Continental 2000-2002

Oil Pan

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Removal & Installation




NOTE
Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the air suspension switch to the OFF position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oil level dipstick
     
    Dual converter Y-pipe
     
    Oil level sensor connector
     
    Power steering pressure hose bracket
     
    Oil pan
     

  6.  

To install:

  1. Apply a bead of silicone sealer to the oil pan flange. Also apply a bead of sealer to the front cover/cylinder block joint and fill the grooves on both sides of the rear main seal cap.
  2.  
  3. Use a new gasket and install the oil pan. Tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Plus 60 degrees

      Click image to see an enlarged view

      Fig. Oil pan bolt torque sequence

    4.  

  4.  
  5. Install or connect the following:

    Power steering pressure hose bracket
     
    Oil level sensor connector
     
    Dual converter Y-pipe
     
    Oil level dipstick
     
    Negative battery cable
     

  6.  
  7. Fill the crankcase with the correct type and quantity of engine oil.
  8.  
  9. Turn the air suspension switch to the ON position.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the oil pan, then remove the oil filter. Position the drain pan out of the way.
  6.  
  7. Remove the dual converter Y-pipe assembly.
  8.  
  9. Remove the starter motor. For details, please refer to the procedure located earlier in this section.
  10.  
  11. Remove the engine rear plate/converter housing cover.
  12.  
  13. Remove the retaining bolts and remove the oil pan.
  14.  



Click image to see an enlarged view

Fig. Exploded view of the oil pan assembly-3.8L engine

To install:

  1. Clean the gasket surfaces on cylinder block and the oil pan.
  2.  
  3. Trial fit oil pan to cylinder block. Ensure that enough clearance has been provided to allow the oil pan to be installed without sealant being scraped off when pan is positioned under the engine.
  4.  
  5. Apply a bead of silicone sealer to the oil pan flange. Also apply a bead of sealer to the front cover/cylinder block joint and fill the grooves on both sides of the rear main seal cap.
  6.  


NOTE
When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to harden and its sealing effectiveness may be reduced.

  1. Install the oil pan and secure to the block with the attaching screws. Tighten the screws to 7-9 ft. lbs. (9-12 Nm).
  2.  
  3. Install a new oil filter.
  4.  
  5. Install the engine rear plate/converter housing cover.
  6.  
  7. Install the starter motor. For details, please refer to the procedure located earlier in this section.
  8.  
  9. Install the Y-pipe converter assembly, then carefully lower the vehicle.
  10.  
  11. Fill the crankcase with the correct viscosity and amount of oil, then connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  

4.6L Engine
  1. Disconnect the battery cables, negative cable first, and remove the air inlet tube.
  2.  
  3. Relieve the fuel system pressure and disconnect the fuel lines; refer to Section 5. Drain the cooling system and remove the cooling fan and shroud.
  4.  


CAUTION
Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. In addition, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the upper radiator hose. Remove the wiper module and support bracket.
  2.  
  3. Discharge the air conditioning system. Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor outlet.
  4.  
  5. Remove the 42-pin engine harness connector from the retaining bracket on the brake vacuum booster and disconnect the connector and transmission harness connector.
  6.  
  7. Disconnect the throttle valve cable from the throttle body and disconnect the heater outlet hose.
  8.  
  9. Remove the nut retaining the ground strap to the right cylinder head. Remove the upper stud and loosen the lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
  10.  
  11. Remove the blower motor resistor. Remove the bolt retaining the right engine mount to the lower engine bracket.
  12.  
  13. Disconnect the vacuum hoses from the EGR valve and tube. Remove the 2 bolts retaining the EGR valve to the intake manifold.
  14.  
  15. Raise and safely support the vehicle. Drain the crankcase and remove the engine mount through bolts.
  16.  
  17. Remove the EGR tube line nut from the right exhaust manifold and remove the EGR valve and tube assembly.
  18.  
  19. Disconnect the exhaust from the exhaust manifolds. Lower the exhaust system and support it with wire from the crossmember.
  20.  
  21. Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. and insert 2 wood blocks approximately 2 1 / 2 in. thick under each engine mount. Lower the engine onto the wood blocks and remove the jack.
  22.  
  23. Remove the 16 bolts retaining the oil pan to the engine block and remove the oil pan.
  24.  


