G01548490Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
  6. Lower the transmission.
  7. Install the transmission mount nuts.
    Fig 5: Installing Transmission Mount Nuts
    G01548491Courtesy of FORD MOTOR CO.
  8. Install the driveshaft. Refer to DRIVESHAFT .
  9. Remove the High Lift Transmission Jack and the special tool from the transmission.
    Fig 6: Removing High Lift Transmission Jack And Special Tool From Transmission
    G01548492Courtesy of FORD MOTOR CO.
  10. Reinstall the transmission pan-to-case bolts that were removed to install the E4OD Transmission Jack Adapter.
    Fig 7: Installing Transmission Pan-To-Case Bolts
    G01548493Courtesy of FORD MOTOR CO.
  11. If the vehicle is equipped with TSS and turbine/OSS, remove the plugs and install the sensors in the transmission.
  12. Install the flywheel inspection plate.
    Fig 8: Installing Flywheel Inspection Plate
    G01548494Courtesy of FORD MOTOR CO.
  13. Install the dual converter Y-pipe. Refer to EXHAUST SYSTEM .
  14. Install the oil bypass filter.
  15. Lower the vehicle.
  16. Align the engine mount studs and lower the engine, using the Heavy Duty Engine Support.
    Fig 9: Aligning Engine Mount Studs And Lower Engine, Using Heavy Duty Engine Support
    G01548495Courtesy of FORD MOTOR CO.
  17. Remove the Heavy Duty Engine Support.
  18. Raise and support the vehicle.
  19. Install the engine mount nuts.
    Fig 10: Installing Engine Mount Nuts
    G01548496Courtesy of FORD MOTOR CO.
  20. Lower the vehicle.
  21. Remove the modular engine support bracket from the engine.
    Fig 11: Removing Modular Engine Support Bracket From Engine
    G01548497Courtesy of FORD MOTOR CO.
  22. Install the fan shroud.
  23. Install the generator. Refer to GENERATORS & REGULATORS .
  24. Install the throttle body adapter.
    • Position a new throttle body adapter gasket.
    • Position the throttle body adapter.
    • Install the four bolts.
    Fig 12: Installing Bolts
    G01548498Courtesy of FORD MOTOR CO.
  25. If equipped, connect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 13: Connecting EGR Vacuum Regulator Solenoid Electrical And Vacuum Connections
    G01548499Courtesy of FORD MOTOR CO.
  26. If equipped, connect the EGR valve vacuum hose.
    Fig 14: Connecting EGR Valve Vacuum Hose
    G01548500Courtesy of FORD MOTOR CO.
  27. If equipped, install the differential pressure feedback EGR system bracket.
    • Position the bracket.
    • Install the bolts.
    Fig 15: Installing Differential Pressure Feedback EGR System Bracket
    G01548501Courtesy of FORD MOTOR CO.
  28. If equipped, install the exhaust manifold to EGR valve tube.
    • Hand-tighten the fittings.
    • Tighten the upper fitting to 40-60 Nm (30-44 lb-ft).
    • Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).
    Fig 16: Installing Exhaust Manifold To EGR Valve Tube
    G01548502Courtesy of FORD MOTOR CO.
  29. If equipped, connect the differential pressure feedback EGR system vacuum lines.
    Fig 17: Connecting Differential Pressure Feedback EGR System Vacuum Lines
    G01548503Courtesy of FORD MOTOR CO.
  30. If equipped, connect the differential pressure feedback EGR system electrical connector.
    Fig 18: Connecting Differential Pressure Feedback EGR System Electrical Connector
    G01548504Courtesy of FORD MOTOR CO.
  31. Connect the TP sensor electrical connector.
    Fig 19: Connecting TP Sensor Electrical Connector
    G01548505Courtesy of FORD MOTOR CO.
  32. Connect the heater hose.
    Fig 20: Connecting Heater Hose
    G01548506Courtesy of FORD MOTOR CO.
  33. Connect the IAC electrical connector.
    Fig 21: Connecting IAC Electrical Connector
    G01548507Courtesy of FORD MOTOR CO.
  34. Connect the brake booster vacuum hose and main vacuum harness to the throttle body adapter.
    Fig 22: Connecting Brake Booster Vacuum Hose And Main Vacuum Harness To Throttle Body Adapter
    G01548508Courtesy of FORD MOTOR CO.
  35. Connect the evaporative emission canister purge valve vacuum hose to the throttle body adapter.
    Fig 23: Connecting Evaporative Emission Canister Purge Valve Vacuum Hose To Throttle Body Adapter
    G01548509Courtesy of FORD MOTOR CO.
  36. Install the IAC fresh air tube and insert it in the routing clip.
    Fig 24: Installing IAC Fresh Air Tube
    G01548510Courtesy of FORD MOTOR CO.
  37. Install the accelerator cable bracket.
    • Position the bracket and cables.
    • Install the bolts.
    Fig 25: Installing Bolts
    G01548511Courtesy of FORD MOTOR CO.
  38. Connect the throttle body cam.
    • Connect the accelerator cable.
    • If equipped, connect the speed control cable.
    • Install the throttle return spring.
    Fig 26: Installing Throttle Return Spring
    G01548512Courtesy of FORD MOTOR CO.
  39. Install the accelerator cable snow shield.
    Fig 27: Installing Accelerator Cable Snow Shield
    G01548513Courtesy of FORD MOTOR CO.
  40. Install the air cleaner outlet pipe.
  41. Connect the battery ground cable.
  42. Connect the upper radiator hose to the radiator.
    43. CAUTION: The oil pump must be primed prior to starting the engine.
  43. Fill the engine with clean engine oil.
  44. Fill and bleed the cooling system. Refer to ENGINE COOLING .
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