Oil Pan: Service and Repair

Oil Pan

Material(s)






Removal

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Jacking and Lifting .

2. Remove the oil level indicator.





3. Remove the engine ACL (Air Cleaner) and ACL (Air Cleaner) outlet pipe assembly. REFER to Intake Air System Components - Exploded View .

4. NOTICE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.197 in).

Loosen the 5 upper bellhousing-to-engine bolts 5 mm (0.197 in).





5. Remove the engine roll restrictor. REFER to Transmission Support Insulator - Anti Roll FWD .

6. Remove the catalytic converter. REFER to Catalytic Converter - 2.0L GTDI .

7. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the A/C (Air Conditioning) compressor.





8. Disconnect the 2 A/C (Air Conditioning) compressor electrical connectors.

- Detach the wiring harness retainer from the A/C (Air Conditioning) tube stud bolt.






9. Remove the A/C (Air Conditioning) compressor nut, stud and the 2 bolts.

- Position the A/C (Air Conditioning) compressor aside and support with a length of mechanics wire.






10. Loosen the 2 engine-to-bellhousing bolts 5 mm (0.197 in).





11. Remove the 3 bellhousing-to-oil pan bolts.





12. Remove the oil pan-to-bellhousing bolt.





13. Separate the engine and transaxle 5 mm (0.197 in).





14. Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).





15. Remove the 4 engine front cover-to-oil pan fasteners.





16. Remove the 13 bolts and the oil pan.





Installation

1. NOTICE: 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, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

Clean and inspect all mating surfaces.

2. NOTICE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.





3. Position the oil pan onto the engine and install the 13 oil pan bolts finger-tight.





4. NOTE: The engine front cover-to-oil pan fasteners must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block.
Install the 4 engine front cover-to-oil pan fasteners.
- Tighten to 10 Nm (89 lb-in).





5. Tighten the 13 oil pan bolts in the sequence shown.
- Tighten to 20 Nm (177 lb-in).





6. Alternate tightening the LH (Left Hand) bellhousing-to-engine and RH (Right Hand) engine-to-bellhousing lower bolts to draw the transaxle and engine together.
- Tighten to 48 Nm (35 lb-ft).





7. Install the oil pan-to-bellhousing bolt.
- Tighten to 48 Nm (35 lb-ft).





8. Tighten the engine-to-transaxle bolt.
- Tighten to 48 Nm (35 lb-ft).





9. Install the 3 bellhousing-to-oil pan bolts.
- Tighten to 48 Nm (35 lb-ft).





10. Install the A/C (Air Conditioning) compressor, the 2 bolts and the stud.
- Tighten the bolts to 25 Nm (18 lb-ft) and the stud to 9 Nm (80 lb-in).
- Install the nut and tighten to 25 Nm (18 lb-ft).





11. Connect the 2 A/C (Air Conditioning) compressor electrical connectors.

- Attach the wiring harness retainer to the A/C (Air Conditioning) tube stud bolt.






12. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt onto the A/C (Air Conditioning) compressor.





13. Install the catalytic converter. REFER to Catalytic Converter - 2.0L GTDI .

14. Install the engine roll restrictor. REFER to Transmission Support Insulator - Anti Roll FWD .

15. Tighten the top 4 bellhousing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





16. Install the engine ACL (Air Cleaner) and ACL (Air Cleaner) outlet pipe assembly. REFER to Intake Air System Components - Exploded View .

17. Install the oil level indicator.





18. Fill the engine with clean engine oil.