Ford Falcon. Manual — part 110

303-01a-11

Engine — I6

303-01a-11

DESCRIPTION AND OPERATION (Continued)

Lower Engine Components

Item

Description

1

Gasket - Front Cover RH

2

Timing Chain Tensioner

3

Lever arm assembly - Timing chain

tensioner

4

Timing chain

5

Guide assembly - Timing chain

6

Oil pump

7

Oil pump pick-up/ Screen

8

Sensor Assembly Engine Spark intensity

(knock sensor)

9

Flywheel assembly

10

Cover - Flywheel housing

11

Filter assembly - Oil

12

Piston compression ring, Upper

13

Piston compression ring, Lower

14

Piston Oil control, Ring

15

Piston

16

Connecting rod

17

Bearing upper - Connecting rod (Big End)

18

Bearing lower - Connecting Rod (Big End)

19

Cap - Connecting rod

20

Pin - Piston

21

Cover - Flywheel

22

Plug - Oil pan drain

23

Pan - Oil

24

Baffle - Oil pan

25

Seal - Oil pan

26

Crank windage oil baffle

27

Brace - Main bearing cap support

28

Crankshaft main bearing caps

29

Crankshaft main bearing - Lower

30

Crankshaft

31

Crankshaft main bearings - Upper

32

Cylinder block

33

Tube - Oil lever indicator

34

Oil lever indicator

35

Damper assembly - Crankshaft

36

Crank sensor

37

Crankshaft sprocket / Tone wheel

38

Switch assembly - Oil pressure

39

Seal - Oil, Cylinder front cover

40

Cover - Cylinder front

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303-01a-12

Engine — I6

303-01a-12

DIAGNOSIS AND TESTING

Visual Inspection Chart

Engine

Mechanical

Inspection and Verification

Coolant leaks

Oil leaks

Since diagnosis and testing actually begins when

Leaks in the fuel system

repairs are taken on, the following procedure is

Visibly damaged or worn parts

recommended.

Loose or missing nuts or bolts

1. Verify the customer concern by operating the

system.

3. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)

2. Visually inspect for obvious signs of mechanical

before proceeding to the next step.

damage or electrical damage. If the concern

cannot be reproduced, carry out a road test

4. If the concern is not visually evident, verify the

and/or visual check with the aid of the following

symptom and refer to the Symptom Chart.

table.

Symptom Chart

Condition

Source

Action

Engine will not crank

Faulty Starter System

Refer Section 303-06 Starting System.

Transmission lever not in P or N.

Place in P.

Seized engine

Replace engine.

Coolant in cylinders

Replace engine.

Engine cranks but will not start

Ignition system inoperative

Refer section 303-06 Starting System

Fuel system inoperative

Refer section 303-04

LPG engine requires "key-off" to

Key-off LPG engine if 1st starting

Engine slow/difficult to start

regain starting enrichment after initial

attempt failed.

failed start.
Variable Cam Timing (VCT) unit lock
pin not engaged at start.

Clean Oil Control Valve. Refer to Valve

VCT unit Oil Control Valve jammed.

Cover Section.

Engine misfires

Fail Safe Cooling in operation

Repair coolant system

Ignition system faulty

Refer Section 303-06

Fuel system faulty

Refer Section 303-04

Restricted exhaust system

Inspect Exhaust system

Carry out Intake Manifold Vacuum test

Intake vacuum leak

in this section

Burned valve/poor seating

Perform a compression check

Broken valve spring

Inspect valve springs

Head gasket leakage

Inspect head gasket

Piston damage

Perform cylinder compression check

Broadband Intake Manifold not

Check switching occurs at 3800 rpm-

Insufficient

Power

operative

refer Section 303-14.

VCT unit(s) not operative

Refer Section 303-14.

Electronic Throttle Control Unit faulty

Refer Section 303-14.

Green(low mileage) engine/vehicle

Establish accurate fuel consumption

Excessive Fuel Consumption

City/stop-start driving

using full-to-full method.

Faulty Fuel System

Refer Section 303-04

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303-01a-13

Engine — I6

303-01a-13

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Excessive Oil Consumption

Green engine

Recheck at 15,000 km

Valve stem seal damaged or missing.

Inspect the seals.

Oil leakage

Repair oil leakage

Incorrect Oil viscosity

Drain and fill with correct oil

Piston/rings/cylinder worn or damaged

Repair. Refer Section 303-00.

Determine cause. Correct. Drain and

Diluted oil

refill oil.

Crankcase overfilled

Adjust oil level.

Faulty PCV Valve

Check and replace.

Engine leaks oil

Joint fasteners loose

Tighten to specification.

Out of position or damaged seal/RTV

Pressurise crankcase to 35kPa. Apply

soapy water, check for leak. Inspect

sealant omitted/inadequate.

and replace.

Worn/out of position crank rotary seal

Inspect and replace.

Clean suspect area, Perform

Porous casting

pressurized crankcase check. Run
engine, check for leak. Replace
casting.

