Ford Falcon. Manual — part 104

303-00-6

Engine System — General Information

303-00-6

DIAGNOSIS AND TESTING (Continued)

7. Install the components in reverse order, observing

Components Tests

the specified tightening torques.

Engine Oil Leaks

8. Reset the PCM fault memory.

NOTE: Before installing new gaskets or oil seals,

Interpretation of the Results

make sure that the fault is clearly established. If the

oil leak cannot be identified clearly by a visual

The indicated compression pressures are considered

inspection, carry out a pressurized crankcase leak

within specification if the lowest reading cylinder is

check:

within 75% of the highest reading.

Pressurised leak check

CAUTION: If engine oil is sprayed into the

combustion chamber, after carrying out the

1. Clean the engine with a suitable cleaning fluid to

measurement run the engine at 2000 rpm for

remove all traces of oil.

about 15 minutes, in order to burn the oil and

2. Block off the line to the PCV valve.

prevent damage to the catalytic converter.

3. Apply a regulated air supply line to the fresh air

If the measurement on one or more cylinders is much

makeup point on the rocker cover.

lower than the specified value, spray some engine oil

4. Pressurise the crankcase to 35 kPa.

into the combustion chamber and repeat the

5. Check for air leaks by washing the suspect area

compression measurement.

with a solution of soapy water and watching for

If the reading greatly improves, the piston rings are

bubbles.

damaged.

6. Repair all leaks as necessary.

If the reading stays the same, the cause is either

damaged valve seats or valve stem seals.

Compression Test

If the measurements for two cylinders next to each

General Remarks

other are both too low then it is very likely that the

cylinder head gasket between them is burnt through.

NOTE: Removing fuses and disconnecting electrical

This can also be recognized by traces of engine oil in

components causes the powertrain control module

the coolant and/or coolant in the engine oil.

(PCM) to log an error message. After the

measurements have been carried out this error

Excessive Engine Oil Consumption

message should be cleared from memory by

The amount of oil an engine uses will vary with the

connecting to PDU.

way the vehicle is driven in addition to normal

The compression pressure should be checked with

engine-to-engine variation. This is especially true

the engine at operating temperature.

during the first 15,000 km when a new engine is being

broken in or until certain internal components become

Check The Compression Pressure

conditioned. Vehicles used in heavy-duty operation

may use more oil. The following are examples of

WARNING: On manual transmissions, shift

heavy-duty operation:

the transmission into neutral. On automatic

trailer towing applications

transmission vehicles, select ’’P’’. Failure to

severe loading applications

follow these instructions may result in personal

sustained high speed operation

injury.

Engines need oil to lubricate the following internal

1. Remove the fuel pump relay.

components:

2. Start the engine - the engine will start, run for a

cylinder block cylinder walls

few seconds then stall.

pistons and piston rings

3. Remove the spark plugs.

intake and exhaust valve stems

4. Install the compression tester.

intake and exhaust valve guides

5. Install an auxiliary starter switch in the starting

circuit. With the ignition switch OFF, using the

all internal engine components

auxiliary starter switch, crank the engine a

When the pistons move downward, a thin film of oil is

minimum of five compression strokes and record

left on the cylinder walls. As the vehicle is operated,

the highest reading.

some oil is also drawn into the combustion chambers

NOTE: The approximate number of compression

past the intake and exhaust valve stem seals and

strokes required to obtain the highest reading.

burned.

6. Repeat the test on each cylinder, cranking the

The following is a partial list of conditions that can

engine approximately the same number of

affect oil consumption rates:

compression strokes.

engine size
operator driving habits

G37831 en

303-00-7

Engine System — General Information

303-00-7

DIAGNOSIS AND TESTING (Continued)

ambient temperatures

4. Add 1 litre of oil. Start the engine and allow to

idle for at least two minutes. Shut off the

quality and viscosity of oil

engine and allow the engine oil to drain back

Operation under varying conditions can frequently be

for at least five minutes. Mark the new oil

misleading. A vehicle that has been run for several

level on the dipstick using the procedure

thousand kilometers on short trips or in cold ambient

above.

temperatures may have consumed a ’’normal’’

5. Record the vehicle’s odometer reading.

amount of oil. However, when checking the engine oil

level, it may measure up to the full mark on the oil

6. Instruct the customer to drive the vehicle as

level indicator due to dilution (condensation and fuel)

usual and:

in the engine crankcase. The vehicle then might be

Check the oil level regularly at intervals of

driven at high speeds on the highway where the

250 km.

condensation and fuel boil off. The next time the

Return to the service point when the oil

engine oil is checked it may appear that a litre of oil

level drops below the ADD mark on the oil

was used in a relatively short distance.

dipstick.

Add only full litres of the same oil in an

Make sure the selected engine oil meets the Ford

emergency.

specification and the recommended API performance

category ’’SJ/CF’’ and SAE viscosity grade as shown NOTE: The mileage at which the oil is

in the vehicle Owner Literature. It is also important

added.

that the engine oil is changed at the intervals

7. Check the oil level under the same conditions

specified for the typical operating conditions.

and at the same location as in steps 3-4.

Measure the distance from the oil level to

Oil consumption Test.

the UPPER mark on the oil dipstick and

The following diagnostic procedure is used to

record.

determine the source of excessive oil consumption.

Measure the distance between the two

NOTE: Oil use is normally greater during the first

scribe marks and record.

