Ford Falcon. Manual — part 120

303-01a-51

Engine — I6

303-01a-51

IN-VEHICLE REPAIR (Continued)

2. Remove the oil pan flange bolts.

4. Apply a bead of sealant Loctite 5900 (or similar)

at the front cover to block joint (2 places), and the

NOTE: The 24 oil pan flange bolts are slightly

rear main bearing cap to block joint (2 places).

longer than the bearing cross bolts. Store them

separately when removed.
NOTE: Only 12 right hand side pan flange bolts

are shown. There are a further 12 on left hand

side.

3. Remove the oil pan.
4. Remove the oil pan seal.

5. Align the rear face of the oil pan with the rear face

of the block when tightening the oil pan flange

bolts.

6. Coat the main bearing cross bolt threads with

Loctite 567 (or similar) thread sealant.

Installation
1. Clean all the joint surfaces.
2. Check the oil pan baffle plates for cracks and

loose rivets.

3. Fit a new seal.

7. Install oil pan flange bolts to specified torque.

Oil Pump Pickup Tube

Removal
1. Remove the oil pump. Refer to Oil Pump in this

section.

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303-01a-52

Engine — I6

303-01a-52

IN-VEHICLE REPAIR (Continued)

2. Remove the oil pump pickup tube.

1. Remove the pickup tube mounting bracket nut

(attached to main bearing bolt stud).

3. Remove the pickup tube attachment bolts to oil

pump.

2. Remove the oil pump to block mounting bolts.

Installation

3. Remove the Front Cover. Refer to Front Cover in

this section.

1. Inspect the intake flanges on the oil pump and

pickup tube for signs of damage.

4. Remove the engine oil pan. Refer to Engine Oil

Pan in this section.

2. Fit a new O-ring to this joint

5. Remove the oil pump pickup tube.

3. Tighten the pickup tube to oil pump bolts and

check that the mounting bracket is sitting lightly

6. Remove the oil pump.

on the head of the main bearing bolt, or just clear

NOTE: The oil pump is a non-repairable item and

by up to 1mm, before fitting the nut.

should be replaced if damaged.

NOTE: Heavy bearing, or a large gap could cause

Installation

an air leak and should be corrected by adjusting

1. Engage the drive flats in the oil pump rotor bore

the bracket.

with the two flats on the crankshaft.

2. Gently push the oil pump into position against the

Oil pump

cylinder block.

Removal

NOTE: Rotating the oil pump body and gently

rocking it fore and aft will assist assembly.

3. DO NOT use force.

Piston and Rod Assembly

Removal

Place the engine on a rollover stand and invert before

performing this procedure.
1. Remove the main bearing bolts.
2. Remove the windage baffle.
3. Remove the main bearing caps and lower main

bearings.

4. Rotate the crankshaft to Bottom Dead Centre on

the respective cylinders to improve access to the

connecting rod bolts.

5. Fit Connecting rod bolt protectors prior to

disengaging the connecting rod from the

crankshaft.

Item

Description

1

Nut

2

Bolt

3

Oil pump

4

Pickup tube

5

Bolt

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303-01a-53

Engine — I6

303-01a-53

IN-VEHICLE REPAIR (Continued)

Installation
1. Use bolt protectors when installing the assembly.

NOTE: Ensure new connecting rod bolts have

been fitted, as the ’Torque to Yield’ bolts are not

reusable.

2. Ensure the cap and the connecting rod carry the

same cylinder number marking on the same side

of the rod.

3. Tighten each pair of bolts to 25Nm, then a further

90 degrees.

Item

Description

1

Main bearing bolts

2

Windage baffle

3

Main bearing caps

4

Lower main crankshaft bearings

5

Crankshaft

6

Upper main crankshaft bearings

Main bearings/Crankshaft

Place the engine on a rollover stand and invert before

performing this procedure.
Removal
1. Remove the main bearing bolts.
2. Remove the windage baffle.
3. Remove the main bearing caps and lower main

bearings.

4. Remove the connecting rod caps, upper and

lower connecting rod bearings, and piston & rod

assemblies. Refer to Piston and Rod Assembly in

this section.

Item

Description

5. Remove

the

crankshaft.

1

Upper main crankshaft thrust bearing

6. Remove the upper main bearings.

2

Upper main crankshaft bearings

3

Crankshaft

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303-01a-54

Engine — I6

303-01a-54

IN-VEHICLE REPAIR (Continued)

Item

Description

3. Ensure the notch on the piston is facing the front

of the engine, the valve cut-outs are on the

4

Pivot bearing (Manual transmission only)

exhaust side, and the connecting rod oil squirt

Installation

hole is on the exhaust side of the engine.

1. For installation reverse the removal procedure.

Rear Main Bearing Cap Assembly

1. Apply silicone sealant Loctite 5900 (or a sealant

which meets the Ford specification

WSS-M4G323-A7) to the rear main bearing cap to

block joint as shown.

2. Fit the rear main bearing cap and tighten within 5

minutes of application of the sealant.

3. Reverse the removal procedure.

Piston Ring

Installation
1. Verify the second piston ring is installed with the

dot upwards.

2. Position the end gaps of the piston rings as

shown.

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