Ford Falcon. Manual — part 164

303-01c-77

Engine — V8 (4V)

303-01c-77

ASSEMBLY (Continued)

22. Install the LH and the RH cylinder heads. Loosely 24. Install the LH and RH exhaust manifold gaskets

install the new bolts.

and the exhaust manifold.

Tighten the nuts in the sequence shown.

25. Compress the tensioner plunger, using the edge

of a soft-jawed vise.

CAUTION: Timing chain procedures must

be followed exactly or damage to the pistons

or valves can result.

23. Tighten the LH and RH bolts in three stages, in

the sequence shown.

Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
Stage 3: Tighten an additional 90 degrees.

26. Install a paper clip into the hose in the tensioner

housing to hold the ratchet assembly.

Remove the tensioner from the vise.

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303-01c-78

Engine — V8 (4V)

303-01c-78

ASSEMBLY (Continued)

27. If the copper links are not visible, mark two links

29. Rotate the LH camshaft sprocket until the timing

on one end and one link on the other end, and

mark is approximately at the 12 o’clock position.

use as timing marks.

Rotate the RH camshaft timing sprocket until the

timing mark is approximately in the 11 o’clock

NOTE: There are 61 links in the timing chain.

position.

28. Install the timing chain guides.

30. Install the special tools on the LH and RH cylinder

heads.
NOTE: LH shown, RH similar.

31. Using the special tool, position the crankshaft.

32. Remove the special tool.

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303-01c-79

Engine — V8 (4V)

303-01c-79

ASSEMBLY (Continued)

33. Install the crankshaft sprocket with the timing

36. Remove the paper clip.

mark facing outward.

37. Verify the camshaft and crankshaft sprocket to

34. Install the LH and RH timing chains onto the

copper link alignment.

crankshaft and camshaft sprockets.

Align the two copper (marked) links with the

timing mark on the camshaft sprocket.
Align the one copper-colored link with the

timing mark on the crankshaft sprocket.

38. Remove the special tools from the LH and RH

cylinder heads.
NOTE: LH shown, RH similar.

35. Position the tensioner arms and tensioners, and

install the bolts.
NOTE: LH shown, RH similar.

39. Position the piston at the bottom of the stroke and

camshaft lobes at the base circle.

40. Repeat the previous steps to install all roller

followers.

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303-01c-80

Engine — V8 (4V)

303-01c-80

ASSEMBLY (Continued)

41. Position the crankshaft sensor ring on the

crankshaft.

42. Apply silicone gasket sealant in the locations

shown.

Item

Description

1

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

43. Position the engine front cover and install the

2

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

bolts and the studs in three stages:

50

Stage 1: Tighten numbers one through five to 25

3

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

Nm (18 lb-ft).

50

Stage 2: Tighten numbers six and seven to 50

Nm (37 lb-ft).

4

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

Stage 3: Tighten numbers 11 through 15 to 25

50

Nm (18 lb-ft).

5

Bolt, Hex Flange Head Pilot, M8 x 1.25 x

50

6

Stud, Hex-Head Pilot, M10 x 1.5 x 30

7

Stud, Hex-Head Pilot, M10 x 1.5 x 30

8

Bolt, Hex-Head Flange, M8 x 1.25 x 50

9

Bolt, Hex-Head Flange, M8 x 1.25 x 50

10

Bolt, Hex-Head Flange, M8 x 1.25 x 50

11

Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 -

M8 x 1.25 x 27

12

Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 -

M8 x 1.25 x 27

13

Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65

14

Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 -

M8 x 1.25 x 27

15

Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65

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