Ford Falcon. Manual — part 119
303-01a-47
Engine — I6
303-01a-47
IN-VEHICLE REPAIR (Continued)
4. Push in plunger slightly so hole in A aligns with
2. Align yellow link at 6 o’clock with its position
hole C and is locked with SST.
indicator. Align orange link at 1 o’clock with the
timing indicator on tone wheel. The orange link
should be half visible within the tone wheel cut
away hole.
Installation
1. Set the crankshaft position to Top Dead Centre:
Cylinder #1 Firing (both VCT phaser timing marks
vertically upwards).
Item
Description
1
Yellow link
2
Yellow link position indicator
3
Timing indent on tone wheel
4
Orange link
3. Remove the SST 303-777 to release the
tensioner.
4. Rotate crankshaft back and forwards to check that
the slack is removed from chain.
5. Reverse removal procedure for camshaft drive
components.
Cylinder Head
Removal
Item
Description
1. Remove the radiator cooling fan assembly.
1
Yellow links
2. Remove
the
radiator.
2
Timing dot on VCT
3. Remove the valve cover. Refer to Valve Cover in
this section.
4. Remove front cover. Refer to Front Cover in this
section.
5. Remove timing chain.
6. Remove camshafts. Refer to Camshaft in this
section.
7. Remove intake manifold. Refer to Throttle Body
and Intake Manifold in this section.
8. Remove exhaust manifold. Refer to Exhaust
Manifold in this section.
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303-01a-48
Engine — I6
303-01a-48
IN-VEHICLE REPAIR (Continued)
9. Disconnect the Cylinder Head Temperature
8. Rotate bolts 90º
± 5º in the sequence shown.
(CHT), and two Camshaft position sensors from
rear of cylinder head.
Engine
10. Loosen the cylinder head bolts in the sequence
Removal
shown.
1. Disconnect Hood struts and securely tie back
Engine Hood, or remove bonnet.
2. Disconnect battery leads and remove battery
cover and battery. Refer to section 414-01.
3. Remove engine accessory drive belt. Refer to
section 303-05.
4. Remove Power steering pump to engine
attachment bolts.
Installation
1. Ensure all joint surfaces are clean and free of oil
and grease.
NOTE: A new cylinder head gasket must be used.
2. Lightly lubricate the bolt threads and washer
surfaces with engine oil.
3. Tighten the cylinder head bolts in the sequence
shown.
Item
Description
4. Rundown all bolts to 30 Nm.
1
Reservoir and Pump
5. Retighten in sequence to 90º.
2
Bolts
6. Back off all bolts by approx. 1 turn each.
3
Bolts
7. Tighten all bolts to 40Nm in sequence.
NOTE: Leave hoses attached and locate pump clear
of engine.
5. Remove Air Cleaner assembly and induction
tubes. Refer to section 303-12.
6. Drain engine coolant at radiator tap.
7. Remove the radiator cooling fan assembly. Refer
to section 303-03a.
8. Remove the radiator assembly. Refer to section
303-03a.
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303-01a-49
Engine — I6
303-01a-49
IN-VEHICLE REPAIR (Continued)
9. Remove air conditioning compressor to engine
13. Disconnect vacuum hoses from intake manifold.
attachment bolts.
14. Disconnect Fuel lines at filter feed pipe under left
NOTE: Leave compressor hoses attached and locate
hand side of firewall.
pump clear of engine.
10. Remove PCM module. Refer to section 303-14.
11. Disconnect the engine loom wiring plugs from the
underside of PCM.
Item
Description
1
Fuel Tube Return
2
Fuel Vapor Hose
3
Fuel Tank to Vapor Hose
Item
Description
4
Rear Brake Lines
1
PCM Module
5
Fuel Tube Return
2
Engine electrical connectors
15. Disconnect Heater hoses from rear of manifold
12. Disconnect transmission wiring plugs. Refer to
section 307-01.
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303-01a-50
Engine — I6
303-01a-50
IN-VEHICLE REPAIR (Continued)
23. Connect suitable engine lifter to the lift brackets
16. Remove Hego sensor electrical connector.
supplied and carefully remove engine assembly.
17. Remove the transmission front dust cover.
Installation
18. Remove the Converter to drive plate bolts (4)
1. For installation of the engine reverse the removal
(Automatic Trans Vehicles Only). Refer to section
procedure.
307-01.
19. Remove starter motor. Refer to section 303-06.
Engine Mounting
20. Remove Transmission to engine bolts (4). Refer
to section 307-01.
1. Mount the engine on an engine rollover stand.
21. Disconnect Exhaust at engine pipe flange to
WARNING: Self-locking brake system of
manifold.
the engine stand may not be effective when
the engine is held in an unbalanced position.
This could lead to sudden, rapid movement of
the engine and mounting stand handle and
cause serious injury. Never keep the engine in
an unbalanced position, and always hold the
rotating handle firmly when turning the
engine.
Engine Oil Pan
Removal
1. Remove the main bearing cross bolts.
NOTE: There are 5 main bearing cross bolts on
the right hand side and 4 on the left hand side of
the oil pan.
22. Remove front engine mount Through bolts.
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