Ford Falcon. Manual - part 115

303-01a-31 

Engine — I6 

303-01a-31

IN-VEHICLE REPAIR (Continued)

8.  Disconnect the main gallery oil pressure and

5.  Remove the upper intake manifold.

temperature switch, knock sensor and crank

timing sensor.

Item

Description

9.  Remove the lower intake manifold.

1

Intake Manifold - Upper

2

M8 screws (x14)

3

Gasket - Intake manifold upper

6.  Remove the 3 lower manifold to cylinder block

braces.

Item

Description

1

Fuel rail

2

Support bracket

3

Knock sensor

7.  Remove the fuel rail and injectors as an

4

M8  Bolts

assembly.

NOTE: The Electronic Throttle Body is a non

adjustable item. For fault finding see Section 303-14.
Installation

When re-installing the Upper intake manifold to Lower

intake manifold bolts, coat the threads with Loctite

242 (or similar) thread locker.
When reinstalling the Lower intake manifold bolts to

the cylinder head, coat the threads with Loctite 242

(or similar) thread locker.
The gaskets sealing the Upper to Lower Manifold and

the Lower Manifold to the head should not be re-used.
When reinstalling the ETB to the intake manifold, use

a new gasket and new bolts or apply Loctite 242 (or

similar) thread locker to the threads.
Torque the M6 bolts to 8-12Nm.
The Broadband throttle shaft Vacuum motor closed

position stop is set in the factory and should not be

touched, unless the vacuum motor or Broadband

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303-01a-32 

Engine — I6 

303-01a-32

IN-VEHICLE REPAIR (Continued)

throttle shaft are serviced, in which case the setting

3.  Screw in the set screw 1-1.5 turns clockwise so

must be adjusted as described below.

the screw now contacts the stop and the

Broadband Throttle Plates are cracked open.

Broadband Throttle Plate

Removal
1.  Unscrew the retaining bolts.
2.  Remove Broadband Throttle Plates.

Item

Description

1

Screws

2

Activator - Throttle control

3

Throttle lever

Installation

4

Clip

1.  Insert plates with tabs facing upwards and to the

screw head side.

Exhaust Manifold Assembly

2.  Loosely install the plate retaining screws.

Removal

3.  Rotate the shaft so the plates are closed and

1.  Remove the heat shield by unscrewing the

snap the plates shut a few times to centralize

retaining bolts.

them in their bores. There must be no gap

between the plates and their bores.

4.  Apply Loctite 242 (or similar) thread locker to the

threads and tighten the plate retaining screws to

specification.

Broadband Throttle Shaft Vacuum

Motor

Removal
1.  When disconnecting the vacuum motor from

throttle shaft level, remove retaining clip first.

2.  Do not adjust the set screw on the throttle shaft

lever. If adjustment is necessary, or of a new

vacuum motor is fitted, reset screw by the

following procedure.

Installation
1.  Apply a 40kPa vacuum to the motor or apply light

finger pressure to push the lever in a clockwise

direction against the stop.

2.  Maintaining the pressure on the lever, unscrew

the set screw until there is a 0.05mm gap

between the screw and the stop.

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303-01a-33 

Engine — I6 

303-01a-33

IN-VEHICLE REPAIR (Continued)

4.  Loosely assemble and finally torque when fitted ti

2.  Disassemble the items in the following order.

engine.

Item

Description

Item

Description

1

Catalytic Converter Inlet Pipe

1

Exhaust Manifold - Rear

2

Lifting Eye

2

Gasket

3

Retaining Bolt

3

M8  -  Nut

4

Heated Exhaust Gas Oxygen (HEGO)

4

Exhaust Manifold - Front

Sensor

5

Exhaust Manifold Assembly

Oil Control Valve Seal

Installation

Removal

1.  Fit 2 M10 x 1.5 bolts with heads removed as

guide pins.

1.  Check metal garter band is still in place on the

seal.

2.  Fit gasket and loosely assembled manifold onto

guide pins. Refer to Exhaust Manifold - Front and

Rear section.

3.  Install lower manifold to head bolts, and nip up

the bolts.

4.  Remove guide pins, install remainder of bolts

excluding those used to attach the heat shield.

5.  Tighten the bolts progressively to specification.
6.  Tighten the front to rear manifold joint nuts to

specification.

7.  Lubricate the HEGO sensor thread with Loctite

767 (or similar) anti-seize compound per

ESE-FM99C100-A.

Exhaust Manifold - Front and Rear

Item

Description

Removal

1

Plate - Gasket valve rocker arm cover

1.  Remove the three nuts from the studs.

2

Bolt

NOTE: If the studs screw out of the Rear Exhaust

Installation

Manifold, simply refit the studs using two suitable

nuts locked together.

1.  After tightening the Valve Cover retaining bolts,

insert the Oil Control Valve seals into the Valve

Installation

Cover without displacing the metal garter band,

1.  Clean all mating surfaces.

and tighten the seal retaining bolts.

2.  Fit a new front to rear manifold sealing ring.
3.  Apply anti-seize compound to the manifold joint

nut threads.

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303-01a-34 

Engine — I6 

303-01a-34

IN-VEHICLE REPAIR (Continued)

4.  Remove the Spark Plug Cover.

Valve Cover

Removal
1.  Remove the air duct assembly.

Item

Description

1

Bolt & Washer

2

Cap - Oil filler

Item

Description

3

PCV  valve

1

Intake duct

4

M5  screw

2

Screw

5

Clip-air line

2.  Remove the Electronic Throttle Body (ETB) as per 6

Spark plug cover

procedure.

5.  Remove the Ignition Coils.

Item

Description

1

Gasket - Throttle body

2

Throttle body

3

Screw

4

Bracket

3.  Remove the oil filler cap, PCV valve, brake and

PCV hoses.

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