mki bafalcon workshop manual_2003

100-00-1 General Information 100-00-1

SECTION : 100-00 General InformationVEHICLE APPLICATION : 2003.0 BA FalconCONTENTS PAGEDESCRIPTION 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

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(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 Dos .....................................................................................................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

01/2003 2003.0 BA Falcon


DESCRIPTION AND OPERATION

NOTE: Notes are used to provide additional essentialAbout this Manualinformation required to carry out a complete andsatisfactory repair.IntroductionAs you read through this manual, you will comeThis manual has been written in a format that isacross 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 beginningand 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 isThis manual provides general descriptions forplaced at the beginning of the specific step (after theaccomplishing service and repair work with tested,step number).effective techniques. Following them will help assure

reliability. How to Use This ManualReplacement 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 undercomponents. 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. Theduring service or repair. manual is divided into five groups, General

Information, Chassis, Powertrain, Electrical and BodySpecial Tools and Paint. The number of the group is the firstThe 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 sectionscarry out a repair. Where possible, illustrations are available. Each section has a contents list detailingprovided to assist in identifying the special tool General Specifications, Description and Operationrequired. 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 identifiedAustralianumerically in a graphic and the corresponding textSPX AUSTRALIA will be numbered accordingly (refer to Samples).

Tel: +61 (03) 9544 6222 All left and right-hand references to the vehicle areFax: +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 towardsAppropriate service methods and correct repairthe front camshaft pulley.procedures are essential for the safe, reliableWhere appropriate, instructions will be given for theoperation of all motor vehicles as well as the personaluse of WDS, diagnostic equipment.safety of the individual carrying out the work.Inspection and VerificationThis manual cannot possibly anticipate all such

variations and provide advice or cautions as to each. Visual Inspection Charts, Symptom Charts and otherAnyone 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 technicalneither his personal safety nor the vehicle integrity by specifications, or navigate the user to a specific testhis choice of methods, tools or parts. procedure.

Sympton ChartWarnings, Cautions and Notes in ThisThe symptom chart indicates symptoms, sources andManualactions 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 toresult in personal injury. identify the source of a concern in a logical,

step-by-step manner. Pinpoint tests have twocolumns: CONDITIONS and CAUTION: Cautions are used to indicate thatDETAILS/RESULTS/ACTIONS.failure to follow a procedure correctly may result

in damage to the vehicle or equipment being The CONDITIONS column is used exclusively forused. graphics and icons (with or without captions) and the

DETAILS/RESULTS/ACTIONS column provides

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DESCRIPTION AND OPERATION (Continued)

direction to another test step or specific corrective Before using any product the Materials Safety Dataactions. Sheet supplied by the manufacturer or supplier should

be consulted.The boxed numbers indicate the order in which thedescribed action is to be performed. Acids and AlkalisComponent Tests

See also Battery Acids.A component test is used when a component is testedFor 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 andGraphics throat. Cause burns. Can destroy ordinary protective

clothing.Test graphics show the measurement or test to beperformed in a test step. Avoid splashes to the skin, eyes and clothing. Wear

suitable protective impervious apron, gloves andA representative tester graphic is used for voltmetersgoggles. Do not breath mists.and ohmmeters.Make sure access to eye wash bottles, shower andIf multiple measurements are made in a singlesoap 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 BagsBreakout box-type testers are represented by adouble circle test pin. Test pins are labelled with the See also Fire, Chemical Materialspin number. Highly flammable, explosive observe No Smoking

policy.SamplesUsed as a safety restraint system mounted in the

Special Tools and Torque Figures steering wheel and passenger side of the instrumentAny 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 propellantTorque settings will be given at the relevant point in which, when ignited, produces a VERY HOT GASthe procedure. (2500C).

The gas generant used in air bags is Sodium Azide.This material is hermetically sealed in the module andis completely consumed during deployment. Noattempt should be made to open an air bag inflator asthis will lead to the risk of exposure to Sodium Azide.If a gas generator is ruptured, full protective clothingshould be worn when dealing with the spillage.After normal deployment, gloves and safety gogglesshould be worn during the handling process.Deployed air bags should be disposed of in a plasticbag in accordance with local regulations at anapproved 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 - DosIntroduction

do store modules in an upright position.Many of the procedures associated with vehicledo keep modules dry.maintenance and repair involve physical hazards ordo carry modules with the cover side pointingother 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 anddo make sure all test equipment is properlyprocedures, and the handling of materials, should becalibrated and maintained.carried out with health and safety in mind.do wash hands after handling deployed air bags.

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Air Bags - Do Nots Solvent-based Adhesives/Sealers - SeeSolventsdo not store highly flammable material together

with modules or gas generators. Follow manufacturers instructions.do not store gas generators at temperatures

Water-based Adhesives/Sealersexceeding 80C.do not store modules upside down. Those based on polymer emulsions and rubber

latexes may contain small amounts of volatile toxicdo not attempt to open a gas generator housing.and harmful chemicals. Skin and eye contact shoulddo not expose gas generators to open flame or be avoided and adequate ventilation provided duringsources of heat. use.

do not place anything on top of a module cover.Hot Melt Adhesivesdo not use damaged modules.In the solid state, they are safe. In the molten statedo not touch a fired module or gas generator forthey may cause burns and health hazards may ariseat least 10 minutes.from the inhalation of toxic fumes.do not use any electrical probes on the wiringUse appropriate protective clothing and acircuit.thermostatically controlled heater with a thermal

Air Conditioning Refrigerant cut-out and adequate extraction.See also Chlorofluorocarbon, Chemical Materials Resin-based Adhesives/Sealers, for exampleHighly flammable, combustible observe No Smoking Epoxide and Formaldehyde Resin-basedpolicy.

Mixing should be carried out in well ventilated areas,Skin contact may result in frostbite. as harmful or toxic volatile chemicals may beInstructions given by the manufacturer must be released.followed. Avoid naked lights, wear suitable protective Skin contact with uncured resins and hardeners cangloves and goggles. result in irritation, dermatitis, and absorption of toxic orIf refrigerant comes into contact with the skin or eyes, harmful chemicals through the skin. Splashes canrinse the affected areas with water immediately. Eyes damage the eyes.should also be rinsed with an appropriate irrigation Provide adequate ventilation and avoid skin and eyesolution and should not be rubbed. SEEK MEDICAL contact.ASSISTANCE IF NECESSARY.

