21-08-10ENGINE, 2.3L High Swirl Combustion (HSC)

3. Drain crankcase.
4. Drain coolant by removing lower radiator hose.
5. Remove roll restrictor (MTX only).
6. Disconnect starter cable.
7. Remove starter.
8. Disconnect exhaust pipe from oil pan.
9. Remove engine coolant tube located at the lower radiator hose, at the water pump and at the tabs on the oil pan. Position air conditioner line off to the side. Remove oil pan.

Installation
1. Clean both mating surfaces of oil pan and cylinder block with Dupont Freon TF, or equivalent.
2. Remove and clean oil pump pick-up tube and screen assembly. After cleaning, install tube and screen assembly.
NOTE: Before proceeding, a trial installation of the pan to cylinder block must be performed to insure smooth pan installation, thus preventing smearing of sealant. Check again for any residual oil that may have leaked down (particularly the rear of the engine) and reclean as necessary.
3. Apply a continuous 3/16-inch diameter bead of Ford Silicone Gasket Sealant E3AZ-19562-A or equivalent to groove in oil pan flange. Double the bead 5/8" on the front cover and rear seal retainer. Sealant must not protrude past rear of the oil pan.
NOTE: Immediately place the oil pan against the block and transaxle beore the sealant "skins" over, approximately 2 minutes.
4. Install oil pan flange bolts tight enough to compress sealant to the point that the two oil pan transaxle holes are aligned with the two tapped holes in transaxle but loose enough to allow the pan to move relative to the block.
5. Install two oil pan to transaxle bolts. Tighten to 40-50 N-m (30-39 lb.ft.) to align oil pan with transaxle, then loosen bolts 1/2-turn.
6. Tighten all oil pan flange bolts to 8-12 N-m (6-9 lb.ft.).
7. Tighten two oil pan to transaxle bolts to 40-54 N-m (30-39 lb.ft.).
8. Install exhaust pipe bracket to oil pan.
9. Install engine coolant tube and air conditioning line.
10. Install starter and cable.
11. Install roll restrictor (MTX only).
12. Lower vehicle.
13. Install engine oil and coolant.
14. Connect negative ground cable at battery.
15. Start engine and check for leaks.

Starter

Removal
1. Disconnect negative cable at battery.
2. Raise vehicle.
3. Remove starter cable.
4. Remove the three roll restrictor attaching nuts (MTX only).
5. Remove roll restrictor (MTX only).
6. Remove the three starter attaching nuts and remove starter.

Installation

1. Install starter.
2. Install the three starter attaching nuts.
3. Install roll restrictor (MTX only).
4. Install three roll restrictor attaching nuts (MTX only).
5. Install starter cable.
6. Lower vehicle.
7. Install negative cable to battery.

Water Pump Inlet Tube Assembly

Removal
1. Open and secure hood.
2. Install protective fender covers.
3. Disconnect negative ground battery cable at battery.
4. Remove radiator cap.
5. Raise vehicle.
6. Position drain pan below radiator under lower radiator hose.
7. Remove one water pump inlet tube screw and washer from bracket located below water pump and remove two screws securing inlet tube to oil pan.
8. Loosen clamp, disconnect lower radiator hose from radiator, and drain engine coolant.

Installation
1. Clean surfaces of inlet tube and water pump where new O-ring gasket is to be installed. Carefully position the inlet tube, with new O-ring gasket to water pump, and secure bracket below water pump.
2. Install lower radiator hose to radiator.
3. Install the two screws attaching inlet tube to oil pan, tighten both screws to 8-11 N-m (6-8 lb.ft.).
4. Install heater return hose to water pump inlet tube.
5. Lower vehicle.
6. Connect negative ground cable at battery.
7. Replace engine coolant. Operate engine until normal operating temperature is reached. Check for leaks and check coolant level.

Water Pump

Removal
1. Drain engine coolant.
2. Disconnect negative ground cable at battery.
3. Loosen thermactor pump adjusting bolt and remove belt.
4. Remove thermactor air pump hose clamp located below the thermactor pump.
5. Remove the three thermactor pump bracket bolts.
6. Remove thermactor pump and bracket as an assembly.
7. Loosen the water pump idler pulley and remove the belt from the water pump pulley.