Ford Falcon. Manual — part 114

303-01a-27

Engine — I6

303-01a-27

IN-VEHICLE REPAIR (Continued)

Crankshaft Position Sensor

Combustion Knock Sensor

Removal and Installation

Removal and Installation

1. Check the condition of the O-ring prior to

1. When re-installing the Knock sensor, coat the

installation.

threads with Loctite 242 (or similar) thread locker.

2. Lubricate the O-ring with engine oil prior to

installation.

Exhaust Gas Oxygen Sensor

Removal and Installation

Oil Pressure & Oil Temperature Sensor

1. Coat the threads with a Nickel Anti- Seize

Removal and Installation

compound (Loctite 767 or similar) per

ESE-FM99C100-A.

1. When re-installing the original sensor, coat the

threads with Loctite 567 (or similar) thread

sealant. New replacement sensors are

pre-coated.

Temperature - Manifold Air Pressure

Sensor

1. Remove the Electronic Throttle Body (ETB) to

gain access to the attachment screw.

2. Inspect the condition of the O-ring prior to

installation.

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Engine — I6

303-01a-28

IN-VEHICLE REPAIR (Continued)

3. When re-installing the ETB, coat the threads with

Crankshaft Front Oil Seal

Loctite 242 (or similar) thread locker.

Removal
1. Disconnect

the

battery.

2. Remove the radiator cooling fan assembly.
3. Remove

the

radiator.

4. Remove the front end accessory drive belt.
5. Remove the Crankshaft Vibration Damper.
6. Protect the crankshaft with a piece of soft metal or

plastic, and use a screwdriver to lever out the oil

seal.

Crankshaft Vibration Damper

Removal
1. Remove the Retaining Bolt.
2. Use SST 303-642 to remove the damper.
3. Remove

key.

Item

Description

1

Screwdriver (flathead)

2

Crankshaft Front Oil Seal

3

Soft Metal or Plastic (shim)

Installation
1. Clean the front cover recess and tap in the seal

until it is fully seated.

2. Lubricate the lip of the seal with engine oil.

Installation
1. Apply sealer in the keyway as shown.
2. Lubricate the seal rubbing area with engine oil.
3. Use SST 303-642 to install the damper.
4. Inspect key for damage. Replace if necessary.

3. Install the Crankshaft Vibration Damper.

Crankshaft Rear Oil Seal

Removal
1. Remove the transmission. Refer to section

307-01A (Auto trans) or 308-03A/B (Man trans).

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Engine — I6

303-01a-29

IN-VEHICLE REPAIR (Continued)

2. Remove the flywheel. Refer to Section 307-01A

Clutch Pilot Bearing

(Auto trans) or 308-01 (Man trans).

Removal and Installation

NOTE: Other potential sources of oil leak should

be eliminated prior to replacing the seal.

1. Use a suitable tool to remove the pilot bearing

and adaptor from the flywheel. The back of the

3. Insert a suitable brass strip between the seal and

adaptor is notched to facilitate removal.

the crankshaft to protect the crankshaft seal

2. Install the new adaptor and bearing into the

surface.

flywheel until the adaptor bottoms out. Do not

4. Insert a screwdriver between the seal and the

change the location of the bearing in the adaptor.

protection strip and lever out the seal.

Installation

Water Pump

1. Clean the seal recess in the block.

Removal

2. Oil the lip of the seal and the shaft.

1. Remove the radiator cooling fan assembly. Refer

3. Install the seal evenly using the SST E9312.

to Section 303-03A.

2. Remove the front end accessory drive belt. Refer

to Section 303-05.

3. Remove the water pump pulley. Refer to Section

303-05.

4. Remove the alternator and brace. Refer to

Section 303-04.

5. Remove the radiator lower hose (and coolant).

Refer to Section 303-03A.

Flywheel/Drive Plate/Clutch Pilot

Bearing

Removal and Installation
1. Remove the transmission. Refer to section

307-01A (Auto trans) or 308-03A/B (Man trans).

2. Remove the clutch pressure and friction plates.

Refer to Section 308-01.

3. Remove the flywheel/drive plate. Refer to Section

Item

Description

308-01.

1

Water Pump

4. Remove the clutch pilot bearing. Refer to Section

308-01.

2

Bolt (x4)

3

Alternator Brace

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Engine — I6

303-01a-30

IN-VEHICLE REPAIR (Continued)

NOTE: Weeping and staining of coolant from the body 2. Remove the ETB.

drain hole is normal and permitted. When the water

pump is suspected of leaking, this should be

confirmed with a cooling system pressure test.

NOTE: The pump is a sealed unit, and should be

replaced complete if faulty.

Installation

To install, reverse the removal procedure.
1. Check the condition of the heater pipe recess in

the rear of the water pump.

2. Check the condition of the O-ring on the end of

the heater pipe and renew if damaged.

3. Lubricate the O-ring to assist assembly.

Item

Description

1

Gasket - Throttle body

2

Throttle body

3

M6 screw (x4)

4

Support bracket

3. Disconnect the brake booster vacuum hose, fuel

pressure regulator hose from the manifold.

Electronic Throttle Body and Intake

Manifold

Removal
1. Remove the air duct assembly.

4. Remove the 2 upper manifold to cylinder head

braces.

Item

Description

1

Air Duct

2

Retaining Bolt

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