Anaerobic, Cyanoacrylate (super-glues) andAir Conditioning Refrigerant - Do Nots other Acrylic Adhesivesdo not expose refrigerant bottles to sunlight or Many are irritant, sensitizing or harmful to the skin andheat. respiratory tract. Some are eye irritants.do not stand refrigerant bottles upright; when Skin and eye contact should be avoided and thefilling, hold them with the valve downwards. manufacturers instructions followed.do not expose refrigerant bottles to frost. Cyanoacrylate adhesives (super-glues) MUST NOTdo not drop refrigerant bottles. contact the skin or eyes. If skin or eye tissue is

bonded, cover with a clean moist pad and SEEKdo not vent refrigerant to atmosphere under anyIMMEDIATE MEDICAL ATTENTION. Do not attemptcircumstance.to pull tissue apart. Use in well ventilated areas asdo not mix refrigerants, for example R12 (Freon)vapours can cause irritation to the nose and eyes.and R134a.For two-pack systems see Resin-based and

Adhesives and Sealers Isocyanate Adhesives/Sealers.See also Fire, Chemical Materials Isocyanate (Polyurethane) Adhesives/SealersHighly flammable, flammable, combustible observe See also Resin-based AdhesivesNo Smoking policy.

Individuals suffering from asthma or respiratoryGenerally should be stored in No Smoking areas. allergies should not work with or near these materialsCleanliness and tidiness in use should be observed, as sensitivity reactions can occur.for example disposable paper covering benches;Over exposure is irritating to the eyes and respiratoryshould be dispensed from applicators where possible;system. Excessive concentrations may producecontainers, including secondary containers, should beeffects on the nervous system including drowsiness.labelled appropriately.In extreme cases, loss of consciousness may result.Long term exposure to vapour concentrations mayresult in adverse health effects.

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Prolonged contact with the skin may have a defatting Brakes Fluids (Polyalkylene Glycols)effect which may lead to skin irritation and in some

See also Fire.cases, dermatitis.Splashes to the skin and eyes are extremely irritating.Splashes entering the eye will cause discomfort andAvoid skin and eye contact as far as possible.possible damage.Inhalation vapour hazards do not arise at ambientAny spraying should preferably be carried out in temperatures because of the very low vapourexhaust ventilated booths, removing vapours and pressure.spray droplets from the breathing zone.BrazingWear appropriate gloves, eye and respiratory

protection. See Welding.Antifreeze Chemical MaterialsSee also Fire, Solvents. See also Legal Aspects.For example isopropanol, ethylene glycol, methanol. Chemical materials such as solvents, sealers,Highly flammable, flammable, combustible. adhesives, paints, resin foams, battery acids,

antifreeze, brake fluids, fuels, oils and grease shouldUsed in vehicle coolant systems, brake air pressurealways be used with caution and stored and handledsystems, screenwash solutions.with care. They may be toxic, harmful, corrosive,Vapours may be given off from coolant antifreezeirritant or highly flammable and give rise to hazardous(glycol) when heated. Avoid breathing these vapours.fumes and dusts.

Antifreeze may be absorbed through the skin in toxicThe effects of excessive exposure to chemicals mayor harmful quantities. Antifreeze, if swallowed, can bebe immediate or delayed; briefly experienced orfatal and MEDICAL ATTENTION SHOULD BEpermanent; cumulative; superficial; life threatening; orSOUGHT IMMEDIATELY.may reduce life expectancy.

These products must not be used in any cooling orindustrial water system which is connected or linked Chemical Materials - Dosto general, food preparation or drinking water Do carefully read and observe hazard andsupplies. precaution warnings given on material containers

(labels) and in any accompanying leaflets, postersAsbestosor other instructions. Material health and safety

See also Warning Symbols on Vehicles at the end of data sheets can be obtained from manufacturers.this subsection. Do remove chemical materials from the skin andBreathing asbestos dust may cause lung damage or, clothing as soon as practicable after soiling.in some cases, cancer. Change heavily soiled clothing and have itUsed in brake and clutch linings, transmission brake cleaned.bands and gaskets. Ford original production and Do organise work practices and protectivegenuine replacement items for this model are clothing to avoid soiling of the skin and eyes;asbestos free. breathing vapours, aerosols, dusts or fumes;The use of drum cleaning units, vacuum cleaning or inadequate container labelling; fire and explosiondamp wiping is preferred. hazards.Asbestos dust waste should be dampened, placed in Do wash before job breaks, before eating,a sealed container and marked for safe disposal. If smoking, drinking or using toilet facilities whenany cutting or drilling is attempted on materials handling chemical materials.containing asbestos the item should be dampened Do keep work areas clean, uncluttered and free ofand only hand tools or low speed power tools used. spills.

Do store chemical materials according to nationalBattery Acidsand local regulations.

See also Acids and Alkalis. Do keep chemical materials out of the reach ofGases released during charging are explosive. Never children.use naked flames or allow sparks near charging or

Chemical Materials - Do Notsrecently charged batteries.Make sure there is adequate ventilation. Do not mix chemical materials except under the

manufacturers instructions; some chemicals canBrake and Clutch Linings and Pads form other toxic or harmful chemicals, give offtoxic or harmful fumes or become explosive whenSee Asbestos.mixed together.Do not spray chemical materials, particularly

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those based on solvents, in confined spaces, for Cuttingexample when people are inside a vehicle.

See Welding.Do not apply heat or flame to chemical materialsexcept under the manufacturers instructions. DewaxingSome are highly flammable and some may

See Solvents and Fuels (Kerosene).release toxic or harmful fumes.Do not leave containers open. Fumes given off Dustscan build up to toxic, harmful or explosive

Powder, dusts or clouds may be irritant, harmful orconcentrations. Some fumes are heavier than airtoxic. Avoid breathing dusts from powdery chemicaland will accumulate in confined areas such asmaterials or those arising from dry abrasionpits.operations. Wear respiratory protection if ventilation isDo not transfer chemical materials to unlabelled inadequate.containers.Fine dusts of combustible material can present anDo not clean hands or clothing with chemicals. explosion hazard. Avoid explosive limits and sourcesChemicals, particularly solvents and fuels, will dry of ignition.skin and may cause irritation leading to dermatitis

or be absorbed through the skin in toxic or Electric Shockharmful quantities.

Electric shock can result from the use of faultyDo not use emptied containers for other materials electrical equipment or from the misuse of equipmentexcept when they have been cleaned under in good condition.supervised conditions.Make sure that electrical equipment is maintained inDo not sniff or smell chemical materials. Brief good condition and frequently tested. Faultyexposure to high concentrations of fumes can be equipment should be labelled and preferably removedtoxic or harmful. from the work station.

Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets arenot frayed, kinked, cut, cracked or otherwiseThere is concern in the scientific community that damaged.CFCs and Halons are depleting the upper ozone layerMake sure that electrical equipment and flexes do notwhich filters out harmful ultraviolet radiation.come into contact with water.Decreased filtration of ultraviolet radiation may result

in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected bysystem suppression in humans, as well as decreased the correct rated fuse.productivity of crops and aquatic systems. Never misuse electrical equipment and never useCFCs are used primarily as refrigerants in vehicle air equipment which is in any way faulty. The resultsconditioning systems and as aerosol propellants. could be fatal.Halons are used as fire extinguishants. Make sure that the cables of mobile electricalFord supports worldwide elimination of CFC usage equipment cannot get trapped and damaged, such asand it is recommended that Company subsidiaries in a vehicle hoist.and affiliates should phase out CFC usage as soon as Make sure that the designated electrical workers areacceptable substitutes are commercially available. trained in basic First Aid.

In cases of electrocution:Clutch Fluidsswitch off the power supply before approachingSee Brake fluids. the victim.

Clutch Linings and Pads if this is not possible push or drag the victim fromthe source of electricity using dry non-conductiveSee Asbestos. material.

Corrosion Protection Materials commence resuscitation if trained to do so.SUMMON MEDICAL ASSISTANCE.See also Solvents, Fire.

Highly flammable, flammable observe No Smoking Engine Oilspolicy.

See Lubricants and Grease.These materials are varied and the manufacturersinstructions should be followed. They may contain Exhaust Fumessolvents, resins or petroleum products. Skin and eye

These contain asphyxiating, harmful and toxiccontact should be avoided. They should only bechemicals and particles such as carbon oxides,sprayed in conditions of adequate ventilation and notnitrogen oxides, aldehydes, lead and aromaticin confined spaces.

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hydrocarbons. Engines should be run only under Foams - Polyurethaneconditions of adequate exhaust extraction or general

See also Fire.ventilation and not in confined spaces.Used in sound and noise insulation. Cured foamsGasolene (petrol) engine used in seat and trim cushioning.

There may not be adequate warning of odour or of Follow manufacturers instructions.irritation before toxic or harmful effects arise. These Unreacted components are irritating and may bemay be immediate or delayed. harmful to the skin and eyes. Wear gloves and

goggles.Diesel engineIndividuals with chronic respiratory diseases, asthma,Soot, discomfort and irritation usually give adequate bronchial medical problems, or histories of allergicwarning of hazardous fume concentrations. diseases should not work in or near uncuredmaterials.Fibre InsulationThe components, vapours or spray mists can causeSee also Dusts. direct irritation, sensitivity reactions and may be toxic

Used in noise and sound insulation. or harmful.The fibrous nature of surfaces and cut edges can Vapours and spray mists must not be inhaled. Thesecause skin irritation. This is usually a physical and not materials must be applied with adequate ventilationa chemical effect. and respiratory protection. Do not remove the

respirator immediately after spraying, wait until thePrecautions should be taken to avoid excessive skinvapour/mists have cleared.contact through careful organization of work practices

and the use of gloves. Burning of the uncured components and the curedfoams can generate toxic and harmful fumes.Fire Smoking, naked flames or the use of electricalequipment during foaming operations and untilSee also Welding, Foams, Legal Aspects.vapours/mists have cleared should not be allowed.Many of the materials found on or associated with theAny heat cutting of cured foams or partially curedrepair of vehicles are highly flammable. Some give offfoams should be conducted with extraction ventilation.toxic or harmful fumes if burnt.See also the vehicle Body Repair Manual.

Observe strict fire safety when storing and handlingflammable materials or solvents, particularly near Freonelectrical equipment or welding processes.

See Air Conditioning Refrigerant.Make sure, before using electrical or weldingequipment, that there is no fire hazard present. FuelsHave a suitable fire extinguisher available when using See also, Fire, Legal Aspects, Chemicals andwelding or heating equipment. Solvents.

Avoid skin contact with fuel where possible. ShouldFirst Aidcontact occur, wash the affected skin with soap and

Apart from meeting any legal requirements it is water.desirable for someone in the workshop to be trainedin First Aid procedures. Gasoline (Petrol)Splashes in the eye should be flushed carefully with Highly flammable - observe No Smoking policy.clean water for at least ten minutes. Swallowing can result in mouth and throat irritationSoiled skin should be washed with soap and water. and absorption from the stomach can result inIn case of cold burns, from alternative fuels, place drowsiness and unconsciousness. Small amounts canaffected area in cool to cold water. be fatal to children. Aspiration of liquid into the lungs,

through vomiting, is a very serious hazard.Individuals affected by inhalation of gases and fumesshould be removed to fresh air immediately. If effects Gasolene dries the skin and can cause irritation andpersist, consult a doctor. dermatitis on prolonged or repeated contact. Liquid in

the eye causes severe smarting.If liquids are swallowed inadvertently, consult a doctorgiving him the information on the container or label. Motor gasolene may contain appreciable quantities ofDo not induce vomiting unless this action is indicated benzene, which is toxic upon inhalation, and theon the label. concentration of gasolene vapours must be kept very

low. High concentrations will cause eye, nose andFluoroelastomer throat irritation, nausea, headache, depression andsymptoms of drunkenness. Very high concentrationsSee Viton.will result in rapid loss of consciousness.

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Make sure there is adequate ventilation when checked for integrity following the specifiedhandling and using gasolene. Great care must be procedures.taken to avoid the serious consequences of inhalation If the fuel tank is to be removed for service or repairin the event of vapour build up arising from spillages the fuel must be evacuated using dedicatedin confined spaces. equipment and following the specified procedures.Special precautions apply to cleaning and Gas Cylindersmaintenance operations on gasolene storage tanks.Gasolene should not be used as a cleaning agent. It See also Fire.must not be siphoned by mouth. See First Aid. Gases such as oxygen, acetylene, argon and propane

are normally stored in cylinders at pressures of up toGas-oil (Diesel Fuel)138 bar (2000 psi) and great care should be taken in

Combustible. handling these cylinders to avoid mechanical damageto them or to the valve gear attached. The contents ofGross or prolonged skin contact with high boiling pointeach cylinder should be clearly identified bygas oils may also cause serious skin disordersappropriate markings.including skin cancer.Cylinders should be stored in well ventilatedKerosene (Paraffin) enclosures, and protected from ice and snow, ordirect sunlight. Fuel gases, for example acetylene andUsed also as heating fuel, solvent and cleaning agent.propane, should not be stored in close proximity toFlammable - observe No Smoking policy.oxygen cylinders.

