SECTION 303-01A: Engine - I6 - Barra Swap LLC

SECTION 303-01A: Engine - I6VEHICLE APPLICATION: 2008.0 Falcon

CONTENTSSPECIFICATIONS

Lubricants and Sealants ..................................................................................................................... 303-01A-01

GeneralSpecifications ........................................................................................................................ 303-01A-01

TorqueSpecifications ........................................................................................................................ 303-01A-03

DESCRIPTION AND OPERATION

Engine - I6 ............................................................................................................................................ 303-01A-05

DIAGNOSIS AND TESTING

InspectionandVerification ................................................................................................................. 303-01A-10

SymptomChart ....................................................................................................................................303-01A-11

ComponentTests ............................................................................................................................... 303-01A-13

GENERAL PROCEDURES

CylinderHeadInspection ................................................................................................................... 303-01A-16

ValveInspection ................................................................................................................................... 303-01A-16

ValveMeasurement ........................................................................................................................... 303-01A-17

ValveGuideInspection ...................................................................................................................... 303-01A-17

ValveGuideReplacement ................................................................................................................ 303-01A-18

ValveSeatInspection/Repair ............................................................................................................ 303-01A-18

ValveSpringInspection ...................................................................................................................... 303-01A-19

CamshaftEndPlayInspection .......................................................................................................... 303-01A-19

CamshaftInspection .......................................................................................................................... 303-01A-20

CamshaftJournalClearance-PlastigaugeMethod .................................................................... 303-01A-20

RollerFollowerInspection .................................................................................................................. 303-01A-21

LashAdjusterBoreInspection .......................................................................................................... 303-01A-21

CylinderBlockInspection/Repair ..................................................................................................... 303-01A-22

CylinderBore-Taper ......................................................................................................................... 303-01A-22

CylinderBore-Out-of-Round .......................................................................................................... 303-01A-22

PistonInspection ................................................................................................................................ 303-01A-23

PistonClearanceInspection/Repair ............................................................................................... 303-01A-23

PistonRingClearanceInspection .................................................................................................... 303-01A-23

PistonRingClearanceInspection .................................................................................................... 303-01A-24

CrankshaftInspection ........................................................................................................................ 303-01A-25

CrankshaftMainBearingClearance ............................................................................................... 303-01A-25

CrankshaftEndPlayInspection/Repair .......................................................................................... 303-01A-26

ConnectingRodInspection .............................................................................................................. 303-01A-26

ConnectingRodBigEndBearingClearance .................................................................................303-01A-27

ConnectingRodSideClearanceInspection...................................................................................303-01A-27

PistonandConnectingRodInspection ...........................................................................................303-01A-27

Version:2008.0FalconWorkshopManual

303-01A Engine - I6 303-01A

GENERAL PROCEDURES

TimingChainElongation .....................................................................................................................303-01A-27

IN-VEHICLE REPAIR

OilFilter ................................................................................................................................................. 303-01A-28

OilLevelIndicator&Tube .................................................................................................................. 303-01A-28

CylinderHeadTemperatureSensor .............................................................................................. 303-01A-29

CamPositionSensor ......................................................................................................................... 303-01A-29

CrankshaftPositionSensor .............................................................................................................. 303-01A-30

OilPressure&OilTemperatureSensor .......................................................................................... 303-01A-30

CombustionKnockSensor ............................................................................................................... 303-01A-31

ExhaustGasOxygenSensor ............................................................................................................ 303-01A-31

Temperature-ManifoldAirPressureSensor ................................................................................ 303-01A-32

CrankshaftVibrationDamper ........................................................................................................... 303-01A-32

CrankshaftFrontOilSeal ................................................................................................................... 303-01A-33

CrankshaftRearOilSeal .................................................................................................................... 303-01A-34

Flexplate/DrivePlate ......................................................................................................................... 303-01A-34

WaterPump ........................................................................................................................................ 303-01A-34

ElectronicThrottleBodyandIntakeManifold ................................................................................ 303-01A-35

IntakeManifoldTuningValve(IMTV) ................................................................................................ 303-01A-38

ExhaustManifoldAssembly ............................................................................................................. 303-01A-39

OilControlValveSeal ......................................................................................................................... 303-01A-40

ValveCover ......................................................................................................................................... 303-01A-40

IgnitionCoils/WiringLoom ................................................................................................................ 303-01A-43

Camshafts,VCTPhaser,OilControlValves,&OCVFilters ......................................................... 303-01A-44

CamshaftRemoval ............................................................................................................................ 303-01A-45

CamshaftandVCTPhasers ............................................................................................................. 303-01A-45

CamshaftInstallation ...........................................................................................................................303-01A-47

TimingChainTensioner ..................................................................................................................... 303-01A-49

VCTPhaser ........................................................................................................................................ 303-01A-49

RockerArm,LashAdjuster,ValveSpringandValveStemSeal .................................................. 303-01A-50

RockerArmandLashAdjuster ......................................................................................................... 303-01A-51

ValvespringandValveStemSeal ..................................................................................................... 303-01A-51

FrontCover ......................................................................................................................................... 303-01A-52

CamshaftDrive ................................................................................................................................... 303-01A-62

TimingChainTensionerRelease ...................................................................................................... 303-01A-63

CylinderHead ..................................................................................................................................... 303-01A-64

Engine .................................................................................................................................................. 303-01A-68

EngineMounting .................................................................................................................................303-01A-72

EngineOilPan ......................................................................................................................................303-01A-72

OilPumpPickupTube.........................................................................................................................303-01A-74

OilPump ................................................................................................................................................303-01A-75


303-01A Engine - I6 303-01A

CONTENTS (Continued)

IN-VEHICLE REPAIR

PistonandRodAssembly ..................................................................................................................303-01A-76

Mainbearings/Crankshaft .................................................................................................................303-01A-77

RearMainBearingCapAssembly ....................................................................................................303-01A-78

PistonRing ............................................................................................................................................303-01A-78

DISASSEMBLY AND ASSEMBLY

KeyRetainer-ValveSpring ...............................................................................................................303-01A-79

ValveStemSeal ...................................................................................................................................303-01A-79

PistonandConnectingRodAssembly ........................................................................................... 303-01A-80

PistonandConnectingRodDisassemblyandAssembly ........................................................... 303-01A-80

ConnectingRodBolt ......................................................................................................................... 303-01A-81


303-01A Engine - I6 303-01A

CONTENTS (Continued)

303-01A Engine - I6 303-01A-1

Version:2008 Falcon Workshop Manual

SPECIFICATIONS

Lubricants and Sealants

Description Specification

EngineOil5W-30ILSAC-GF4/GF5

WSS-M2C929-A/WSS-M2C946-A(I6DOHCVCT)

SiliconeSealant(Loctite5900)

WSSM4G323A7

AntiSeizecompound(Loctite767orsimilar)

ESEFM99C100A

RubberGrease ESZM1C223A

General Specifications


Displacement 3983cc

Numberofcylinders In line 6

CompressionRatio

DOHCVCT 10.3:1

Poweratspecifiedrpm(DIN)on95RON

DOHCVCT 198kW@5000

Torqueatspecifiedrpm(DIN)on95RON

DOHCVCT 409Nm@3250

Bore/Stroke 92.25mm/99.31mm

FiringOrder 1-5-3-6-2-4

OilPressure-2000rpm@80°C(normaloperatingtemperature)OilPressure-700rpm(idle)@80°C(normaloperatingtemperature)

300kPaminimum

120kPaminimum

SparkPlug-I6

DOHCVCT AGSP22Z13

CompressionPressureatMaximumcrankingspeed

DOHCVCT 1010kPa

Idle Speed

AutotransinNeutral

DOHCVCT 700 ± 50 rpm

AutotransinDrive

DOHCVCT 530 ± 50 rpm

IntakeManifoldVacuum@Idlerpm

DOHCVCT 60kPa@Drive

Cylinder Head/Valve Train CombustionChamberVolume

63.25 - 65.75cc

Jointfaceflatness 0.08mmin150mmor0.18mmoverall

Cylinderheadjointfacesurfacefinish

2.5Rz(Din)@2.5cut-off,Wt<10.0,Mr68%[email protected] um

MinimumCylinderheaddeckheight

Std - 0.3 mm

Valveseatwidth-Intake 1.0mm - 1.4mm

Valveseatwidth-Exhaust 1.25mm - 1.75mm

Valveseatangle 44.75°

Valveseatrunout 0.04mm

Valvestemtoguideclearance

0.020mm - 0.069mm

Valveguideparentborediameter

9.975mm - 10.025mm

Valveguideoutsidediameter

10.028mm - 10.039mm

Valveguideinsidediameter

6.015mm - 6.044mm

Valveheaddiameter-intake

35mm

Valveheaddiameter-exhaust

32mm

Gauge Diameters Valvefacerunout 0.05mm

Valvefaceangle 45.5°

Valvestemdiameter(In&Ex)

5.975mm - 5.995mm

Valveseatinsertrecessdiameter(In)

35.07mm - 35.12mm

Valveseatinsertrecessdiameter(Ex)

32.37mm - 32.42mm

Valveseatinsertouterdiameter(In)

35.192mm - 35.208mm

Valveseatinsertouterdiameter(Ex)

32.492mm - 32.508 mm

Valvespringfreelength 50.0 mm

Valvespringinstalledload/length

280N/37.8mm

Valvespringcompressedload/length

550N/26.8mm

Valvespringallowableloadloss

[email protected]

Valvespring-outofsquare

2°

Rockerarmratio 2.04

HydraulicLashAdjusterdiameter

13.972mm - 13.984mm

Lashadjusterboreincylinderhead

13.990mm - 14.007mm

CollapsedLashadjusterclearance at cam

0.5mm - 1.1mm (desired)

303-01A Engine - I6 303-01A-2



Camshaft

Lobelift(In&Ex) 5.39mm

Valvelift(In&Ex) 11.00mm

Camshaftendplay 0.1mm - 0.3mm

Camshaftjournaldiameter

34.928mm - 34.968mm -Front

29.928mm - 29.968mm -Remainder

CamshaftJournalmaxoutofround

0.015mm

Cylinderheadbearingdiameter

34.987mm - 35.012mm -Front

29.987mm - 30.012mm -Remainder

Journaltobearingclearance

0.019mm - 0.084mm

ServiceLimit 0.120mm

ValveTiming EngineStopped,VCTPhasersFullyAdvanced&VCTLockingPinsEngaged

IntakeOpens 27.5°BTDC

IntakeCloses 48.5°ABDC

ExhaustOpens 78.5°BBDC

ExhaustCloses 2.5°BTDC

IntakeCamCentre-line(MaximumLift)

99.5°ATDC

ExhaustCamCentre-line(MaximumLift)

131.5°BTDC

TimingChainMaximumElongation

0.35%

Cylinder Block

Headgasketthickness 0.25mmatbody,0.37mmatcylinderbore

Mainbearingborediameter

71.517mm - 71.541mm

Cylinderborediameter 92.24mm - 92.26mm Std

92.79mm - 92.31mm (0.05mmO/S)

93.74mm - 92.76mm (0.5mmO/S)

93.24mm - 93.26mm (1.0mmO/S)

Outofroundlimit 0.015mm

Outofroundservicelimit 0.125mm

Taperservicelimit 0.25mm

Crankshaft

Mainbearingjournaldiameter

67.481mm - 67.505mm

Connectingrodjournaldiameter

53.93mm - 53.95mm

Crankshaftfreeendplay 0.10mm - 0.20mm

ServiceLimit 0.30mm

Connectingrodbearings-clearancetocrankshaft-desired

0.025mm - 0.04mm

Connectingrodbearings-clearancetocrankshaft-servicelimit

0.06mm

Mainbearings-clearancetocrankshaft-desired

0.02mm - 0.04mm

Mainbearings-clearancetocrankshaft-servicelimit

0.06mm

Connecting Rod

SmallendborediameterFixedPin(WithoutBushing)

23.104mm - 23.144mm

Bigendborediameter 56.871mm - 56.889mm

Length(centretocentre) 153.78mm - 153.92mm

Alignment(boretobore-maxdifference)Twist

0.20mmServiceLimit

Bend 0.10mmServiceLimit

Side clearance (assembledtocrank)Standard

0.09mm - 0.27mm

SideclearanceServicelimit

0.36mm

SPECIFICATIONS (Continued)

303-01A Engine - I6 303-01A-3



BoreDiameter 92.24 92.25 92.26

Installedpistonringgap-TopCompression-New

TBATopRingInstalled Gap

0.267mm ~ 0.417mm

0.299mm ~ 0.449mm

0.330mm ~ 0.480mm

Installedpistonringgap-2ndRing-New

TBA2ndRingInstalled Gap

0.287mm ~ 0.447mm

0.319mm ~ 0.479mm

0.350mm ~ 0.510mm

OilRing(Rail)Gap-New0.15mm - 0.75mm OilRing

Installed Gap0.087mm ~ 0.687mm

0.119mm ~ 0.719mm

0.150mm ~ 0.750mmOilRing(Rail)Gap-

ServiceLimit1.0mm


Piston

Pistondiameter(STD)

(Measuredat12.5upfromPistonSkirt)

92.201mm-92.215mm (WithoutSkirtCoating)92.211mm-92.235mm (WithSkirtCoating)

Pistontoboreclearance(new)

0.025mm-0.059mm 0.005mm-0.049mm

PistonPinborediameter(FixedPin)

Notethe“PintoPistonClearance”requiredbelow

23.169mm - 23.174mm

Ringgroovewidth-TopCompression

1.23mm - 1.25mm

Ringgroovewidth-LowerCompression

1.52mm - 1.54mm

Ringgroovewidth-OilRing

2.99mm - 3.01mm

Pistonpinlength 65.10mm - 65.30mm

Pistonpindiameter(FixedPin)

Notethe“PintoPistonClearance”requiredbelow.