15,000 km of service. As mileage increases, oil use

Divide the first measurement by the

decreases. High speed driving, towing, high ambient

second.

temperature and other factors may result in greater oil

Divide the distance driven during the oil

use.

test by the result. This quantity is the

approximate oil consumption rate in

1. Define excessive consumption, such as the

kilometers per litre.

number of kilometers driven per liter of oil used.

If the oil consumption rate is unacceptable

Also determine customer’s driving habits, such as

go to Step 6.

sustained high speed operation, towing, extended

6. Check the positive crankcase ventilation (PCV)

idle and other considerations.

system. Make sure the system is not plugged.

2. Verify that the engine has no external oil leaks as

7. Check for plugged oil drain-back holes in the

described under Engine Oil Leaks.

cylinder head and cylinder block.

3. Verify that the engine has the correct oil level.

8. If the condition still exists after carrying out the

4. Verify that the engine is not being run in an

above tests go to Step 9.

overfilled condition. Check the oil level at least

9. Carry out a cylinder compression test. Refer to

five minutes after a hot shutdown with the vehicle

the procedure in this section: Compression Test.

parked on a level surface.

This can help determine the source of oil

5. Carry out an oil consumption test:

consumption such as valves, piston rings or other

1. Drain the engine oil and fill with one litre less

areas.

than the recommended amount.

10. Check valve guides for excessive guide

2. Run the engine for three minutes (10 minutes

clearance. Install new valve stem seals after

if cold), and allow oil to drain back for at least

verifying valve guide clearance.

five minutes with vehicle parked on level

11. Worn or damaged internal engine components

surface.

can cause excessive oil consumption. Small

3. Remove the oil dipstick and wipe clean. (Do

deposits of oil on the tips of the spark plugs can

not wipe with anything contaminated with

be a clue to internal oil consumption.

silicone compounds.) Install the oil dipstick,

making sure to seat the oil dipstick level firmly

in the oil dipstick tube. Remove the oil dipstick

and scribe a mark on the back (unmarked)

surface at the indicated oil level. (This level

should be about the same as the ADD mark

on the face of the oil dipstick.)

G37831 en

303-00-8

Engine System — General Information

303-00-8

GENERAL PROCEDURES

Camshaft Journal — Diameter

Camshaft — End Play, OHC Engines

1. Measure each camshaft journal diameter in two

1. Remove the roller followers. Refer to the

directions.

appropriate section in Group 303 for the

procedure.

If it is out of specification, install new

components as necessary. Refer to the

2. Use a Dial Indicator with Bracketry to measure

appropriate section in Group 303 for the

camshaft end play.

procedure.

3. Position the camshaft to the rear of the cylinder

head.

4. Zero the indicator.
5. Move the camshaft to the front of the cylinder

head. Note and record the camshaft end play.

If camshaft end play exceeds specifications,

install new camshaft and recheck end play.

Refer to the appropriate section in Group 303

for the procedure.
If camshaft end play exceeds specification

after camshaft installation, install a new

cylinder head. Refer to the appropriate

section in Group 303 for the procedure.

Camshaft Journal — Clearance,

Plastigage Method

NOTE: The camshaft journals must meet

specifications before checking camshaft journal

clearance.

1. Remove the camshaft bearing cap and lay

Plastigage across the surface. Refer to the

appropriate section in Group 303 for the

procedure.

2. Position the camshaft bearing cap and install the

bolts. Refer to the appropriate section in Group

303 for the procedure.

Camshaft — Lobe Surface

NOTE: Do not turn the camshaft while carrying

out this procedure.

1. Inspect camshaft lobes for pitting or damage in

the active area. Minor pitting is acceptable outside

the active area.

If excessive pitting or damage is present,

install new components as necessary. Refer

to the appropriate section in Group 303 for

the procedure.

3. Use Plastigage to verify the camshaft journal

clearance.

If it is out of specification, install new

components as necessary. Refer to the

appropriate section in Group 303 for the

procedure.

G37832 en

303-00-9

Engine System — General Information

303-00-9

GENERAL PROCEDURES (Continued)

Crankshaft Main Bearing Journal —

Camshaft — Runout

Taper

NOTE: Camshaft journals must be within

specifications before checking runout.

1. Measure each of the crankshaft main bearing

journal diameters in at least two directions at each

1. Use a Dial Indicator with Bracketry to measure the

end of the main bearing journal.

camshaft runout.

For additional information, refer to

Rotate the camshaft and subtract the lowest

Specifications in the appropriate section in

indicator reading from the highest indicator

Group 303.

reading.

If it out of specification, install new

For additional information, refer to the

components as necessary. Refer to the

specification chart in the appropriate engine

appropriate section in Group 303 for the

section.

procedure.

If it is out of specification, install new

components as necessary. Refer to the

appropriate section in Group 303 for the

procedure.

Crankshaft Main Bearing Journal —

Clearance

NOTE: Crankshaft main bearing journals must be

Crankshaft Main Bearing Journal —

within specifications before checking journal

clearance.

Diameter

1. Remove the crankshaft main bearing caps and

1. Measure each of the crankshaft main bearing

crankshaft main bearing.

journal diameters in at least two directions.

2. Lay a piece of Plastigage across the face of each

For additional information, refer to

crankshaft main bearing surface.

Specifications in the appropriate section in

NOTE: Do not turn the crankshaft while carrying

Group 303.

out this procedure. Install and remove the

If it is out of specification, install new

crankshaft main bearing cap.

components as necessary. Refer to the

appropriate section in Group 303 for the

procedure.

G37839 en