Ford Falcon. Manual — part 117

303-01a-39

Engine — I6

303-01a-39

IN-VEHICLE REPAIR (Continued)

6. Do not use the chain to prevent rotation when

7. Whilst holding the VCT phaser and timing chain,

loosening the central bolt as this load will be

slide the VCT phaser forward off the camshafts

transmitted through the locked phaser mechanism

and rest on top of the timing cover.

and could cause damage.

NOTE: Do not remove the timing chain from the

VCT phasers.

8. Remove

the

tool.

9. Loosen the camshaft cap bolts 2 turns at a time in

the order shown below.

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303-01a-40

Engine — I6

303-01a-40

IN-VEHICLE REPAIR (Continued)

10. Remove camshaft caps.

3. Fit the respective Intake and Exhaust camshafts

with the timing pin positioned vertically upwards.

11. Remove inlet & exhaust camshaft.

Take care not to damage the thrust surfaces on

journal #2.

Camshaft Installation

Installation
1. Check the camshaft journal clearance.
2. Lubricate the head-cam bearing surfaces with

engine oil.

4. Check for burrs and damage on the cap-to-head

joints and the cam-to-VCT phaser joint. Tighten

bolts 2 turns at a time in the same order shown in

the removal section.
NOTE: The cam-cap oil passage must be

absolutely clean.

NOTE: Use the following illustration to identify the

5. Rotate the crankshaft so the VCT timing marks

Exhaust and Inlet camshafts.

(on the sprocket) are vertically upwards and the

crankshaft at Top Dead Centre.

6. Align the marked the two timing chain links with

the VCT timing marks sprocket.
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).

Item

Description

1

Exhaust

2

Inlet

NOTE: If a camshaft timing error is suspected, and it

is necessary to check the basic cam timing using the

valve lift loss method, then the cams must be fully

advanced and both VCT Phaser locking pins

engaged.

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303-01a-41

Engine — I6

303-01a-41

IN-VEHICLE REPAIR (Continued)

7. Check that the cams are fully advanced and the

1. Release the timing chain tension by compressing

locking pins engaged by gripping each camshaft

the tensioner. Refer this section.

between the journals numbers 4 & 5 with a

suitable wrench using soft protective pads, and

attempt to rotate the camshaft backwards and

forwards relative to the VCT Phaser.

8. Establish the point of maximum lift on a No. 1

cylinder intake cam lobe by determining the

positions where the lift is reduced by 0.25 mm

either side of maximum lift. Note the crankshaft

angles while rotating the crankshaft in a clockwise

direction only.

9. Average the two crankshaft angles to give the

point of maximum lift.

10. Repeat this procedure for the No.1 cylinder

exhaust cam lobe.

11. Check the piston TDC in a similar way by fitting

VCT Phaser

an adaptor in the spark plug hole in cylinder No. 1

with an adjustable length pin protruding into the

Special Tool(s)

cylinder so that it just prevents the piston from

reaching TDC. Lock the adjustment using a

Camshaft holding tool

suitable locknut.

303-778

12. Rotate the engine clockwise until the piston

touches the pin and noting the crankshaft angle,

and then rotating it anti-clockwise, and again note

the angle.

13. Average the two crankshaft angles to give TDC,

and compare it to the timing mark on the

Removal

Crankshaft Vibration Damper to ensure that the

1. Remove valve cover. Refer to Valve Cover in this

Damper outside element has not rotated. If there

section.

is a significant discrepancy, replace the Damper.

Refer to Crankshaft Vibration Damper in this

2. Fit the SST 303-778 to the camshafts in the

section.

central position between caps and tighten to

prevent rotation.

Standard Intake Cam

Maximum lift @ 97.5

°

Timing

ATDC

Standard Exhaust Cam

Maximum lift @ 126.5

°

Timing

BTDC

Timing Chain Tensioner

Special Tool(s)

Timing chain tensioner special

service tool

303-777

3. Loosen the bolt attaching the VCT units to the

camshafts.

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303-01a-42

Engine — I6

303-01a-42

IN-VEHICLE REPAIR (Continued)

4. Do not use the chain to prevent rotation when

3. The filters and cam cap oil passages must be

loosening the central bolt as this load will be

absolutely clean.

transmitted through the locked phaser mechanism

and could cause damage.

Rocker Arm, Lash Adjuster, Valve

5. Whilst holding the VCT phaser and timing chain,

Spring and Valve Stem Seal

slide the VCT phaser forward off the camshafts

and rest on top of the timing cover.

1. Disassemble in the order indicated in the table.

NOTE: Do not remove the timing chain from the

VCT phasers.

6. Remove

the

tool.

Installation
1. To install, reverse the removal procedure.
2. The oil control valves & cam cap bores must be

absolutely clean.

Item

Description

1

Cam follower

2

Lash adjuster retaining clip

3

Lash adjuster

4

Valve spring retainers

5

Valve spring retainer keys

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