Ford Falcon. Manual - part 172

 

  Index      Ford     Ford Falcon - service repair manual 2002-2005 year

 

Search            

 

 

 

 

 

 

 

  

 

Content   ..  170  171  172  173   ..

 

 

Ford Falcon. Manual - part 172

 

 

303-03-15 Engine 

Cooling 303-03-15

REMOVAL AND INSTALLATION (Continued)

9.  Remove the screws securing the fan shroud and

8 Cylinder

fans to the top of the radiator, lift the shroud from

the clips on the bottom of the radiator and lay it

back.

Item

Description

1

Hose assy. to bleed

10. Remove the radiator upper mounting brackets

2

Hose assy. Upper

and carefully lift the radiator from the vehicle.

3

Hose assy. Radiator overflow

Installation

3.  On vehicles equipped with automatic transmission

1.  Locate the radiator in the vehicle and install the

disconnect the oil cooler lines at the radiator by

upper support brackets.

unscrewing the AF 17mm fittings and plug to

2.  Locate the fan shroud in the brackets on the

guard against contamination entry.

bottom of the radiator and install the two securing

4.  Remove the air cleaner intake duct.

screws at the top of the shroud.

5. Remove 

the 

grille.

3.  Connect the upper and lower hoses and the

6.  XR6 Turbo vehicles: remove intercooler (see

coolant supply hose. Connect the bleed hose to

303-04b for procedure).

the radiator.

7.  Remove the 4 bolts holding the A/C condenser

4.  Connect the electrical connections to the fans.

and wire or cable tie the condenser to the top

5.  Remove the support cable tie/wire from the top

crossmember.

condensor and install the 4 A/C condensor

mounting bolts

6.  Install the air cleaner intake duct.
7.  XR6 Turbo vehicles: install intercooler (see

303-04b for procedure).

8.  Connect the oil cooler lines (auto only) do not

over tighten the fittings as this will demage the oil

cooler.

9.  Install air cleaner intake duct.
10. Install the grille.
11. Fill the cooling system as described in General

Procedures Section.

8.  Disconnect the electrical connections to the fans.

G97842 en

303-03-16 Engine 

Cooling 303-03-16

REMOVAL AND INSTALLATION (Continued)

3.  Insert a new ‘C’ Spring Clip. Do not re-use the old

Fan

clip.

Removal

4.  Rotate fan (in the direction of normal operation) to

ensure it rotates freely.

1.  Remove fan and shroud from vehicle.

5.  Install fan and shroud assembly into vehicle.

Radiator Hose

Removal and Installation
NOTE: Radiator hoses should be replaced whenever

they become cracked, rotted or have a tendency to

collapse, See Draining and Filling the Cooling

System.

1.  Drain radiator: then loosen the clamps at each

end of hose to be removed. Slide hose off radiator

connection and the cylinder head water outlet or

water pump connection.

2.  Position the clamps and hoses as shown in the

applicable installation in this chapter. Tighten

Item

Description

clamps.

1

Condensor assy.

3.  Fill coolant supply tank to the “FULL/MAX” mark.

2

Radiator assy.

4.  Fill and bleed the cooling system as described in

3

Motor and Fan assy.

Draining and Filling the Cooling System in this

4

Screw and washer assy.

section.
NOTE: The hose clamps initial factory fit make

2.  Lay the assembly flat.

use of a torque limiting cap that’s drive shears off

3.  Remove and discard the ‘C’ Spring Clip by gently

once the torque valve is reached.

sliding sideways.

For service remove the cap body by prying off to

4.  Gently prise drive plate from cavity.

reveal the hand tool drive feature.

5. Remove 

fan.

Install the hose clamps as close as possible to the

bead on the inlet and outlet pipes. Use only Ford

approved hoses and clamps when replacement is

necessary. Clamps with a “ bow spring‘‘ show

improved resistance to compression set of the

rubber hoses

Coolant Supply Tank

Removal
1.  Remove supply tank cap and loosen radiator

drain tap and drain cooling system until no coolant

remains in the supply tank.

2.  Remove the bleed tubes found on upper surface

of supply tank.

Item

Description

1

Shroud

2

Fan

3

Drive plate

4

‘C’ Spring clip

5

Screw

6

Motor

Installation
1.  Place fan on spindle.
2.  Install drive plate ensuring locating peg fits into

hole correctly.

G97842 en

303-03-17 Engine 

Cooling 303-03-17

REMOVAL AND INSTALLATION (Continued)

3.  Remove the two bolts which retain the supply tank

6 Cylinder

to the vehicle and release the leg to the RH

suspension tower.

Item

Description

1

Hose assy. Upper

Item

Description

2

Hose assy. Bleed

1

Supply tank cap

3

Hose to engine vent

2

Screw

8 Cylinder

4.  Remove coolant feed hose on side surface of

supply tank.

Installation
1.  Remove supply tank cap.
2.  Position coolant feed hose onto supply tank.
3.  Position supply tank in vehicle and tighten coolant

feed hose.

4.  Attach supply tank to vehicle using the locating

leg and two attaching screws.

5.  Attach bleed tubes to the top of the supply tank.
6.  Fill the supply tank with coolant as described in

General Procedures Section.

Item

Description

1

Hose assy. to bleed

2

Hose assy. Upper

3

Hose assy. Radiator overflow

G97846 en

303-04b-1 

Fuel Charging and Controls — Turbocharger 

303-04b-1

SECTION : 303-04b Fuel Charging and Controls —

Turbocharger

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS  

PAGE

SPECIFICATIONS

 Specifications  .......................................................................................................................303-04b-2

DESCRIPTION AND OPERATION

 Turbocharger  ........................................................................................................................303-04b-3

 Boost 

Control 

 

.....................................................................................................................303-04b-3

  Charge Air Cooler (Intercooler)  ..........................................................................................303-04b-4

 Heatshielding 

 

.....................................................................................................................303-04b-5

DIAGNOSIS AND TESTING

 Turbocharger  ........................................................................................................................303-04b-6

  Inspection and Verification  .................................................................................................303-04b-6

 Symptom 

Chart 

 

..................................................................................................................303-04b-6

 Pinpoint 

Tests 

 

....................................................................................................................303-04b-7

REMOVAL AND INSTALLATION

 Turbocharger  ......................................................................................................................303-04b-16

  Boost Pressure Sensor  ......................................................................................................303-04b-20

  Wastegate Control Solenoid (WCS)   .................................................................................303-04b-21

  Charge Air Cooler (Intercooler)  ..........................................................................................303-04b-21

 

 

 

 

 

 

 

Content   ..  170  171  172  173   ..