Irritation of the mouth and throat may result fromCare should be exercised to prevent leaks from gasswallowing. The main hazard from swallowing arises ifcylinders and lines, and to avoid sources of ignition.liquid aspiration into the lungs occurs.Only trained personnel should undertake workLiquid contact dries the skin and can cause irritationinvolving gas cylinders.or dermatitis. Splashes in the eye may be slightly

irritating. GasesIn normal circumstances the low volatility does not

See Gas Cylinders.give rise to harmful vapours. Exposure to mists andvapours from kerosene at elevated temperature Gaskets (Fluoroelastomer)should be avoided (mists may arise in dewaxing).

See Viton.Avoid skin and eye contact and make sure there isadequate ventilation. General Workshop Tools and EquipmentAlternative Fuel It is essential that all tools and equipment areHighly flammable. Observe NO SMOKING signs. maintained in good condition and the correct safety

equipment is used where required.Make sure there is adequate ventilation when workingon alternative fuelled vehicles. Great care must be Never use tools or equipment for any purpose othertaken to avoid the serious consequences of inhalation than that for which they were designed. Neverin the event of vapour build up in confined spaces. overload equipment such as hoists, jacks, axle and

chassis stands or lifting slings. Damage caused byInhalation in high concentrations may causeoverloading is not always immediately apparent anddizziness, headache, nausea and loss ofmay result in a fatal failure the next time that theco-ordination. Very high concentrations may result inequipment is used.loss of consciousness.Do not use damaged or defective tools or equipment,Contact with liquidified petroleum gas (LPG) orparticularly high speed equipment such as grindingcompressed natural gas (CNG) to skin may causewheels. A damaged grinding wheel can disintegratecold burns and may cause frost bite.without warning and cause serious injury.Long sleeved cotton overalls, steel toe capped safetyWear suitable eye protection when using grinding,boots and rubber neoprene gloves should be wornchiselling or sand blasting equipment.during removal and installation of LPG/CNG fuel

system components. Wear a suitable breathing mask when using abrasiveblasting equipment, working with asbestos-basedLPG/CNG fuel leaks could cause a fire and be amaterials or using spraying equipment.hazard to health that can lead to personal injury,

illness or even death. Make sure there is adequate ventilation to controldusts, mists and fumes.If a leak is detected, under no circumstances attempt

to seal the leak by tightening the union/connectionuntil the fuel in the system or component isdepressurised. Once tightened the system should be

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Wash with soap and water to make sure all oil isHigh Pressure Air, Lubrication and Oilremoved (skin cleansers and nail brushes willTest Equipmenthelp). Preparations containing lanoline replace the

See also Lubricants and Greases. natural skin oils which have been removed.Always keep high pressure equipment in good Do not use gasolene (petrol), kerosene (paraffin),condition, and regularly maintained, particularly at diesel fuel (gas oil), thinners or solvents forjoints and unions. cleaning skin.Never direct a high pressure nozzle, for example If skin disorders develop, obtain medical advicediesel injector, at the skin as the fluid may penetrate without delay.to the underlying tissue, and cause serious injury. Where practicable, degrease components prior to

handling.HalonWhere there is a risk of eye contact, eye

See CFCs. protection should be worn, for example chemicalgoggles or face shields; in addition an eye washLegal Aspectsfacility should be provided.

There are many laws and regulations relating to Environmental Precautionshealth and safety in the use and disposal of materialsand equipment in a workshop. Burning used engine oil in small space heaters orFor a safe working environment and to avoid boilers can be recommended only for units ofenvironmental pollution, workshops should be familiar, approved design. If in doubt check with thein detail, with the many health and safety laws and appropriate local authority and manufacturer ofregulations within their country, published by both approved appliances.national and local authorities. Dispose of used oil and used oil filters through

authorized waste disposal contractors or licensedLubricants and Greases waste disposal sites, or to the waste oil reclamationAvoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authorityoils. All lubricants and greases may be irritating to the for advice on disposal facilities.eyes and skin. It is illegal to pour used oil on to the ground, down

sewers or drains, or into water courses.Used Engine OilNoiseProlonged and repeated contact with mineral oil will

result in the removal of natural fats from the skin, Some operations may produce high noise levelsleading to dryness, irritation and dermatitis. In which could, in time, damage hearing. In these cases,addition, used engine oil contains potentially harmful suitable ear protection must be worn.contaminants which may cause skin cancer. Adequatemeans of skin protection and washing facilities must Noise Insulation Materialsbe provided.

See Foams, Fibre Insulation.Do not employ used engine oils as lubricants or forany application where appreciable skin contact is O-Rings (Fluoroelastomer)likely to occur.

See Viton.Health Protection Precautions Paints

Avoid prolonged and repeated contact with oils,See also Solvents, Chemical Materials.particularly used engine oils.Highly flammable, flammable - observe No SmokingWear protective clothing, including imperviouspolicygloves where practicable.

Do not put oily rags into pockets. One PackAvoid contaminating clothes, particularly Can contain harmful or toxic pigments, driers andunderpants, with oil. other components as well as solvents. SprayingHeavily soiled clothing and oil-impregnated should be carried out only with adequate ventilation.footwear should not be worn. Overalls must be Two Packcleaned regularly.First Aid treatment should be obtained Can also contain harmful and toxic unreacted resinsimmediately for open cuts and wounds. and resin hardening agents. The manufacturers

instructions should be followed. See also Resin-basedUse barrier creams, applying them before eachAdhesives and Isocyanate Adhesives and Sealerswork period, to help the removal of oil from theunder Adhesives and Sealers.skin.

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Spraying should preferably be carried out in Avoid splashes to the skin, eyes and clothing. Wearexhausted ventilated booths removing vapour and protective gloves, goggles and clothing if necessary.spray mists from the breathing zone. Individuals Make sure there is good ventilation when in use,working in booths should wear appropriate respiratory avoid breathing fumes, vapours and spray mists andprotection. Those doing small scale repair work in the keep containers tightly sealed. Do not use in confinedopen workshop should wear air-fed respirators. spaces.

