Ford Falcon. Manual - part 1

100-00-1 General 

Information 100-00-1

SECTION : 100-00 General Information

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS  

PAGE

DESCRIPTION AND OPERATION

  About this Manual   .................................................................................................................100-00-3

 Introduction 

 

..........................................................................................................................100-00-3

 Replacement 

Parts 

...............................................................................................................100-00-3

 Special 

Tools 

........................................................................................................................100-00-3

  Important Safety Instructions  ...............................................................................................100-00-3

  Warnings, Cautions and Notes in This Manual  ....................................................................100-00-3

  How to Use This Manual  ......................................................................................................100-00-3

 Samples 

 

...............................................................................................................................100-00-4

  Health and Safety Precautions   .............................................................................................100-00-4

 Introduction 

 

..........................................................................................................................100-00-4

  Acids and Alkalis  ..................................................................................................................100-00-4

 Air 

Bags 

................................................................................................................................100-00-4

  Air Conditioning Refrigerant  .................................................................................................100-00-5

  Adhesives and Sealers  ........................................................................................................100-00-5

 Antifreeze 

 

.............................................................................................................................100-00-6

 Asbestos 

 

..............................................................................................................................100-00-6

 Battery 

Acids 

 

........................................................................................................................100-00-6

  Brake and Clutch Linings and Pads  .....................................................................................100-00-6

  Brakes Fluids (Polyalkylene Glycols)  ...................................................................................100-00-6

 Brazing 

 

.................................................................................................................................100-00-6

 Chemical 

Materials 

...............................................................................................................100-00-6

 Chlorofluorocarbons 

(CFC) 

 

..................................................................................................100-00-7

 Clutch 

Fluids 

 

........................................................................................................................100-00-7

  Clutch Linings and Pads  ......................................................................................................100-00-7

  Corrosion Protection Materials  .............................................................................................100-00-7

 Cutting 

 

..................................................................................................................................100-00-7

 Dewaxing 

 

.............................................................................................................................100-00-7

 Dusts 

 

....................................................................................................................................100-00-7

 Electric 

Shock 

 

......................................................................................................................100-00-7

 Engine 

Oils 

 

...........................................................................................................................100-00-7

 Exhaust 

Fumes 

 

....................................................................................................................100-00-8

 Fibre 

Insulation 

.....................................................................................................................100-00-8

 Fire 

 

.......................................................................................................................................100-00-8

 First 

Aid 

 

................................................................................................................................100-00-8

 Fluoroelastomer 

 

...................................................................................................................100-00-8

  Foams - Polyurethane  ..........................................................................................................100-00-8

 Freon 

 

....................................................................................................................................100-00-8

 Fuels 

 

....................................................................................................................................100-00-8

 Gas 

Cylinders 

.......................................................................................................................100-00-9

 Gases 

 

...................................................................................................................................100-00-9

 Gaskets 

(Fluoroelastomer) 

...................................................................................................100-00-9

  General Workshop Tools and Equipment  ............................................................................100-00-9

  High Pressure Air, Lubrication and Oil Test Equipment  ....................................................100-00-10

 Halon 

 

..................................................................................................................................100-00-10

 Legal 

Aspects 

.....................................................................................................................100-00-10

  Lubricants and Greases  .....................................................................................................100-00-10

 Noise 

 

..................................................................................................................................100-00-10

  Noise Insulation Materials  ..................................................................................................100-00-10

100-00-2 General 

Information 100-00-2

(Continued)

 O-Rings 

(Fluoroelastomer) 

 

.................................................................................................100-00-10

 Paints 

 

.................................................................................................................................100-00-10

 Pressurized 

Equipment 

 

......................................................................................................100-00-11

 Solder 

 

.................................................................................................................................100-00-11

 Solvents 

 

.............................................................................................................................100-00-11

 Sound 

Insulation 

 

................................................................................................................100-00-11

 Suspended 

Loads 

 

..............................................................................................................100-00-11

  Transmission Brake Bands  ................................................................................................100-00-11

  Underseal  ...........................................................................................................................100-00-11

