Ford Falcon. Manual — part 107

303-00-18

Engine System — General Information

303-00-18

GENERAL PROCEDURES (Continued)

1. Use a slide hammer or tools suitable to remove

Valve — Seat Runout

the cylinder block core plug.

1. Use the Valve Seat Runout Gauge to check valve

seat runout.

2. Inspect the cylinder block plug bore for any

damage that would interfere with the correct

sealing of the plug.

Cylinder Bore — Cleaning

Cup-Type

CAUTION: If these procedures are not

CAUTION: Use care during this procedure so

followed, rusting of the cylinder bores may occur.

as not to disturb or distort the cup sealing

1. Clean the cylinder bores with soap or detergent

surface.

and water.

2. Thoroughly rinse with clean water and wipe dry

CAUTION: When installed, the flanged edge

with a clean, lint-free cloth.

must be below the chamfered edge of the bore to

effectively seal the bore.

3. Use a clean, lint-free cloth and lubricate the

cylinder bores.

1. Use a tool suitable to seat the cup-type cylinder

block core plug.

Use Super Premium SAE Motor Oil meeting

Ford specification.

Cylinder Block — Core Plug

Replacement

Special Tool(s)

Impact Slide Hammer

100-001 (T50T-100-A)

Expansion-Type

CAUTION: Do not contact the crown when

installing an expansion-type cylinder block core

plug. This could expand the plug before seating

and result in leakage.

G37870 en

303-00-19

Engine System — General Information

303-00-19

GENERAL PROCEDURES (Continued)

1. Use tool suitable to seat the expansion-type

cylinder block core plug.

Exhaust Manifold — Inspection

1. Place a Straight edge across the exhaust

manifold flanges and check for warping with a

feeler gauge.

Item

Description

1

cratering-fatigue failure

2

spot glazing-improper seating

3

scratching-dirty

4

base exposed-poor lubrication

Bearing -Inspection

5

both edges worn-journal damaged

1. Inspect bearings for the following defects.

6

one edge worn-journal tapered or bearing

Possible causes are shown:

not seated

1.

cratering-fatigue

failure

2. spot glazing-improper seating

3.

scratching-dirty

4. base exposed-poor lubrication

5. both edges worn-journal damaged

6. one edge worn-journal tapered or bearing not

seated

G37875 en

303-01a-1 Engine

—

I6 303-01a-1

SECTION : 303-01a Engine — I6

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-3

DESCRIPTION AND OPERATION

Engine — I6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-7

DIAGNOSIS AND TESTING

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-12

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-12

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-12

Component

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-13

GENERAL PROCEDURES

Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-16

Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-16

Valve Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-17

Valve Guide Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-17

Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-17

Valve Seat Inspection/Repair . . . . . . . . . . . . . . . . . . . . . . . .303-01a-18

Valve Spring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-18

Camshaft End Play Inspection . . . . . . . . . . . . . . . . . . . . . . ...303-01a-19

Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-19

Camshaft Journal Clearance - Plastigauge Method . . . . . . . . . . . . . . ..303-01a-20

Roller Follower Inspection . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-20

Lash Adjuster Bore Inspection . . . . . . . . . . . . . . . . . . . . . . ...303-01a-20

Cylinder Block Inspection/Repair . . . . . . . . . . . . . . . . . . . . . ...303-01a-20

Cylinder Bore - Taper . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-21

Cylinder Bore — Out-of-Round . . . . . . . . . . . . . . . . . . . . . . ..303-01a-21

Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-21

Piston Clearance Inspection/ Repair . . . . . . . . . . . . . . . . . . . . ..303-01a-21

Piston Ring Clearance Inspection . . . . . . . . . . . . . . . . . . . . . ..303-01a-22

Piston Pin Clearance Inspection . . . . . . . . . . . . . . . . . . . . . . 303-01a-22

Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-23

Crankshaft Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . ..303-01a-23

Crankshaft End Play Inspection/Repair . . . . . . . . . . . . . . . . . . . .303-01a-24

Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-24

Connecting Rod Big End Bearing Clearance . . . . . . . . . . . . . . . . . .303-01a-24

Connecting Rod Side Clearance Inspection . . . . . . . . . . . . . . . . . ..303-01a-25

Piston and Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . ..303-01a-25

Timing Chain Elongation . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-25

IN-VEHICLE REPAIRS

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-26

Oil Level Indicator & Tube . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-26

Cylinder Head Temperature Sensor . . . . . . . . . . . . . . . . . . . . .303-01a-26

Cam Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-26

Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-27

303-01a-2 Engine

—

I6 303-01a-2

(Continued)

Oil Pressure & Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . 303-01a-27

Combustion Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-27

Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . .303-01a-27

Temperature - Manifold Air Pressure Sensor . . . . . . . . . . . . . . . . . 303-01a-27

Crankshaft Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . .303-01a-28

Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-28

Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-28

Flywheel/Drive Plate/Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . ..303-01a-29

Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-29

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-29

Electronic Throttle Body and Intake Manifold . . . . . . . . . . . . . . . . . 303-01a-30

Broadband Throttle Plate . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-32

Broadband Throttle Shaft Vacuum Motor . . . . . . . . . . . . . . . . . . ..303-01a-32

Exhaust Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-32

Exhaust Manifold - Front and Rear . . . . . . . . . . . . . . . . . . . . . 303-01a-33

Oil Control Valve Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-33

Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-34

Ignition Coils/Wiring Loom . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-36

Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters . . . . . . . . . . . .303-01a-37

Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-38

Camshaft and VCT Phasers . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-38

Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-40

Timing Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-41

VCT Phaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-41

Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal . . . . . . . . . ..303-01a-42

Rocker Arm and Lash Adjuster . . . . . . . . . . . . . . . . . . . . . . ..303-01a-43

Valve spring and Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 303-01a-43

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-44

Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-46

Timing Chain Tensioner Release . . . . . . . . . . . . . . . . . . . . . ...303-01a-46

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-47

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-48

Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-50

Engine Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-50

Oil Pump Pickup Tube . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01a-51

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-52

Piston and Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-52

Main bearings/Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . ..303-01a-53

Rear Main Bearing Cap Assembly . . . . . . . . . . . . . . . . . . . . . .303-01a-5

4

Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-54

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Key Retainer — Valve Spring . . . . . . . . . . . . . . . . . . . . . . . 303-01a-55

Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01a-55

Piston and Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . ..303-01a-56

Piston and Connecting Rod Disassembly and Assembly . . . . . . . . . . . . ..303-01a-56

Connecting Rod Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01a-56