When spraying materials containing solvents, forPressurized Equipmentexample paints, adhesive, coatings, use extraction

See High Pressure Air, Lubrication and Oil Test ventilation or personal respiratory protection in theEquipment. absence of adequate general ventilation.

Do not apply heat or flame except under specific andSolderdetailed manufacturers instructions.

Solders are mixtures of metals such that the meltingpoint of the mixture is below that of the constituent Sound Insulationmetals (normally lead and tin). Solder application See Fibre Insulation, Foams.does not normally give rise to toxic lead fumes,provided a gas/air flame is used. Oxy-acetylene Suspended Loadsflames should not be used, as they are much hotterand will cause lead fumes to be produced. CAUTION: Never improvise lifting tackle.Some fumes may be produced by the application of There is always a danger when loads are lifted orany flame to surfaces coated with grease, and suspended. Never work under an unsupported,inhalation of these should be avoided. suspended or raised load, for example a suspendedRemoval of excess solder should be undertaken with engine.care, to make sure that fine lead dust is not produced, Always make sure that lifting equipment such aswhich can give toxic effects if inhaled. Respiratory jacks, hoists, axle stands and slings are adequate andprotection may be necessary. suitable for the job, in good condition and regularlySolder spillage and filings should be collected and maintained.removed promptly to prevent general aircontamination by lead. Transmission Brake BandsHigh standards of personal hygiene are necessary in See Asbestos.order to avoid ingestion of lead or inhalation of solderdust from clothing. Underseal

See Corrosion Protection.SolventsSee also Chemical Materials, Fuels (Kerosene), Fire. VitonFor example acetone, white spirit, toluene, xylene, In common with many other manufacturers vehicles,trichloroethane. some components fitted to the Ford range haveUsed in cleaning and dewaxing materials, paints, O-rings, seals or gaskets which contain a materialplastics, resins and thinners. known as Viton.Some may be highly flammable or flammable. Viton is a fluoroelastomer, that is a synthetic rubber

type which contains Fluorine. It is commonly used forSkin contact will degrease the skin and may result inO-rings, gaskets and seals of all types. Although Vitonirritation and dermatitis following repeated oris the most well known fluoroelastomer, there areprolonged contact. Some can be absorbed throughothers, including Fluorel and Tecmoflon.the skin in toxic or harmful quantities.When used under design conditions fluoroelastomersSplashes in the eye may cause severe irritation andare perfectly safe. If, however, they are exposed tocould lead to loss of vision.temperatures in excess of 400C, the material will notBrief exposure of high concentrations of vapours or burn, but will decompose, and one of the productsmists will cause eye and throat irritation, drowsiness, formed is hydrofluoric acid.dizziness, headaches and, in the worstThis acid is extremely corrosive and may be absorbedcircumstances, unconsciousness.directly, through contact, into the general bodyRepeated or prolonged exposure to excessive but system.lower concentrations of vapours or mists, for whichO-rings, seals or gaskets which have been exposed tothere might not be adequate warning indications, canvery high temperatures will appear charred or as acause more serious toxic or harmful effects.black sticky substance.Aspiration into the lungs, for example throughDO NOT, under any circumstances touch them or thevomiting, is the most serious consequence ofattached components.swallowing.

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Enquiries should be made to determine whether Viton Gas Welding (and Cutting)or any other fluoroelastomer has been used in the

Oxy-acetylene torches may be used for welding andaffected O-ring, seal or gasket. If they are of naturalcutting, and special care must be taken to preventrubber or nitrile there is no hazard. If in doubt, beleakage of these gases, with consequent risk of firecautious as the material may be Viton or anyand explosion.fluoroelastomer.The process will produce metal spatter and eye andIf Viton or any other fluoroelastomers have beenskin protection is necessary.used, the affected area should be decontaminatedThe flame is bright, and eye protection should bebefore the commencement of work.used, but the ultra-violet emission is much less thanDisposable heavy duty plastic gloves should be wornthat from arc welding, and lighter filters may be used.at all times, and the affected area washed down usingThe process itself produces few toxic fumes, but suchwire wool and a limewater (calcium hydroxide)fumes and gases may be produced from coatings onsolution to neutralise the acid before disposing of thethe work, particularly during cutting away of damageddecomposed Viton residue and final cleaning of thebody parts, and inhalation of the fumes should bearea. After use, the plastic gloves should be discardedavoided.carefully and safely.In brazing, toxic fumes may be produced from theWelding metals in the brazing rod, and a severe hazard mayarise if brazing rods containing cadmium are used. InSee also Fire, Electric Shock, Gas Cylinders.this event particular care must be taken to avoidWelding processes include Resistance Welding (Spotinhalation of fumes and expert advice may beWelding), Arc Welding and Gas Welding.required.

Resistance Welding Special precautions must be taken before any weldingor cutting takes place on vessels which haveThis process may cause particles of molten metal tocontained combustible materials, for example boilingbe emitted at a high velocity, and the eyes and skinor steaming out of fuel tanks .must be protected.Warning Symbols on VehiclesArc WeldingDecals showing warning symbols will be found onThis process emits a high level of ultra-violet radiationvarious vehicle components.which may cause arc-eye and skin burns to the

operator and to other persons nearby. Gas-shielded These decals must not be removed. The warnings arewelding processes are particularly hazardous in this for the attention of owners/operators and personsrespect. Personal protection must be worn, and carrying out service or repair operations on thescreens used to shield other people. vehicle.CONTACT LENS WEARERS ARE ADVISED TO The most commonly found decals are reproducedREVERT TO ORDINARY SPECTACLES WHEN ARC below together with an explanation of the warnings.WELDING as the arc spectrum is believed to emitmicrowaves which dry out the fluid between the lensand the eye. This may result in blindness when thelens is removed from the eye.Metal spatter will also occur, and appropriate eye andskin protection is necessary.The heat of the welding arc will produce fumes andgases from the metals being welded, the rods andfrom any applied coatings or contamination on thesurfaces being worked on. These gases and fumesmay be toxic and inhalation of these should beavoided. The use of extraction ventilation to removethe fumes from the working area may be necessaryparticularly in cases where the general ventilation ispoor, or where considerable welding work is 1. Components or assemblies displaying the cautionanticipated. In extreme cases or confined spaces triangle and open book symbol advisewhere adequate ventilation cannot be provided, consultation of the relevant section of the ownersair-fed respirators may be necessary. handbook before touching or attempting

adjustments of any kind.

