Ford Falcon. Manual — part 108

303-01a-3 Engine

—

I6 303-01a-3

SPECIFICATIONS

Lubricants and Sealants

Description

Specification

Description

Specification

Intake Manifold Vacuum

@ Idle rpm

Engine Oil 10W-30

WSS M2C910 2 (I6

ILSAC - GF2

DOHC VCT)

DOHC VCT 60 kPa @ Idle in Neutral

Engine Oil 15W-40 API

WSE M2C905 A (I6 LPG)

LPG 60 kPa @ Idle in Neutral

SG/CE

Cylinder Head/Valve Train

Silicone Sealant (Loctite

WSS M4G323 A7

Combustion Chamber

65.5 - 66.5cc

5900 or similar)

Volume

Anti Seize compound

ESE FM99C100 A

Joint face flatness

0.08mm in 150mm or

(Loctite 767 or similar)

0.18mm overall

Rubber Grease

ESZ M1C223 A

Cylinder head joint face

2.5 RZ (Din) @2.5

Synthetic Grease

ESF M1C229 A

surface finish

cut-off, Wt <10.0, Mr 68%

(Dupont Krytox)

min @ 2.0 um

Minimum Cylinder head

Std - 0.3 mm

General Specifications

deck height

Description

Specification

Valve seat width- Intake

1.0mm - 1.4mm

Displacement

3984cc

Valve seat width-Exhaust 1.25mm - 1.75mm

Number of cylinders

In line 6

Valve seat angle

44.75º

Compression Ratio

Valve seat runout

0.04mm

DOHC VCT 9.7:1

Valve stem to guide

0.020mm - 0.069mm

LPG 10.7:1

clearance

Power at specified

Valve guide parent bore

9.975mm - 10.025mm

rpm(DIN)

diameter

DOHC VCT 182 kW @ 5000

Valve guide outside

10.028mm - 10.039mm

LPG 156 kW @ 4750

diameter

Torque at specified rpm

Valve guide inside

6.015mm - 6.044mm

(DIN)

diameter

DOHC VCT 380 Nm @ 3250

Valve head diameter-

35mm

intake

LPG 372 Nm @ 3000

Valve head diameter -

32mm

Bore/Stroke

92.26mm / 99.31mm

exhaust

Firing Order

1-5-3-6-2-4

Gauge Diameters

Oil Pressure - Hot @

230kPa min

Valve face runout

0.05mm

2000 rpm

Valve face angle

45.5º

Spark Plug - I6

Valve stem diameter (In

5.975mm - 5.995mm

DOHC VCT K16SR14

& Ex)

LPG K20SR11

Valve seat insert recess

35.07mm - 35.12mm

Compression Pressure at

diameter (In)

Maximum cranking speed

Valve seat insert recess

32.37mm - 32.42mm

DOHC VCT 1010 Kpa

diameter (Ex)

LPG 1110 Kpa

Valve seat insert outer

35.192mm - 35.208mm

Idle Speed

diameter (In)

Manual Trans (A/C off)

Valve seat insert outer

32.492mm - 32.508 mm

DOHC VCT 700

± 50 rpm

diameter (Ex)

LPG 700

± 50 rpm

Valve spring free length

50.0 mm

Auto trans in Neutral

Valve spring installed

280N / 37.8 mm

load/length

DOHC VCT 660

± 50 rpm

Valve spring compressed 550N / 26.8mm

LPG 700

± 50 rpm

load/length

Auto Trans in Drive

Valve spring allowable

50N @ 26.8mm

DOHC VCT 580

± 50 rpm

load loss

LPG 700

± 50 rpm

G99770 en

303-01a-4 Engine

—

I6 303-01a-4

SPECIFICATIONS (Continued)

Description

Specification

Description

Specification

Valve spring - out of

2º

Taper service limit

0.25mm

square

Crankshaft

Rocker arm ratio

2.04

Main bearing journal

67.481mm - 67.505mm

Hydraulic Lash Adjuster

13.972mm - 13.984mm

diameter

diameter

Connecting rod journal

53.93mm - 53.95mm

Lash adjuster bore in

13.990mm - 14.007mm

diameter

cylinder head

Crankshaft free end play 0.10mm - 0.20mm

Collapsed Lash adjuster

0.5mm - 1.1mm (desired)