Sealant in Crank Damper keyway

Replace

sealant.

omitted or inadequate

Sealant between Rear Main Cap and

Perform pressurized crankcase leak

block omitted or inadequate

check. Repair.

Excessive Crankshaft Main bearing or

Inspect and repair. Refer relevant

Engine

Noise

big end clearance.

Section.

Excessive Crankshaft end play
Excessive camshaft end play
Excessive piston to bore
clearance/damaged piston/bent
connecting rod.
Excessive hydraulic valve adjuster
clearance
Worn cam lobe or roller finger follower
Excessive valve guide clearance
Broken valve spring
Loose timing chain
Loose crank damper
Worn/noisy Front End Accessory Drive
Belt
Worn/noisy tensioner/idler pulley
Exhaust gas leakage

Check for excessively low or high oil

Soft or spongy lash adjusters

level. Air leak in suction side of oil
pump.

Carbon in combustion chamber/top

Remove carbon using proprietary

land of piston

carbon removal treatment

Pressurised leak check

Component Tests

Engine Oil Leaks

1. Clean the engine with a suitable cleaning fluid to

remove all traces of oil.

NOTE: Before installing new gaskets or oil seals,

2. Block off the line to the PCV valve.

make sure that the fault is clearly established. If the

oil leak cannot be identified clearly by a visual

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

inspection, carry out a pressurized crankcase leak

makeup point on the rocker cover.

check.

4. Pressurise the crankcase to 35 kPa.

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303-01a-14

Engine — I6

303-01a-14

DIAGNOSIS AND TESTING (Continued)

5. Check for air leaks by washing the suspect area

If the reading stays the same, the cause is either

with a solution of soapy water and watching for

damaged valve seats, or valve stem seals.

bubbles.

If the measurements for two adjacent cylinders are

6. Repair all leaks as necessary.

both too low, then it is very likely that the cylinder

head gasket between the cylinder is burnt through.

General Remarks

This can also be recognized by traces of engine oil in

the coolant and/or coolant in the engine oil.

NOTE: Removing fuses and disconnecting electrical

components causes the powertrain control module

Excessive Engine Oil Consumption

(PCM) to log an error message. After the

measurements have been carried out this error

The amount of oil an engine uses will vary with the

message should be cleared from memory by

way the vehicle is driven in addition to normal

connecting to WDS.

engine-to-engine variation. This is especially true

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

The compression pressure should be checked with

broken in or until certain internal components become

the engine at operating temperature.

conditioned. Vehicles used in heavy-duty operation

may use more oil. The following are examples of

Check The Compression Pressure

heavy-duty operation:

trailer towing applications

WARNING: On manual transmissions, shift

the transmission into neutral. On automatic

severe loading applications

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

sustained high speed operation

follow these instructions may result in personal

Engines need oil to lubricate the following internal

injury.

components:

1. Remove the fuel pump relay.

cylinder block cylinder walls

2. Start the engine and run for a few seconds, then

pistons and piston rings

stall.

intake and exhaust valve stems

3. Remove the spark plugs.

intake and exhaust valve guides

4. Install an adaptor and compression tester.

all internal engine components

5. Install an auxiliary starter switch in the starting

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

circuit. With the ignition switch OFF, use the

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

auxiliary starter switch to crank the engine a

some oil is also drawn into the combustion chambers

minimum of five compression strokes, and record

past the intake and exhaust valve stem seals and

the highest reading. Note the approximate

burned.

number of compression strokes required to obtain

the highest reading.

The following is a partial list of conditions that can

affect oil consumption rates:

6. Repeat the test on each cylinder, cranking the

engine approximately the same number of

engine size

compression strokes.

operator driving habits

7. Install the components in reverse order, observing

ambient temperatures

the specified tightening torques.

quality and viscosity of oil

8. Reset the PCM fault memory.

Operation under varying conditions can frequently be

Interpretation of the Results

misleading. A vehicle that has been run for several

thousand kilometers on short trips or in cold ambient

The indicated compression pressure is considered to

temperatures may have consumed a ’’normal’’

be within specification if the lowest reading cylinder is amount of oil. However, when checking the engine oil

within 75% of the highest reading.

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

level indicator due to dilution (condensation and fuel)

CAUTION: If engine oil is sprayed into the

in the engine crankcase. If the vehicle is then driven

combustion chamber, run the engine at 2000rpm

at high speeds on a highway where the condensation

for about 15 minutes (in order to burn the oil and

and fuel boil off, the next time the engine oil is

prevent damage to the catalytic converter) after

checked it may appear that a litre of oil was used in a

carrying out the measurement.

relatively short distance.

If the measurement on one or more cylinders is

Make sure the selected engine oil meets the Ford

significantly lower than the specified value, spray

specification and the recommended API performance

some engine oil into the combustion chamber and

category ’’SJ/CF’’ and SAE viscosity grade as shown

repeat the compression measurement.

in the vehicle’s Owner’s Manual. It is also important

If the reading greatly improves, the piston rings are

that the engine oil is changed at the intervals

damaged.

specified for the typical operating conditions.

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