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2. Components or assemblies displaying the warning 5. Displaying this symbol (normally in conjunctiontriangle with the electrified arrow and open book with 5 above) warn of the presence of potentiallysymbol give warning of inherent high voltages. explosive matter within the immediate vicinity.Never touch these with the engine running or theignition switched on. See Electric Shock in thissubsection.

6. Displaying this symbol warn that children shouldnot be allowed in the immediate vicinityunsupervised.

3. Components or assemblies displaying this symbol White Spiritgive warning that the component contains acorrosive substance. See Acids and Alkalis in this See Solvents.subsection.

Standard Workshop PracticesVehicle in WorkshopWhen working on a vehicle in the workshop alwaysmake sure that:

the parking brake is applied or the wheels aresecurely chocked to prevent the vehicle movingforwards or backwards.the key is removed from key operated hood locksbefore any work is carried out around the front ofthe vehicle.if the engine is to be run, there is adequateventilation, or an extraction hose to removeexhaust fumes.

4. Displaying the caution circle with a deleted lightedthere is adequate room to raise the vehicle andmatch symbol, caution against the use of nakedremove the wheels, if necessary.lights or flames within the immediate vicinity duefender covers are always fitted if any work is to beto the presence of highly flammable or explosivecarried out in the engine compartment.liquids or vapours. See Fire in this subsection.

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the battery is disconnected if working on the do not work on the fuel lines or systemengine. components unless the alternative fuel has been

evacuated and the pressure in the system isreduced to atmospheric, or less CAUTION: When electric arc welding on a

vehicle, always disconnect the generator wiring to do not use anything other than the specified leakprevent the possibility of a surge of current detector fluid to trace fuel leakscausing damage to the internal components of the Be aware of situations that may cause the LPG orgenerator. CNG fuel system to vent off fuel, such as:

If using welding equipment on the vehicle, a extremely hot dayssuitable fire extinguisher is readily available.parking by a space heater

Alternative Fuel hoisting a vehicle up near a ceiling heaterOnly personnel fully trained to Ford and local

WARNING: When servicing the fuel system standards are to work on alternative fuel vehicles.always follow the recommended procedures.

Towing the VehicleFailure to follow these instructions may result inpersonal injury.If the odour of liquified petroleum gas (LPG) or WARNING: When the vehicle is being towedcompressed natural gas (CNG) is present in the air in the ignition switch must be in position II (steeringthe workshop, warn all persons in the area to: lock released and warning lights illuminated).

Only then will the steering, turn signal lamps,extinguish all flames and lighted tobacco.horn and stop lamps be operational. Failure toshut off electrical and air powered equipment. follow these instructions may result in personal

evacuate the area. injury.ventilate the area. When a vehicle with automatic transmission is towed,

the gear selector must be in position N (Neutral).contact fire control authorities.Never tow a vehicle with automatic transmissionremove the vehicle to a dedicated, ventilatedfaster than 30 mph (50 km/h) or further than 30 milesarea.(50 km). If it is necessary to tow the vehicle a greaterdistance, the drive wheels must be lifted clear off theAlternative Fuel Dosground.do work on the vehicle in a designated area thatAlternatively the vehicle can be transported on a lowis well ventilated and its access restricted toloader or a trailer.qualified personnel only

install new warning labels to their original Connecting a Slave Battery Using Jumperlocations Cablesif possible always isolate the alternative fuel tank,run the vehicle on the alternative fuel until it WARNING: If the slave battery has recentlyautomatically switches to its normal fuel prior to been charged and is gassing, cover the vent plugstaking the vehicle into the workshop/service area or covers with a damp cloth to reduce the risk ofonly use tested and approved components and explosion should arcing occur when connectingpipes when repairing or servicing LPG and CNG the jumper cables. Failure to follow thesesystems instructions may result in personal injury.

Alternative Fuel Do Nots CAUTION: A discharged battery conditionmay have been caused by an electrical shortdo not vent off LPG fuelcircuit. If this condition exists there will be ando not use shop air pressure to force LPG fuel apparently live circuit on the vehicle even when allfrom the fuel tank normal circuits are switched off. This can cause

do not use paint drying ovens above 40C for any arcing when the jumper cables are connected.alternative fuel vehicles. LPG and CNG fuel tanksshould be removed from the vehicles prior to CAUTION: While it is not recommended thatbeing put into paint drying ovens above 40C the vehicle is jump started, it is recognized thatdo not modify the system or install new this may occasionally be the only practical way tocomponents with parts not designed for gas mobilize a vehicle. In such an instance thevehicles discharged battery must be recharged

immediately after jump starting to avoiddo not evacuate fuel tanks unless there is repairpermanent damage.that requires removed of the fuel tank

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Always make sure that the jumper cables are Component Cleaningadequate for the task. Heavy duty cables must be

To prevent ingress of dirt, accumulations of loose dirtused.and greasy deposits should be removed beforeAlways make sure that the slave battery is of the disconnecting or dismantling components orsame voltage as the vehicle battery. The batteries assemblies.must be connected in parallel.Components should be thoroughly cleaned beforeAlways make sure that switchable electric circuits inspection prior to reassembly.are switched off before connecting jumper cables.

This reduces the risk of arcing occurring when the Cleaning Methods:final connection is made.

dry cleaningremoval of loose dirt with soft or cable brushesscraping dirt off with a piece of metal or woodwiping off with a rag

CAUTION: Compressed air is sometimeswet so use with caution, especially on hydraulicsystems.

blowing dirt off with compressed air. (Eyeprotection must be worn when using this method)removal of dry dust using vacuum equipment.This method should always be used to removefriction lining material dust (asbestos particles)steam cleaning

WARNING: Make sure that the ends of the WARNING: Most solvents require carefuljumper cables do not touch each other or ground

handling and some are harmful. Refer to Healthagainst the vehicle body at any time while theand Safety Precautions and to the manufacturerscables are attached to the battery. A fully chargedliterature for safety precautions. Failure to followbattery, if shorted through jumper cables, canthese instructions may result in personal injury.discharge at a rate well above 1000 amps causingVarious solvents are available which are suitable forviolent arcing and very rapid heating of thecomponent cleaning. Some components such asjumper cables and terminals, and can even causebrake hydraulic parts and electrical assemblies shouldthe battery to explode. Failure to follow thesebe cleaned only with recommended solvents referinstructions may result in personal injury.to Solvents, Sealers and Adhesives or to the sectionAlways connect the jumper cables in the followingof the manual relevant to the component.sequence:

slave battery positive first then vehicle battery Calibration of Essential Measuringpositive Equipmentslave battery negative next and then vehicleground at least 12 inches (300 mm) from the WARNING: Failure to follow thesebattery terminal, for example engine lifting eye instructions may result in personal injury or