Service Limit 0.30mm

clearance at cam

Connecting rod bearings- 0.02mm - 0.04mm

Camshaft

clearance to crankshaft-

Lobe lift (In & Ex)

5.39mm

desired

Valve lift(In & Ex)

11.00mm

Connecting rod bearings- 0.06mm

clearance to crankshaft-

Camshaft end play

0.1mm - 0.3mm

service limit

Camshaft journal

34.928mm - 34.968mm -

Main bearings- clearance 0.02mm - 0.04mm

diameter

Front

to crankshaft-desired

29.928mm - 29.968mm -

Remainder

Main bearings- clearance 0.06mm

to crankshaft- service

Camshaft Journal max

0.015mm

limit

out of round

Connecting Rod

Cylinder head bearing

34.987mm - 35.012mm -

diameter

Front

Small end bore diameter

29.987mm - 30.012mm -

DOHC VCT & LPG 23.132mm - 23.144mm

Remainder

Big end bore diameter

56.871mm - 56.891mm

Journal to bearing

0.019mm - 0.084mm

Length (centre to centre) 153.78mm - 153.92mm

clearance

Alignment ( bore to bore- 0.20mm

Service Limit

0.120mm

max difference)Twist

Valve Timing

Engine Stopped, VCT

Bend

0.10mm

Phasers Fully Advanced

Side clearance

0.09mm - 0.27mm

& VCT Locking Pins

(assembled to crank)

Engaged

Standard

Intake Opens

27.5º BTDC

Side clearanceService

0.36mm

Intake Closes

43.5º ABDC

limit

Exhaust Opens

68.5º BBDC

Piston

Exhaust Closes

2.5º BTDC

Piston diameter

92.24mm - 92.31mm

Intake Cam Centre-line

97.5º ATDC

Piston to bore clearance

0.020mm interference to

(Maximum Lift)

(new)

0.030mm clearance

Exhaust Cam Centre-line 126.5º BTDC

Piston to bore clearance- 0.09mm

(Maximum Lift)

service limit

Timing Chain Maximum

0.35 %

Intake Manifold Vacuum

Elongation

@ Idle rpm

Cylinder Block

DOHC VCT 60 kPa @ Idle in Neutral

Head gasket thickness

0.25mm at body, 0.3mm

LPG 60 kPa @ Idle in Neutral

at cylinder bore

Pin bore diameter

Main bearing bore

71.517mm - 71.541mm

(piston)

diameter

DOHC, VCT & LPG 23.173mm - 23.178mm

Cylinder bore diameter

92.25mm - 92.31mm Std

Ring groove width - Top

1.22mm - 1.24mm

92.75mm - 92.77 0.5mm

Compression

O/S

93.25mm - 93.27 1.0mm

Ring groove width -

1.52mm - 1.54mm

O/S

Lower Compression

Out of round limit

0.025mm

Ring groove width - Oil

3.01mm - 3.03mm

Ring

Out of round service limit 0.125mm

G99770 en

303-01a-5 Engine

—

I6 303-01a-5

SPECIFICATIONS (Continued)

Description

Specification

Description

Nm

Piston pin length

64.50mm - 65.00mm

Oil Pan Rear Face

Flush or

0.25mm

Piston pin diameter

forward of

DOHC VCT, LPG 23.157mm - 23.162mm

rear face of

Pin to piston clearance

block

DOHC VCT & LPG 0.014mm - 0.019mm

Oil Pan Drain Plug

26

Ring groove clearance-

0.03mm - 0.075mm

Intake manifold- Upper to Lower

16

Top Compression New

(Apply

thread

Ring groove clearance-

0.15mm

locker)

Top Compression

Service limit

Intake Manifold- Lower to Cylinder

20

head

(Apply

Ring groove clearance-

0.03mm - 0.075mm

thread

2nd Ring New

locker)

Ring groove clearance -

0.15mm

Intake Manifold Strut (Upper)

2nd Ring Service limit

To Upper Manifold

16

Oil ring groove clearance Nil

(Delete

- new

thread lock)

Oil ring groove clearance 0.20mm

To Cylinder Head

16

- service limit

Intake Manifold Strut (Lower)

