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2.0 L Zetec
Oil Pan
Removal

1. Remove the catalytic converter.

2. Drain the engine oil.
^ Install the drain plug.


3. Remove the 17 bolts and the oil pan.


Installation
1. CAUTION: The oil pan sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.

Clean and inspect the mounting faces of both the oil pan and the cylinder block with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Both surfaces must be flat, clean and dry.

2. NOTE: The oil pan must be installed and the bolts tightened to specification within seven minutes of sealer application or oil leaks may occur.
NOTE: Apply a 3 mm (0.1 in.) continuous bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the oil pan.

Install the oil pan. Tighten the bolts using the sequence shown in two stages:
^ Stage 1: Tighten to 6 Nm (53 in. lbs.).
^ Stage 2: Tighten 12 Nm (9 in. lbs.).


3. Install the catalytic converter.

4. Fill the crankcase with Super Premium SAL 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.

Parts
OEM Part
Price (Q1 2009)
Oil PanYS4Z-6710-AA
30.34​
Labor
Replace
Skill Level
Mfg. Warr.
Std.
B​
1.5​
2.1​
3.0 L Duratec
Oil Pan Baffle
Removal

1. Remove the oil pump screen cover and tube.

2. Remove the nuts and the tail pan baffle.


Installation
1. Position the oil pan baffle and install the nuts.
- Tighten the nuts in two stages.
- Stage 1: Tighten to 5 Nm (44 in. lbs.).
- Stage 2: Tighten 45 degrees.

2. Install the oil pump screen cover and tube.

Oil Pan
Removal

1. Remove the flexible exhaust pipe.

2. Disconnect the downstream catalyst monitor sensor.


3. Drain the oil.

4. Install the drain plug.


5. Remove and discard the oil filter.

6. Remove the 15 bolts.


7. Remove the three bolts and the oil pan.


Installation
CAUTION: 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 all traces of the head gasket.

1. Clean all sealing surfaces on the engine and the oil pan with metal surface cleaner.

2. Position a new gasket on the oil pan.

3. NOTE: Clean and degrease all sealing surfaces with metal surface cleaner.
NOTE: The oil pan must be installed and the bolts tightened with in four minutes of sealant application.

Apply a 10 mm (0.40 in.) diameter dot of silicone gasket and sealer to the areas indicated.


4. Position the oil pan and gasket and loosely install the bolts in the sequence shown


5. Install the oil pan-to-transaxle bolts.


6. Tighten the oil pan bolts in the sequence shown.


7. Lubricate the oil filter O-ring with clean engine oil and install the oil filter.


8. Install the exhaust flexible exhaust pipe.

9. Connect the downstream catalyst monitor.


10. Lower the vehicle.

11. Fill the crankcase with clean engine oil.

Parts
OEM Part
Price (Q1 2009)
Oil Pan7L8Z-6675-A
195.53​
Baffle PlateYL8Z-6687-AA
24.08​
Oil Pan Gasket2R8Z-6710-AA
45.75​
Labor
Replace
Skill Level
Mfg. Warr.
Std.
B​
1.2​
1.7​
 
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