Ford Falcon. Manual - part 119

303-01a-47 

Engine — I6 

303-01a-47

IN-VEHICLE REPAIR (Continued)

4.  Push in plunger slightly so hole in A aligns with

2.  Align yellow link at 6 o’clock with its position

hole C and is locked with SST.

indicator. Align orange link at 1 o’clock with the

timing indicator on tone wheel. The orange link

should be half visible within the tone wheel cut

away hole.

Installation
1.  Set the crankshaft position to Top Dead Centre:

Cylinder #1 Firing (both VCT phaser timing marks

vertically upwards).

Item

Description

1

Yellow link

2

Yellow link position indicator

3

Timing indent on tone wheel

4

Orange link

3.  Remove the SST 303-777 to release the

tensioner.

4.  Rotate crankshaft back and forwards to check that

the slack is removed from chain.

5.  Reverse removal procedure for camshaft drive

components.

Cylinder Head

Removal

Item

Description

1.  Remove the radiator cooling fan assembly.

1

Yellow links

2. Remove 

the 

radiator.

2

Timing dot on VCT

3.  Remove the valve cover. Refer to Valve Cover in

this section.

4.  Remove front cover. Refer to Front Cover in this

section.

5.  Remove timing chain.
6.  Remove camshafts. Refer to Camshaft in this

section.

7.  Remove intake manifold. Refer to Throttle Body

and Intake Manifold in this section.

8.  Remove exhaust manifold. Refer to Exhaust

Manifold in this section.

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303-01a-48 

Engine — I6 

303-01a-48

IN-VEHICLE REPAIR (Continued)

9.  Disconnect the Cylinder Head Temperature

8.  Rotate bolts 90º 

± 5º in the sequence shown.

(CHT), and two Camshaft position sensors from

rear of cylinder head.

Engine

10. Loosen the cylinder head bolts in the sequence

Removal

shown.

1.  Disconnect Hood struts and securely tie back

Engine Hood, or remove bonnet.

2.  Disconnect battery leads and remove battery

cover and battery. Refer to section 414-01.

3.  Remove engine accessory drive belt. Refer to

section 303-05.

4.  Remove Power steering pump to engine

attachment bolts.

Installation
1.  Ensure all joint surfaces are clean and free of oil

and grease.
NOTE: A new cylinder head gasket must be used.

2.  Lightly lubricate the bolt threads and washer

surfaces with engine oil.

3.  Tighten the cylinder head bolts in the sequence

shown.

Item

Description

4.  Rundown all bolts to 30 Nm.

1

Reservoir and Pump

5.  Retighten in sequence to 90º.

2

Bolts

6.  Back off all bolts by approx. 1 turn each.

3

Bolts

7.  Tighten all bolts to 40Nm in sequence.

NOTE: Leave hoses attached and locate pump clear

of engine.

5.  Remove Air Cleaner assembly and induction

tubes. Refer to section 303-12.

6.  Drain engine coolant at radiator tap.
7.  Remove the radiator cooling fan assembly. Refer

to section 303-03a.

8.  Remove the radiator assembly. Refer to section

303-03a.

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303-01a-49 

Engine — I6 

303-01a-49

IN-VEHICLE REPAIR (Continued)

9.  Remove air conditioning compressor to engine

13. Disconnect vacuum hoses from intake manifold.

attachment bolts.

14. Disconnect Fuel lines at filter feed pipe under left

NOTE: Leave compressor hoses attached and locate

hand side of firewall.

pump clear of engine.

10. Remove PCM module. Refer to section 303-14.
11. Disconnect the engine loom wiring plugs from the

underside of PCM.

Item

Description

1

Fuel Tube Return

2

Fuel Vapor Hose

3

Fuel Tank to Vapor Hose

Item

Description

4

Rear Brake Lines

1

PCM Module

5

Fuel Tube Return

2

Engine electrical connectors

15. Disconnect Heater hoses from rear of manifold

12. Disconnect transmission wiring plugs. Refer to

section 307-01.

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303-01a-50 

Engine — I6 

303-01a-50

IN-VEHICLE REPAIR (Continued)

23. Connect suitable engine lifter to the lift brackets

16. Remove Hego sensor electrical connector.

supplied and carefully remove engine assembly.

17. Remove the transmission front dust cover.

Installation

18. Remove the Converter to drive plate bolts (4)

1.  For installation of the engine reverse the removal

(Automatic Trans Vehicles Only). Refer to section

procedure.

307-01.

19. Remove starter motor. Refer to section 303-06.

Engine Mounting

20. Remove Transmission to engine bolts (4). Refer

to section 307-01.

1.  Mount the engine on an engine rollover stand.

21. Disconnect Exhaust at engine pipe flange to

 WARNING: Self-locking brake system of

manifold.

the engine stand may not be effective when

the engine is held in an unbalanced position.

This could lead to sudden, rapid movement of

the engine and mounting stand handle and

cause serious injury. Never keep the engine in

an unbalanced position, and always hold the

rotating handle firmly when turning the

engine.

Engine Oil Pan

Removal
1.  Remove the main bearing cross bolts.

NOTE: There are 5 main bearing cross bolts on

the right hand side and 4 on the left hand side of

the oil pan.

22. Remove front engine mount Through bolts.

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