Always reduce the engine speed to idle before damage to components.disconnecting the jumper cables. It is of fundamental importance that certain essentialBefore removing the jumper cables from the vehicle equipment, for example torque wrenches,that had the discharged battery, switch on the heater multimeters, exhaust gas analysers or rolling roads,blower (high) or the heated rear window, to reduce the are regularly calibrated in accordance with thevoltage peak when the cables are removed. manufacturers instructions.Always disconnect the jumper cables in the reverse Solvents, Sealers and Adhesivesorder to the connecting sequence and do not shortthe ends of the cables. IntroductionDo not rely on the generator to restore a dischargedbattery. For a generator to recharge a battery, it would

WARNING: Always handle all solvents,take in excess of eight hours continuous driving withsealers and adhesives with extreme care. Someno additional loads placed on the battery.contain chemicals or give off fumes which can bedangerous to health. Always follow themanufacturers instructions. If in doubt about any

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substance, particularly a solvent, DO NOT use it.

CAUTION: If in doubt about the suitability ofany proprietary solvent or sealer for a particularapplication, contact the manufacturer of theproduct for information regarding storage,handling and application.The Health and Safety Precautions subsection refersto some commonly used chemicals and materials,hazards associated with their use, and safetymeasures to be taken. Some of these chemicals maybe included in the following list either in their own rightor as an ingredient in a sealer or adhesive.

General SpecificationsAnti-Seize Compound

Ford Spec.General SAM-1C-9107A

SAM-1C-9107ASpark plug threads ESE-M1244-A

SealersApplication Ford Spec. Manufacturer and Identification

For camshaft bearing caps ESK-M4G260-A Loctite 518For cylinder block WSK-M4G320-A Hylosil 502For fitting rear lamp assembly WSK-M4G329-ABCFor transmission housing (80 gram can) Finis Code 6 160 443

AdhesivesApplication Ford Spec.

PU for windscreen, side and rear glass Finis Code 6 997 259

Engine oil levelRoad/Roller TestingEngine coolant level

Road or roller testing may be carried out for various Tires, for correct pressure, compatible types andreasons and a procedure detailing pre-test checks, tread patterns, and wear within limits.through engine starting and stopping, pre-drivingThere is sufficient fuel in the tank to complete thechecks, on-test checks to final checks on completiontest.of the test is given overleaf.All around the engine, transmission and under theUnless complete vehicle performance is beingvehicle for oil, coolant, hydraulic and fuel leaks.checked, the full road test procedure need not beMake a note of any apparent leaks and wipe offcarried out. Instead, those items particularly relevantthe surrounding areas to make it easier to identifyto the system/s being checked can be extracted.the extent of the leak on completion of the test.

Pre-Test Checks Starting the EngineNOTE: On initial drive away from cold and within the WARNING: If the brake system hydraulic fluidfirst 1.5 km (1 mile), do not depress accelerator pedallevel is low, pedal travel is excessive or abeyond half travel until the vehicle has attained ahydraulic leak is found, do not attempt to roadminimum speed of 25 km/h (15 miles/h). Nevertest the vehicle until the reason for the low fluidoperate at high engine speed or with the acceleratorlevel, excessive pedal travel or hydraulic leak ispedal at full travel whilst the engine is cold.found and rectified.

It is suggested that pre-test checks, and functional With the ignition switched off, check:tests of those systems/circuits which affect the safe The handbrake is applied.and legal operations of the vehicle, such as brakes,

The gear lever is in neutral.lights and steering, should always be carried outbefore the road or roller test.

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All instrument gauges (except fuel gauge) read Brake Testingzero.

With the ignition switched on, check: WARNING: When brake testing, avoidbreathing the smoke or fumes from hot brakes,Ignition controlled warning lights come on.this may contain asbestos dust which isEngine temperature gauge registers a readinghazardous to health, see Health and Safetycompatible with the engine temperature.Precautions.Fuel gauge registers a reading appropriate to theAvoid brake testing on busy roads where it can causefuel level in the tank.inconvenience or danger to other road users.The operation of the handbrake warning light and

fluid level warning indicator light. CAUTION: Brake testing which includesheavy brake applications should not be carriedOn Road or Roller Test Check:out with new brake pads/discs or linings/drumsuntil the components have bedded-in. New brake CAUTION: If road testing, check the brake friction components will not reach full efficiencyoperation while still travelling at low speed before until the bedding-in process is complete.continuing with the test. If the brakes pull to oneTest the brakes at several speeds within the normalside, or appear to be otherwise faulty, do notoperating range using both light and heavy pedalcontinue with the road test until the fault has beenpressure. Note any tendency to snatch, pull or drag,found and rectified.and any undue delay in application or release.Clutch pedal operation is not stiff or heavy.Allow the vehicle to coast and note any tendency toInitial gear engagement is smooth and there is no pull to one side, or evidence that the brakes areevidence of clutch drag. binding.

Handbrake control operates smoothly and the After stopping the vehicle (not immediately after ahandbrake releases quickly and completely. period of heavy braking), carefully check the brakeClutch takes up the drive smoothly, without slip or temperature. A disc which feels hot, or appreciablyjudder. hotter than the others, indicates that the brake is

binding.Gear changing is smooth, and there are noabnormal noises or vibrations from the After completion of the test, check for:transmission. Oil, coolant, hydraulic, air and fuel leaks.The engine power output is satisfactory, full power Abnormal temperature of any moving componentsis achieved, acceleration is smooth and pedal or assemblies, e.g. wheel hubs, transmission,operation not stiff or heavy, and engine speed axle etc., which might indicate overtightness orreturns to idle correctly. lack of lubrication.There is no excessive or abnormally coloredsmoke from the engine under normal driving,heavy load or overrun conditions.Steering operation, including power steeringwhere fitted, is smooth, accurate, not excessivelyheavy or with excessive free play or vibration.Does not pull to one side and self centressmoothly after cornering.Speedometer, oil pressure warning lamp, coolanttemperature gauge and tachometer (where fitted)register the correct readings or operate correctly.Switches and controls operate smoothly andpositively, warning or indicator lights operatecorrectly and the direction indicator control selfcancels when the steering is returned to thestraight ahead position.Heating and ventilation systems work correctlyand effectively.Brake operation and efficiency.

