Ford Falcon. Manual — part 112

303-01a-19

Engine — I6

303-01a-19

GENERAL PROCEDURES (Continued)

2. Measure the out-of-square of the valve spring.

Camshaft Inspection

Replace the valve spring if necessary.

1. Set the No.1 and No.7 journals on V-blocks.

Measure the camshaft runout. Replace the

camshaft if necessary.

Maximum valve spring

1.75mm

out-of-square

Maximum runout

0.1mm

Camshaft End Play Inspection

2. Check the cam lobe for cracks and pitting. Minor

1. Remove the roller followers. Refer to section

indentations are acceptable. Replace if

303-00 for procedure.

necessary.

2. Use a Dial Indicator with Bracketry to measure

camshaft end play.

3. Position the camshaft to the rear of the cylinder

head.

4. Zero the indicator.
5. Move the camshaft to the front of the cylinder

head. Note and record the camshaft end play.

1. If camshaft end play exceeds specifications,

install new camshaft and recheck end play.

2. If camshaft end play exceeds specification

after camshaft installation, install a new

cylinder head.

Standard end play

0.1 - 0.3 mm

3. Measure the journal diameter in 2 directions.

Maximum end play

0.4 mm

Replace the camshaft if necessary.

Standard diameter

Journal 1

34.928 - 34.968 mm

Journal 2 - 7

29.928 - 29.968 mm

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303-01a-20

Engine — I6

303-01a-20

GENERAL PROCEDURES (Continued)

Minimum diameter

Lash Adjuster Bore Inspection

Journal 1

34.900 mm

1. Measure the diameter of each lash adjuster bore

Journal 2 - 7

29.900 mm

Camshaft Journal Clearance -

Plastigauge Method

1. Remove the camshaft bearing cap and lay the

plastigauge across the surface.

2. Reinstall the camshaft bearing cap - DO NOT

rotate the camshaft.

3. Remove the camshaft bearing cap and measure

the width of the plastigauge with the scale

provided to determine the clearance. Replace the

components as required if necessary.

Standard diameter

13.990 - 14.007 mm

2. Measure the diameter of each lash adjuster.

Standard diameter

13.972 - 13.984 mm

3. Calculate the clearance between the lash adjuster

and the related lash adjuster bore. Replace the

lash adjuster or cylinder head if necessary.

Standard clearance

0.019 - 0.084 mm

Maximum clearance

0.100 mm

Roller Follower Inspection

1. Inspect the roller for flat spots or scoring.
2. Check the ball socket and valve pad for scuffing

and wear.

Standard clearance

0.006 - 0.035 mm

Maximum clearance

0.050 mm

Cylinder Block Inspection/Repair

Measure the distortion of the cylinder block top

surface in the two directions as shown. Repair by

grinding or replace if necessary.

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303-01a-21

Engine — I6

303-01a-21

GENERAL PROCEDURES (Continued)

Maximum cylinder block distortion

Service limit

0.125 mm

Direction A

0.15 mm

Cylinder bore - Reboring sizes

Direction B

0.05 mm

Size

Diameter (mm)

Maximum grinding

0.20 mm

Standard

92.25 - 92.31

Minimum Piston-Deck

0.50 mm

0.5 oversize

92.75 - 92.77

Maximum Surface

13.5

1.0 oversize

93.25 - 93.27

finish Rz

Piston Inspection

Cylinder Bore - Taper

Measure the outer diameter of each piston at a right

Measure the cylinder bore at the top and bottom.

angle (90º) to the piston pin, 45mm below the crown.

Verify the cylinder bore is within the wear limit. The

difference indicates the cylinder bore taper. Bore the

cylinder to the next oversize.

Piston Clearance Inspection/ Repair

1. Calculate the piston-to-cylinder clearance.

Replace the piston or rebore the cylinders to fit

Service limit

0.25 mm

oversize piston if necessary.

Cylinder Bore — Out-of-Round

Standard Clearance

0.020 mm interference to

Measure the cylinder bore in two directions. The

0.030 mm clearance

difference is the out-of-round. Verify the out-of-round

is within the wear limit and bore the cylinder to the

Service Limit

0.09 mm clearance

next oversize limit.

2. If the piston is replaced, the piston rings must also

be replaced.

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303-01a-22

Engine — I6

303-01a-22

GENERAL PROCEDURES (Continued)

Oil

1.0 mm

Piston Ring Clearance Inspection

1. Measure the piston ring-to-ring land clearance

Piston Pin Clearance Inspection

around the entire circumference. Replace the

1. Measure each piston pin hole diameter in X and Y

piston ring if necessary.

directions at the four points (A, B, C, and D) as

shown.

Standard Clearance

Top

0.03 - 0.075 mm

Standard Diameter

Second

0.03 - 0.075 mm

DOHC VCT & LPG

23.173 - 23.178 mm

Oil

Zero

2. Measure each connecting rod small end inner

Service Limit

diameter in X and Y directions as shown.

Top

0.15 mm

Second

0.15 mm

Oil

0.20 mm

2. Insert the piston ring into the cylinder by hand and

use the piston to push it to the bottom of the ring

travel.

3. Measure each piston ring end gap using a feeler

gauge. Replace the piston ring if necessary.

Standard Diameter

DOHC VCT & LPG

23.132 - 23.144 mm

Standard End Gap

Top

0.21 - 0.36 mm

Second

0.35 - 0.51 mm

Oil

0.30 - 0.90 mm

Maximum End Gap

Top

0.45 mm

Second

0.60 mm

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