Oil Pan

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	3-Jaw Puller	303-D121
Courtesy of FORD MOTOR CO.	Handle	205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal	303-409 (T92C-6700CH)
Courtesy of FORD MOTOR CO.	Remover, VCT Spark Plug Tube Seal	303-1247/1
Courtesy of FORD MOTOR CO.	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, detach the block heater wiring harness retainer from the upper intake manifold.
Fig 3: Identifying Block Heater Wiring Harness Retainer From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
Fig 4: Identifying Block Heater Wiring Harness
Courtesy of FORD MOTOR CO.
7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the Power Steering Pressure (PSP) hose.
   • Remove the block heater wiring harness from the engine.
Fig 5: Identifying Block Heater Wiring Harness From Engine
Courtesy of FORD MOTOR CO.
8. Disconnect the PCV hose from the PCV valve.
Fig 6: Identifying PCV Hose
Courtesy of FORD MOTOR CO.
9. Disconnect the Throttle Body (TB) electrical connector.
Fig 7: Locating Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
10. Detach the wiring harness retainers from the upper intake manifold.
Fig 8: Locating Wiring Harness Retainers From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
11. Remove the upper intake manifold support bracket bolt.
Fig 9: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.
12. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
Fig 10: Identifying Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
13. Disconnect the PSP switch electrical connector.
Fig 11: Locating PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

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

All vehicles 

15. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
Fig 13: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
16. Disconnect the 3 RH coil-on-plug electrical connectors.
Fig 14: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
18. Disconnect the LH catalyst monitor sensor electrical connector.
Fig 15: Identifying LH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
19. Disconnect the LH VCT solenoid electrical connector.
Fig 16: Locating LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
20. Disconnect the 3 LH coil-on-plug electrical connectors.
Fig 17: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
21. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan.
22. Remove the A/C compressor nut and stud.
Fig 18: Identifying A/C Compressor Nut & Stud
Courtesy of FORD MOTOR CO.
23. Detach the PSP hose retainer from the engine lifting eye.
Fig 19: Locating PSP Hose Retainer From Engine Lifting Eye
Courtesy of FORD MOTOR CO.
24. Remove the PSP hose bracket nut.
Fig 20: Identifying PSP Hose Bracket Nut
Courtesy of FORD MOTOR CO.
25. Remove the 3 bolts and position the power steering pump aside.
Fig 21: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
26. Remove the 3 bolts and the accessory drive belt tensioner.
Fig 22: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
27. Remove the 4 nuts (3 shown) and the LH catalytic converter.
    • Discard the nuts and the gasket.
Fig 23: Locating LH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.

FWD vehicles 

28. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
Fig 24: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.

All vehicles 

29. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
Fig 25: Locating RH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
30. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
Fig 26: Locating LH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
31. Remove the 6 bolts and the 6 coil-on-plugs.
Fig 27: Locating Coil-On-Plugs & Bolts
Courtesy of FORD MOTOR CO.
32. Remove the 2 nuts and the wiring harness retaining bracket.
Fig 28: Identifying Wiring Harness Retaining Bracket & Nuts
Courtesy of FORD MOTOR CO.
33. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
Fig 29: Locating LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
34. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
    • Discard the gasket.
Fig 30: Locating Stud Bolts On RH Valve Cover
Courtesy of FORD MOTOR CO.
NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
35. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
Fig 31: Removing Seals Using Special Tools (205-153) & (303-1247/1)
Courtesy of FORD MOTOR CO.
36. Using the Strap Wrench, remove the crankshaft bolt and washer.
    • Discard the bolt.
Fig 32: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
Courtesy of FORD MOTOR CO.
37. Using the 3-Jaw Puller, remove the crankshaft pulley.
Fig 33: Identifying Special Tools (303-D121) And Crankshaft Pulley
Courtesy of FORD MOTOR CO.
38. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
Fig 34: Removing Crankshaft Front Seal Using Special Tool (303-409)
Courtesy of FORD MOTOR CO.
39. Remove the 2 bolts and the engine mount bracket.
Fig 35: Locating Engine Mount Bracket & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools to remove the studs.
40. Remove the 2 engine mount studs.
Fig 36: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
41. Remove the 3 bolts and the engine mount bracket.
Fig 37: Locating Engine Mount Bracket & Bolts
Courtesy of FORD MOTOR CO.
42. Remove the 22 engine front cover bolts.
Fig 38: Identifying Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
43. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover in the following sequence.
    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.
Fig 39: Tightening Bolts One Turn At A Time In A Criss-Cross Pattern Until Engine Front Cover-To-Cylinder Block Seal Is Released
Courtesy of FORD MOTOR CO.
44. Remove the 16 oil pan bolts.
Fig 40: Identifying Oil Pan Bolts
Courtesy of FORD MOTOR CO.
45. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan in the following sequence.
    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.
Fig 41: Installing 2 Of Oil Pan Bolts (Finger Tight) Into 2 Threaded Holes In Oil Pan
Courtesy of FORD MOTOR CO.
NOTE: 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 crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
46. 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.
NOTE: 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.
NOTE: 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.
47. Clean all engine 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.