Ford Falcon. Manual — part 115
303-01a-31
Engine — I6
303-01a-31
IN-VEHICLE REPAIR (Continued)
8. Disconnect the main gallery oil pressure and
5. Remove the upper intake manifold.
temperature switch, knock sensor and crank
timing sensor.
Item
Description
9. Remove the lower intake manifold.
1
Intake Manifold - Upper
2
M8 screws (x14)
3
Gasket - Intake manifold upper
6. Remove the 3 lower manifold to cylinder block
braces.
Item
Description
1
Fuel rail
2
Support bracket
3
Knock sensor
7. Remove the fuel rail and injectors as an
4
M8 Bolts
assembly.
NOTE: The Electronic Throttle Body is a non
adjustable item. For fault finding see Section 303-14.
Installation
When re-installing the Upper intake manifold to Lower
intake manifold bolts, coat the threads with Loctite
242 (or similar) thread locker.
When reinstalling the Lower intake manifold bolts to
the cylinder head, coat the threads with Loctite 242
(or similar) thread locker.
The gaskets sealing the Upper to Lower Manifold and
the Lower Manifold to the head should not be re-used.
When reinstalling the ETB to the intake manifold, use
a new gasket and new bolts or apply Loctite 242 (or
similar) thread locker to the threads.
Torque the M6 bolts to 8-12Nm.
The Broadband throttle shaft Vacuum motor closed
position stop is set in the factory and should not be
touched, unless the vacuum motor or Broadband
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303-01a-32
Engine — I6
303-01a-32
IN-VEHICLE REPAIR (Continued)
throttle shaft are serviced, in which case the setting
3. Screw in the set screw 1-1.5 turns clockwise so
must be adjusted as described below.
the screw now contacts the stop and the
Broadband Throttle Plates are cracked open.
Broadband Throttle Plate
Removal
1. Unscrew the retaining bolts.
2. Remove Broadband Throttle Plates.
Item
Description
1
Screws
2
Activator - Throttle control
3
Throttle lever
Installation
4
Clip
1. Insert plates with tabs facing upwards and to the
screw head side.
Exhaust Manifold Assembly
2. Loosely install the plate retaining screws.
Removal
3. Rotate the shaft so the plates are closed and
1. Remove the heat shield by unscrewing the
snap the plates shut a few times to centralize
retaining bolts.
them in their bores. There must be no gap
between the plates and their bores.
4. Apply Loctite 242 (or similar) thread locker to the
threads and tighten the plate retaining screws to
specification.
Broadband Throttle Shaft Vacuum
Motor
Removal
1. When disconnecting the vacuum motor from
throttle shaft level, remove retaining clip first.
2. Do not adjust the set screw on the throttle shaft
lever. If adjustment is necessary, or of a new
vacuum motor is fitted, reset screw by the
following procedure.
Installation
1. Apply a 40kPa vacuum to the motor or apply light
finger pressure to push the lever in a clockwise
direction against the stop.
2. Maintaining the pressure on the lever, unscrew
the set screw until there is a 0.05mm gap
between the screw and the stop.
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303-01a-33
Engine — I6
303-01a-33
IN-VEHICLE REPAIR (Continued)
4. Loosely assemble and finally torque when fitted ti
2. Disassemble the items in the following order.
engine.
Item
Description
Item
Description
1
Catalytic Converter Inlet Pipe
1
Exhaust Manifold - Rear
2
Lifting Eye
2
Gasket
3
Retaining Bolt
3
M8 - Nut
4
Heated Exhaust Gas Oxygen (HEGO)
4
Exhaust Manifold - Front
Sensor
5
Exhaust Manifold Assembly
Oil Control Valve Seal
Installation
Removal
1. Fit 2 M10 x 1.5 bolts with heads removed as
guide pins.
1. Check metal garter band is still in place on the
seal.
2. Fit gasket and loosely assembled manifold onto
guide pins. Refer to Exhaust Manifold - Front and
Rear section.
3. Install lower manifold to head bolts, and nip up
the bolts.
4. Remove guide pins, install remainder of bolts
excluding those used to attach the heat shield.
5. Tighten the bolts progressively to specification.
6. Tighten the front to rear manifold joint nuts to
specification.
7. Lubricate the HEGO sensor thread with Loctite
767 (or similar) anti-seize compound per
ESE-FM99C100-A.
Exhaust Manifold - Front and Rear
Item
Description
Removal
1
Plate - Gasket valve rocker arm cover
1. Remove the three nuts from the studs.
2
Bolt
NOTE: If the studs screw out of the Rear Exhaust
Installation
Manifold, simply refit the studs using two suitable
nuts locked together.
1. After tightening the Valve Cover retaining bolts,
insert the Oil Control Valve seals into the Valve
Installation
Cover without displacing the metal garter band,
1. Clean all mating surfaces.
and tighten the seal retaining bolts.
2. Fit a new front to rear manifold sealing ring.
3. Apply anti-seize compound to the manifold joint
nut threads.
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303-01a-34
Engine — I6
303-01a-34
IN-VEHICLE REPAIR (Continued)
4. Remove the Spark Plug Cover.
Valve Cover
Removal
1. Remove the air duct assembly.
Item
Description
1
Bolt & Washer
2
Cap - Oil filler
Item
Description
3
PCV valve
1
Intake duct
4
M5 screw
2
Screw
5
Clip-air line
2. Remove the Electronic Throttle Body (ETB) as per 6
Spark plug cover
procedure.
5. Remove the Ignition Coils.
Item
Description
1
Gasket - Throttle body
2
Throttle body
3
Screw
4
Bracket
3. Remove the oil filler cap, PCV valve, brake and
PCV hoses.
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