23.157mm - 23.162mm

Pintopistonclearance 0.010mm-0.015mm

Ringgrooveclearance-TopCompressionNew

0.04mm - 0.080mm

Ringgrooveclearance-TopCompressionServicelimit

0.15mm

Ringgrooveclearance-2ndRingNew

0.03mm - 0.075mm

Ringgrooveclearance-2ndRingServicelimit

0.15mm

Oilringgrooveclearance-new

0.028mm - 0.17mm

Oilringgrooveclearance-servicelimit

0.20mm


Lubrication system

Oilcapacity-InitialFill(Dryengine)

7.0L

OilChangewithoutFilter 5.8L

OilChangewithFilter 6.8L

Torque Specifications

Oilthreadswithengineoil.Donotoilthreadsthatrequirethreadsealantorthreadlocker.

Description Nm

MainBearingCapbolts 85

CylinderHeadBolts(exceptfrontandrear)

Step1:40NmStep2:Rotate120°

clockwise

FrontandRearCylinderHeadBolts(X4Bolts)


clockwise

OilPantoCylinderblock/frontcover

10

OilPantomainbearingcrossbolts

58(Applythreadsealant)

OilPanRearFace Flushor0.25mmforwardofrearfaceof

block

OilPanDrainPlug 26

IntakeManifold-CylinderHead

17-24

IntakeManifoldBracket(Upper)

16

ToManifold 8-12

ToCylinderHead 8-12

IntakeManifoldPencilStrut(Lower)

20

ToManifold 17-24

ToCylinderHead 17-24

ToEngineMt.Support 44-55

FuelRailtoIntakeManifold

8-12

IntakeManifoldETB 8-12

303-01A Engine - I6 303-01A-4


Description Nm

IntakeManifoldMTV 4.5-5.5

IntakeManifoldPressure/TemperatureSensor

2

IntakeManifoldDipStickTube

10

ExhaustManifoldtoCylinderHead

27

ExhaustManifoldHeatShield-Lower

20

ExhaustManifoldSlipJoint

Stud 16

Nut 23

FlywheeltoCrankshaft(Manual)

90

FlywheeltoCrankshaft(Auto)

70

ManualFlywheelHousingtoBlock

50

OilPumptoCylinderBlock

10

OilPumpPickupTubetoOilPump

10

OilPumpPickupTubetoMainBearingBolt

20

OilFilterAdaptortoCylinderBlock

17

OilFiltertoCylinderblock Withoiledgasket,handtightenuntilgasketcontactsblockface,tightenafurther¾turn

OilPressureSensor 20(Applythreadsealant)

OilTemperatureSensor 20(Applythreadsealant)

KnockSensortoCylinderBlock

20-25(Applythreadsealant)

TimingCovertoCylinderBlock

28(Applythreadsealant)

CrankshaftPositionSensortoTimingCover

10-12

ThermostatHousingtoCylinderHead

20(Applythreadlocker)

WaterOutlettoThermostatHousing

20

HeaterTubetoThermostatHousing

20

HeaterTubetoBlock(Exhaustside)

27

WaterPumptoCylinderBlock

20


Description NmEngineMountBrackettoCylinderBlock


EngineMounttoEngineMountBracket

102

AlternatorBracket(rear)toCylinderBlock

25

SparkPlugs 17

VariableCamTimingUnittoCamshaft


clockwise

SparkPlugCovertoRockerCover

7

IgnitionCoiltoRockerCover

24

CamCovertoCylinderHead-Fronttwolongbolts

13

CamCovertoCylinderHead-Sixshortbolts


OilControlValveSealstoCamCover

7

CamCapstoCylinderHead

10

Camshaftpositionsensortocylinderhead

9

CylinderHeadTemperaturesensortoCylinderHead

15

TimingChainFixedChainGuidetoCylinderBlockandCylinderHead

20

TimingChainTensionertoCylinderHead

9

TimingChainGuidePivotBolttoOilPump

47

TimingChainGuidePivotNut

9

CrankshaftVibrationDamper/FrontPulleytoCrankshaft

145

ConnectingRodCaptoConnectingrod

Step1:25NmStep2:90°clockwise.

303-01A Engine - I6 303-01A-5


Engine - I6

The4.0LI6isafourvalvepercylinder,DualOverheadCamshaftEnginewithindividualintakeandexhaustvariablecamtimingunits.Adistributorlessignitionsystemwithindividualcoilsmountedabovethesparkplugsisused.Thecylinderblockiscastiron,andisattachedtoanaluminiumoilpanwithcross-boltedmainbearingcapstoincreaserigidity.Theoilpumpismountedonthenoseofthecrankshaft,andasinglestagerollerchaindrivesthehollowcamshafts.Hydrauliclashadjustersandrollerfingerfollowersactivatethevalves.Anelectronicthrottlebodyisemployedtogetherwithavariablelengthintakemanifold.Petrolversiononlyisavailable.

WARNING

EngineswithplasticinletmanifoldsarenotsuitableforconversiontoLPG.Theplasticinlet

manifoldisonlydesignedtoworkwithpetrolengines-itisdangeroustotrytousethistypeofmanifoldwithvapourbasedLPGfuelsystems.

DESCRIPTION AND OPERATION

303-01A Engine - I6 303-01A-6


Upper Engine Components

AUS00356A

21

20

19

18

17

16

15

23

9

33

30

28

34

14

8

13

31

2726

25

5

1

2

12

22

7

3

11

29

4

10

32

24

6

DESCRIPTION AND OPERATION (Continued)

303-01A Engine - I6 303-01A-7


Upper Engine Components

Item Description

1 CoilandBootAssembly

2 SparkPlug

3 Cap-Camshaftintakebridge-Rear

4 Camshaft-Intake

5 Cylinderheadtemperaturesensor

6 Engineliftingeye,LH,FRT

7 SensorAssemblycamshafttiming

8 Headgasket

9 SensorAssemblycamshafttiming

10 Cylinderhead

11 Lashadjusterassembly

12 Clip

13 Engineliftingeye,RH,RR

14 Valve-Inlet

15 Valve-Exhaust

16 Insert-CylinderHead

17 Bushing-Valveguide

18 Seal-Valvestem

19 Spring-Valve

20 Retainer-Valvespring

21 Key-Valvespringretainer

22 Rockerarm

23 Camtimingassembly-Enginevariable

24 Toptimingchainguide

25 Cap-Camshaftexhaustbridge,FRT

26 HousingandValveassemblycamshaftvariabletiming

27 Gasket-Valverockerarmcover

28 Seal-Gasketvalverockerarmcover

29 Gasket-Rockerarmcover

30 Gasket-Sparkplug

31 Cover-Valverockerarm

32 Sparkplugcoverassembly

33 Oilfillercapgasket

34 Oilfillercap


303-01A Engine - I6 303-01A-8


Lower Engine Components

AUS04701A

22

23a

26

27

24

16

3

4

12

33

831

32

36

37

38

15

19

10

7

6

5

21

25

17

1128

20

18

13

14

9

734

29

30

23b

23c

35

2

1


303-01A Engine - I6 303-01A-9


Lower Engine Components

Item Description

1 TimingChainTensioner

2 Leverarmassembly-Timingchaintensioner

3 Timingchain

4 Guideassembly-Timingchain

5 Oilpump

6 Oilpumppick-up/Screen

7 SensorAssemblyEngineSparkintensity(knocksensors)

8 Driveplate/Flexplate

9 Cover-Flywheelhousing

10 Filterassembly-Oil

11 Pistoncompressionring,Upper

12 Pistoncompressionring,Lower

13 PistonOilcontrol,Ring

14 Piston

15 Connectingrod

16 Bearingupper-Connectingrod(BigEnd)

17 Bearinglower-Connectingrod(BigEnd)

18 Cap-ConnectingRod

19 Pin-Piston

20 Cover-Flywheel

21 Plug-OilPandrain

22 Pan-Oilpan

23a FrontHalfMoonSeal-OilPan

23b FrontHalfMoonSeal-OilPan

23c FIPGasket(SiliconRTV)-OilPan

24 Crankwindageoilbaffle

25 Brace-Mainbearingcapsupport

26 Crankshaftmainbearingcaps

27 Crankshaftmainbearing-Lower

28 Crankshaft

29 Crankshaftmainbearings-Upper

30 Cylinderblock

31 Tube-Oilleverindicator

32 Oilleverindicator

33 Damperassembly-Crankshaft

34 Cranksensor

35 Crankshaftsprocket/Tonewheel

36 Switchassembly-Oilpressure

37 Seal-Oil,Cylinderfrontcover

38 Cover-Cylinderfront


303-01A Engine - I6 303-01A-10


Engine

Inspection and Verification

Sincediagnosisandtestingactuallybeginswhenrepairsaretakenon,thefollowingprocedureisrecommended.

1. Verifythecustomerconcernbyoperatingthesystem.

2. Visuallyinspectforobvioussignsofmechanicaldamageorelectricaldamage.Iftheconcerncannotbereproduced,carryoutaroadtestand/orvisualcheckwiththeaidofthefollowingtable.

Visual Inspection Chart

Mechanical

• Coolantleaks

• Oilleaks

• Leaksinthefuelsystem

• Visiblydamagedorwornparts

• Looseormissingnutsorbolts

3. Ifanobviouscauseforanobservedorreportedconcernisfound,correctthecause(ifpossible)beforeproceedingtothenextstep.

4. Iftheconcernisnotvisuallyevident,verifythesymptomandrefertotheSymptomChart.

DIAGNOSIS AND TESTING

303-01A Engine - I6 303-01A-11


Symptom Chart

Condition Possible Sources Action

Enginewillnotcrank

• FaultyStarterSystem.• RefertoSection303-06Starting

System.

• TransmissionlevernotinPorN.

• PlaceinP.

• Seized engine. • Replaceengine.

• Coolantincylinders. • Replaceengine.

Enginecranksbutwillnotstart• Ignitionsysteminoperative.

• RefertoSection303-06StartingSystem.

• Fuelsysteminoperative. • RefertoSection303-04.

Engineslow/difficulttostart

• VariableCamTiming(VCT)unitlockpinnotengagedatstart.

• VCTunitOilControlValvejammed.

• CleanOilControlValve.RefertoValveCoverSection.

Enginemisfires

• FailSafeCoolinginoperation. • Repaircoolantsystem.

• Ignitionsystemfaulty. • RefertoSection303-06.

• Fuelsystemfaulty. • RefertoSection303-04.

• Restrictedexhaustsystem. • InspectExhaustsystem.

• Intakevacuumleak.• CarryoutIntakeManifoldVacuum

testinthissection.

• Burnedvalve/poorseating. • Performacompressioncheck.

• Brokenvalvespring. • Inspectvalvesprings.

• Headgasketleakage. • Inspectheadgasket.

• Pistondamage.• Performcylindercompression

check.

Rough-RollingIdle

• FaultyintakeOilControlValve(OCV)

• ReplaceintakeOCVonly

• Lowidleoilpressure• Measureminimumidleoil

pressureandrepair.Referrelevantsection.

• Incorrectsparkpluggap• Re-gapsparkplugto

specification.ReferSection303-06

InsufficientPower

• DualPlenumIntakeManifoldnotoperative.

• Checkswitchingoccursat3700rpm-refertoSection303-14.

• VCTunit(s)notoperative. • RefertoSection303-14.

• ElectronicThrottleControlUnitfaulty.

• RefertoSection303-14.

ExcessiveFuelConsumption

• Green(lowmileage)engine/vehicle.City/stop-startdriving.

• Establishaccuratefuelconsumptionusingfull-to-fullmethod.

• FaultyFuelSystem. • RefertoSection303-04.

• Green engine. • Recheckat15,000km.

• Valvestemsealdamagedormissing.

• Inspecttheseals.

• Oilleakage. • Repairoilleakage.

• IncorrectOilviscosity. • Drainandfillwithcorrectoil.

• Piston/rings/cylinderwornordamaged.

• Repair.RefertoSection303-00.

DIAGNOSIS AND TESTING (Continued)

303-01A Engine - I6 303-01A-12


Condition Possible Sources Action

ExcessiveOilConsumption

• Dilutedoil• Determinethecause.Correct.

Drainandrefilloil.

• Crankcaseoverfilled. • Adjustoillevel.

• FaultyPCVValve. • Checkandreplace.

Engineleaksoil

• Jointfastenersloose. • Tightentospecification.

• Outofpositionordamagedseal/RTVsealantomitted/inadequate.

• Pressurisecrankcaseto35kPa.Applysoapywater,checkforleak.Inspect and replace.

• Worn/outofpositioncrankrotaryseal.

• Inspect and replace.

• Porouscasting.

• Cleansuspectarea,Performpressurizedcrankcasecheck.Runengine,checkforleak.Replacecasting.

• SealantinCrankDamperkeywayomittedorinadequate.

• Replacesealant.

• SealantbetweenRearMainCapandblockomittedorinadequate.

• Performpressurizedcrankcaseleakcheck.Repair.

EngineNoise

• ExcessiveCrankshaftMainbearingorbigendclearance.

• ExcessiveCrankshaftendplay.

• Excessivecamshaftendplay.

• Excessivepistontocylinderboreclearance/damagedpiston/bentconnectingrod.

• Excessivepistonpintopistonpinboreclearance.

• Excessivehydraulicvalveadjusterclearance.

• Worncamlobeorrollerfingerfollower.

• Excessivevalveguideclearance.

• Brokenvalvespring.

• Loosetimingchain.

• Loosecrankdamper.

• Worn/noisyFrontEndAccessoryDriveBelt.

• Worn/noisytensioner/idlerpulley.

• Exhaustgasleakage.

• Inspectandrepair.ReferrelevantSection.

• Softorspongylashadjusters.• Checkforexcessivelyloworhigh

oillevel.Airleakinsuctionsideofoilpump.

• Carbonincombustionchamber/toplandofpiston.

• Removecarbonusingproprietarycarbonremovaltreatment.


303-01A Engine - I6 303-01A-13


Component Tests

Engine Oil Leaks

Note:Beforeinstallingnewgasketsoroilseals,makesurethatthefaultisclearlyestablished.Iftheoilleakcannotbeidentifiedclearlybyavisualinspection,carryoutapressurizedcrankcaseleakcheck.

