Ford Falcon. Manual — part 116
303-01a-35
Engine — I6
303-01a-35
IN-VEHICLE REPAIR (Continued)
6. Remove the Oil control valve seals retaining bolts. 8. Slide the valve cover backwards 20-30mm, then
Check metal garter band is still in place on the
lift the front to clear the oil control valves, and
seal.
then slide the cover forwards, raising the rear to
clear the camshafts and dash panel.
Item
Description
1
Plate - Gasket valve rocker arm cover
2
Bolt
7. Remove valve cover retaining bolts (8).
Item
Description
1
Bolt and washer
2
Bolt and washer
3
Valve cover
Installation
1. Clean the cover including PCV and fresh air
chambers, and seal grooves. Fit new seals.
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303-01a-36
Engine — I6
303-01a-36
IN-VEHICLE REPAIR (Continued)
2. Apply sealer WSS-M4G323 A7 in 2 places on the 2. Remove the Electronic Throttle Body (ETB).
Valve Cover to cylinder head/front cover joints as
shown, refit the cover, check the peripheral seal is
not displaced out of the groove using a mirror for
the rear of the engine.
3. When
re-installing the six short bolts which retain
the Valve Cover to the cylinder head assembly,
coat the threads with Loctite 242 (or similar)
thread locker. 4. Check the Oil Control Valve
Seals, replace if necessary and refit after the
Valve Cover is tightened down.
Item
Description
1
Gasket
2
Electronic Throttle Body
3
Bolt
4
Bracket
3. Remove the oil filler cap, PCV valve, brake and
PCV hoses.
4. Remove the Spark Plug Cover.
Ignition Coils/Wiring Loom
Removal
1. Remove the air duct assembly.
Item
Description
1
Bolt
2
Oil filler cap
3
PCV valve
Item
Description
4
Screw
1
Air intake tube assembly
5
Vacuum hose clip
2
Bolt
6
Spark plug cover
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303-01a-37
Engine — I6
303-01a-37
IN-VEHICLE REPAIR (Continued)
Installation
2. Refit the ignition coils and reconnect the wiring
1. Every time the Ignition Coils are removed, apply 2
loom to the coils & oil control valves.
grams of synthetic grease ESF-M1C229-A
NOTE: The short lead is attached to the intake oil
(Dupont Krytox) using a suitable applicator (cotton
control valve and the long lead is connected to
bud) to the inside of the tapered section of the coil
the exhaust oil control valve.
boot, smearing it evenly over the surface.
3. Ensure all of the wiring is clear of the Spark Plug
Cover seal surfaces, and that the wiring does not
obstruct any hardware mounting points.
4. Ensure that the wiring is located correctly in the
grooves in the Valve Cover where it exits the
Spark Plug Cover when refitting the Spark Plug
Cover.
Camshafts, VCT Phaser, Oil Control
Valves, & OCV Filters
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303-01a-38
Engine — I6
303-01a-38
IN-VEHICLE REPAIR (Continued)
Item
Description
1
VCT Oil Control Valve
2
Camshaft Bearing caps
3
Camshaft - Intake
4
Chain Guide
5
Variable Cam Timing ( VCT) unit
6
Camshaft - exhaust
7
Filter- VCT Oil Control Valve
Camshaft Removal
Removal
Remove valve cover. Refer to section 303-01.
3. Release the timing chain tension by compressing
the tensioner using SST 303-777. Refer to section
Camshaft and VCT Phasers
303-01.
Special Tool(s)
Timing chain tensioner special
service tool
Camshaft holding tool
4. Fit the SST 303-778 to the camshafts in the
central position between the caps and tighten to
prevent rotation.
1. Rotate the crankshaft so the VCT timing marks
(on the sprocket) are vertically upwards and the
crankshaft at Top Dead Centre.
2. Mark the two timing chain links above the timing
marks with a marker pen.
NOTE: The yellow and orange coloured links
used for original assembly, and assembly with the
front cover removed, are only synchronized with
the timing marks once every 38 crankshaft
revolutions, and should be ignored when working
with the front cover in place (unless
synchronized).
5. Loosen the bolt attaching the VCT units to the
camshafts.
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