Oil Pan Removal on 2003 Ford Focus?

Oil Pan

Removal & Installation

2.0L (VIN 3) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Catalytic converter

   Oil pan

To install:

Fig. Oil pan torque sequence-2.0L (VIN 3) engine

NOTE

Apply a bead of silicone gasket sealer to the oil pan flange.

1. Install or connect the following:
   
   
   Oil pan. Tighten the bolts in sequence and in several passes to 18 ft. lbs. (24 Nm).

   Oil lever sensor connector

   Catalytic converter

   Negative battery cable
2. Fill the crankcase to the correct level.
3. Start the engine and check for leaks.

2.0L (VIN 5) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the catalytic converter.
3. Drain the engine oil.
4. Remove the oil pan retaining bolts.
   
   CAUTION

   To prevent damage to the sealing surface, only use the Slide Hammer 205-047 and Adapter 303-633 as shown to remove the oil pan.
   
   
   
   
   

   

   Fig. Removing the oil pan with the Slide Hammer 205-047 and Adapter 303-633-2.0L (VIN 5) engine
5. Tighten the locknut against the oil pan and tap the special tool several time to release the oil pan from the lower crankcase.

To install:

NOTE

Do not damage the mating faces.

1. Clean the mating faces. The mating faces must be free from oil and sealant residue.
2. Clean all traces of oil residue and oil sludge from the oil pan.
   
   CAUTION

   The lower crankcase may be damaged if sealant enters the blind holes.
3. Install ten M6 x 20 mm studs into the blind holes shown (engine shown removed for clarity).
   
   NOTE

   Attach the oil pan within ten minutes of applying the sealant.
   
   
   
   
   

   

   Fig. Install ten M6 x 20 mm studs into the blind holes indicated
   
   
   
   

   

   Fig. Oil pan torque sequence-2.0L (VIN 5) engine
4. Apply a 3 mm diameter bead of sealant to the mating face of the oil pan.
   
   NOTE

   The oil pan must not be removed once it comes into contact with the lower crankcase housing.
5. Attach the oil pan to the lower crankcase housing.
6. Remove the studs.
7. Install the oil pan retaining bolts and tighten them in sequence as follows:
   1. Step 1: 53 inch lbs. (6 Nm)
   2. Step 2: 88 inch lbs. (10 Nm)
      
      NOTE

      Inspect the oil drain plug and gasket. Install a new oil drain plug and gasket if necessary.
8. Install the oil pan drain plug and tighten it to 17 ft. lbs. (24 Nm).
9. Install the catalytic converter.
10. Fill the engine with clean oil.

2.0L (VIN N) & 2.3L (VIN Z) Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   
   
   Oil level indicator tube.

   Wiring harness from the retainers and position aside

   Front cover-to-oil pan bolts

   Oil pan-to-bell housing bolts

   Oil pan mounting bolts

   Oil pan.

To install:

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 traces of sealant.

1. Clean and inspect all mating surfaces.
   
   NOTE

   If the oil pan is not secured within four minutes of sealant application 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.
   
   
   
   NOTE

   The oil pan must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
2. Apply a 2.5 mm bead of silicone gasket and sealant to the oil pan.
3. Install or connect the following:
   
   
   Oil pan

   Oil pan-to-bell housing bolts and tighten to 35 ft. lbs. (48 Nm)

   Front cover-to-oil pan bolts and tighten to 89 inch lbs. (10 Nm)

   Wiring harness and retainers
4. Tighten the oil pan bolts in sequence to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Oil pan bolt torque sequence-2.0L (VIN N) and 2.3L (VIN Z) engines
5. Install the engine oil level indicator tube and tighten the bolts to 89 inch lbs. (10 Nm).
6. Fill the engine with clean engine oil.
7. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the battery tray.
4. Detach the 2 positive battery cable pin-type retainers and position aside.
5. Detach the transmission connector wire harness pin-type retainer and position aside.
   
   
   

   

   Fig. Detach the transmission connector wire harness pin-type retainer and position aside
6. Remove the nut from the heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket.
   