Pressurised leak check

1. Cleantheenginewithasuitablecleaningfluidtoremovealltracesofoil.

2. BlockoffthelinetothePCVvalve.

3. Applyaregulatedairsupplylinetothefreshairmakeuppointontherockercover.

4. Pressurisethecrankcaseto35kPa.

5. Checkforairleaksbywashingthesuspectareawithasolutionofsoapywaterandwatchingforbubbles.

6. Repairallleaksasnecessary.

General Remarks

Note:Removingfusesanddisconnectingelectricalcomponentscausesthepowertraincontrolmodule(PCM)tologanerrormessage.AfterthemeasurementshavebeencarriedoutthiserrormessageshouldbeclearedfrommemorybyconnectingtoIDS.

Thecompressionpressureshouldbecheckedwiththeengineatoperatingtemperature.

Check The Compression Pressure

WARNING

Onautomatictransmissionvehicles,select‘’P’’.Failuretofollowtheseinstructionsmay

resultinpersonalinjury.

1. Removethefuelpumprelay.

2. Starttheengineandrunforafewseconds,thenstall.

3. Removethesparkplugs.

4. Installanadaptorandcompressiontester.

5. Installanauxiliarystarterswitchinthestartingcircuit.WiththeignitionswitchOFF,usetheauxiliarystarterswitchtocranktheengineaminimumoffivecompressionstrokes,andrecordthehighestreading.Notetheapproximatenumberofcompressionstrokesrequiredtoobtainthehighestreading.

6. Repeatthetestoneachcylinder,crankingtheengineapproximatelythesamenumberofcompressionstrokes.

7. Installthecomponentsinreverseorder,observingthespecifiedtighteningtorques.

8. ResetthePCMfaultmemory.


Interpretation of the Results

Theindicatedcompressionpressureisconsideredtobewithinspecificationifthelowestreadingcylinderiswithin75%ofthehighestreading.

CAUTION

Ifengineoilissprayedintothecombustionchamber,runtheengineat2000rpmforabout

15minutes(inordertoburntheoilandpreventdamagetothecatalyticconverter)aftercarryingoutthemeasurement.

Ifthemeasurementononeormorecylindersissignificantlylowerthanthespecifiedvalue,spraysomeengineoilintothecombustionchamberandrepeatthecompressionmeasurement.

Ifthereadinggreatlyimproves,thepistonringsaredamaged.

Ifthereadingstaysthesame,thecauseiseitherdamagedvalvesorvalveseats.

Ifthemeasurementsfortwoadjacentcylindersarebothtoolow,thenitisverylikelythatthecylinderheadgasketbetweenthecylinderisburntthrough.Thiscanalsoberecognizedbytracesofengineoilinthecoolantand/orcoolantintheengineoil.

Excessive Engine Oil Consumption

Theamountofoilanengineuseswillvarywiththewaythevehicleisdriveninadditiontonormalengine-to-enginevariation.Thisisespeciallytrueduringthefirst15,000kmwhenanewengineisbeingbrokeninoruntilcertaininternalcomponentsbecomeconditioned.Vehiclesusedinheavy-dutyoperationmayusemoreoil.Thefollowingareexamplesofheavy-dutyoperation:

• Trailertowingapplications

• Severeloadingapplications

• Sustainedhighspeedoperation

Enginesneedoiltolubricatethefollowinginternalcomponents:

• Cylinderblockcylinderwalls

• Pistonsandpistonrings

• Intakeandexhaustvalvestems

• Intakeandexhaustvalveguides

• Allinternalenginecomponents

Whenthepistonsmovedownward,athinfilmofoilisleftonthecylinderwalls.Asthevehicleisoperated,someoilisalsodrawnintothecombustionchamberspasttheintakeandexhaustvalvestemsealsandburned.

303-01A Engine - I6 303-01A-14


Thefollowingisapartiallistofconditionsthatcanaffectoilconsumptionrates:

• Engine size

• Operatordrivinghabits

• Ambient temperatures

• Qualityandviscosityofoil

Operationundervaryingconditionscanfrequentlybemisleading.Avehiclethathasbeenrunforseveralthousandkilometresonshorttripsorincoldambienttemperaturesmayhaveconsumeda‘’normal’’amountofoil.However,whencheckingtheengineoillevel,itmaymeasureuptothefullmarkontheoillevelindicatorduetodilution(condensationandfuel)intheenginecrankcase.Ifthevehicleisthendrivenathighspeedsonahighwaywherethecondensationandfuelboiloff,thenexttimetheengineoilischeckeditmayappearthatalitreofoilwasusedinarelativelyshortdistance.

MakesuretheselectedengineoilmeetstheFordspecificationandtherecommendedAPIperformancecategory‘’SJ/CF’’andSAEviscositygradeasshowninthevehicle’sOwner’sManual.Itisalsoimportantthattheengineoilischangedattheintervalsspecifiedforthetypicaloperatingconditions.

Oil Consumption Test

Thefollowingdiagnosticprocedureisusedtodeterminethesourceofexcessiveoilconsumption.

Note:Oiluseisnormallygreaterduringthefirst15,000kmofservice.Asmileageincreases,oilusedecreases.Highspeeddriving,towing,highambienttemperatureandotherfactorsmayresultingreateroiluse.

1. Defineexcessiveconsumptionsuchasthenumberofkilometresdrivenperlitreofoilused.Alsodeterminecustomer’sdrivinghabits,suchassustainedhighspeedoperation,towing,extendedidleandotherconsiderations.

2. VerifythattheenginehasnoexternaloilleaksasdescribedintheEngineOilLeakssection.

3. Verifythattheenginehasthecorrectoillevel.

4. Verifythattheengineisnotbeingruninanoverfilledcondition.Checktheoillevelatleastfiveminutesafterahotshutdownwiththevehicleparkedonalevelsurface.

5. CarryoutanOilConsumptionTest:

1. Fora4.0LI6engine,draintheengineoilandrefilltheengine.Runfor10minutes,andallowtheenginetostandfor5minutestoallowtheoiltodraintothecrankcase.

2. Topuptheoillevelexactlytothefullmark.Allowtostandfor5minutesandre-check.

Note:Forenginesotherthanthe4.0LI6,refilltheenginewithonelitrelessoilthanspecified.


Runtheenginefor10minutesandallowtostandfor5minutes.Cleanthedipstickandscribealineonthebackfaceofthedipstickbladecorrespondingwiththislevel,thenreinsert.Addexactly1litreofoiltotheengine.Runfor5minutesandallowtostandfor5minutes.Markthenewlevelonthebackofthedipstick.ThisshouldcorrespondcloselytotheFULLmark.

3. Recordthevehicle’sodometerreading.

4. Instructthecustomertodrivethevehicleasusualand:

• Checktheoillevelregularlyatintervalsof250km.

• ReturntotheservicepointwhentheoilleveldropsbelowtheADDmarkontheoildipstick.

• Addonlyfulllitresofthesameoilinanemergency.Notethemileageatwhichtheoilisadded.

5. Checktheoillevelunderthesameconditionsandatthesamelocationasinsteps1-3.

6. Measurethedistancefromthefullmarktothecurrentoillevelontheoildipstickandcalculatetheoilusagebasedonavolumeof1.0litresusedfor10mmdistancebelowtheFULLmarkforthe4.0LI6engines.Forenginesemployingthealternatemethodofmarkingthedipstickwithlevelscorrespondingtoavolumedifferenceof1litre,notethedistancethenewoillevelisbelowtheTopscribedmarkanddividethisbythedistancebetweentheoriginaltwoscribedmarks.Thisgivesthevolumeofoilinlitresusedduringthetest.

7. Dividethedistancetravelled(kilometres)duringthetestbytheamountofoilused(litres)toproducetheoilconsumptioninkilometresperlitre.

8. IftheoilconsumptionisunacceptablegotoStep 9.

6. Checkthepositivecrankcaseventilation(PCV)system.Makesurethesystemisnotplugged.

7. Checkforpluggedoildrain-backholesinthecylinderheadandcylinderblock.

8. IftheconditionstillexistsaftercarryingouttheabovetestsgotoStep9.

9. CarryoutacylindercompressiontestasoutlinedintheCompressionTestsection.Thiscanhelpdeterminethesourceofoilconsumptionsuchasvalves,pistonringsorotherareas.

10. Checkvalveguidesforexcessiveguideclearance.Installnewvalvestemsealsifrequired.

303-01A Engine - I6 303-01A-15


11. Wornordamagedinternalenginecomponentscancauseexcessiveoilconsumption.Smalldepositsofoilonthetipsofthesparkplugscanbeacluetointernaloilconsumption.

Intake Manifold Vacuum Test

Bringtheenginetonormaloperatingtemperature.Connectavacuumgaugeorequivalenttotheintakemanifold.Runtheengineatthespecifiedidlespeed.

Thevacuumgaugeshouldreadbetween51-74kPadependingupontheengineconditionandthealtitudeatwhichthetestiscarriedout.Subtract4.0kPafromthespecifiedreadingforevery300mofelevationabovesealevel.

Thereadingshouldbesteady.Adjustthegaugedampercontrol(whereused)iftheneedleisflutteringrapidly.Adjustdamperuntilneedlemoveseasilywithoutexcessiveflutter.


303-01A Engine - I6 303-01A-16


Cylinder Head Inspection

WARNING

ContinuousexposurewithUSEDengineoilhascausedskincancerinlaboratorymice.

Protectyourskinbywashingwithsoapandwaterimmediatelyafterthiswork.

1. Conductadyepenetrant(orsimilar)cracktest.Replacethecylinderheadifnecessary.

2. Inspectforthefollowingandrepairifnecessary.

• Sunkenvalveseats

• Excessivecamshaftbearingclearanceandend play

• Excessivelashadjusterboresize

3. Measurethecylinderheadfordistortion.Thiscanbeachievedbyusingastraightedgeandfeelergaugealongthehorizontalandverticallyalignedboltholesontheshadedsurface.

4. Repeattheprocedurealongthediagonalfromthetopleftboltholetothebottomrightboltholeandalongthediagonalfromthetoprightboltholetothebottomleftbolthole.

AUS00296

Maximum distortion

0.18mmlengthwaysor0.075mmin150mmtransversely

5. Ifthecylinderheaddistortionexceedsthemaximum,repairbygrindingthejointfaceorreplacethecylinderhead.

Maximum joint face machining 0.3mm

Minimum surface combustion chamber volume

64.0cc

GENERAL PROCEDURES

6. Measurethemanifoldcontactsurfacedistortionasshown.

AUS00297

Maximum distortion 0.15mm

7. Ifthedistortionexceedsthespecification,grindthesurface.

Maximum grinding 0.20mm

Valve Inspection

Inspectthefollowingvalveareas:

1. Thevalvetip,forpittingandwear.

2. Thekeepergrooves,forburnsandwear.

3. Thestem,forwear,scuffingandbending.

4. Thevalvehead,forburning,cracksandpittingoftheseat.

5. Thevalveheadthickness.

AUS00298

4

2 3

1

Item Description

1 Valvetip

2 Keepergrooves

3 Stem

4 Valvehead

5 Valveheadthickness

303-01A Engine - I6 303-01A-17


Valve Measurement

1. Measurethevalveheadmarginthicknessofeachvalve.Replacethevalveifnecessary.

AUS00299

Margin thickness (min) IN:1.1mm

EX:1.1mm

2. MeasurethestemdiameterofeachvalveinXandYdirectionsatthethreepoints(A,B,andC)shown.Replacethevalveifnecessary.

AUS00300

CBAY

X

Standard Diameter (IN and EX)

5.975 - 5.995mm

Minimum Diameter 5.950mm

GENERAL PROCEDURES (Continued)

Valve Guide Inspection

MeasuretheinnerdiameterofeachvalveguideinXandYdirectionsatthethreepoints(A,B,andC)shown.

AUS00301

CBAY

X

Standard Inner Diameter

6.015 - 6.044 mm

Maximum diameter 6.070mm

303-01A Engine - I6 303-01A-18


Valve Guide Replacement

Removal

1. Removethevalveguidefromthecombustionchambersidebyusingadrift.

AUS00303

Installation

1. Installtheguideusingadriftsotheprotrusion(A)isasspecified.

AUS00302

A

Protrusion A 13.5 - 14.1 mm

2. Reamtheguidetosize.

Diameter 6.015 - 6.044 mm


Valve Seat Inspection/Repair

1. Measuretheseatcontactwidth.Ifnecessary,resurfacethevalveseatusinga45°valveseatcutterand/orresurfacethevalveface.

AUS00304

Intake 1.0 - 1.4 mm

Exhaust 1.25 - 1.75 mm

Note:Afterresurfacingvalvesorseats,checkcollapsedlashadjusterclearance.

2. Verifythattheseatingpositionisatthecentreofthevalveface.

• Iftheseatingpositionistoohigh,correctthevalveseatusinga65°(IN)or75°(EX)cutter,anda45°cutter.

• Iftheseatingpositionistoolow,correctthevalveseatusinga35°cutter,anda45°cutter.

INLET

AUS0030535O

45O

65O

EXHAUST

35O

45O

75O

303-01A Engine - I6 303-01A-19


3. Measuretheprotrudinglength(L)ofthevalvestem.Replacethevalveorvalveseatifnecessary.

L

AUS00306

Standard dimension L IN:50.00 EX:47.92

Maximum dimension L IN:51.0 EX:48.9

Valve Spring Inspection1. Checkthevalvespringloadatsetlength

L

AUS00307

Minimum Load 250N at 37.8 mm


2. Measuretheout-of-squareofthevalvespring.Replacethevalvespringifnecessary.

X

AUS00308

Maximum valve spring out-of-square

1.75mm

Camshaft End Play Inspection

1. Removetherollerfollowers.Foradditionalinformation,refersection303-00ofthe2008.0FalconWorkshopManual.

2. UseaDialIndicatorwithbasketrytomeasurecamshaftendplay.

3. Positionthecamshafttotherearofthecylinderhead.

4. Zerotheindicator.

5. Movethecamshafttothefrontofthecylinderhead.Noteandrecordthecamshaftendplay.

• Ifcamshaftendplayexceedsspecifications,installnewcamshaftandrecheckendplay.

• Ifcamshaftendplayexceedsspecificationaftercamshaftinstallation,installanewcylinderhead.

