21-08-29ENGINE, 2.3L High Swirl Combustion (HSC)

c. Bolt transaxle case to rear face of cylinder block to align oil pan.
d. Apply a continuous 3/16-inch wide bead of Ford Silicone Gasket Sealer E3AZ-19562-A or equivalent, to the groove in the oil pan flange. Apply an extra bead of sealer to the cylinder block on each side of the front cover.
e. Immediately place the oil pan against the cylinder block and install four corner bolts. Tighten bolts snug enough to allow horizontal movement of pan. Install and tighten oil pan to transaxle bolts, then back off bolts. Install the oil pan attaching bolts and tighten to 8-12 N-m (6-9 lb.ft.).
f. Remove transaxle case.
21. Install water pump and gasket with the attaching bolts. Note that the lower front bolt is longer. Tighten the attaching bolts to 20-30 N-m (15-23 lb.ft.).
22. Coat fuel pump pushrod with heavy engine oil, SAE 50 weight or equivalent and install in cylinder block. Install gasket on fuel pump. Position arm of fuel pump over pushrod. Install attaching bolts and tighten to 20-28 N-m (14.8-20.7 lb.ft.).
23. Install the following component brackets:
a. Install accelerator shaft bracket. Tighten bolts to 10-15 N-m (7-11 lb.ft.).
b. Install air pump bracket. Tighten bolts to 20-30 N-m (15-23 lb.ft.).
c. Install fuel tube bracket. Tighten bolt to 20-30 N-m (15-23 lb.ft.).
d. Install check valve connector and EGR tube connector. Tighten each to 34-47 N-m (25-35 lb.ft.).
24. Lubricate outside of crankshaft pulley with SAE 50 weight, ESE-M2C39-F or equivalent engine oil or grease. Install pulley, flatwasher and bolt. Tighten to 111-139 N-m (82-103 lb.ft.). Apply sealant in the groove of the key-way, prior to installation.
25. Install gasket and EGR valve on intake manifold. Install attaching bolts and tighten to 18-26 N-m (13-19 lb.ft).
Position EGR tube between exhaust manifold and EGR valve. Tighten attaching nuts at each end to 34-47 N-m (25-35 lb.ft.).
26. Install the following ignition components:
a. Position distributor cap on distributor and tighten screws to 2-2.6 N-m (53-43 lb.in.).
b. Install spark plug wire terminals (1, 2, 3 and 4) in distributor cap in the order and position shown in Fig. 30.
c. Hand start spark plugs, Tighten to 7-14 N-m (5.5-10.5 lb.ft.).
d. Push spark plug wire terminals onto spark plugs until firmly seated.
27. Position carburetor base gasket over manifold studs. Install carburetor over studs and tighten attaching nuts to 20-34 N-m (14.8-25.1 ft.lb.).
28. Install the following fuel system components:
a. Connect the fuel supply line (from tank) and the fuel pressure line (to carburetor) to fuel pump. Tighten to 20-24 N-m (15-18 lb.ft.).
b. Position inline fuel filter on engine and install fuel pressure line (from pump). Install fuel line (from carburetor) to other side of filter. Tighten to 20-24 N-m (15-18 lb.ft.).
c. Connect the fuel vapor return line to the top of the filter. Tighten to 8-12 N-m (6-9 lb.ft.).
29. Press PCV vent valve into rocker cover. Connect crankcase vent hose between the vent valve and nipple at the throttle body of the carburetor. Insert the cap and tube assembly in the rocker cover and twist cap until seated. Connect the end of the flexible tube to the air cleaner assembly nipple, at the right front corner of the engine compartment.
30. Apply thread sealer to flywheel attaching bolts. Position rear cover plate over dowel pins. Install flywheel and attaching bolts, Fig. 13. Tighten to 73-87 N-m (54-64 lb.ft.). On ATX only, install reinforcement plate over flywheel before installing attaching bolts.