   
   

   

   Fig. Remove the nut from the heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket
7. Remove the nut and position the HO2S and catalyst monitor sensor wire connector bracket aside.
   
   
   

   

   Fig. Remove the nut and position the HO2S and catalyst monitor sensor wire connector bracket aside
8. Loosen the upper bellhousing-to-engine bolt and stud bolt 0.19 in. (5 mm) maximum.
   
   
   

   

   Fig. Loosen the upper bellhousing-to-engine bolt and stud bolt 0.19 in. (5 mm) maximum
9. Remove the oil level indicator and tube.
10. Loosen the 2 (automatic transmission) or 3 (manual transmission) front lower bellhousing-to-engine bolts 0.19 in. (5 mm).
    
    
    

    

    Fig. Loosen the 2 (automatic transmission) or 3 (manual transmission) front lower bellhousing-to-engine bolts 0.19 in. (5 mm)
11. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 0.19 in. (5 mm).
    
    
    

    

    Fig. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 0.19 in. (5 mm)
12. Remove the 2 bellhousing-to-oil pan bolts and the 2 oil pan bolts.
13. Remove the 2 oil pan-to-bellhousing bolts.
14. Slide the transmission rearward 0.19 in. (5 mm).
15. Remove the 2 bolts and the accessory drive belt splash shield.
16. Drain the engine oil. Install the drain plug; tighten to 21 ft. lbs. (28 Nm).
17. Remove the 4 engine front cover-to-oil pan bolts.
18. Remove the 11 bolts and the oil pan.

To install:

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 traces of sealant.

1. Clean and inspect all mating surfaces.
   
   NOTE

   If the oil pan is not secured within four minutes of sealant application 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.
2. Apply a 2.5 mm bead of silicone gasket and sealant to the entire oil pan mating surface, avoiding the bolt holes.
3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 89 inch lbs. (10 Nm).
5. Tighten the oil pan bolts in sequence to 18 ft. lbs. (25 Nm).
   
   
   

   

   Fig. Oil pan bolt torque sequence-2.0L (VIN N) and 2.3L (VIN Z) engines
6. Install the accessory drive belt splash shield and the 2 bolts.
7. Alternately tighten the 1 front bellhousing-to-engine and 1 rear engine-to-bellhousing lower bolts to slide the transmission and engine together. Tighten to 35 ft. lbs. (48 Nm).
8. Tighten the remaining 1 (automatic transmission) or 2 (manual transmission) lower front bellhousing-to-engine bolts. Tighten to 35 ft. lbs. (48 Nm).
9. Tighten the remaining rear engine-to-bellhousing stud bolt. Tighten to 35 ft. lbs. (48 Nm).
10. Install the 2 bellhousing-to-oil pan bolts and the 2 oil pan-to-bellhousing bolts. Tighten to 35 ft. lbs. (48 Nm).
11. Install the oil level indicator and tube.
12. Tighten the top bellhousing-to-engine bolt and stud bolt to 35 ft. lbs. (48 Nm).
13. Position the HO2S and catalyst monitor sensor wire connector bracket and install the nut. Tighten to 18 ft. lbs. (25 Nm).
14. Install the HO2S and catalyst monitor sensor wire connector bracket nut. Tighten to 18 ft. lbs. (25 Nm).
15. Position and attach the transmission connector wire harness pin-type retainer.
16. Position and attach the 2 positive battery cable pin-type retainers.
17. Install the battery tray.
18. Fill the engine with new oil.

2.0L (VIN P) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the engine oil.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Catalytic converter and brackets

   Intake manifold bracket

   Intermediate shaft bracket

   Coolant pipe bolt

   Oil pan

To install:

Fig. Oil pan torque sequence-2.0L (VIN P) engine

1. Apply silicone sealant to the oil pump and rear seal retainer joints.
2. Install or connect the following:
   
   
   Oil pan. Tighten the bolts in sequence to 18 ft. lbs. (25 Nm).

   Coolant pipe bolt

   Intermediate shaft bracket

   Intake manifold bracket

   Catalytic converter and brackets

   Negative battery cable
3. Fill the crankcase to the correct level.
4. Start the engine and check for leaks.