Standard end play 0.1 - 0.3 mm

Maximum end play 0.4 mm

303-01A Engine - I6 303-01A-20


Camshaft Inspection

1. SettheNo.1andNo.7journalsonV-blocks.Measurethecamshaftrunout.Replacethecamshaftifnecessary.

AUS00310

Maximum runout 0.1mm

2. Checkthecamlobeforcracksandpitting.Minorindentationsareacceptable.Replaceifnecessary.

AUS00311


3. Measurethejournaldiameterin2directions.Replacethecamshaftifnecessary.

AUS00312

2

1 1

2

Standard diameter

Journal 1 34.928 - 34.968 mm

Journal 2 - 7 29.928 - 29.968 mm

Minimum diameter

Journal 1 34.900 mm

Journal 2 - 7 29.900 mm

Camshaft Journal Clearance - Plastigauge Method

1. Removethecamshaftbearingcapandlaytheplastigaugeacrossthesurface.

2. Reinstallthecamshaftbearingcap-DONOTrotatethecamshaft.

3. Removethecamshaftbearingcapandmeasurethewidthoftheplastigaugewiththescaleprovidedtodeterminetheclearance.Replacethecomponentsasrequiredifnecessary.

AUS01528

Standard clearance 0.019 - 0.084 mm

Maximum clearance 0.100 mm

303-01A Engine - I6 303-01A-21


Roller Follower Inspection

1. Inspecttherollerforflatspotsorscoring.

2. Checktheballsocketandvalvepadforscuffingandwear.

AUS00313

Lash Adjuster Bore Inspection

1. Measurethediameterofeachlashadjusterbore

AUS00314

Y

X

Standard diameter 13.990 - 14.007 mm

2. Measurethediameterofeachlashadjuster.

Standard diameter 13.972 - 13.984 mm


3. Calculatetheclearancebetweenthelashadjusterandtherelatedlashadjusterbore.Replacethelashadjusterorcylinderheadifnecessary.

AUS00315

Standard clearance 0.006 - 0.035 mm

Maximum clearance 0.050 mm

303-01A Engine - I6 303-01A-22


Cylinder Block Inspection/Repair

Measurethedistortionofthecylinderblocktopsurfaceinthetwodirectionsasshown.Repairbygrindingorreplaceifnecessary.

AUS00316

B

A

Maximum cylinder block distortion

Direction A 0.15 mm

Direction B 0.05 mm

Maximum grinding 0.20 mm

Minimum Piston-Deck 0.50 mm

Maximum Surface finish Rz 13.5

Cylinder Bore - Taper

Measurethecylinderboreatthetopandbottom.Verifythecylinderboreiswithinthewearlimit.Thedifferenceindicatesthecylinderboretaper.Borethecylindertothenextoversize.

AUS00317

Service limit 0.25 mm


Cylinder Bore - Out-of-Round

Measurethecylinderboreintwodirections.Thedifferenceistheout-of-round.Verifytheout-of-roundiswithinthewearlimitandborethecylindertothenextoversizelimit.

AUS00318

Y

X

Service limit 0.125 mm

Cylinder bore - Reboring sizes

Size Diameter (mm)

Standard 92.24 - 92.26

0.5 oversize 92.74 - 92.76

1.0 oversize 93.24 - 93.26

303-01A Engine - I6 303-01A-23


Piston Inspection

Measuretheouterdiameterofeachpistonatarightangle(90°)tothepistonpin,44.5mmbelowthecrown.

AUS00319

Piston Clearance Inspection/ Repair

1. Calculatethepiston-to-cylinderclearance.Replacethepistonorreborethecylinderstofitoversizepistonifnecessary.

Standard Clearance 0.030mminterferenceto0.025mmclearance

Service limit 0.09 mm clearance

2. Ifthepistonisreplaced,thepistonringsmustalsobereplaced.

Piston Ring Clearance Inspection1. Measurethepistonring-to-ringlandclearance

aroundtheentirecircumference.Replacethepistonringifnecessary.

Standard Limit Top 0.04 - 0.08 mm

Second 0.03 - 0.075 mm

Oil 0.028 - 0.170 mm

AUS00320


Service LimitTop 0.15 mm

Second 0.15 mm

Oil 0.20 mm

2. Insertthepistonringintothecylinderbyhandandusethepistontopushittothebottomoftheringtravel.

3. Measureeachpistonringendgapusingafeelergauge.Replacethepistonringifnecessary.

AUS00321

X

Standard End Gap Top TBA

Second TBA

Oil 0.15 - 0.75 mm

Maximum End GapTop 0.45 mm

Second 0.60 mm

Oil 1.0 mm

303-01A Engine - I6 303-01A-24


Piston Ring Clearance Inspection

1. MeasureeachpistonpinholediameterinXandYdirectionsatthefourpoints(A,B,CandD)asshown.

AUS00322

A

B

C

D

Y

X

Standard Diameter

DOHC VCT 23.169 - 23.174 mm

2. MeasureeachconnectingrodsmallendinnerdiameterinXandYdirectionsasshown.

AUS00323

Y

X

Standard Diameter

DOHC VCT 23.132 - 23.144 mm


3. MeasureeachpistonpindiameterinXandYdirectionsatthefourpoints(A,B,CandD)asshown.

AUS00324

DCBAY

X

Standard Diameter

DOHC VCT 23.157 - 23.162 mm

4. Calculatethepistonpintopiston-pinboreclearance.Replacethepistonand/orpistonpinifnecessary.

Standard Clearance

DOHC VCT TBA

5. Connectingrodbushasrequired.

Standard Interference

DOHC VCT 0.013 - 0.030 mm

303-01A Engine - I6 303-01A-25


Crankshaft Inspection

1. Measurethecrankshaftrunout.Replacethecrankshaftifnecessary.

AUS00325

Standard End Gap

Maximum runout - between adjacent journals

0.05 mm

Maximum runout - between any journals

0.08 mm

2. MeasurethejournaldiameterinXandYdirectionatthetwopoints(AandB)asshown.Replacethecrankshaftorgrindthejournalandinstalltheundersizebearingifnecessary.

AUS00326

BA

YX

Main Journal

Bearing Diameter 67.481 - 67.505 mm

Out-of-round 0.006 mm

Taper 0.008 mm

Crank Pin

Bearing Diameter 53.93 - 53.95 mm

Out-of-round 0.006 mm

Taper 0.008mm(max)


Crankshaft Main Bearing Clearance

1. Positionaplastigaugeontopofthejournalsintheaxialdirection.

2. Installthemainbearingcap.DONOTrotatethecrankshaft.

3. Removethemainbearingcap.

4. Measurethemainjournalclearance.Iftheclearanceexceedsthemaximum,replacethemainbearingorgrindthemainjournalandinstalltheundersizebearingssothatthespecifiedclearanceisobtained.

AUS00327

Standard Clearance 0.025 - 0.04 mm

Maximum Clearance 0.06mm

Bearing size Bearing thickness

Standard 1.996 - 2.000 mm

0.250 mm undersize 2.118 - 2.128 mm

0.508 mm undersize 2.245 - 2.255 mm

1.016 mm undersize 2.499 - 2.509 mm

303-01A Engine - I6 303-01A-26


Crankshaft End Play Inspection/Repair

1. Installthethrustmainbearingandcap.

2. Measurethecrankshaftendplay.Useadialindicatorwithbracketrytomeasurecrankshaftend play.

3. Positionthecrankshafttotherearofthecylinderblock.

4. Zerotheindicator.

5. Movethecrankshafttothefrontofthecylinderblock.Noteandrecordthecrankshaftendplay.

• Ifthecrankshaftendplayexceedsspecifications,installanewcrankshaftthrustwasherorcrankshaftthrustmainbearing.

AUS00287

Standard end play 0.10 - 0.20 mm

Maximum end play 0.30 mm


Connecting Rod Inspection

1. Measureeachconnectingrodforbendingandtwist.Replacetheconnectingrodifnecessary.

AUS01333

Bending 0.10 mm

AUS01334

Twist 0.20 mm

AUS00329

Centre-to-centre distance

153.82 - 153.89 mm

303-01A Engine - I6 303-01A-27


Connecting Rod Big End Bearing Clearance1. Positionaplastigaugeontopofthejournalsinthe

axialdirection.

2. Installtheconnectingrodcap.

3. Removetheconnectingrodcap.

4. Measurethecrankpinclearance.Iftheclearanceexceedsthemaximum,replacetheconnectingrodbearingorgrindthecrankpinanduseundersizebearingsothatthespecifiedclearanceisobtained.

AUS01226



Bearing size Bearing thickness Standard 1.445 - 1.458 mm

0.051 mm undersize 1.470 - 1.483 mm

0.254 mm undersize 1.572 - 1.585 mm

0.508 mm undersize 1.699 - 1.712 mm

Connecting Rod Side Clearance Inspection

1. Installtheconnectingrodcap.

2. Measuretheconnectingrodbigendsideclearance.

AUS01227




Piston and Connecting Rod Inspection

Checktheoscillationtorqueasshown.Ifthelargeenddoesnotdropbyitsownweight,replacethepistonorthepistonpin.

AUS00328

Timing Chain Elongation

ToestablishthepercentageelongationoftheTimingchain:

1. Hangthechainverticallyoverasuitablepin&hookaweighttothefreeend.

2. Measurethelength(frompinO.D.topinO.D)overthemaximumnumberofchainpinspossibleusingverniercallipers.Notethenumberofpinsmeasured.

3. Repeatthemeasurementacrossthreeseparatelengthsofthechainandaveragetheresults.

4. MeasuretheO.Dofonechainpinwithverniers.

5. Calculatethetheoreticalchainlength=(measurednumberofpins-1)x8.0mmpitch+measuredpinO.D.

6. Comparetheactuallengthmeasuredwiththetheoreticallength:maximumelongationpermissible=0.35%.

Alternativelymeasuretheactuallengthofanewchain(asabove)andcomparewiththeoriginalchainandcompareasapercentageofthenewchainlength.

303-01A Engine - I6 303-01A-28


Oil Filter

Removal

1. Unscrewfilterusingafilterwrench.

AUS07866

Installation

1. Install as indicated.

2. Lubricatethesealwithengineoilpriortoinstallation.

Oil Level Indicator & Tube

Removal

1. RemovetheOilLevelindicatorfromtheOilLevelTube.

2. Detachthewiringretainerandpositionasidethewiringharness.

AUS07868

3. Unscrewretainingbolt.

IN-VEHICLE REPAIR

4. RemoveOilLevelTube.

AUS07867

Installation

1. InspecttheO-ringatthebaseofthetubefordamageandrenewifnecessary.Lubricatewithengineoilpriortoreinstallationofthetube.

2. InserttheOilLevelTubeandsecurewithretainingscrew.

3. Withthetubereinstalledintheblock,ensuretheO-ringisfullyseatedintheblockcounterbore.

AUS01275

4. InserttheOilLevelIndicatorandattachthewiringharnessretaineronthebracket.

AUS07868

303-01A Engine - I6 303-01A-29


Cylinder Head Temperature Sensor

Removal

1. Thecylinderheadtappedholeisblind.

2. DisconnecttheelectricalconnectorfromCylinderHeadTemperatureSensor.

AUS08041

3. UnscrewandremovethesensorfromCylinderHead.

AUS01413

15 Nm

Installation

1. Installationisreversaloftheremovalprocedure.

2. Donotusethreadsealant/locker.

IN-VEHICLE REPAIR (Continued)

Cam Position Sensor

Removal and Installation

1. Raiseandsupportthevehicle.Foradditionalinformation,refertosection100-02ofthe2008FalconWorkshopManual

2. Removethe“NVHEngineUndertray”.

AUS07386

x15

x4

3. DisconnectCamPositionSensorelectricalconnectors.

AUS08039

AUS08040

4. Unscrewretainingbolt&removeCamPositionSensor.

5. ChecktheconditionoftheO-ringpriortoinstallation.

303-01A Engine - I6 303-01A-30


6. LubricatetheO-ringwithengineoilpriortoinstallation.

9 Nm

AUS01366

Crankshaft Position Sensor



2. Removethelowerairdeflector.

x18x18

AUS07165

3. RemoveAccessoryDriveBelt.Foradditionalinformation,refertosection303-05Aofthe2008FalconWorkshopManual

4. Disconnecttheelectricalconnectortothecrankshaftpositionsensor.

AUS07947


5. Unscrewretainingbolt&removeCrankshaftPositionSensor.

6. ChecktheconditionoftheO-ringpriortoinstallation.

7. LubricatetheO-ringwithengineoilpriortoinstallation.

AUS01326

9 Nm

Oil Pressure & Oil Temperature Sensor



2. Whenre-installingtheoriginalsensor,coatthethreadswithLoctite567(orsimilar)threadsealant.Newreplacementsensorsarepre-coated.Tightentheoiltemperaturesensor(notshowninthisillustration)to18-25Nm.Tightentheoilpressuresensor(directlyleftofthepressuresensor,showninthisillustrationto24Nm.

AUS07084

303-01A Engine - I6 303-01A-31



Combustion Knock Sensors



2. Removethe“NVHEngineUndertray”.

AUS07386

x15

x4

3. Unscrewretainingbolt&removethe2CombustionKnockSensor

AUS07083

4. Whenre-installingtheKnocksensor,coatthethreadswithLoctite242(orsimilar)threadlocker.

Exhaust Gas Oxygen Sensor (Pre Catalytic Convertor)



2. Disconnecttheelectricalconnector.

3. UnscrewandremovetheExhaustGasOxygenSensorfromthevehicle.

4. CoatthethreadswithaNickelAnti-Seizecompound(Loctite767orsimilar)perESE-FM99C100-A.

AUS01418

45 7Nm

Exhaust Gas Oxygen Sensor (Post Catalytic Convertor)




3. UnscrewandremovetheExhaustGasOxygenSensorfromthevehicle.

4. CoatthethreadswithaNickelAnti-Seizecompound(Loctite767orsimilar)perESE-FM99C100-A.

303-01A Engine - I6 303-01A-32


Temperature - Manifold Air Pressure Sensor


AUS08042

2. UnscrewtheretainingscrewandremovetheManifoldAirPressureSensor.

AUS08043

2 Nm

3. InspecttheconditionoftheO-ringpriortoinstallation.

4. Whenreplacingthefasteningscrewinthenormallyaspiratedinletmanifold,becarefulnottoexceed2Nmoftorque.Excessivetorquewillstripthethreadintheplasticmaterial.