 Viton 

 

...................................................................................................................................100-00-11

 Welding 

 

..............................................................................................................................100-00-12

  Warning Symbols on Vehicles  ...........................................................................................100-00-12

 White 

Spirit 

 

.........................................................................................................................100-00-13

  Standard Workshop Practices   ............................................................................................100-00-13

  Vehicle in Workshop  ..........................................................................................................100-00-13

 Alternative 

Fuel 

 

..................................................................................................................100-00-14

  Alternative Fuel — Do’s  .....................................................................................................100-00-14

  Alternative Fuel — Do Nots  ...............................................................................................100-00-14

  Towing the Vehicle  .............................................................................................................100-00-14

  Connecting a Slave Battery Using Jumper Cables  ............................................................100-00-14

 Component 

Cleaning 

 

.........................................................................................................100-00-15

  Calibration of Essential Measuring Equipment  ..................................................................100-00-15

  Solvents, Sealers and Adhesives   .......................................................................................100-00-15

 Introduction 

 

........................................................................................................................100-00-15

 General 

Specifications 

 

.......................................................................................................100-00-16

  Road/Roller Testing   ............................................................................................................100-00-16

 Pre-Test 

Checks 

 

................................................................................................................100-00-16

  Starting the Engine  ............................................................................................................100-00-16

  On Road or Roller Test Check:  ..........................................................................................100-00-17

 Brake 

Testing 

 

.....................................................................................................................100-00-17

100-00-3 General 

Information 100-00-3

DESCRIPTION AND OPERATION

NOTE: Notes are used to provide additional essential

About this Manual

information required to carry out a complete and

satisfactory repair.

Introduction

As you read through this manual, you will come

This manual has been written in a format that is

across WARNINGS, CAUTIONS and NOTES.

designed to meet the needs of Ford technicians

worldwide. The objective is to use common formats

A warning, caution or note is placed at the beginning

and include similar content in each manual worldwide. of a series of steps if it applies to multiple steps. If the

warning, caution or note only applies to one step, it is

This manual provides general descriptions for

placed at the beginning of the specific step (after the

accomplishing service and repair work with tested,

step number).

effective techniques. Following them will help assure

reliability.

How to Use This Manual

Replacement Parts

This manual covers service and repair procedures.

Ford and Motorcraft parts are made to the same

This manual is structured into groups and sections,

exacting standards as the original factory fitted

with specific system sections collected together under

components. For this reason, it is recommended that

their relevant group.

only genuine Ford or Motorcraft parts are installed

A group covers a specific portion of the vehicle. The

during service or repair.

manual is divided into five groups, General

Information, Chassis, Powertrain, Electrical and Body

Special Tools

and Paint. The number of the group is the first

The Special Tool(s) Table provided at the beginning

number of a section number.

of each procedure shows all special tools required to

Pages at the start of the manual list all sections

carry out a repair. Where possible, illustrations are

available. Each section has a contents list detailing

provided to assist in identifying the special tool

General Specifications, Description and Operation

required.

and Service Adjustment and Checks.

Special tools may be ordered from:

If components need to be removed or disassembled

in sequence, the sequence will be identified

Australia

numerically in a graphic and the corresponding text

SPX AUSTRALIA

will be numbered accordingly (refer to ‘Samples’).

Tel: +61 (03) 9544 6222

All left and right-hand references to the vehicle are

Fax: +61 (03) 9544 5222

taken from a position sitting in the driver seat looking

forward.

Important Safety Instructions

All left and right-hand references to the engine are

taken from a position at the flywheel looking towards

Appropriate service methods and correct repair

the front camshaft pulley.

procedures are essential for the safe, reliable

Where appropriate, instructions will be given for the

operation of all motor vehicles as well as the personal

use of WDS, diagnostic equipment.

safety of the individual carrying out the work.

Inspection and Verification

This manual cannot possibly anticipate all such

variations and provide advice or cautions as to each.

