Ford Falcon. Manual — part 111

303-01a-15

Engine — I6

303-01a-15

DIAGNOSIS AND TESTING (Continued)

1.0 litres used for 10mm distance below the

Oil consumption Test

FULL mark for the 4.0L I6 engines. For

The following diagnostic procedure is used to

engines employing the alternate method of

determine the source of excessive oil consumption.

marking the dipstick with levels corresponding

NOTE: Oil use is normally greater during the first

to a volume difference of 1 litre, note the

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

distance the new oil level is below the Top

decreases. High speed driving, towing, high ambient

scribed mark and divide this by the distance

temperature and other factors may result in greater oil

between the original two scribed marks. This

use.

gives the volume of oil in litres used during

the test.

1. Define excessive consumption such as the

7. Divide the distance travelled (kilometres)

number of kilometers driven per litre of oil used.

during the test by the amount of oil used

Also determine customer’s driving habits, such as

(litres) to produce the oil consumption in

sustained high speed operation, towing, extended

kilometres per litre.

idle and other considerations.

8. If the oil consumption is unacceptable go to

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

Step 9.

described in the Engine Oil Leaks section.

6. Check the positive crankcase ventilation (PCV)

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

system. Make sure the system is not plugged.

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

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

overfilled condition. Check the oil level at least

cylinder head and cylinder block.

five minutes after a hot shutdown with the vehicle

parked on a level surface.

8. If the condition still exists after carrying out the

above tests go to Step 9.

5. Carry out an Oil Consumption Test:

9. Carry out a cylinder compression test as outlined

1. For a 4.0L I6 engine, drain the engine oil and

in the Compression Test section. This can help

refill the engine. Run for 10 minutes, and

determine the source of oil consumption such as

allow the engine to stand for 5 minutes to

valves, piston rings or other areas.

allow the oil to drain to the crankcase.

10. Check valve guides for excessive guide

2. Top up the oil level exactly to the full mark.

clearance. Install new valve stem seals if

Allow to stand for 5 minutes and re-check.

required.

NOTE: For engines other than the 4.0L I6,

11. Worn or damaged internal engine components

refill the engine with one litre less oil than

can cause excessive oil consumption. Small

specified.

deposits of oil on the tips of the spark plugs can

Run the engine for 10 minutes and allow to

be a clue to internal oil consumption.

stand for 5 minutes. Clean the dipstick and

scribe a line on the back face of the dipstick

Intake Manifold Vacuum Test

blade corresponding with this level, then

Bring the engine to normal operating temperature.

reinsert.

Connect a vacuum gauge or equivalent to the intake

Add exactly 1 litre of oil to the engine. Run for

manifold. Run the engine at the specified idle speed.

5 minutes and allow to stand for 5 minutes.

Mark the new level on the back of the

The vacuum gauge should read between 51-74 kPa

dipstick. This should correspond closely to the depending upon the engine condition and the altitude

FULL mark.

at which the test is carried out. Subtract 4.0 kPa from

the specified reading for every 300m of elevation

3. Record the vehicle’s odometer reading.

above sea level.

4. Instruct the customer to drive the vehicle as

The reading should be steady. Adjust the gauge

usual and:

damper control (where used) if the needle is fluttering

Check the oil level regularly at intervals of

rapidly. Adjust damper until needle moves easily

250 km.

Return to the service point when the oil

without excessive flutter.

level drops below the ADD mark on the oil

dipstick.

Add only full litres of the same oil in an

emergency. Note the mileage at which the

oil is added.

5. Check the oil level under the same conditions

and at the same location as in steps 1-3.

6. Measure the distance from the full mark to the

current oil level on the oil dipstick and

calculate the oil usage based on a volume of

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303-01a-16

Engine — I6

303-01a-16

GENERAL PROCEDURES

6. Measure the manifold contact surface distortion

Cylinder Head Inspection

as shown.

WARNING: Continuous exposure with USED

engine oil has caused skin cancer in laboratory

mice. Protect your skin by washing with soap and

water immediately after this work.
1. Conduct a dye penetrant (or similar) crack test.

Replace the cylinder head if necessary.

2. Inspect for the following and repair if necessary.

1. Sunken valve seats

2. Excessive camshaft bearing clearance and

end play

3. Excessive lash adjuster bore size

3. Measure the cylinder head for distortion. This can

be achieved by using a straight edge and feeler

gauge along the horizontal and vertically aligned

Maximum distortion

0.15mm

bolt holes on the shaded surface.

7. If the distortion exceeds the specification, grind

4. Repeat the procedure along the diagonal from the

the surface.

top left bolt hole to the bottom right bolt hole and

along the diagonal from the top right bolt hole to

Maximum grinding

0.20mm

the bottom left bolt hole.

Valve Inspection

Inspect the following valve areas:
1. The valve tip, for pitting and wear.
2. The keeper grooves, for burns and wear.
3. The stem, for wear, scuffing and bending.
4. The valve head, for burning, cracks and pitting of

the seat.

5. The valve head thickness.

Maximum distortion

0.18mm lengthways or

0.075mm in 150mm

transversely

5. If the cylinder head distortion exceeds the

maximum, repair by grinding the joint face or

replace the cylinder head.

Maximum joint face

0.3mm

machining
Minimum surface

64.0cc

Item

Description

combustion chamber

volume

1

Valve tip

2

Keeper grooves

3

Stem

4

Valve head

5

Valve head thickness

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303-01a-17

Engine — I6

303-01a-17

GENERAL PROCEDURES (Continued)

Valve Measurement

1. Measure the valve head margin thickness of each

valve. Replace the valve if necessary.

Standard Inner

6.015 - 6.044 mm

Diameter
Maximum diameter

6.070mm

Margin thickness (min)

IN: 1.1mm

Valve Guide Replacement

EX: 1.1mm

Removal

2. Measure the stem diameter of each valve in X

1. Remove the valve guide from the combustion

and Y directions at the three points (A, B, and C)

chamber side by using a drift.

shown. Replace the valve if necessary.

Installation

Standard Diameter (IN

5.975 - 5.995mm

1. Install the guide using a drift so the protrusion (A)

and EX)

is as specified.

Minimum Diameter

5.950mm

Valve Guide Inspection

Measure the inner diameter of each valve guide in X

and Y directions at the three points (A, B, and C)

shown.

Protrusion A

13.5 - 14.1 mm

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303-01a-18

Engine — I6

303-01a-18

GENERAL PROCEDURES (Continued)

2. Ream the guide to size.

3. Measure the protruding length (L) of the valve

stem. Replace the valve or valve seat if

necessary.

Diameter

6.015 - 6.044 mm

Valve Seat Inspection/Repair

1. Measure the seat contact width. If necessary,

resurface the valve seat using a 45º valve seat

cutter and/or resurface the valve face.
NOTE: After resurfacing valves or seats, check

collapsed lash adjuster clearance.

Standard dimension L

IN: 50.00

EX: 47.92

Maximum dimension L

IN: 51.0

EX: 48.9

Valve Spring Inspection

1. Check the valve spring load at set length

Intake

1.0 - 1.4 mm

Exhaust

1.25 - 1.75 mm

2. Verify that the seating position is at the centre of

the valve face.

1. If the seating position is too high, correct the

valve seat using a 65º (IN) or 75º (EX) cutter,

and a 45º cutter.

2. If the seating position is too low, correct the

valve seat using a 35º cutter, and a 45º cutter.

Minimum Load

500N at 26.8 mm

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