21-08-22ENGINE, 2.3L High Swirl Combustion (HSC)

3. Install valve spring and damper assembly over the valve, then install spring retainer. Compress spring and install retainer key locks.
4. Measure the assembled height of the valve spring from the underside of the spring damper to the underside of the spring retainer with dividers. Check the dividers against a scale. If the assembled height is not within specification, valve spring load loss may be excessive. Install a new valve spring or spring and damper assembly.
5. Position rocker arms and fulcrums on the cylinder head and install the fulcrum attaching bolt fingertight. Install remaining rocker arms and fulcrums with camshaft properly positioned as outlined under Collapsed Tappet Gap. Tighten fulcrum bolts to specification.
6. Install exhaust manifolds, if removed and spark plugs.

Engine

Assembly During the engine assembly, a sealant will be applied to some components before installation. When the sealant is applied the component should be installed within 15 minutes. After this time the sealant begins to set up and the sealing effectiveness is reduced.
NOTE: Lightly oil all attaching bolt and stud threads before installation, except those specifying special sealant.
1. Wash cylinder block thoroughly to remove all foreign material and dry before assembling other components. All oil holes must be fully open and clean.
2. Install the crankshaft as follows:
a. Install main bearings in cylinder block, Fig. 20. Note that the center front bearing is a thrust bearing and the front upper bearing has a small V notch on the parting line face.
b. Lubricate bearings with SAE 50 weight, ESEM2C39-F or equivalent oil. Carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.
c. Coat main bearing journals on crankshaft with SAE 50 weight, ESE-M2C39-F or equivalent engine oil.
d. Install main bearing caps in proper location (refer to numbers on caps) with arrows pointing toward front of engine, Fig. 20. Oil bolts and tighten to 70-90 N-m (51.6-66.4 lb.ft.).
e. Turn crankshaft to check for turning torque. Turning torque should be no more than 6 N-m (4.5 lb.ft.).
3. Install piston rings.
NOTE: Oil rings segment gaps must be staggered at least 12.7 mm (0.50 inch) from expander gap. Gap ink markings on rings must appear to the left of the gap when assembled on the piston (view with top of piston up).

FIGURE 21 PISTON, CONNECTING ROD, BEARINGINSTALLATION:

4. Install the pistons as follows:
a. Coat all cylinder bores and pistons with SAE 50 weight, ESE-M2C39-F or equivalent engine oil.
b. Install bearings in connecting rods and caps. The oil squirt hole in the bearing must be aligned with the squirt hole in the connecting rod.
NOTE: Make sure bearing tangs are seated in the appropriate slots in the rod and cap.
c. Install piston and rod assemblies using ring compressor D81L-6002-C or equivalent, Fig. 21. The notch in piston dome must face front of engine.
NOTE: Scratching of the crankshaft journal can be prevented by covering the connecting rod bolt threads with spark plug boots.
d. Install connecting rod cap nuts. Tighten to 28-35 N-m (21-26 lb.ft.).
5. Install rear crankshaft seal as follows:
a. Apply a thin coat of Ford Polyethylene Grease D0AZ-19584-A or equivalent to crankshaft seal journal. Fit seal lip replacer Tool T81P-6701-A or equivalent to the gasket and retainer assembly, and assemble to crankshaft, Fig. 22.
b. Align retainer assembly with holes in block and secure fingertight with two bolts. Remove seal replacer tool.