Crankshaft Vibration Damper

Removal



x18x18

AUS07165

3. RemovetheAccessoryDrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008FalconWorkshopManual

4. RemovetheRetainingBolt.

5. UseSST303-642toremovethedamper.

6. Removekey.

145 Nm

AUS07914

Installation

1. Applysealerinthekeywayasshown.

2. Lubricatethesealrubbingareawithengineoil.

3. UseSST303-642toinstallthedamper.

303-01A Engine - I6 303-01A-33



4. Inspectkeyfordamage.Replaceifnecessary.

145 Nm

AUS07914

5. InstalltheRetainingbolt.

6. InstalltheAccessoryDrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008FalconWorkshopManual

7. Installthelowerairdeflector.

x18x18

AUS07165

8. Lowerthevehicle.Foradditionalinformation,refertosection100-02ofthe2008FalconWorkshopManual

Crankshaft Front Oil Seal

Removal

1. Disconnectthebatterygroundcable.Foradditionalinformation,refertosection414-01ofthe2008FalconWorkshopManual



x18x18

AUS07165

4. Removetheradiatorcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008FalconWorkshopManual

5. Removetheradiator.Foradditionalinformation,refertosection303-03Aofthe2008FalconWorkshopManual

6. Removethefrontendaccessorydrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008FalconWorkshopManual

7. RemovetheCrankshaftVibrationDamper.Foradditionalinformation,referCrankshaftVibrationDamperprocedureinthissection.

8. Protectthecrankshaftwithapieceofsoftmetalorplastic,anduseascrewdrivertoleverouttheoilseal.

1

3

2

AUS01284

Item Description

1 Screwdriver(flathead)

2 CrankshaftFrontOilSeal

3 SoftMetalorPlastic(shim)

303-01A Engine - I6 303-01A-34



Installation

1. Cleanthefrontcoverrecessandtapinthesealuntilitisfullyseated.

2. Lubricatethelipofthesealwithengineoil.

AUS01285

3. InstalltheCrankshaftVibrationDamper.

Crankshaft Rear Oil Seal

Removal

1. Removethetransmission.Foradditionalinformation,refertosection307-01Aofthe2008FalconWorkshopManual.

2. Removetheflexplate/driveplate.Foradditionalinformation,refertosection307-01Aofthe2008FalconWorkshopManual

Note:Otherpotentialsourcesofoilleakshouldbeeliminatedpriortoreplacingtheseal.

3. Insertasuitablebrassstripbetweenthesealandthecrankshafttoprotectthecrankshaftsealsurface.

4. Insertascrewdriverbetweenthesealandtheprotectionstripandleverouttheseal.

AUS01286

Installation

1. Cleanthesealrecessintheblock.

2. Oilthelipofthesealandtheshaft.

3. InstallthesealevenlyusingtheSSTE9312.

AUS01287

Flexplate/ Drive Plate


1. Removethetransmission.Foradditionalinformation,refertosection307-01Aofthe2008FalconWorkshopManual.

2. Removetheflexplate/driveplate.Foradditionalinformation,refertosection307-01Aofthe2008FalconWorkshopManual

Water Pump

Removal

1. Removetheradiatorcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008FalconWorkshopManual

2. Removethefrontendaccessorydrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008FalconWorkshopManual

3. Removethewaterpumppulley.Foradditionalinformation,refertosection303-03Aofthe2008FalconWorkshopManual

4. Removethealternatorandbrace.Foradditionalinformation,refertosection414-02ofthe2008FalconWorkshopManual

303-01A Engine - I6 303-01A-35



5. Removetheradiatorlowerhose(andcoolant).Foradditionalinformation,refertosection303-03Aofthe2008FalconWorkshopManual

AUS01291

12

3

21 Nm

Item Description

1 WaterPump

2 Bolt(x4)

3 AlternatorBrace

6. UnscrewheaterpipeY-clamponrearofwaterpumphousing.

AUS04407

Note:Weepingandstainingofcoolantfromthewaterpumpdrainreservoircanhappenunderextremecircumstances.Whenthewaterpumpissuspectedofleaking,thisshouldbeconfirmedwithacoolingsystempressuretest.

Note:Thepumpisasealedunit,andshouldbereplacedcompleteiffaulty.

Installation

Toinstall,reversetheremovalprocedurewithspecialconsiderationgiventothefollowing.

1. Checktheconditionoftheheaterpiperecessintherearofthewaterpump.

2. ChecktheconditionoftheO-ringontheendoftheheaterpipeandrenewifdamaged.

3. LubricatetheO-ringtoassistassembly.

AUS01292

Electronic Throttle Body and Intake Manifold

WARNING

EngineswithplasticinletmanifoldsarenotsuitableforconversiontoLPG.Theplasticinlet

maniifoldisonlydesignedtoworkwithpetrolengines-itisdangeroustotrytousethistypeofmanifoldwithLPGfuel.

Removal

1. Backofftheaircleanerlidwormdriveclampuntillooseonitscollar.

AUS07174

2. DetachthePositiveCrankcaseVentilation(PCV)hosefromtheduct&backoffthethrottlebody

303-01A Engine - I6 303-01A-36


wormdriveclampuntillooseonitscollar

AUS07180

3. DisconnecttheelectricalconnectorandremovetheETB.

AUS07283

x4

AUS07871

3

21

8-12 Nm

Item Description

1 Gasket-Throttlebody

2 Throttlebody

3 M6screw(x4)

4. Removedipstickandtube.

AUS07872

8-12 Nm

5. Disconnectthebrakeboostervacuumhose,disconnectthehosetovacuumreservoirfromintakemanifold,fuelpressureregulatorhose,PCVhose,andtheMTVvacuumhosefromthemanifold,manifoldabsolutepressureandtemperaturesensor.

AUS01278A

6. Detachcanistervacuumhoseandhosetovacuumreservoirfromintakemanifold.

AUS07874

7. Removethe2uppercylinderheadtomanifoldbracketsfromthefrontendoftheintake


303-01A Engine - I6 303-01A-37


manifold.

AUS08088

x2

8. Removethe2uppercylinderheadtomanifoldbracketsfromtherearendoftheintakemanifold.

AUS08089

x2

9. Removethe4fuelrailmountingbolts.

AUS08090

x4

8-12 Nm

10. Removethe2lowercylinderblocktomanifoldpencil struts.

AUS08086

x4

11. Depressuriseanddrainthefuelsystemandfuelrail.Foradditionalinformation,refertosection310-00ofthe2008FalconWorkshopManualDisconnectthereturnandsupplylinesonthefuelrailfromthevehiclelines.Removethefuelrailandinjectorsasanassembly.

AUS05571

12. Removetheintakemanifold.

AUS08087

x12

21 Nm 2

1

3

4

Item Description

1 Fuelrail

2 Supportbracket

3 Knocksensor

4 M8Bolts

Note:TheElectronicThrottleBodyisanonadjustableitem.Thesetscrewispermanentlyset


303-01A Engine - I6 303-01A-38



Intake Manifold Tuning Valve (IMTV)

Removal

1. Removetheairductassembly.Foradditionalinformation,refertosection303-12Aofthe2008.0FalconWorkshopManual.

AUS01276A

1

2. DetachthehosefromtheIMTV.

3. Unscrewtheretainingscrews.

AUS05558

4. RemovetheIMTV.

Installation

1. InserttheIMTVcartridgeintothemanifoldwhiletakingcarenottopinchtheO-ring.Orientitintothecorrectposition.

2. Takingcarenottocrossthreadorstripthethreadsinthemanifoldfortheselfformingscrews.TorquetheM6screwsto4.5-5.5Nm.

AUS05559

intothehousing.Foradditionalinformation,refertosection303-14ofthe2008FalconWorkshopManual

Installation

1. Whenreinstallingtheintakemanifoldboltstothecylinderheadensurethattheaxi-radsforthecylinderheadboltsarepresent.Iftheaxi-radsappeartobewornordamaged,theyshouldbereplaced.

2. TorquetheM8boltsto17-24Nm.

3. Replacethesealsbetweenthecylinderheadandthemountingflangeoftheintakemanifold.

4. WhenreinstallingtheETBtotheintakemanifold,useanewgasketandnewboltsorapplyLoctite242(orsimilar)threadlockertothethreads.

5. TorquetheETBM6boltsto8-12Nm.

6. Whenreinstallingthefuelrailtotheintakemanifold,replacetheO-Ringsealsoneachinjector.

7. TorquethefuelrailM6boltsto8-12Nm.

8. WhenreinstallingthedipsticktubeandanewboltorapplyLoctite242(orsimilar)threadlockertothethread.TorquetheM6boltto8-12Nm.

9. Theintakemanifoldtuningvalve(IMTV)positionissetinthefactoryandshouldnotbetouched,unlesstheIMTVistobeserviced.

303-01A Engine - I6 303-01A-39



Exhaust Manifold AssemblyRemoval1. Removetheheatshieldbyunscrewingthe

retainingbolts.

AUS01296A

27 Nm

2. Disassembletheitemsinthefollowingorder.

AUS07873

32

1

5

4

27 Nm

Item Description1 CatalyticConverterInletPipe

2 LiftingEye

3 RetainingBolt

4HeatedExhaustGasOxygen(HEGO)Sensor

5 ExhaustManifoldAssembly

Installation

1. Fit2M10x1.5boltswithheadsremovedasguide pins.

2. Fitanewgasketandlooselyassembledmanifoldontoguidepins.

WARNINGDonotfitausedgasket,throwawayanyoldgaskets.Alwaysfitanewgasket.

Donotinstallusedstudsandnuts,throwawayalloldstudsandnuts.Alwaysusenewfasteners.

3. Installlowermanifoldtoheadstuds,andnipupthenuts.

4. Removeguidepins,installremainderofstudsandnutsexcludingtheboltsthoseusedtoattachtheheatshield.

5. Tightenthenutsprogressivelytospecification.

6. Tightenthefronttorearmanifoldjointnutstospecification.

7. Installthecatalyticconvertorinletpipewiththeexhaustmanifold.Torquethestudsandnutstospecifications.

WARNINGDonotfitausedgasket,throwawayanyoldgaskets.Alwaysfitanewgasket.

Donotinstallusedstudsandnuts,throwawayalloldstudsandnuts.Alwaysusenewfasteners.

8. LubricatetheHEGOsensorthreadwithLoctite767(orsimilar)anti-seizecompoundperESE-FM99C100-A.

9. Installtheliftingeyeandtheretainingbolt.

303-01A Engine - I6 303-01A-40


Oil Control Valve Seal

Removal

1. RemovetheSparkPlugcover.Foradditionalinformation,refertheValveCoverprocedureinthissection.

AUS07917

2

5

3

41

Item Description1 Bolt(X8)2 Oilfillercap3 PCVhoseconnector(front)4 PCVhoseconnector(rear)5 Sparkplugcover

2. Disconnecttheelectricalconnectorsforthecamshaftvariabletimingsensor.

AUS07941


3. Checkmetalgarterbandisstillinplaceontheseal.

1

AUS013002

7 Nm

Item Description

1 Plate-Gasketvalverockerarmcover

2 Bolt

Installation

1. AftertighteningtheValveCoverretainingbolts,inserttheOilControlValvesealsintotheValveCoverwithoutdisplacingthemetalgarterband,andtightenthesealretainingbolts.

Valve Cover

Removal


AUS01276A

1

Item Description

1 Air duct

303-01A Engine - I6 303-01A-41


2. DisconnecttheelectricalconnectorandremovetheETB.

AUS07283

x4

AUS07871

3

21

8-12 Nm

Item Description

1 Gasket-Throttlebody

2 Throttlebody

3 M6screw(x4)

3. RemovetheSparkPlugCover.

AUS07917

2

5

3

41


4. Removethe6IgnitionCoilretainingbolts.

0.12 pt

AUS01304A

24 Nm

5. DisconnecttheIgnitionCoilelectricalconnectors.

AUS01304

6. Removetheigntioncoils.

7. Disconnecttheelectricalconnectorsforthecamshaftvariabletimingsensor.

AUS07941


303-01A Engine - I6 303-01A-42



8. RemovetheOilcontrolvalvesealsretainingbolts.Checkmetalgarterbandisstillinplaceontheseal.

1

AUS013002

7 Nm

Item Description1 Plate-Gasketvalverockerarmcover2 Bolt

9. Removevalvecoverretainingbolts(8).

10. Removethevalvecover.

AUS01301

3

1

14 Nm

13 Nm2

Item Description

1 Boltandwasher

2 Boltandwasher

3 Valvecover

Installation

1. CleanthecoverincludingPCVandfreshairchambers,andsealgrooves.Fitnewseals.

AUS01302

2. ApplysealerWSS-M4G323A7in2placesontheValveCovertocylinderhead/frontcoverjointsasshown,refitthecover,checktheperipheralsealisnotdisplacedoutofthegrooveusingamirrorfortherearoftheengine.

3. Whenre-installingthe8shortboltswhichretaintheValveCovertothecylinderheadassembly,coatthethreadswithLoctite242(orsimilar)threadlocker.

AUS01303

4. Connectthecamshaftvariabletimingsensorelectricalconnectors.

5. ChecktheOilControlValveSeals,replaceifnecessaryandrefitaftertheValveCoveristighteneddown.

6. Connecttheignitioncoilelectricalconnectors.

7. InstalltheIgnitionCoilsanditsretainingbolts.

8. Installthesparkplugcover.

9. ReinstalltheElectronicThrottleBody(ETB).Foradditionalinformation,refertheElectronicThrottleBodyprocedureinthissection.

10. Refittheairductassembly.Foradditionalinformation,refertosection303-12Aofthe2008.0FalconWorkshopManual.

303-01A Engine - I6 303-01A-43


Ignition Coils/Wiring Loom

Removal


AUS01276A

1

Item Description

1 Airintaketubeassembly

2 Bolt

2. RemovetheElectronicThrottleBody(ETB).Foradditionalinformation,refertheElectronicThrottleBodyprocedureinthissection.

3. Removetheoilfillercap,PCVvalveandPCVhoses.

4. RemovetheSparkPlugCover.

AUS07917

2

5

3

41


5. RemovetheIgnitionCoilretainingbolts.


6. DisconnecttheIgnitionCoilelectricalconnectors.

AUS01304

7. RemovetheIgntionCoils.

Installation

1. EverytimetheIgnitionCoilsareremoved,apply2gramsofsyntheticgreaseESF-M1C229-A(DupontKrytox)usingasuitableapplicator(cottonbud)totheinsideofthetaperedsectionofthecoilboot,smearingitevenlyoverthesurface.

