Ford Falcon. Manual - part 151

303-01c-25 

Engine — V8 (4V) 

303-01c-25

IN-VEHICLE REPAIR (Continued)

Removal

7.  Drain the engine oil.

1.  Remove the left and right valve cover (6582). For

additional information, refer to Valve Cover—LH

and Valve Cover—RH in this section.

2.  Remove the water pump pulley.
 

1.  Remove the four bolts.

 

2.  Remove the water pump pulley.

8.  Remove the four front sump bolts (as shown).

3.  Remove the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this

section.

4.  Remove the Power Steering (P/S) bolts and

position the power steering pump aside.

9.  Remove the crankshaft front oil seal. For

additional information, refer to Crankshaft Front

Oil Seal in this section.

10. Disconnect the camshaft position (CMP) sensor.

5.  Remove A/C Compressor.
6.  Disconnect the crankshaft position (CKP) sensor.

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303-01c-26 

Engine — V8 (4V) 

303-01c-26

IN-VEHICLE REPAIR (Continued)

11. Remove the bolt and the belt idler pulley (8678).

2.  Position the engine front cover and install the

bolts and the studs in three stages:

Stage 1: Tighten numbers one through five to

25 Nm (18 lb-ft).
Stage 2: Tighten numbers six and seven to 50

Nm (37 lb-ft).
Stage 3: Tighten numbers 11 through 15 to

25 Nm (18 lb-ft).

12. Remove the engine front cover, bolts, studs, and

the gaskets.

Clean and inspect the front cover and oil pan

sealing surfaces.

Installation
NOTE: If the front cover and gasket are not secured

within four minutes, the sealant must be removed and

the sealing surface cleaned with metal surface

cleaner.

Item

Description

1.  Apply silicone gasket and sealant in the locations

1

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

shown.

50

2

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

3

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

4

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

5

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

6

Stud, Hex-Head Pilot, M10 x 1.5 x 30

7

Stud, Hex-Head Pilot, M10 x 1.5 x 30

8

Bolt, Hex-Head Flange, M8 x 1.25 x 50

9

Bolt, Hex-Head Flange, M8 x 1.25 x 50

10

Bolt, Hex-Head Flange, M8 x 1.25 x 50

11

M8 x 1.25 x 53

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303-01c-27 

Engine — V8 (4V) 

303-01c-27

IN-VEHICLE REPAIR (Continued)

Item

Description

7.  Install the crankshaft front oil seal. For additional

information, refer to Crankshaft Front Oil Seal in

12

M8 x 1.25 x 53

this section.

13

Bolt Hex Shoulder Pilot, M8 x 1.25 x 65

8.  Install the drain plug.

14

Stud Hex Shoulder Pilot, M8 x 1.25 x 65 -

M8 x 1.25 x 27

15

Bolt Hex Shoulder Pilot, M8 x 1.25 x 65

3.  Install the belt idler and the bolt.

9.  Connect the CKP sensor.

4.  Connect the CMP sensor.

10.  Refit A/C compressor.
11. Position the power steering pump and install the

bolts.

5. Raise 

the 

vehicle.

6.  Tighten the sump bolts in three stages:

Stage 1: Tighten to 2 Nm (18 lb-in).
Stage 2: Tighten to 20 Nm (15 lb-ft).
Stage 3: Tighten an additional 60 degrees.

12. Install the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this

section.

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303-01c-28 

Engine — V8 (4V) 

303-01c-28

IN-VEHICLE REPAIR (Continued)

13. Install the water pump pulley and install the bolts. 2.  Remove the crankshaft sensor ring from the

crankshaft.

14. Install the left and right valve cover. For additional

information, refer to Valve Cover—LH and Valve

3.  Using the crankshaft holding special tool, position

Cover—RH in this section.

the crankshaft as shown.

This will set the crankshaft. Keyway facing the top

15. Refill the engine crankcase with clean engine oil.

of engine.

All pistons will now be away from top of the stroke

Timing Drive Components

and will ensure piston and valves cannot clash.

Special Tool(s)

 CAUTION: Unless otherwise instructed, at

no time when the timing chains are removed

Alignment Plate, Camshaft

and the cylinder heads are installed is the

303-445 (T93P-6256-A)

crankshaft or the camshaft to be rotated.

Severe piston and valve damage will occur.

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Removal

 CAUTION: Since the engine is not

free-wheeling, if the crankshaft or the camshafts

4.  Install the camshaft alignment special tool.

are moved in any manner during removal and

installation, the crankshaft and the camshafts

must be re-synchronized.
1.  Remove the engine front cover. For additional

information, refer to Engine Front Cover in this

section.

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