Ford Falcon. Manual — part 121

303-01a-55

Engine — I6

303-01a-55

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

2. Ensure the cylinder head joint face is free from

Key Retainer — Valve Spring

scratches and nicks in the sealing areas around

the cylinder bore and oil and waterways.

Disassembly

3. Lubricate the valve guides with engine oil.

1. Remove the keys using a valve spring

compressor.

2. Remove the valve spring retainer.
3. Remove the valve spring.
4. Remove the valve stem seal.

4. Fit new seals using an 18 mm inside diameter

drift.

Item

Description

1

Key - Valve spring retainer

2

Valve spring retainer

3

Valve spring

4

Valve stem seal

Assembly
1. To assemble Reverse the disassemble procedure.

NOTE: The LPG intake valve is identified with an

"L" forged into the combustion chamber face.

Valve Stem Seal

Disassembly
1. Remove the seal using a pair of pliers.

Assembly
1. Ensure the cylinder head is clean.

G99849 en

303-01a-56

Engine — I6

303-01a-56

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Piston and Connecting Rod

Piston and Connecting Rod Assembly

Disassembly and Assembly

Assembly

Assembly
1. Use SST 303-D034 to remove and install the

piston from the connecting rod assembly.
NOTE: Do not separate the piston and rod unless

the rod, pin or piston is to be replaced.

Item

Description

1

Compression ring upper

2

Compression ring lower

3

Oil rings

4

Piston

Connecting Rod Bolt

5

Connecting rod

6

Connecting rod bolt

The connecting rod bolts are permanently stretched

each time they are tightened and should only be used

7

Connecting rod cap

once.

8

Connecting rod nut

Replace the connecting rod bolts prior to rebuilding

9

Gudgeon Pin

the engine. The old bolts can be used to establish

bearing clearances. The correct level bolts are

marked WR/AB.

G99850 en

303-01a-57

Engine — I6

303-01a-57

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Item

Description

1

WR/AA marking

2

Straight knurl

3

Diamond knurl

4

Pilot point

G99852 en

303-01b-1

Engine — 5.4L (3V)

303-01b-1

SECTION : 303-01b Engine — 5.4L (3V)

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01b-3

DESCRIPTION AND OPERATION

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-6

DIAGNOSIS AND TESTING

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-8

IN-VEHICLE REPAIRS

Intake Manifold Upper . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-9

Valve Cover LH and RH (shown) . . . . . . . . . . . . . . . . . . . . . ...303-01b-10

Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-13

Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . .303-01b-14

Engine Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01b-15

Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings . . 303-01b-19

Camshaft (LH shown, RH opposite hand) . . . . . . . . . . . . . . . . . . 303-01b-30

Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal . . . . . . . . . ..303-01b-38

Valve Spring and Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . 303-01b-38

Exhaust Manifold (LH shown, RH opposite hand) . . . . . . . . . . . . . . . .303-01b-39

Oil Filter Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01b-40

Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-41

Oil Level Indicator and Tube . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-41

Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01b-42

Oil Pump Screen and Pickup Tube . . . . . . . . . . . . . . . . . . . . . 303-01b-44

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01b-44

Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . ..303-01b-45

Engine Mounts - RH . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01b-46

Engine Mounts - LH . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01b-47

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01b-47

DISASSEMBLY

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01b-56