Visual Inspection Charts, Symptom Charts and other

Anyone who departs from the instructions provided in information charts (such as diagnostic routines),

this manual must first establish that he compromises

supplement test procedures with technical

neither his personal safety nor the vehicle integrity by specifications, or navigate the user to a specific test

his choice of methods, tools or parts.

procedure.
Sympton Chart

Warnings, Cautions and Notes in This

The symptom chart indicates symptoms, sources and

Manual

actions to address a condition.
Pinpoint Tests

 WARNING: Warnings are used to indicate

that failure to follow a procedure correctly may

For electrical systems, pinpoint test steps are used to

result in personal injury.

identify the source of a concern in a logical,

step-by-step manner. Pinpoint tests have two

columns: CONDITIONS and

 CAUTION: Cautions are used to indicate that

DETAILS/RESULTS/ACTIONS.

failure to follow a procedure correctly may result

in damage to the vehicle or equipment being

The CONDITIONS column is used exclusively for

used.

graphics and icons (with or without captions) and the

DETAILS/RESULTS/ACTIONS column provides

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100-00-4 General 

Information 100-00-4

DESCRIPTION AND OPERATION (Continued)

direction to another test step or specific corrective

Before using any product the Materials Safety Data

actions.

Sheet supplied by the manufacturer or supplier should

be consulted.

The boxed numbers indicate the order in which the

described action is to be performed.

Acids and Alkalis

Component Tests

See also Battery Acids.

A component test is used when a component is tested

For example caustic soda, sulphuric acid.

in multiple pinpoint tests, or if a procedure is too

complicated to be formatted within a single page of

Used in batteries and cleaning materials.

the pinpoint test.

Irritant and corrosive to the skin, eyes, nose and

Graphics

throat. Cause burns. Can destroy ordinary protective

clothing.

Test graphics show the measurement or test to be

performed in a test step.

Avoid splashes to the skin, eyes and clothing. Wear

suitable protective impervious apron, gloves and

A representative tester graphic is used for voltmeters

goggles. Do not breath mists.

and ohmmeters.

Make sure access to eye wash bottles, shower and

If multiple measurements are made in a single

soap are readily available for splashing accidents.

graphic, the test leads are drawn with a solid line until

the test lead splits to indicate the multiple

Display Eye Hazard sign.

measurements, at which point dashed lines are used.

Air Bags

Breakout box-type testers are represented by a

double circle test pin. Test pins are labelled with the

See also Fire, Chemical Materials

pin number.

Highly flammable, explosive – observe No Smoking

policy.

Samples

Used as a safety restraint system mounted in the

Special Tools and Torque Figures

steering wheel and passenger side of the instrument

Any requirement for special tools will picture the tool,

panel and side impact Airbags.

showing it in use and with its tool number shown.

The inflator contains a high-energetic propellant

Torque settings will be given at the relevant point in

which, when ignited, produces a VERY HOT GAS

the procedure.

(2500

°C).

The gas generant used in air bags is Sodium Azide.

This material is hermetically sealed in the module and

is completely consumed during deployment. No

attempt should be made to open an air bag inflator as

this will lead to the risk of exposure to Sodium Azide.

If a gas generator is ruptured, full protective clothing

should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles

should be worn during the handling process.
Deployed air bags should be disposed of in a plastic

bag in accordance with local regulations at an

approved chemical waste site.
Following any direct contact with gas generant.

wash affected areas thoroughly with water.

Health and Safety Precautions

seek medical assistance if necessary.

Air Bags - Do’s

Introduction

do store modules in an upright position.

Many of the procedures associated with vehicle

do keep modules dry.

maintenance and repair involve physical hazards or

do carry modules with the cover side pointing

other risks to health. This subsection lists,

away from the body.

alphabetically, some of these hazardous operations

and the materials and equipment associated with

do place modules with their cover side upwards.

them. Precautions necessary to avoid these hazards

do carefully inspect modules for damage.

are identified.

do stand to one side when connecting modules.

The list is not exhaustive and all operations and

do make sure all test equipment is properly

procedures, and the handling of materials, should be

calibrated and maintained.

carried out with health and safety in mind.

do wash hands after handling deployed air bags.

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