NOTE
It may be necessary to loosen, but not remove, the 2 nuts on the rear transmission mount and with a jack, raise the transmission extension housing slightly to remove the pan.

  1. If necessary, remove the 2 bolts retaining the oil pickup tube to the oil pump and remove the bolt retaining the pickup tube to the main bearing stud spacer. Remove the pickup tube.
  2.  

To install:

  1. Clean the oil pan and inspect for damage. Clean the sealing surfaces of the front cover and engine block. Clean and inspect the oil pickup tube and replace the O-ring.
  2.  
  3. If removed, position the oil pickup tube on the oil pump and hand start the 2 bolts. Install the bolt retaining the pickup tube to the main bearing stud spacer hand tight.
  4.  
  5. Tighten the pickup tube-to-oil pump bolts to 6.0-8.8 ft. lbs. (8-12 Nm), then tighten the pickup tube-to-main bearing stud spacer bolt to 15-22 ft. lbs. (20-30 Nm).
  6.  
  7. Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and rear seal retainer meets the cylinder block. Position the oil pan on the engine and install the bolts. Tighten the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
  8.  
  9. Position the jack and wood block under the oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack.
  10.  
  11. Install the engine mount through bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
  12.  
  13. Position the EGR valve and tube assembly in the vehicle and connect to the exhaust manifold. Tighten the line nut to 26-33 ft. lbs. (35-45 Nm).
  14.  


NOTE
Loosen the line nut at the EGR valve prior to installing the assembly into the vehicle. This will allow enough movement to align the EGR valve retaining bolts.

  1. Cut the wire and position the exhaust system to the manifolds. Install the 4 nuts and tighten to 20-30 ft. lbs. (27-41 Nm). Make sure the exhaust system clears the crossmember. Adjust as necessary.
  2.  
  3. Install a new oil filter and lower the vehicle.
  4.  
  5. Install the bolt retaining the right engine mount to the lower engine bracket. Tighten to 15-22 ft. lbs. (20-30 Nm).
  6.  
  7. Install a new gasket on the EGR valve and position on the intake manifold. Install the 2 bolts retaining the EGR valve to the intake manifold and tighten to 15-22 ft. lbs. (20-30 Nm). Tighten the EGR tube line nut at the EGR valve to 26-33 ft. lbs. (35-45 Nm). Connect the vacuum hoses to the EGR valve and tube.
  8.  
  9. Install the blower motor resistor. Position the heater outlet hose, install the upper stud and tighten the upper and lower bolts to 15-22 ft. lbs. (20-30 Nm). Install the ground strap on the stud and tighten to 15-22 ft. lbs. (20-30 Nm).
  10.  
  11. Connect the heater outlet hose and the throttle valve cable. If necessary, adjust the throttle valve cable.
  12.  
  13. Connect the 42-pin connector and transmission harness connector. Install the harness connector on the brake vacuum booster.
  14.  
  15. Connect the air conditioning compressor outlet hose to the compressor and install the bolt retaining the hose to the right coil bracket.
  16.  
  17. Install the upper radiator hose and connect the fuel lines. Install the wiper module and retaining bracket.
  18.  
  19. Install the cooling fan and shroud and fill the cooling system. Fill the crankcase with the proper type and quantity of engine oil.
  20.  
  21. Connect the negative battery cable and install the air inlet tube. Start the engine and check for leaks.
  22.  
  23. Have a MVAC certified evacuate and recharge the air conditioning system.
  24.  