Installed piston ring gap - 0.21mm - 0.36mm

Top Compression - New

To Lower Manifold

20

(Apply

Installed piston ring gap - 0.45mm

thread

Top Compression-

locker)

Service limit

To Cylinder Block

20

Installed piston ring gap-

0.35mm - 0.51mm

2nd Ring - New

To Engine Mt. Support

50

Installed piston ring

0.60mm

Fuel Rail to Intake Manifold

20

gap-2nd Ring - service

Intake Manifold Butterfly Shaft Actuator

20

limit

Assembly

Oil ring (rail) gap- new

0.3mm - 0.9mm

Intake Manifold Vacuum Connectors

4

Oil ring (rail) gap-service

1.0mm

(Apply

limit

thread

sealant)

Lubrication system

Intake Manifold Pressure/Temperature

3

Oil capacity - Initial Fill

7.0L

Sensor

(Dry engine)

Electronic Throttle Body to Upper

10

Oil Change without Filter 5.8L

Intake Manifold

(Apply

Oil Change with Filter 6.8L

thread

Torque Specifications

locker)

Oil threads with engine oil. Do not oil threads that

Exhaust Manifold to Cylinder Head

27

require thread sealant or thread locker.

Exhaust Manifold Heat Shield - Lower

20

Description

Nm

Exhaust Manifold Slip Joint

Main Bearing Cap bolts

85

Stud

15

Cylinder Head Bolts

Step 1: 40

Nut

23

Nm

Flywheel/Flex Plate to Crankshaft

75

Step 2:

Clutch Pressure Plate to Flywheel

25

Rotate 90º

clockwise

Manual Flywheel Housing to Block

50

Oil Pan to Cylinder block/front cover

9

Oil Pump to Cylinder Block

10

Oil Pan to main bearing cross bolts

58

Oil Pump Pickup Tube to Oil Pump

10

(Apply

Oil Pump Pickup Tube to Main Bearing

20

thread

Bolt

sealant)

Oil Filter Adaptor to Cylinder Block

17

G99770 en

303-01a-6 Engine

—

I6 303-01a-6

SPECIFICATIONS (Continued)

Description

Nm

Description

Nm

Oil Filter to Cylinder block

With oiled

Cam Cover to Cylinder Head - Six

10

gasket,

short bolts

(Apply

hand

thread

tighten until

locker)

gasket

Oil Control Valve Seals to Cam Cover

7

contacts

Cam Caps to Cylinder Head

10

block face,

VCT Oil Control Valves to Cam Caps

9

tighten a

further ¾

Camshaft position sensor to cylinder

9

turn

head

Oil Pressure Sensor

20

Cylinder Head Temperature sensor to

15

(Apply

Cylinder Head

thread

Timing Chain Fixed Chain Guide to

20

sealant)

Cylinder Block and Cylinder Head

Oil Temperature Sensor

20

Timing Chain Tensioner to Cylinder

9

(Apply

Head

thread

Timing Chain Guide Pivot Bolt to Oil

27

sealant)

Pump

Knock Sensor to Cylinder Block

20

Timing Chain Guide Pivot Nut

9

(Apply

Crankshaft Vibration Damper/Front

125

thread

Pulley to Crankshaft

locker)

Connecting Rod Cap to Connecting

Step 1: 25

Timing Cover to Cylinder Block

20

rod

Nm

Crankshaft Position Sensor to Timing

9

Step 2: 90º

Cover

clockwise.

Thermostat Housing to Cylinder Head

20

(Apply

thread

locker)

Water Outlet to Thermostat Housing

20

Heater Tube to Thermostat Housing

20

Heater Tube to Block (Exhaust side)

27

Water Pump to Cylinder Block

20

Engine Mount Bracket to Cylinder

50

Block

(Apply

thread

locker)

Engine Mount to Engine Mount Bracket

102

Power Steering Brackets to Cyl. Head

43

and Cylinder Block
Alternator Bracket(rear) to Cylinder

25

Block
Spark Plugs

17

Variable Cam Timing Unit to Camshaft

Step 1: 20

Nm

Step 2:

Rotate 40º

clockwise

Spark Plug Cover to Rocker Cover

8

Brake Hose Clip to Spark Plug Cover

3

Cam Cover to Cylinder Head - Front

13

two long bolts

G99770 en