AUS01677A

2. Refittheignitioncoilsandreconnectthewiringloomtothecoils&oilcontrolvalves.Installcoilsecuringboltsandtorquetospecification(24Nm).

Note:Theshortleadisattachedtotheintakeoilcontrolvalveandthelongleadisconnectedtotheexhaustoilcontrolvalve.

3. EnsureallofthewiringisclearoftheSparkPlugCoversealsurfaces,andthatthewiringdoesnotobstructanyhardwaremountingpoints.

4. EnsurethatthewiringislocatedcorrectlyinthegroovesintheValveCoverwhereitexitstheSparkPlugCoverwhenrefittingtheSparkPlugCover.

303-01A Engine - I6 303-01A-44


Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters

AUS01305

1

4

5 6

3

2

4

Item Description

1 VCTOilControlValve

2 CamshaftBearingcaps

3 Camshaft-Intake

4 ChainGuide

5 VariableCamTiming(VCT)unit

6 Camshaft-exhaust


303-01A Engine - I6 303-01A-45


Camshaft Removal

Removal

• Removevalvecover.Foradditionalinformation,refertoValveCoverprocedureinthissection.

Camshaft and VCT Phasers

Special Tool(s)

SST303-777

Timingchaintensionerspecialservicetool

303-777

SST303-778

Camshaftholdingtool

303-778

1. RotatethecrankshaftsotheVCTtimingmarks(onthesprocket)areverticallyupwardsandthecrankshaftatTopDeadCentre.

2. Markthetwotimingchainlinksabovethetimingmarkswithamarkerpen.

AUS01306

1

2

Note:Theyellowandorangecolouredlinksusedfororiginalassembly,andassemblywiththefrontcoverremoved,areonlysynchronizedwiththetimingmarksonceevery38crankshaftrevolutions,andshouldbeignoredwhenworkingwiththefrontcoverinplace(unlesssynchronized).


3. ReleasethetimingchaintensionbycompressingthetensionerusingSST303-777.Foradditionalinformation,refertoTimingChainTensionerprocedureinthissection.

AUS01308

4. FittheSST303-778tothecamshaftsinthecentralpositionbetweenthecapsandtightentopreventrotation.

AUS01309

5. LoosentheboltattachingtheVCTunitstothecamshafts.

6. Donotusethechaintopreventrotationwhenlooseningthecentralboltasthisloadwillbetransmittedthroughthelockedphasermechanismandcouldcausedamage.

AUS01310

20 Nm then 40

20 Nm then 40

303-01A Engine - I6 303-01A-46


7. WhilstholdingtheVCTphaserandtimingchain,slidetheVCTphaserforwardoffthecamshaftsandrestontopofthetimingcover.

Note:DonotremovethetimingchainfromtheVCTphasers.

8. Removethetool.

9. Loosenthecamshaftcapbolts2turnsatatimeintheordershownbelow.

AUS01311

19 20 22 18 24 28 2621 17 23 27 2516 15

5 6 8 4 10 14 127 3 9 13 112 1

10. Removecamshaftcaps.

11. Removeinlet&exhaustcamshaft.


303-01A Engine - I6 303-01A-47


Camshaft Installation

Installation

1. Checkthecamshaftjournalclearance.

2. Lubricatethehead-cambearingsurfaceswithengineoil.

AUS01598

Note:UsethefollowingillustrationtoidentifytheExhaustandInletcamshafts.

AUS01793

1

2

Item Description

1 Exhaust

2 Inlet


3. FittherespectiveIntakeandExhaustcamshaftswiththetimingpinpositionedverticallyupwards.Takecarenottodamagethethrustsurfacesonjournal#2.

AUS01312

4. Checkforburrsanddamageonthecap-to-headjointsandthecam-to-VCTphaserjoint.Tightenbolts2turnsatatimeinthesameordershownintheremovalsection.

Note:Thecam-capoilpassagemustbeabsolutelyclean.

5. RotatethecrankshaftsotheVCTtimingmarks(onthesprocket)areverticallyupwardsandthecrankshaftatTopDeadCentre.

6. AlignthemarkedthetwotimingchainlinkswiththeVCTtimingmarkssprocket.

AUS01306

1

2

Note:Theyellowandorangecolouredlinksusedfororiginalassembly,andassemblywiththefrontcoverremoved,areonlysynchronizedwiththetimingmarksonceevery38crankshaftrevolutions,andshouldbeignoredwhenworkingwiththefrontcoverinplace(unlesssynchronized).

Note:Ifacamshafttimingerrorissuspected,anditisnecessarytocheckthebasiccamtimingusingthevalveliftlossmethod,thenthecamsmustbefullyadvancedandbothVCTPhaserlockingpinsengaged.

303-01A Engine - I6 303-01A-48


7. Checkthatthecamsarefullyadvancedandthelockingpinsengagedbygrippingeachcamshaftbetweenthejournalsnumbers4&5withasuitablewrenchusingsoftprotectivepads,andattempttorotatethecamshaftbackwardsandforwardsrelativetotheVCTPhaser.

8. EstablishthepointofmaximumliftonaNo.1cylinderintakecamlobebydeterminingthepositionswheretheliftisreducedby0.25mmeithersideofmaximumlift.Notethecrankshaftangleswhilerotatingthecrankshaftinaclockwisedirectiononly.

9. Averagethetwocrankshaftanglestogivethepointofmaximumlift.

10. RepeatthisprocedurefortheNo.1cylinderexhaustcamlobe.

11. CheckthepistonTDCinasimilarwaybyfittinganadaptorinthesparkplugholeincylinder No.1withanadjustablelengthpinprotrudingintothecylindersothatitjustpreventsthepistonfromreachingTDC.Locktheadjustmentusingasuitablelocknut.

12. Rotatetheengineclockwiseuntilthepistontouchesthepinandnotingthecrankshaftangle,andthenrotatingitanti-clockwise,andagainnotetheangle.

13. AveragethetwocrankshaftanglestogiveTDC,andcompareittothetimingmarkontheCrankshaftVibrationDampertoensurethattheDamperoutsideelementhasnotrotated.Ifthereisasignificantdiscrepancy,replacetheDamper.RefertoCrankshaftVibrationDamperinthissection.

StandardIntakeCamTiming

[email protected]°ATDC

StandardExhaustCamTiming

[email protected]°BTDC


303-01A Engine - I6 303-01A-49


Timing Chain Tensioner

Special Tool(s)

SST303-777


303-777

1. Releasethetimingchaintensionbycompressingthetensioner.Referthissection.

AUS01308

VCT Phaser

Special Tool(s)

SST303-778

Camshaftholdingtool

303-778


Removal

1. Removevalvecover.Foradditionalinformation,refertoValveCoverprocedureinthissection.

2. FittheSST303-778tothecamshaftsinthecentralpositionbetweencapsandtightentopreventrotation.

AUS01309

3. LoosentheboltattachingtheVCTunitstothecamshafts.

4. Donotusethechaintopreventrotationwhenlooseningthecentralboltasthisloadwillbetransmittedthroughthelockedphasermechanismandcouldcausedamage.

AUS01310

20 Nm then 40

20 Nm then 40

5. WhilstholdingtheVCTphaserandtimingchain,slidetheVCTphaserforwardoffthecamshaftsandrestontopofthetimingcover.

Note:DonotremovethetimingchainfromtheVCTphasers.

6. Removethetool.

303-01A Engine - I6 303-01A-50


Installation

1. Toinstall,reversetheremovalprocedure.

2. Theoilcontrolvalves&camcapboresmustbeabsolutelyclean.

AUS01599

3. The camcapoilpassagesmustbeabsolutelyclean.

Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal

1. Disassembleintheorderindicatedinthetable.

3

1

42

7

5

6

AUS01601


Item Description

1 Camfollower

2 Lashadjusterretainingclip

3 Lashadjuster

4 Valvespringretainers

5 Valvespringretainerkeys

6 Valvespring

7 Valvestemseal

303-01A Engine - I6 303-01A-51


Rocker Arm and Lash Adjuster

Therockerarmandlashadjusterareclippedtogethertopreventrockerdisplacementunderextraordinarystartupconditions.

Careshouldbetakenwhenremovingtheassembly,soasnottostraintheclip.

Donotremovetheclipunlesseithertherockerarmorlashadjusteraretobereplacedandfitanewclip.

Iftheclipislooseontherockerarmitshouldbereplacedwhentherockerandlashadjusterassemblyisremovedfromthecylinderhead.

Removal

1. Removethecamshaft.Foradditionalinformation,refertotheCamshaftprocedureinthissection.

2. Disengagetherockerarmfromthevalvetip.

3. Therockerarm&lashadjusterassemblycanberaisedandthelashadjusterremovedfromthecylinderhead.

Installation

1. Toinstall,reversetheremovalprocedure.


Valve spring and Valve Stem Seal

Removal

1. Removetheappropriatesparkplug,andpressurisethecylinderviaanairlineandadaptor.DONOTexceed800kPa.

2. Removethekeys,retainersandvalvespringusingasuitablevalvespringcompressor.

AUS01602

3. Removethevalvestemseal/springseatassemblywithpliersormulti-grips,beingcarefulnottomarkthevalvestem.

Installation

1. Pressurisethecylinderviaanairlineandadaptor.Donotexceed800kPa.

2. Usean18mminsidediametertubetogentlyseatthevalvestemseal.

3. Reassembleinthereverseordertotheprocedureabove.

AUS01603

Note:Thevalvespringmustbefittedwiththesmallerdiameterendupwards.

303-01A Engine - I6 303-01A-52


Front Cover

6

2

1

7

4

5

3

AUS01604

Item Description

1 Idle pulley

2 Frontcover

3 Crankshaftsensor

4 Drivebelttensionerassembly

5 Crankshaftvibrationdamper

6 Dowelfrontcoverlocation

7 Bolt-Frontcover


303-01A Engine - I6 303-01A-53


Front cover

Removal

Specialtool

Harmonicbalancerstrapwrenchholdingtool,SST303-D055oranequivalantsuitableholdingtool.

SST303-642

specialservicetoolSST 303-642

1. Raiseandsupportthevehicle.Foradditionalinformation,refertosection100-02ofthe2008.0FalconWorkshopManual.

2. Disconnectthebatterygroundcable.Foradditionalinformation,refertosection414-01ofthe2008.0FalconWorkshopManual.

3. Removethecoolingfanmotorandshroudassembly. Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

4. Removetheaccessorydrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008.0FalconWorkshopManual.

5. Removethetwoidlerpulleysretainingboltsandremovetheidlerpulleys.

AUS09759

6. Removetheaccessorydrivebelttensionerpulleyretainingboltandthetensionerpulley.

AUS09760

7. Removethecrankshaftpulleyretainingboltandwasher.

• Installthespecialservicetool303-D055orequivalenttoholdthecrankshaftpulley.

AUS09741

8. InstallthespecialservicetoolSST303-642toremovethecrankshaftpulley.

9. Cleanthesealant(silastic)fromthecrankshaftkeywayandcrankshaftpulley.


303-01A Engine - I6 303-01A-54



10. Repositionthealternator.

• Removethealternatorretainingboltsx3.

• Loosenthewaterpumptoalternatorbracketretainingboltandpostionthebracketaside

• Removetherearalternatormountingboltx1andpositionasidethealternator.

AUS09742

x3x1

11. Disconnectthecrankshaftsensorelectricalconnectorandremovethecrankshaftsensor.

AUS09743

12. Disconnectthevacuumhosefromthebrakebooster.

AUS09756

13. DisconnectthePCVandenginebreatherhosesx2.

AUS09744

14. Removetheengineoilfillercap.

15. Removetheignitioncoilcoverretainingtorquescrewsx8.

AUS09745

x8

16. Removethebrakeboostervacuumhosebracketretainingscrewsx2andre-positionthebracketandhose.

AUS09746

x2

303-01A Engine - I6 303-01A-55



17. RemovetheignitioncoilandVCTsolenoidwiringharness.

• Removethewiringharnessretainingscrewx1.

• DisconnecttheVCTsolenoidelectricalconnectorsx2.

• Disconnecttheignitioncoilelectricalconnectorsx6.

AUS09747

18. RemovetheignitioncoilandVCTsolenoids.

• Removetheignitioncoilretainingboltsx6andremovetheignitioncoils.

• RemovetheVCTsolenoidretainingboltsx4andremovetheVCTsolenoidswithretainers.

AUS09748

x6

x4x4

19. Removethevalvecoverfastenersandremovethevalvecover.

AUS09749

x8

x2

20. Cleanthevalvecoverandthecylinderheadsurface.

21. Removethefrontcoverretainingboltsx9

AUS09750

x9

22. Raisethevehicle.

23. Removetheairdeflectorretainingsrcewsx18andremovetheairdeflector.

x18x18

AUS07165

303-01A Engine - I6 303-01A-56


24. Removethefrontsumpretainingboltsx4.

AUS09751

x4

25. Lowerthevehicle.

26. Carefullyseparatetheenginefrontcoverfromtheblock.

AUS09752

CAUTION

Placesuitablecoveringtoexposedinternalenginecomponents.(Toavoidforeigndebris

enteringintotheenginewhilecleaningthefrontcovertotheengineblockarea).

27. Removethefrontcoverdowelsx2fromthefrontcover.

AUS09757

Inspection

• Removeanysealantfromthefrontcovertotheblocksurfaceandthefrontcovertotheoilpansurface.

• Checktheconditionoftheoilpan,frontcovertoblockandcrankshaftrotarysealsandreplaceifrequired.

• Ensurethejointsurfacesarecleanandfreeofoil.


