Ford Falcon. Manual — part 118

303-01a-43

Engine — I6

303-01a-43

IN-VEHICLE REPAIR (Continued)

Item

Description

2. Remove the keys, retainers and valve spring

using a suitable valve spring compressor.

6

Valve spring

7

Valve stem seal

Rocker Arm and Lash Adjuster

The rocker arm and lash adjuster are clipped together

to prevent rocker displacement under extraordinary

start up conditions.
Care should be taken when removing the assembly,

so as not to strain the clip.
Do not remove the clip unless either the rocker arm or

lash adjuster are to be replaced and fit a new clip.
If the clip is loose on the rocker arm it should be

replaced when the rocker and lash adjuster assembly

is removed from the cylinder head.

3. Remove the valve stem seal/spring seat assembly

Removal

with pliers or multi-grips, being careful not to mark

the valve stem.

1. Remove the camshaft. Refer to Camshaft in this

section.

Installation

2. Disengage the rocker arm from the valve tip.

1. Pressurise the cylinder via an air line and adaptor.

Do not exceed 800 KPa.

3. The rocker arm & lash adjuster assembly can be

raised and the lash adjuster removed from the

2. Use an 18mm inside diameter tube to gently seat

cylinder head.

the valve stem seal.

Installation

3. Reassemble in the reverse order to the procedure

above.

1. To install, reverse the removal procedure.

NOTE: The valve spring must be fitted with the

smaller diameter end upwards.

Valve spring and Valve Stem Seal

Removal
1. Remove the appropriate spark plug, and

pressurise the cylinder via an air line and adaptor.

DO NOT exceed 800 KPa.

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303-01a-44

Engine — I6

303-01a-44

IN-VEHICLE REPAIR (Continued)

Front Cover

9. Remove the two bolts and hollow dowels locating

Item

Description

cover to block.

1

Idle pulley

10. Remove the four oil pan to cover bolts.

2

Front cover

11. Remove all the cover to cylinder block bolts.

3

Gasket front cover

12. Remove the Front cover.

4

Crankshaft sensor

13. Raise cover before moving forward to avoid

5

Drive belt tensioner assembly

damage to oil pan seal.

6

Crankshaft vibration damper

7

Dowel front cover location

8

Bolt - Front cover

Removal
1. Disconnect

the

battery.

2. Remove the radiator cooling fan assembly. Refer

to Section 303-03A.

3. Remove the radiator.
4. Remove the valve cover.
5. Remove the front-end accessory drive

components (except A/C compressor), alternator

bracket and power steering pump.

6. Remove the water pump.

Inspection

7. Remove the crankshaft vibration damper.

1. Remove any sealant from the oil pan to

8. Disconnect the crankshaft sensor wiring

block/front cover joints and the front cover to

connector.

cylinder head/rocker cover joints.

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303-01a-45

Engine — I6

303-01a-45

IN-VEHICLE REPAIR (Continued)

2. Check the condition of the oil pan, front cover to

4. Place the front cover against the cylinder block,

block and crankshaft rotary seals and replace if

sitting on the uncompressed oil pan seal.

required.

5. Place two cross head type screwdrivers or similar

3. Ensure the joint surfaces are clean and free of oil.

through two bolt holes in the front cover and into

the cylinder block and lever the front cover down

Installation

into position.

1. Apply a small bead of sealant meeting Ford

6. Fit the two lower dowels into the front cover and

specification WSS M4G323 A7 to the oil pan to

into the cylinder block. Check the peripheral seals

block to front cover joint in 2 places as shown.

are not displaced out of the grooves.

2. Apply a small bead of sealant WSS M4G323 A7

to the front face joint between the cylinder head

Item

Description

and cylinder block in 2 places as shown.

1

Bolt

2

Front cover

3

Dowel

4

Dowel

3. Apply a small bead of sealant WSS M4G323 A7

to the rocker cover to head to front cover joint in 2

places as shown.

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303-01a-46

Engine — I6

303-01a-46

IN-VEHICLE REPAIR (Continued)

Camshaft Drive

6. Remove the fixed chain guide.

Item

Description

7. Remove the chain guide (top run).

1

Front cover

2

Gasket - Front cover

Timing Chain Tensioner Release

3

Tensioner assembly timing chain

4

Timing chain guide tension

Special Tool(s)

5

Timing chain guide fixed

Timing chain tensioner special

6

Timing chain

service tool

303-777

7

Crankshaft tone wheel

8

Crankshaft sensor

9

Front seal

10

Crankshaft vibration damper

Removal

Removal

1. Remove the front cover.

1. Rotate Lever A anti clockwise by engaging pin of

SST 303-777 into hole in lever.

2. Remove the tensioner.

2. Push in plunger until 3-4mm is visible.

3. Remove the timing chain.

3. Release load from Lever A so ratchet teeth

4. Remove the crank sprocket/timing wheel.

engage with 1st teeth on plunger.

5. Remove the moving chain guide.

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