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Oil Pan - Manual Transmission: Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Clean and inspect the oil pump screen cover and tube mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.
    NOTE: The oil pump screen cover and 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. Install the oil pump screen and pickup tube.
    1. Install and tighten the spacer.
    2. Insert the oil pump screen pickup tube into the oil pump and position the support bracket over the spacer.
    3. Install and tighten the bolts.
    Fig 1: Installing Oil Pump Screen And Pickup Tube
    G01544822Courtesy of FORD MOTOR CO.
    3. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  3. Apply a bead of silicone gasket and sealant where the front cover and rear crankshaft seal retainer fit to the engine block.
    4. NOTE: Be sure to tighten the bolts in three stages.
    Fig 2: Identifying Bolts Tightening Sequence
    G01544823Courtesy of FORD MOTOR CO.
  4. 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.
  5. Attach the transmission cooling tube bracket and install the nut.
    Fig 3: Attaching Transmission Cooling Tube Bracket And Installing Nut
    G01544824Courtesy of FORD MOTOR CO.
  6. Lower the transmission.
  7. Install the transmission mount nuts.
    Fig 4: Installing Transmission Mount Nuts
    G01544825Courtesy of FORD MOTOR CO.
  8. Remove the High Lift Transmission Jack.
  9. If the vehicle is equipped with output shaft sensors (OSS), remove the plugs and install the sensors in the transmission.
  10. Install the flywheel inspection plate.
  11. Install the dual converter Y-pipe. Refer to EXHAUST SYSTEM .
  12. Position the engine oil cooler adapter and install the bolt.
    Fig 5: Positioning Engine Oil Cooler Adapter And Installing Bolt
    G01544826Courtesy of FORD MOTOR CO.
  13. Install the oil bypass filter.
  14. Lower the vehicle.
  15. Using a floor crane, remove the special tool.
    Fig 6: Removing Special Tool Using Floor Crane
    G01544827Courtesy of FORD MOTOR CO.
  16. Align the engine mount studs and lower the engine.
  17. Remove the floor crane.
  18. Raise and support the vehicle.
  19. Install the engine mount nuts.
    Fig 7: Installing Engine Mount Nuts
    G01544828Courtesy of FORD MOTOR CO.
  20. Lower the vehicle.
  21. Remove the special tool from the engine.
    Fig 8: Removing Special Tool From Engine
    G01544829Courtesy of FORD MOTOR CO.
  22. Install the generator. Refer to GENERATORS & REGULATORS .
  23. Install the fan shroud.
  24. Position the degas bottle and install the bolts.
    Fig 9: Positioning Degas Bottle And Installing Bolts
    G01544830Courtesy of FORD MOTOR CO.
  25. Install the jack handle.
    Fig 10: Installing Jack Handle
    G01544831Courtesy of FORD MOTOR CO.
    26. NOTE: The idle air control valve is shown removed for clarity.
    Fig 11: Installing Throttle Body Adapter
    G01544832Courtesy of FORD MOTOR CO.
  26. Install the throttle body adapter
    • Position a new throttle body adapter gasket.
    • Position the throttle body adapter.
    • Install four bolts and tighten in two stages.
      • Stage 1: Tighten to 8-10 Nm (71-89 lb-in).
      • Stage 2: Tighten an additional 85-95 degrees.
    27. NOTE: The EGR valve is shown removed for clarity.
    Fig 12: Connecting EVR Solenoid Electrical And Vacuum Harness
    G01544833Courtesy of FORD MOTOR CO.
  27. If equipped, connect the EVR solenoid electrical and vacuum harness.
  28. If equipped, connect the EGR valve vacuum line.
    Fig 13: Connecting EGR Valve Vacuum Line
    G01544834Courtesy of FORD MOTOR CO.
  29. If equipped, install the EGR valve-to-exhaust manifold tube.
    • Hand-tighten the fittings.
    • Tighten the upper fitting to 60 Nm (44 lb-ft).
    • Tighten the lower fitting to 60 Nm (44 lb-ft).
    Fig 14: Installing EGR Valve-To-Exhaust Manifold Tube
    G01544835Courtesy of FORD MOTOR CO.
  30. If equipped, install the EGR transducer bracket.
    • Position the bracket.
    • Install the bolts.
    Fig 15: Installing EGR Transducer Bracket
    G01544836Courtesy of FORD MOTOR CO.
  31. If equipped, connect the EGR transducer vacuum lines.
    Fig 16: Connecting EGR Transducer Vacuum Lines
    G01544837Courtesy of FORD MOTOR CO.
  32. If equipped, connect the EGR transducer and the throttle position sensor connectors.
    Fig 17: Connecting EGR Transducer And Throttle Position Sensor Connectors
    G01544838Courtesy of FORD MOTOR CO.
  33. Connect the idle air control motor electrical connector and the bypass hose.
    Fig 18: Connecting Idle Air Control Motor Electrical Connector And Bypass Hose
    G01544839Courtesy of FORD MOTOR CO.
  34. Connect the vacuum line.
    Fig 19: Connecting Vacuum Line
    G01544840Courtesy of FORD MOTOR CO.
  35. Connect the following vacuum lines:
    • brake booster
    • engine sensor control wiring harness
    Fig 20: Connecting Brake Booster Vacuum Lines
    G01544841Courtesy of FORD MOTOR CO.
  36. Connect the PCV vacuum and coolant hoses.
    Fig 21: Connecting PCV Vacuum And Coolant Hoses
    G01544842Courtesy of FORD MOTOR CO.
  37. Install the accelerator cable bracket.
    • Position the bracket and cables.
    • Install the bolts.
    Fig 22: Installing Accelerator Cable Bracket
    G01544843Courtesy of FORD MOTOR CO.
  38. Connect the accelerator and speed control cables and return spring.
    Fig 23: Connecting Accelerator And Speed Control Cables And Return Spring
    G01544844Courtesy of FORD MOTOR CO.
  39. Install the accelerator cable splash shield.
    Fig 24: Installing Accelerator Cable Splash Shield
    G01544845Courtesy of FORD MOTOR CO.
  40. Install the air cleaner outlet tube.
  41. Connect the battery ground cable.
  42. Connect the upper radiator hose to the radiator.
  43. Fill the engine with clean engine oil.
  44. Fill and bleed the cooling system. Refer to ENGINE COOLING .
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