303-01A Engine - I6 303-01A-57


Installation

1. ApplyasmallbeadofLoctite5900totheoilpantoblockthefrontcoverjointin2placesasshown.

AUS01809

2. ApplyasmallbeadofLoctite5900tothefrontfacejointbetweenthecylinderheadandcylinderblockin2placesasshown.

AUS01810

3. ApplyasmallbeadofLoctite5900tothefrontfacejointbetweenthecylinderheadandcylinderblockin2placesasshown.

AUS01811

4. ApplyacontinuousbeadofLoctite5900aroundthefrontcoverattopofridge,notbottom.

AUS09755

CAUTION

Placethefrontcoveragainstthecylinderblock,usingtwocrossheadtypescrewdrivers

orsimilarthroughtwoboltholesinthefrontcoverandintothecylinderheadtopositionthefrontcover.

5. Fitthetwolowerdowelsintothefrontcoverandintothecylinderblock.

AUS09757

6. Inserttheretainingboltsandapplythreadsealantintothefrontcovertoholditinposition,tightenthefrontcoverretainingboltsx9to28Nm.

AUS09750

x9


303-01A Engine - I6 303-01A-58


7. Raisethevehicle

8. Installthefrontsumpretainingboltsx4.

AUS09751

x4

9. Lowerthevehicle

10. Replacethevalvecovergasketandsparkplugseals.

11. ApplyLoctite5900tothefrontcovertotheblockarea.

AUS09758

12. Installthevalvecover.

• Looselystartallthevalvecoverfasteners.

• Inspectthevalvecovergasketforcorrectfitment.

• Tightenthevalvecoverfasteners.

AUS09749

x8

x2

13. InstalltheignitioncoilandtheVCTsolenoids.

• Installtheignitioncoilandtightentheretainingboltsx6.

• InstalltheVCTsolenoidandtightentheretainingboltsx4.

AUS09748

x6

x4x4

14. InstalltheignitioncoilandtheVCTsolenoidwiringharness.

• Connecttheignitioncoilelectricalconnectorsx6.

• ConnecttheVCTsolenoidelectricalconnectorsx2.

• Installtheharnessretainingscrewx1andtighten.

AUS09747


303-01A Engine - I6 303-01A-59


15. Positionthebracketandthevacuumsupplyhosebacktotheorigionalplaceandinstallthebrakeboostervacuumhosebracketretainingscrewsx2andtighten.

AUS09746

x2

16. Installthecoilcoverandtightentheretainingtorquescrewsx8

AUS09745

x8

17. ConnectthePCVandtheenginebreatherhosesx2

AUS09744

18. Connectthevacuumsupplyhosetothebrakebooster.

AUS09756

19. Installthecrankshaftsensor.

• Installthecrankshaftsensorretaingboltx1andtighten.

• Connectthecrankshaftelectricalconnector.

AUS09743


303-01A Engine - I6 303-01A-60


20. Positionthealternatorbacktoorigionalplace.

• Positionthealternatortoorigionalplaceandlooselyinstallthealternatorretainingx3.

• Looselyinstalltherearalternatormountingboltx1.

• Positionthewaterpumptoalternatorbrackettoorigionalposition.

• Tightenalltheretainingbolts.

AUS09754

x3x1

21. Positiontheharmonicbalancerontothecrankshaftandinstallthespecialservicetool303-D055orequivalenttoholdthecrankshaftpulley.

• Applysealanttotheharmonicbalancerandtothecrankshaftkeyway.

• Installtheharmonicbalancerretainingboltx1.

• Torquethebolttothespecification.

145 Nm

AUS07914

22. Installthedrivebelttenionerandtightentheretainingbolttothespecifications.

AUS09760

23. Installthetwoidlerpulleysandtightentheretainingboltstothespecifications.

AUS09759

24. Installtheaccessorydrivebelt.Foradditionalinformation,refertosection303-05Aofthe2008.0FalconWorkshopManual.

25. Installtheenginecoolingfanmotorandshroudassembly. Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

26. Checkengineoillevel,topupasrequired.

27. Connectthebattery.Foradditionalinformation,refertosection414-01ofthe2008.0FalconWorkshopManual.

CAUTION

Allow 2 hours for sealant to cure

28. Starttheengine.

29. Raisethevehicle.


303-01A Engine - I6 303-01A-61


30. Inspecttheengineforoilleaks.

31. Installtheairdeflectorshieldx18screws.

x18x18

AUS07165

32. Lowerthevehicle.


303-01A Engine - I6 303-01A-62


Camshaft Drive

AUS01630

32

1

9

4

5

7

6

8

Item Description

1 Frontcover

2 Gasket-Frontcover

3 Tensionerassemblytimingchain

4 Timingchainguidetension

5 Timingchainguidefixed

6 Timingchain

7 Crankshafttonewheel

8 Crankshaftsensor

9 Frontseal

10 Crankshaftvibrationdamper

Removal

1. Removethefrontcover.Foradditionalinformation,refertheFrontCoverprocedureinthissection.

2. Removethetensioner.Foradditionalinformation,refertheTensionerprocedureinthissection.

3. Removethetimingchain.

4. Removethecranksprocket/timingwheel.

5. Removethemovingchainguide.

6. Removethefixedchainguide.

7. Removethechainguide(toprun).


303-01A Engine - I6 303-01A-63


Timing Chain Tensioner Release

Special Tool(s)

SST303-777


303-777

Removal

1. RotateLeverAanticlockwisebyengagingpinofSST303-777intoholeinlever.

2. Pushinplungeruntil3-4mmisvisible.

3. ReleaseloadfromLeverAsoratchetteethengagewith1stteethonplunger.

4. PushinplungerslightlysoholeinAalignswithholeCandislockedwithSST.

AUS01631

303-777

A

C


Installation

1. SetthecrankshaftpositiontoTopDeadCentre:Cylinder#1Firing(bothVCTphasertimingmarksverticallyupwards).

AUS01306

1

2

Item Description

1 Yellowlinks

2 TimingdotonVCT

2. Alignyellowlinkat6o’clockwithitspositionindicator.Alignorangelinkat1o’clockwiththetimingindicatorontonewheel.Theorangelinkshouldbehalfvisiblewithinthetonewheelcutawayhole.

AUS01632

2

4

3

1

Item Description

1 Yellowlink

2 Yellowlinkpositionindicator

3 Timingindentontonewheel

4 Orangelink

3. RemovetheSST303-777toreleasethetensioner.

4. Rotatecrankshaftbackandforwardstocheckthattheslackisremovedfromchain.

5. Reverseremovalprocedureforcamshaftdrivecomponents.

303-01A Engine - I6 303-01A-64


Cylinder Head

Removal

1. Removetheradiatorcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

2. Removetheradiator.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

3. Removethevalvecover.Foradditionalinformation,refertoValveCoverprocedureinthissection.

4. Removetimingchain.

5. Removecamshafts.Foradditionalinformation,refertocamshaftsprocedureinthissection.

6. Removeintakemanifold.Foradditionalinformation,refertoIntakeManifoldprocedureinthissection.

7. Removeexhaustmanifold.Foradditionalinformation,refertoexhaustmanifoldprocedureinthissection.

8. DisconnecttheCylinderHeadTemperatureSensor,andtwocamshaftpositionsensorsfromrearofcylinderhead.

AUS01413

15 Nm

9. Loosenthecylinderheadboltsinthesequenceshown.

4 8 12 14 10 6 2

37 11 13 9 5 1

AUS01633


Installation

1. Ensurealljointsurfacesarecleanandfreeofoiland grease.

Note:Anewcylinderheadgasketmustbeused.

2. Lightlylubricatetheboltthreadsandwashersurfaceswithengineoil.

3. Rundownallboltsto30Nminthetighteningsequenceshown.

11 7 3 1 5 9 13

128 4 2 6 10 14

AUS01633A

4. Tightenallboltsto90Nminthetighteningsequenceshown.

5. Backoffallboltsuntilloose,usingtheboltlooseningsequence.Foradditionalinformation,referCylinderHead-Removalprocedureinthissection.

6. Tighteninnerbolts(#1to#10)to40Nmusingthetighteningsequenceshown.

7. Tightenouterbolts(#11to#14)to30Nmusingthetighteningsequenceshown.

8. Rotatebolts(#1to#10)anadditional120°±5°usingthetighteningsequenceshown.

9. Rotatebolts(#11to#14)anadditional90°±5°usingthetighteningsequenceshown.

303-01A Engine - I6 303-01A-65


10. Lubricatethehead-cambearingsurfaceswithengineoil.

Note: UsethefollowingillustrationtoidentifytheExhaustandInletcamshafts.

AUS01793

1

2

Item Description

1 Exhaust

2 Inlet


1. Installthecamshafts.

AUS09787

303-01A Engine - I6 303-01A-66


Note: Installthecamshaftcapsaspertheillustrationshownbelow,failuretofollowinstructionsmayresultindamagetotheengine.

AUS09775

2. Tightenthecamshaftcapretainingboltstwoturnsatatimeintheordershownbelow.

AUS01311

19 20 22 18 24 28 2621 17 23 27 2516 15

5 6 8 4 10 14 127 3 9 13 112 1

3. UsingasuitabletoolrotatethecamshaftstoalignthetimingdotontheVCTphasers(bothcamshaftsatthe12o’clockposition).


303-01A Engine - I6 303-01A-67


AUS09785

4. Installthetimingchain.

AUS01306

1

2

Item Description

1 Yellowlinks

2 TimingdotonVCT

5. Alignyellowlinkat6o’clockwithitspositionindicator.Alignorangelinkat1o’clockwiththetimingindicatorontonewheel.Theorangelinkshouldbehalfvisiblewithinthetonewheelcutawayhole.

AUS01632

2

4

3

1

6. RemovetheSST303-777toreleasethetensioner.

7. Rotatethecrankshafttocheckthattheslackisremovedfromthechain.

8. Recheckallthetimingmarks.

9. Installthefrontenginecover.Foradditionalinformation,refertotheFrontEngineCoverremovalandinstallationprocedureinthissection.

10. Installthevalvecover.Foradditionalinformation,refertotheValveCoverremovalandinstallationprocedureinthissection.

11. Installtheexhaustmanifold.Foradditionalinformation,refertotheexhaustmanifoldremovalandinstallationprocedureinthissection.

12. Installtheinletmanifold.

13. Installtheelectronicthrottlebody.Foradditionalinformation,refertotheElectronicThrottleBodyremovalandinstallationprocedureinthissection.

14. Installtheaircleanerbody.Foradditionalinformation,refertosection:303-12IntakeAirDistributionandFilteringofthe2008.0FGFalconWorkshopManual.

Note: Installanewthermostathousinggasket.

15. Installthethermostathousingtothecylinderheadx2retainingbolts.

AUS09786

x2

16. Installtheairdeflectorretainingscrewsx18.

17. Installtheradiatorcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

18. Connectthebattery.Foradditionalinformation,refertosection414-01ofthe2008.0FalconWorkshopManual.

19. Checktheengineoillevel,topupengineoillevelasrequired.

20. FillandbleedthecoolingsystemForadditionalinformation,refertosection:303-03AEngineCoolingofthe2008.0FGFalconWorkshopManual.


303-01A Engine - I6 303-01A-68


EngineRemoval1. DisconnectHoodstrutsandsecurelytieback

EngineHood,orremovebonnet.

2. RecovertheA/Cgas.Foradditionalinformation,refertoSection412-03ofthe2008.0FalconWorkshopManual.

3. Disconnectbatteryleadsandremovebattery.Foradditionalinformation,refertosection414-01ofthe2008.0FalconWorkshopManual.

4. RemoveAirCleanerassemblyandinductiontubes.Foradditionalinformation,refertosection303-12Aofthe2008.0FalconWorkshopManual.

5. Raisethevehicle.Foradditionalinformation,refertosection100-02ofthe2008.0FalconWorkshopManual.

6. Drainenginecoolantfromradiatortap.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

7. Removetheradiatorandcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

8. RemovetheA/Ccondensor.Foradditionalinformation,refertosection412-03Aofthe2008.0FalconWorkshopManual.

9. Removetheintakemanifoldtuningvalve(IMTV)vacuumhose.

10. Detachthevacuumreservoirsupplyhose.

11. Detachtheactivatedcharcoalcanisterpipeconnectorsinthevicinityofthethrottlebody.

12. Disconnectthealternatorpositivesupply,thealternatorharnessconnectorandharnessretainer.

13. Detach2connectorsontheLHSenginemounting.

14. Removethe2theairconditioningcompressorhosesanddisconnecttheelectronicconnector.Donotremovethecompressor.

AUS07299

15. Disconnectvacuumhosefromvacuumcheck


valve.

AUS01566

16. Detachthecoolantpipesattheheatercoreinletandoutletpipesatthefirewall.

AUS08000

x2

17. RemovePCMmodule.Foradditionalinformation,refertosection303-14Aofthe2008.0FalconWorkshopManual.

18. DisconnecttheHegosensorelectricalconnector.

AUS01418

45 7Nm

19. Disconnecttheengineloomwiringplugsfrom

303-01A Engine - I6 303-01A-69


theundersideofPCM.

1

2

AUS02186

Item Description

1 PCMModule

2 Engineelectricalconnectors

20. Detachtransmissionmultiplugandtransmissionwiringharnessretainersfromthetransmission.

AUS07885

21. Disconnectvacuumhosesfromintakemanifold.

AUS02187

22. DisconnectFuellinesatthequickrelease

connectorsbelowlefthandsideoffirewall.

AUS01441

4

15 2

3

Item Description1 FuelTubeSupply

2 FuelVapourHose

3 FuelTanktoVapourHose

4 RearBrakeLines

5 FuelTubeReturn

23. Removethecatalyticconvertor.Foradditionalinformation,refertosection309-00Aofthe2008.0FalconWorkshopManual.

24. Removethestartermotor.Foradditionalinformation,refertosection303-06Aofthe2008.0FalconWorkshopManual.

25. Removethe4boltsfromconvertortoflexplatethroughthestarterholeinthebellhousing.Foradditionalinformation,refertosection307-01Aofthe2008.0FalconWorkshopManual.

