Ford Falcon. Instruction - page 1
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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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