CHANGING THE XR5 ENGINE OIL AND FILTER I recently changed my engine oil and filter.

Its not a technically difficult job, but you need the right tools for the job and you need to remove a few bits and pieces to gain adequate access to replace the filter. Removal of the oil filter cap is quite difficult as it only just fits through the gap you will create, even after much trial and error. Most people will be able to work out how to do this job without instructions, but for those who cant, heres a summary of how I did it(noting that there are probably other ways depending on what tools and facilities you have access to.) Parts required Approx 6L of engine oil (I use Castrol Edge Sport 5W-30 about $48 per 5L bottle) Replacement oil filter element and O-ring (Part number: FO- 6M5G 6744 AA costs around $30 from Ford) Tools Required Allen key (sorry, I forget which size) Phillips head screwdriver 17mm ring spanner or socket Ratchet drive for sockets (I used a 3/8 drive) 36mm oil filter socket tool (see details below for where to get one of these) Optional - 375mm extension bar with universal joints at each end (see details below for where to get one of these). Other extension bars and wobble bars may also be suitable. Container to catch waste oil (at least 6L capacity)

Oil filter - look down here

Oil filler cap

Air inlet

Cover 1 Oil dipstick

Oil filter canister

Oil filter element and O-ring (Thanks to Hyper for these photos) INSTRUCTIONS NOTE: These are the steps I followed to successfully replace my XR5 engine oil and filter. If you choose to follow these instructions, you do so at your own risk. I will not be responsible for any loss or damage caused by any person attempting to follow these instructions. Draining Engine Oil Put front of car on ramps or chassis stands to get better access under front of car. Open the bonnet. WARNING: Allow engine to cool sufficiently before touching any part of the engine. Remove the oil filler cap on top of the engine. Remove main plastic undertray under engine bay by removing the seven allen head fasteners. Locate the oil drain plug its a 17mm bolt head at the rear bottom edge of the engine sump Place a container under the oil drain to catch the old oil needs to hold 6L of waste oil Remove oil drain plug by unscrewing with a 17mm ring spanner or socket. The plug comes out quite a few turns before oil starts flowing. My drain plug was extremely difficult to loosen I had to use a hollow steel bar to extend the handle length of my ratchet drive and create more torque. Be very careful not to burr the corners of the drain plug bolt head. Allow the oil to drain into the waste container leave it to drain for at least half an hour (until oil virtually stops dripping out of the plug hole). Replacing Oil Filter Locate the oil filter cap. You can see the top of the oil filter cap if you look down through the gap to the left of the air box at the front of the engine. It is a black plastic cap with a 36 mm hex head. In the engine bay, remove the plastic cover at the very front of the engine bay (se Cover 1 in first picture above) by removing the six Phillips head screws and carefully popping out the little circular retainers, then carefully popping out the lip towards the right side of the rear edge of the cover) Remove the top part of the plastic air inlet by removing one screw and the retainer and then carefully lifting the edges and popping it off the base section. Remove the bottom part of the plastic air inlet by removing one screw and the retainer and then carefully twisting it away from the intake tube into which it is inserted. Remove first section of plastic air intake tube by carefully lifting the edges of the bottom rim until it pops off and lifts away. Make sure the oil has drained from car before removing oil filter cap (or youll get oil everywhere)

3
Place 36mm socket with extension bar and ratchet drive on oil the filter cap. Turn oil filter cap anticlockwise to remove. Remove oil filter cap upwards through gap. This can be quite a struggle. You may need to fiddle around with the position of the filter cap to get it through the gap it might not come out top first. You will probably need to place some pressure on the remaining piece of air intake pipe (unless you can work out how to remove it I couldnt) to make enough space to get the filter cap out Once you get the cap out, remove the old oil filter element and discard it Place the new oil filter element in the filter housing, with the VOLVO labeling facing up (I dont think this really matters, but mine had the old filter installed this way so I did the same) Remove the old O-ring from oil filter cap Fit new O-ring to oil filter cap (should be supplied with oil filter to oil filter cap otherwise just refit the old one if its not damaged) Smear some oil around the O-ring to lubricate it. Refit the oil filter cap and screw it back on until it stops moving freely not too tight or you might damage the cap or filter housing. If you have a torque wrench, the recommended torque setting is written on the top of the oil filter cap. Wipe up any oil around the filter area as best you can.

Refilling Engine Oil Refit the oil drain plug to the engine sump. Wipe up any oil around the drain plug area. Fill with the engine with new oil check the level on the dip stick until the oil level is in the middle of the cross-hatched fill range on the dip stick. My car took about 6 Litres. Replace the engine oil filler cap Check for any signs of oil leaking around the drain plug or oil filter area Start the engine and run it for a few minutes Check again for oil leaks around the drain plug and oil filter Once satisfied that there are no leaks, replace any of the following parts that were removed earlier. Installation is basically the reverse of the removal process: a. Air intake tube b. Air inlet lower section c. Air inlet upper section d. Cover at front of engine bay e. Engine undertray Check all tools, rags, etc are removed from the engine bay and under the car Remove car from ramps/chassis stands and place on level ground. Re-check the engine oil level and top up if required Job done time for a drive and then a well deserved beer (in that order)! SPECIAL TOOLS

36mm Oil Filter Socket Tool I bought a 36mm oil filter socket on eBay from rooprict. It was listed on eBay as Ford 6.0 Powerstroke Oil Filter Socket Tool 36mm. It has a 3/8 inch drive, which means it can be used with the socket drives that many of us are likely to already own. Most standard 36mm sockets require a inch drive which can be very expensive and which you probably wouldnt use for much else. The part cost me US$13.25 plus postage and arrived from the US in just 4 days. I was charged $US13.75 for packaging and handling but the actual postage charge was only US$7.20, so we could probably get this reduced a bit. It fits the XR5 oil filter cap perfectly. Extension Bar I also bought a 3/8 drive 375mm extension bar with a universal joint at each end (see below). This allows this job to be done very easily, but you may be able to undo the filter cap with other extension or wobble bars you already own. I bought this one as it allows you to unscrew the filter cap without removing any other parts from the car however, Ive now discovered that you need to remove some of the air inlet plumbing anyone to get the filter cap out of the way and access the filter element. I bought this tool on eBay from Minimaxtools (Minimaxmen on eBay) for AU$20.10 (including postage). They have many extension bars and wobble bars that you might be able to use with your existing tools to make removal of the oil filter easier. Service and price seemed pretty good.

Cheers, Matt HunterXR5 24 July 2007