Click image to see an enlarged view

Fig. Position of wood blocks under the engine mounts-4.6L engine



Click image to see an enlarged view

Fig. Oil pump pickup tube-4.6L engine



Click image to see an enlarged view

Fig. Oil pan bolt torque sequence-4.6L engine

5.0L Engine
  1. Disconnect the negative battery cable. Relieve the fuel system pressure; refer to Section 5.
  2.  
  3. Disconnect the accelerator and throttle valve cables at the throttle body or carburetor.
  4.  
  5. Remove the fan shroud attaching bolts, positioning the fan shroud back over the fan. Remove the dipstick and tube assembly.
  6.  
  7. Disconnect the wiper motor electrical connector and remove the wiper motor. Disconnect the windshield washer hose and remove the wiper motor mounting cover.
  8.  
  9. Remove the thermactor air dump tube-retaining clamp on 5.0L engine. Remove the thermactor crossover tube at the rear of the vehicle.
  10.  
  11. Raise and safely support the vehicle. Drain the crankcase. Remove the filler tube from the oil pan and drain the transmission.
  12.  
  13. Disconnect the starter cable and remove the starter. Disconnect the fuel line.
  14.  
  15. Disconnect the exhaust system from the manifolds. Remove the oxygen sensors from the exhaust manifolds.
  16.  
  17. Remove the thermactor secondary air tube to torque converter housing clamps. Remove the converter inspection cover.
  18.  
  19. Disconnect the exhaust pipes to the catalytic converter outlet. Remove the catalytic converter secondary air tube; and the inlet pipes to the exhaust manifold.
  20.  
  21. Loosen the rear engine mount attaching nuts and remove the engine mount through bolts. Remove the shift crossover bolts at the transmission.
  22.  
  23. Remove the brake line retainer from the front crossmember and disconnect the transmission kick-down rod.
  24.  
  25. Position a jack and wood block under the engine and raise the engine as high as it will go. Place wood blocks between the engine mounts and the chassis brackets, lower the engine, and remove the jack.
  26.  
  27. Remove the oil pan retaining bolts and lower the oil pan. Remove the 2 bolts retaining the oil pump pickup tube and screen to the oil pump and the nut from the main bearing cap stud. Allow the pickup tube to drop into the oil pan.
  28.  
  29. Rotate the crankshaft, as required, for clearance and remove the oil pan from the vehicle.
  30.  

To install:

  1. Clean the oil pan and the gasket mating surfaces. Clean the oil pump pickup tube and screen assembly.
  2.  
  3. Install a new oil filter. Position a new oil pan gasket on the cylinder block. Place the oil pickup tube and screen in the oil pan and position the oil pan on the crossmember.
  4.  
  5. Install the pickup tube and screen with a new gasket. Install the bolts and tighten to 12-18 ft. lbs. (16-24 Nm). Position the oil pan and install the retaining bolts. Tighten to 7-10 ft. lbs. (9-14 Nm).
  6.  
  7. Position the jack and wood block under the engine and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack. Install the engine mount through bolts and tighten to 33-46 ft. lbs. (45-62 Nm).
  8.  
  9. Connect the fuel lines. Install the converter inspection cover. Tighten the rear mount attaching nuts to 35-50 ft. lbs. (48-68 Nm).
  10.  
  11. Install the shift crossover. Position the catalytic converters, secondary air tube and inlet pipes to the exhaust manifold and then install the retaining nuts.
  12.  
  13. Install the catalytic converter outlet attaching bolts and install the secondary air tube on the converter housing. Install the starter and connect the starter cable.
  14.  
  15. Install the oxygen sensors and lower the vehicle. Install the dipstick and tube. Install the thermactor air dump valve to exhaust manifold clamp.
  16.  
  17. Connect the windshield wiper hose and install the wiper motor mounting plate. Install the wiper motor.
  18.  
  19. Position the shroud and install the retaining bolts. Install the thermactor tube to the rear of the engine. Install the air cleaner assembly and air ducts.
  20.  
  21. Fill the crankcase with the proper type and quantity of engine oil. Fill the transmission with the proper type and quantity of transmission fluid.
  22.  
  23. Connect the negative battery cable. Start the engine and check for leaks.
  24.  



Click image to see an enlarged view

Fig. Oil pan installation-5.0L engines

 
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