26. Removethetransmissiontoenginebolts.Foradditionalinformation,refertosection307-01Aofthe2008.0FalconWorkshopManual.

27. Disconnectthetransmissioncoolerpipesfromthetransmissioncooler,locatedontheLHSoftheengineoilsump.

AUS07556

28. Removetheenginemountingtochassisnuts.

29. RemovetheearthwiringcablefromtheRHSof


303-01A Engine - I6 303-01A-70



thecylinderblock.

AUS08011

26 Nm

30. Installthespecialtool‘liftingeye’.

31. Installanappropriateliftingcranetotheengine.

32. Connectsuitableengineliftertotheliftbracketssuppliedandcarefullyremoveengineassembly.Onbasemodelsonly,installfrontliftingeyeandboltto40±6Nm.

AUS02189

Installation

1. Installengineliftingcrane.

2. Installtheengine.

3. Installtransmissiontoenginebolts.Foradditionalinformation,refertosection307-01Aofthe2008.0FalconWorkshopManual.

4. Installenginemountingtochassisnuts.

5. Installthe(4)torqueconvertertodriveplateboltsthroughthestartermotoropeninginthebellhousing.Foradditionalinformation,refertosection307-01Aofthe2008.0FalconWorkshopManual.

6. Installthestartermotor.Foradditionalinformation,refertosection303-06Aofthe2008.0FalconWorkshopManual.

7. Installthecatalyticconverter.Foradditionalinformation,refertosection309-00Aofthe2008.0FalconWorkshopManual.

8. Installthetransmissionmultiplugandtransmissionwiringharnessretainerstothetransmission.

9. InstalltheearthwiringcabletotheRHSofthecylinderblock.

10. ConnectthefuellinesatthequickreleaseconnectorsbelowtheLHSfirewall.

11. Connectthetransmissioncoolerpipestothetransmissioncooler.TransmissioncoolerislocatedontheLHSoftheengineoilsump.Foradditionalinformation,refertosection412-03ofthe2008.0FalconWorkshopManual.

AUS07556

12. ConnecttheHegosensorelectricalconnector.(Hegosensorislocatedontheexhaustmanifold).

13. Installthevacuumhoseatthetandembooster.

14. Removethespecialtool‘liftingeye’.

15. Installthecoolantpipesattheheatercoreinletandoutletpipesatthefirewall.

303-01A Engine - I6 303-01A-71


AUS08000

x2

16. InstallthePCMmodule.Foradditionalinformation,refertosection303-14Aofthe2008.0FalconWorkshopManual.

17. InstallthedischargeandsuctionpipesattheA/Ccompressor.Foradditionalinformation,refertosection412-03ofthe2008.0FalconWorkshopManual.

18. InstallthetwoharnessretainersontheLHSenginemounting.

19. Connectthealternatorpositivesupply,thealternatorharnessconnectorandharnessretainer.

20. Attachtheintakemanifoldtuningvalve(IMTV)vacuumhose.

21. Attachtheactivatedcharcoalcanisterpipeconnectorinthevicinityofthethrottlebody.

22. Attachthevacuumreservoirsupplyhose.

23. InstalltheA/Ccondensor.Foradditionalinformation,refertosection412-03ofthe2008.0FalconWorkshopManual.

24. Installtheradiatorandcoolingfanassembly.Foradditionalinformation,refertosection303-03Aofthe2008.0FalconWorkshopManual.

25. Filltheenginecoolantsystem.Foradditionalinformation,refertoSection303-03Aofthe2008.0FalconWorkshopManual.

26. Installtheairinductionpipeswiththeaircleanerassembly.Foradditionalinformation,refertosection303-12Aofthe2008.0FalconWorkshopManual.

27. Installthebattery.Foradditionalinformation,refertosection414-01ofthe2008.0FalconWorkshopManual.

28. FilltheA/Csystem.Foradditionalinformation,refertosection412-03ofthe2008.0FalconWorkshopManual.

29. Installtheenginehoodandattachthehoodstruts.


303-01A Engine - I6 303-01A-72


Engine Mounting

1. Mounttheengineonanenginerolloverstand.

WARNING

Self-lockingbrakesystemoftheenginestandmaynotbeeffectivewhentheengineisheld

inanunbalancedposition.Thiscouldleadtosudden,rapidmovementoftheengineandmountingstandhandleandcauseseriousinjury.Neverkeeptheengineinanunbalancedposition,andalwaysholdtherotatinghandlefirmlywhenturningtheengine.

Engine Oil Pan

Removal

1. Raisethevehicle.Foradditionalinformation,refertosection100-02ofthe2008.0FalconWorkshopManual.

2. Removethemainbearingcrossbolts.

58 Nm

AUS00289

Note:Thereare5mainbearingcrossboltsontherighthandsideand4onthelefthandsideoftheoilpan.

3. Removetheoilpanflangebolts.

Note:The23oilpanflangeboltsareslightlylongerthanthebearingcrossbolts.Storethemseparatelywhenremoved.

Note:Only12righthandsidepanflangeboltsareshown.Thereareafurther11onlefthandside.

4. Removetheoilpanseal.Todosouseasuitabletooltoleverouteachcorneroftheoilpantobreaktheseal.

Note:Takecarenottodamagethesealingsurfaceoftheoilpan.


5. Removetheoilpan.

AUS07946

x23

9 Nm

Installation

1. Cleanblockandsumpcontactsurfaces.Todosowipeoffexcessoil.(Particularnoteshouldbegiventotheareacircledinredtotheleft).

AUS05027

2. Useascrapertoremovethebulkofthesiliconmaterial,ensurenoneofthismaterialenterstheengine.

AUS05028

303-01A Engine - I6 303-01A-73


3. UseaScotchbriteorasimilarpadtoremovetherestofthesiliconmaterial.

AUS05029

4. Usecontactcleanertoensurenooilisleftonthesurfaces.

C

ON

TAC

T

CLE

AN

ER

AUS05030

5. Checktheoilpanbaffleplatesforcracksandlooserivets.

6. Fitanewhalfmoonseal,ensuringthatitfitsintothegrove.

AUS05032

7. Fitanewrearhalfmoonseal,ensuringthatitfitsintothegrove.


8. Insertdowelsinblockasshowntoguidethesumpintothecorrectposition.

AUS05025

9. ApplyacontinuousbeadofLoctite5900aroundthesump.Thebeadshouldbepositionedonthetopridge,notonthebottomarea.

10. Atthe4locationsshown,applyadditionalLoctite5900(orsimilar).

11. ApplyabeadofsealantLoctite5900(orsimilar)atthefrontcovertoblockjoint(2places),andtherearmainbearingcaptoblockjoint(2places).

AUS00292

303-01A Engine - I6 303-01A-74


AUS00294

12. Placesumponblockandinsertflangebolts.

13. Replacedowelswithflangebolts.

14. CoatthemainbearingcrossboltthreadswithLoctite567(orsimilar)threadsealant.

58 Nm

AUS00289

15. Installoilpanflangeboltstospecifiedtorque.

Oil Pump Pickup Tube

Removal

1. Removetheoilpan.Foradditionalinformation,refertheoilpanprocedureinthissection.

AUS07946

x23

9 Nm

2. Removethepickuptubeattachmentboltstooilpump.

AUS07944

x2

x2

10 Nm

21 Nm

1

2

3

Item Description

1 Nut

2 Pickuptube

3 Bolt

3. Removetheoilpumppickuptube.

Installation

1. Inspecttheintakeflangesontheoilpumpandpickuptubeforsignsofdamage.

2. FitanewO-ringtothisjoint

3. Tightenthepickuptubetooilpumpboltsandcheckthatthemountingbracketissittinglightlyontheheadofthemainbearingbolt,orjustclearbyupto1mm,beforefittingthenut.

Note:Heavybearing,oralargegapcouldcauseanairleakandshouldbecorrectedbyadjustingthebracket.


303-01A Engine - I6 303-01A-75


Oil pump

Removal

1. Removetheoilpan.Foradditionalinformation,refertheoilpanprocedureinthissection.

AUS07946

x23

9 Nm

2. RemovetheFrontCover.Foradditionalinformation,referthefrontcoverprocedureinthissection.

3. Removethepickuptubemountingbracketnut(attachedtomainbearingboltstud).

AUS07944

x2

x2

10 Nm

21 Nm

1

2

3

Item Description

1 Nut

2 Pickuptube

3 Bolt

4. Removetheoilpickuptube.Foradditionalinformation,refertheoilpickuptubeprocedureinthissection.


5. Removetheoilpumptoblockmountingbolts.

AUS07945

x5

10 Nm

2

1

Item Description

1 Bolt

2 Oilpump

6. Removetheoilpump.

Note:Theoilpumpisanon-repairableitemandshouldbereplacedifdamaged.

Installation

1. Engagethedriveflatsintheoilpumprotorborewiththetwoflatsonthecrankshaft.

2. Gentlypushtheoilpumpintopositionagainstthecylinderblock.

Note:Rotatingtheoilpumpbodyandgentlyrockingitforeandaftwillassistassembly.

3. DONOTuseforce.

303-01A Engine - I6 303-01A-76


Piston and Rod Assembly

Removal

Placetheengineonarolloverstandandinvertbeforeperformingthisprocedure.

1. Removethemainbearingbolts.

2. Removethewindagebaffle.

3. Removethemainbearingcapsandlowermainbearings.

4. RotatethecrankshafttoBottomDeadCentreontherespectivecylinderstoimproveaccesstotheconnectingrodbolts.

5. FitConnectingrodboltprotectorspriortodisengagingtheconnectingrodfromthecrankshaft.

AUS01635

48 Nm


Installation

1. Useboltprotectorswheninstallingtheassembly.

AUS01639

Note:Ensurenewconnectingrodboltshavebeenfitted,asthe‘TorquetoYield’boltsarenotreusable.

2. Ensurethecapandtheconnectingrodcarrythesamecylindernumbermarkingonthesamesideoftherod.

3. Tighteneachpairofboltsto25Nm,thenafurther90 degrees.

AUS01635

48 Nm

303-01A Engine - I6 303-01A-77


Main bearings/CrankshaftPlacetheengineonarolloverstandandinvertbeforeperformingthisprocedure.

Removal

1. Removethemainbearingbolts.

2. Removethewindagebaffle.

3. Removethemainbearingcapsandlowermainbearings.

4. Removetheconnectingrodcaps,upperandlowerconnectingrodbearings,andpiston&rodassemblies.Foradditionalinformation,RefertoPistonandRodAssemblyprocedureinthissection.

5. Removethecrankshaft.

6. Removetheuppermainbearings.

AUS01634

1

84 Nm

2

3

4

5

6

Item Description

1 Mainbearingbolts

2 Windagebaffle

3 Mainbearingcaps

4 Lowermaincrankshaftbearings

5 Crankshaft

6 Uppermaincrankshaftbearings


AUS01636

2

1

3

4

Item Description

1 Crankshaft

2 Pivotbearing(Manualtransmissiononly)

3 Uppermaincrankshaftthrustbearing

4 Uppermaincrankshaftbearings

Installation

1. Forinstallationreversetheremovalprocedure.

303-01A Engine - I6 303-01A-78


Rear Main Bearing Cap Assembly

1. ApplysiliconesealantLoctite5900(orasealantwhichmeetstheFordspecificationWSS-M4G323-A7)totherearmainbearingcaptoblockjointasshown.

2. Fittherearmainbearingcapandtightenwithin5minutesofapplicationofthesealant.

3. Reversetheremovalprocedure.

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Piston Ring

Installation

1. Verifythesecondpistonringisinstalledwiththedotupwards.

2. Positiontheendgapsofthepistonringsasshown.

COMPRESSIONRING

COMPRESSIONRING

OIL RING SPACER

25.0 25.0

150 DEG 150 DEG

A

BB

C C

OIL RINGSEGMENT

OIL RINGSEGMENT

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mm

3. Ensurethenotchonthepistonisfacingthefrontoftheengine,thevalvecut-outsareontheexhaustside,andtheconnectingrodoilsquirtholeisontheexhaustsideoftheengine.

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303-01A Engine - I6 303-01A-79


Key Retainer - Valve Spring

Disassembly

1. Removethekeysusingavalvespringcompressor.

2. Removethevalvespringretainer.

3. Removethevalvespring.

4. Removethevalvestemseal.

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1

2

3

4

Item Description

1 Key-Valvespringretainer

2 Valvespringretainer

3 Valvespring

4 Valvestemseal

Assembly

ToassembleReversethedisassembleprocedure.

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DISASSEMBLY AND ASSEMBLY

Valve Stem Seal

Disassembly

1. Removethesealusingapairofpliers.

Assembly

1. Ensurethecylinderheadisclean.

2. Ensurethecylinderheadjointfaceisfreefromscratchesandnicksinthesealingareasaroundthecylinderboreandoilandwaterways.

3. Lubricatethevalveguideswithengineoil.

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4. Fitnewsealsusingan18mminsidediameterdrift.

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303-01A Engine - I6 303-01A-80


Piston and Connecting Rod Assembly

Assembly

7

6

5

4

9

8

1

2 3

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Item Description

1 Compressionringupper

2 Compressionringlower

3 Oilrings

4 Piston

5 Connectingrod

6 Connectingrodbolt

7 Connectingrodcap

8 Connectingrodnut

9 GudgeonPin

DISASSEMBLY AND ASSEMBLY (Continued)

Piston and Connecting Rod Disassembly and Assembly

Assembly

1. UseSST303-D034toremoveandinstallthepistonfromtheconnectingrodassembly.

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Note:Donotseparatethepistonandrodunlesstherod,pinorpistonistobereplaced.

303-01A Engine - I6 303-01A-81


Connecting Rod Bolt

Theconnectingrodboltsarepermanentlystretchedeachtimetheyaretightenedandshouldonlybeusedonce.

Replacetheconnectingrodboltspriortorebuildingtheengine.Theoldboltscanbeusedtoestablishbearingclearances.ThecorrectlevelboltsaremarkedWR/AB.

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1

2

3

4

Item Description

1 WR/AAmarking

2 Straightknurl

3 Diamondknurl

4 Pilotpoint

DISASSEMBLY AND ASSEMBLY (Continued)

SECTION 303-01A: Engine - I6 - Barra Swap LLC

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Transcript of SECTION 303-01A: Engine - I6 - Barra Swap LLC