Ford Falcon. Manual — part 103

303-00-2

Engine System — General Information

303-00-2

(Continued)

Valve — Spring Squareness . . . . . . . . . . . . . . . . . . . . . . . . 303-00-16

Valve — Spring Strength . . . . . . . . . . . . . . . . . . . . . . . . . 303-00-17

Valve — Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . ..303-00-17

Valve — Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-00-17

Valve — Seat Runout . . . . . . . . . . . . . . . . . . . . . . . . . . .303-00-18

Cylinder Bore — Cleaning . . . . . . . . . . . . . . . . . . . . . . . . ...303-00-18

Cylinder Block — Core Plug Replacement . . . . . . . . . . . . . . . . . . ..303-00-18

Exhaust Manifold — Inspection . . . . . . . . . . . . . . . . . . . . . . ...303-00-19

Bearing -Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-00-19

303-00-3

Engine System — General Information

303-00-3

DESCRIPTION AND OPERATION

Engine

NOTE: This section contains information, steps and

procedures that may not be specific to your engine.

This section covers general procedures and diagnosis

and testing of the engine system, except for exhaust

emission control devices, which are covered in the

Chapter 303-14, Powertrain Control Module.
The engine incorporates the following features:

a closed positive crankcase ventilation (PCV)

system. For additional information, refer to

Section 303-08.
an exhaust emission control system. For

additional information, refer to Section 303-08.
an evaporative emission control system. For

additional information, refer to Section 303-13.

Some engines incorporate a fail-safe cooling system.

Refer to the appropriate section in Group 303 for the

procedure.
The engine, fuel system, ignition system, emissions

system and exhaust system all affect exhaust

emission levels and must be maintained according to

the maintenance schedule. Refer to the scheduled

Maintenance Guide.
For engine identification, refer to Section 100-01. For

engine number location, refer to figure.

Engine Number Locations (I6)

Engine Number Locations (V8)

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303-00-4

Engine System — General Information

303-00-4

DIAGNOSIS AND TESTING

Visual Inspection Chart

Engine

Mechanical

Inspection and Verification

Coolant leaks

Oil leakso Leaks in the fuel system

Since diagnosis and testing actually begins when

Visibly damaged or worn parts

repairs are taken on, the following procedure is

Loose or missing nuts or bolts

recommended.

3. If an obvious cause for an observed or reported

1. Verify the customer concern by operating the

concern is found, correct the cause (if possible)

system.

before proceeding to the next step.

2. Visually inspect for obvious signs of mechanical

4. If the concern is not visually evident, verify the

damage or electrical damage. If the concern

symptom and refer to the Symptom Chart.

cannot be reproduced, carry out a road test

and/or visual check with the aid of the following

table.

Symptom Chart

Condition

Source

Action

Engine will not crank

Faulty Starter System

Refer to Section 303-05.

Transmission lever not in P or N.

Place in P.

Seized engine

Replace engine

Coolant in cylinders

Replace engine

Refer to appropriate Section in group

Engine cranks but will not start

Ignition system inoperative

303.

Fuel system inoperative

Refer Section 310-00.

LPG engine requires "key-off" to

Key-off LPG engine if 1st starting

Engine slow/difficult to start

regain starting enrichment after initial

attempt failed.

failed start.

Variable Cam Timing (VCT) unit lock

Refer to appropriate Section in group

pin not engaged at start.

303.

Clean Oil Control Valve. Refer to

VCT unit Oil Control Valve jammed.

appropriate Section in group 303.

Engine misfires

Fail Safe Cooling in operation

Repair coolant system

Refer to appropriate Section in group

Ignition system faulty

303.

Fuel system faulty

Refer Section 310-00.

Restricted exhaust system

Inspect Exhaust system

Carry out Intake Manifold Vacuum test

Intake vacuum leak

in this section

Burned valve/poor seating

Perform a compression check

Broken valve spring

Inspect valve springs

Head gasket leakage

Inspect head gasket

Piston damage

Perform cylinder compression check

Broadband Intake Manifold not

Check switching occurs at 3800 rpm -

Insufficient

Power

Refer to appropriate Section in group

operative

303.

Refer to appropriate Section in group

VCT unit(s) not operative

303.

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303-00-5

Engine System — General Information

303-00-5

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Refer to appropriate Section in group

Electronic Throttle Control Unit faulty

303.

Green(low mileage) engine/vehicle

Establish accurate fuel consumption

Excessive Fuel Consumption

City/stop-start driving

using full to full method.

Refer to appropriate Section in group

Faulty Fuel System

303.

Excessive Oil Consumption

Green engine

Recheck at 15,000 km

Inspect the seals. Refer to appropriate

Valve stem seal damaged or missing.

Section in group 303.

Oil leakage

Repair oil leakage

Incorrect Oil viscosity

Drain and fill with correct oil

Repair. Refer to appropriate Section in

Piston/rings/cylinder worn or damaged

group 303.

Determine cause. Correct. Drain and

Diluted oil

refill oil.

Crankcase overfilled

Adjust oil level.

Check and replace. Refer to

Faulty PCV Valve

appropriate Section in group 303.

Engine leaks oil

Joint fasteners loose

Tighten to specification.

Out of position or damaged seal/RTV

Pressurise crankcase to 35kPa. Apply

soapy water, check for leak. Inspect

sealant omitted/inadequate.

and replace. Refer to appropriate
Section in group 303.

Inspect and replace. Refer to

Worn/out of position crank rotary seal

appropriate Section in group 303.

Clean suspect area, Perform

Porous casting

pressurized crankcase check. Run
engine, check for leak. Replace
casting.

Sealant in Crank Damper keyway

Replace sealant. Refer to appropriate

omitted or inadequate

Section in group 303.

Sealant between Rear Main Cap and

Perform pressurized crankcase leak

block omitted or inadequate check. Repair.

Excessive Crankshaft Main bearing or

Inspect and repair. Refer relevant

Engine

Noise.

big end clearance.

Section.

Excessive Crankshaft end play
Excessive camshaft end play
Excessive piston to bore
clearance/damaged piston/bent
connecting rod.
Excessive hydraulic valve adjuster
clearance

Soft or spongy lash adjusters

Check for excessively low or high oil

Worn cam lobe or roller finger follower

level. Air leak in suction side of oil

Excessive valve guide clearance

pump.

Broken valve spring
Loose timing chain
Loose crank damper
Worn/noisy Front End Accessory Drive
Belt
Worn/noisy FEAD tensioner/idler
pulley
Exhaust gas leakage

Carbon in combustion chamber/top

Remove carbon using proprietary

land of piston

carbon removal treatment

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