Ford Falcon. Manual — part 113

303-01a-23

Engine — I6

303-01a-23

GENERAL PROCEDURES (Continued)

3. Measure each piston pin diameter in X and Y

2. Measure the journal diameter in X and Y direction

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

at the two points (A and B) as shown. Replace the

shown.

crankshaft or grind the journal and install the

undersize bearing if necessary.

Standard Diameter

Main Journal

DOHC VCT & LPG

23.157 - 23.162 mm

Bearing Diameter

67.481 - 67.505 mm

4. Calculate the piston pin to piston -pin bore

Out-of-round

0.010 mm

clearance. Replace the piston and/or piston pin if

necessary

Taper

0.008 mm

Crank Pin

Standard Clearance

Bearing Diameter

53.93 - 53.95 mm

DOHC VCT & LPG

0.014 - 0.019 mm

Out-of-round

0.010 mm

5. Connecting rod bush as required.

Taper

0.010 mm (max)

Crankshaft Main Bearing Clearance

Standard Interference

DOHC VCT & LPG

0.013 - 0.030 mm

1. Position a plastigauge on top of the journals in the

axial direction.

Crankshaft Inspection

2. Install the main bearing cap. DO NOT rotate the

crankshaft.

1. Measure the crankshaft runout. Replace the

crankshaft if necessary.

3. Remove the main bearing cap.
4. Measure the main journal clearance. If the

clearance exceeds the maximum, replace the

main bearing or grind the main journal and install

the undersize bearings so that the specified

clearance is obtained.

Standard End Gap

Maximum runout -

0.05 mm

between adjacent

journals
Maximum runout -

0.08 mm

Standard Clearance

0.02 - 0.04 mm

between any journals

Maximum Clearance

0.06mm

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303-01a-24

Engine — I6

303-01a-24

GENERAL PROCEDURES (Continued)

Bearing size

Bearing thickness

Standard

1.996 - 2.000 mm

0.250 mm undersize

2.118 - 2.128 mm

0.508 mm undersize

2.245 - 2.255 mm

1.016 mm undersize

2.499 - 2.509 mm

Crankshaft End Play Inspection/Repair

1. Install the thrust main bearing and cap.
2. Measure the crankshaft end play. Use a dial

indicator with bracketry to measure crankshaft

end play.

3. Position the crankshaft to the rear of the cylinder

block.

Twist

0.20 mm

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

block. Note and record the crankshaft end play.

1. If the crankshaft end play exceeds

specifications, install a new crankshaft thrust

washer or crunkshaft thrust main bearing.

Centre-to-centre

153.78 - 153.92 mm

distance

Connecting Rod Big End Bearing

Clearance

1. Position a plastigauge on top of the journals in the

Standard end play

0.10 - 0.20 mm

axial direction.

Maximum end play

0.30 mm

2. Install the connecting rod cap.

Connecting Rod Inspection

3. Remove the connecting rod cap.

1. Measure each connecting rod for bending and

twist. Replace the connecting rod if necessary.

Bending

0.10 mm

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303-01a-25

Engine — I6

303-01a-25

GENERAL PROCEDURES (Continued)

4. Measure the crankpin clearance. If the clearance

exceeds the maximum, replace the connecting

rod bearing or grind the crankpin and use

undersize bearing so that the specified clearance

is obtained.

Timing Chain Elongation

To establish the percentage elongation of the Timing

chain:
1. Hang the chain vertically over a suitable pin &

hook a weight to the free end.

Standard Clearance

0.02 - 0.04 mm

2. Measure the length (from pin O.D. to pin O.D)

Maximum Clearance

0.06mm

over the maximum number of chain pins possible

using vernier callipers. Note the number of pins

Bearing size

Bearing thickness

measured.

Standard

1.445 - 1.458 mm

3. Repeat the measurement across three separate

0.051 mm undersize

1.471 - 1.483 mm

lengths of the chain and average the results.

0.254 mm undersize

1.572 - 1.585 mm

4. Measure the O.D of one chain pin with verniers.

0.508 mm undersize

1.699 - 1.712 mm

5. Calculate the theoretical chain length =

(measured number of pins - 1) x 8.0 mm pitch +

Connecting Rod Side Clearance

measured pin O.D.

Inspection

6. Compare the actual length measured with the

theoretical length: maximum elongation

1. Install the connecting rod cap.

permissible = 0.35 %.

2. Measure the connecting rod big end side

Alternatively measure the actual length of a new chain

clearance.

(as above) and compare with the original chain and

compare as a percentage of the new chain length.

Standard clearance

0.09 - 0.27 mm

Maximum clearance

0.36 mm

Piston and Connecting Rod Inspection

Check the oscillation torque as shown. If the large end

does not drop by its own weight, replace the piston or

the piston pin.

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303-01a-26

Engine — I6

303-01a-26

IN-VEHICLE REPAIR

3. With the tube reinstalled in the block, ensure the

Oil Filter

O-ring is fully seated in the block counterbore.

Removal
1. Unscrew filter using a filter wrench.
Installation
1. Install as indicated.
2. Lubricate the seal with engine oil prior to

installation.

Cylinder Head Temperature Sensor

Removal and Installation
1. The cylinder head tapped hole is blind.
2. Do not use thread sealant/locker.

Oil Level Indicator & Tube

Removal
1. Remove the Oil Level indicator from the Oil Level

Tube.

2. Unscrew retaining bolt.
3. Remove Oil Level Tube.

Cam Position Sensor

Removal and Installation
1. Check the condition of the O-ring prior to

installation.

2. Lubricate the O-ring with engine oil prior to

installation.

Installation
1. Inspect the O-ring at the base of the tube for

damage and renew if necessary. Lubricate with

engine oil prior to reinstallation of the tube.

2. Insert the Oil Level Tube and secure with

retaining screw.

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