Ford Falcon. Manual - part 116

303-01a-35 

Engine — I6 

303-01a-35

IN-VEHICLE REPAIR (Continued)

6.  Remove the Oil control valve seals retaining bolts. 8.  Slide the valve cover backwards 20-30mm, then

Check metal garter band is still in place on the

lift the front to clear the oil control valves, and

seal.

then slide the cover forwards, raising the rear to

clear the camshafts and dash panel.

Item

Description

1

Plate - Gasket valve rocker arm cover

2

Bolt

7.  Remove valve cover retaining bolts (8).

Item

Description

1

Bolt and washer

2

Bolt and washer

3

Valve cover

Installation
1.  Clean the cover including PCV and fresh air

chambers, and seal grooves. Fit new seals.

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303-01a-36 

Engine — I6 

303-01a-36

IN-VEHICLE REPAIR (Continued)

2.  Apply sealer WSS-M4G323 A7 in 2 places on the 2.  Remove the Electronic Throttle Body (ETB).

Valve Cover to cylinder head/front cover joints as

shown, refit the cover, check the peripheral seal is

not displaced out of the groove using a mirror for

the rear of the engine.

3. When 

re-installing the six short bolts which retain

the Valve Cover to the cylinder head assembly,

coat the threads with Loctite 242 (or similar)

thread locker. 4. Check the Oil Control Valve

Seals, replace if necessary and refit after the

Valve Cover is tightened down.

Item

Description

1

Gasket

2

Electronic Throttle Body

3

Bolt

4

Bracket

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

PCV hoses.

4.  Remove the Spark Plug Cover.

Ignition Coils/Wiring Loom

Removal
1.  Remove the air duct assembly.

Item

Description

1

Bolt

2

Oil filler cap

3

PCV  valve

Item

Description

4

Screw

1

Air intake tube assembly

5

Vacuum hose clip

2

Bolt

6

Spark plug cover

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303-01a-37 

Engine — I6 

303-01a-37

IN-VEHICLE REPAIR (Continued)

Installation

2.  Refit the ignition coils and reconnect the wiring

1.  Every time the Ignition Coils are removed, apply 2

loom to the coils & oil control valves.

grams of synthetic grease ESF-M1C229-A

NOTE: The short lead is attached to the intake oil

(Dupont Krytox) using a suitable applicator (cotton

control valve and the long lead is connected to

bud) to the inside of the tapered section of the coil

the exhaust oil control valve.

boot, smearing it evenly over the surface.

3.  Ensure all of the wiring is clear of the Spark Plug

Cover seal surfaces, and that the wiring does not

obstruct any hardware mounting points.

4.  Ensure that the wiring is located correctly in the

grooves in the Valve Cover where it exits the

Spark Plug Cover when refitting the Spark Plug

Cover.

Camshafts, VCT Phaser, Oil Control

Valves, & OCV Filters

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303-01a-38 

Engine — I6 

303-01a-38

IN-VEHICLE REPAIR (Continued)

Item

Description

1

VCT Oil Control Valve

2

Camshaft Bearing caps

3

Camshaft - Intake

4

Chain Guide

5

Variable Cam Timing ( VCT) unit

6

Camshaft - exhaust

7

Filter- VCT Oil Control Valve

Camshaft Removal

Removal

Remove valve cover. Refer to section 303-01.

3.  Release the timing chain tension by compressing

the tensioner using SST 303-777. Refer to section

Camshaft and VCT Phasers

303-01.

Special Tool(s)

Timing chain tensioner special

service tool

Camshaft holding tool

4.  Fit the SST 303-778 to the camshafts in the

central position between the caps and tighten to

prevent rotation.

1.  Rotate the crankshaft so the VCT timing marks

(on the sprocket) are vertically upwards and the

crankshaft at Top Dead Centre.

2.  Mark the two timing chain links above the timing

marks with a marker pen.
NOTE: The yellow and orange coloured links

used for original assembly, and assembly with the

front cover removed, are only synchronized with

the timing marks once every 38 crankshaft

revolutions, and should be ignored when working

with the front cover in place (unless

synchronized).

5.  Loosen the bolt attaching the VCT units to the

camshafts.

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