21-08-24ENGINE, 2.3L High Swirl Combustion (HSC)

c. Tighten all four bolts to 8-12 N-m (6-9 lb.ft.) with sealer tool in place. The bottom sealing flange of the retainer must not extend below the sealing flange (pan rail) of the block. Use double bead of sealer between retainer and oil pan.
6. Install the camshaft as follows:
a. Before installing camshaft, coat camshaft gear, lobes and journals with SAE 50 weight, ESEM2C39-F or equivalent engine oil.
b. Install camshaft. Use care to prevent damage to bearing surfaces.
c. If removed, coat rear camshaft cover with sealant and install.
NOTE: After installation, the camshaft must turn freely. Bearing clearance must be 0.025- 0.076 mm (.001 -.003 inch).
7. Install the timing chain tensioner, sprockets and timing chain as follows:
a. Install camshaft thrust plate and attaching bolts. Tighten to 8-12 N-m (6-9 lb.ft.), Fig. 23.
b. Position crankshaft keyway in vertical position with No. 1 piston at Top Dead Center (TDC), Fig. 23.
c. Apply a drop of sealer in the crankshaft keyway or to crankshaft key and install key in crank.
d. Assemble timing chain, camshaft and crankshaft sprockets with timing marks or sprockets aligned. Position components on crankshaft and camshaft. Install camshaft sprocket bolt and washer and tighten to 55-75 N-m (41-56 lb.ft.), Fig. 23.
e. Coat blade face of tensioner, timing chain, and all sprocket teeth with SAE 50 weight, ESEM2C39-F or equivalent engine oil. Install tensioner and attaching bolts. Tighten to 8-12 N-m (6-9 lb.ft.).
NOTE: Crankshaft and camshaft end play and connecting rod side clearance must be checked at this time. Refer to Adjustments.
8. Coat tappets with SAE 50 weight, ESE-M2C39-F or equivalent engine oil and install in block.
9. Install the cylinder head as follows:
a. Position cylinder head gasket on cylinder block using sealer to retain gasket.
b. Before installing cylinder head gasket, cut two cylinder head bolts off at the head to be used as guides. Install these guides into opposite corners of the cylinder block.
c. Install cylinder head over guide bolts and onto cylinder block. Remove guide bolts and install cylinder head bolts plus two new bolts (M11 x 1.50 x 100.0 mm) to replace the bolts used as guides.
d. Tighten all bolts to 70-80 N-m (53-59 lb.ft.). Tighten in sequence shown in Fig. 24.
e. Tighten again in sequence to 95-103 N-m (70.1-76.0 ft.lb.).
10. Install exhaust manifold as follows:
a. Install guide bolts N800413-S2 or equivalent through exhaust manifold and into the cylinder head (holes 6 and 7), Fig. 25.
b. Install attaching bolts in holes 1 through 5.
c. Run down bolts until snug, then remove guide bolts and install attaching bolts in holes 6 and 7.
d. Tighten all bolts in sequence shown in Fig. 25, to 7-10 N-m (5-7 lb.ft.) then tighten to 27-41 N-m (20-30 lb.ft.).
11. Coat intake manifold gasket with sealer. Position intake manifold and gasket onto cylinder head and install the attaching bolts, Fig. 26. Tighten bolts in sequence shown in Fig. 26 to 20-30 N-m (15-23 lb.ft.).
12. Install the intake manifold plugs and fittings as follows:
a. Apply sealer to all plugs and fittings in intake manifold and install.
b. Tighten vacuum fittings in intake manifold to 8-14 N-m (6-10 lb.ft.). Rotate to the correct position.
c. If removed, install engine coolant temperature sensor ans tighten to 16-24 N-m (12-18 lb.ft.).
d. Install intake manifold support brace. Tighten attaching bolts to 40-55 N-m (30-40 lb.ft.).
13. Install distributor, Fig. 27. Tighten the holddown clamp bolt to 23-34 N-m (17-25 lb.ft.). Camshaft and crankshaft sprocket marks must be aligned and No. 1 piston must be at TDC.
NOTE: Canadian engines do not use the Universal distributor.
14. Install dipstick and tube assembly. Tighten tube retaining bolt to 8-12 N-m (6-9 lb.ft.).
15. Install thermostat in water outlet connection by rotating clockwise and engaging tabs on thermostat with slot in water outlet connection. Install new gasket, thermostat and water outlet connection to cylinder head. Apply sealer ESEM46203/AA192 to the studs, torque to 16-24 N-m (12-18 lb.ft.). Install cooling fan switch in water outlet connection. Tighten to 11-24 N-m (8-18 lb.ft.).
16. Install valve train components as follows:
a. Install pushrods into cylinder block, Fig. 28.
b. Align timing marks on crankshaft and camshaft sprockets with keyway on crankshaft in the vertical position (position A). Install rocker arms, fulcrums and bolts on valves as shown in Camshaft Position A, Fig. 28. Tighten bolts 6-10 No m (4.5-7.5 lb.ft).
c. Rotate camshaft 180 degrees. Install remaining rocker arms, fulcrums and bolts on valves as shown in Camshaft Position B, Fig. 28. Tighten bolts to 6-10 N-m (4.5-7.5 lb.ft).
d. Apply SAE 50 weight, ESE-M2C39-F or equivalent engine oil to rocker arms, fulcrums and pushrods. Tighten all fulcrum bolts to 26-38 Ne m (19.5-26.5 lb.ft).
17. Apply Ford Silicone Gasket Sealant E3AZ-19562-A or equivalent to rocker arm cover and gasket. Install rocker arm cover attaching bolts and tighten to 10-13.5 N-m (7.4-10 lb.ft.).
NOTE: Fulcrums must be fully seated in cylinder head slots and pushrods must be seated in rocker arm and tappet sockets prior to final tightening. Return to position "A" before distributor installation.