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100-01-1 Identification Codes 100-01-1

SECTION : 100-01 Identification CodesVEHICLE APPLICATION : 2003.0 BA FalconCONTENTS PAGEDESCRIPTION AND OPERATION

Identification Codes ..............................................................................................................100-01-2 Vehicle Identification Number ..............................................................................................100-01-2 Vehicle Compliance (VC) Label .............................................................................................100-01-5 Emission Decal ....................................................................................................................100-01-6

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Identification CodesVehicle Identification NumberThe vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN isprinted on a label located in the engine compartment or on the drivers side A-pillar as shown. The VINnumber is also found on the vehicle compliance (VC) label located in the same area.

Typical Identification Plate Locations

Identification Label (engine bay)

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Identification Label (A-pillar)

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Body Style CodeBODY TYPE CODEXT Sedan SWXT Wagon WAFutura Sedan SWFutura Wagon WAXR Sedan SWXR Ute CMGT Sedan SWFairmont Sedan SWFairmont Wagon WAFairmont Ghia Sedan SWFairlane Ghia LWLTD LWXL Ute CMXLS Ute CM

Model CodeBody Type Body Style Model CodeSedan XT 18333Wagon XT 18363Sedan Futura 18334Wagon Futura 18364Sedan XR 18335Sedan FMT 18332Wagon FMT 18332Sedan FMT Ghia 18338Sedan Fairlane Ghia 18349Sedan LTD 18346Ute XL Tray 45313Ute XL SSB 45373Ute XR Tray 45375Ute XLS Tray 45314Ute XLS SSB 45374

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Paint Colour and Code with the Design Rules referred to on the compliancelabel of the vehicle.Colour CodeSuch Laws must be complied with at all times.Winter White A1Failure to do so may result in Substantial FinancialVenom VF Penalties. Where State/Territory Laws differ from the

Ice Mint Silver EI repair manual procedures, the Laws MUST takeprecedence.Barossa Reb B7To ensure continuing compliance it is imperative thatCongo Green DGthe engine/emission system is serviced according toSilhouette STthe specified procedure. A typical compliance plate is

Blue Print UU shown below.Narooma Blue NR

Compliance Plate (engine bay)Phantom P3Mercury Silver M7Blue Pearl CPAcid Rush RHCitric Acid JABlood Orange HOVictorian Taxi Yellow 44Taxi Orange 22

Trim Colour and CodeColour CodeStone S1Warm Charcoal B1

Vehicle Compliance (VC) LabelAustralian Design Rules (A.D.R.) reuire vehiclemanufacturere to comply with specific requirementsregarding consumer, environment protection, andsafety devices. A compliance plate is fitted to thevehicle and this contains codes which relate tospecific design rules in effect at the time of vehiclemanufacture.Legiclation requires that no alteration be made to avehicle that would result in the vehicle not complying

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Compliance Plate (A-pillar)

Emission DecalEmission Control Information Decal is affixed to theunderside of the bonnet. Should this decal becomemutilated or unreadable, a new decal must beobtained and affixed to the vehicla. To ensurecontained compliance it is imperative that the engineand emission system is serviced according to theservice procedures outlined in this manual.Should it become necessary to replace a componentwhich affects vehicle emissions, it is mandatory thatthe replacement part be of the same calibration as theoriginal part.No circumstances would permit the disconnection,alteration or modification of any emission relatedcomponent on vehicles marketed by Ford SalesCompany of Australia Limited, except in accordancewith the diagnostic, maintenance and repairprocedures specified in the Companys servicematerials.Any person who removes, modifies or otherwiserenders ineffective any emission control componentsfitted to a vehicle could be contravening the relevantregulations and be guilty of an offence under theregulations. Any person who owns and/or operatessuch a vehicle could also be guilty of an offenceunder the regulations.

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100-02-1 Jacking and Lifting 100-02-1

SECTION : 100-02 Jacking and LiftingVEHICLE APPLICATION : 2003.0 BA FalconCONTENTS PAGEDESCRIPTION AND OPERATION

Jacking ..................................................................................................................................100-02-2 Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-2 Jacking/Lifting Points - Ute ..................................................................................................100-02-2

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100-02-2 Jacking and Lifting 100-02-2


Jacking/Lifting Points - UteJacking

WARNING: Do not run the engine whenjacking the vehicle. The wheels contacting theground could cause the vehicle to move. Failureto follow these instructions may result in personalinjury.

WARNING: Make sure the jack and jackstands are correctly located to prevent the vehiclefrom falling. Failure to follow these instructionsmay result in personal injury.

WARNING: Wheel chocks should be used toprevent the vehicle from rolling and falling off thejack. Failure to follow these instructions may 1. The front jacking\lifting point for the ute is on theresult in personal injury. sill at the point where the rocker moulding has

been cut away to expose the sill. CAUTION: The service jack provided with the 2. The rear jacking\lifting point for the ute is on thevehicle is only intended to be used in an leaf spring hanger bracket.emergency for changing a deflated tire. Never use

the service jack to hoist the vehicle for any otherservice. Refer to the Owner Guide when using thejack supplied with the vehicle.

Jacking/Lifting Points - Sedan/Wagon

1. The front jacking\lifting point for sedan and wagonis on the sill at the point where the rockermoulding has been cut away to expose the sill.

2. The rear jacking\lifting point for the sedan andwagon is on the sill at the point where the rockermoulding has been cut away to expose the sill.

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100-04-1 Noise, Vibration and Harshness 100-04-1

SECTION : 100-04 Noise, Vibration and HarshnessVEHICLE APPLICATION : 2003.0 BA FalconCONTENTS PAGEDESCRIPTION AND OPERATION

Noise, Vibration and Harshness (NVH) ................................................................................100-04-2 Acceptable Noise, Vibration and Harshness .......................................................................100-04-2 Diagnostic Theory ................................................................................................................100-04-2 Glossary of Terms ................................................................................................................100-04-2

DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH) ................................................................................100-04-7 1: Customer Interview ........................................................................................................100-04-10 2: Pre-Drive Check .............................................................................................................100-04-10 3: Preparing for the Road Test ..........................................................................................100-04-10 4: Verify the Customer Concern ........................................................................................100-04-10 5: Road Test ......................................................................................................................100-04-10 6: Check OASIS/TSBs/Repair History ...............................................................................100-04-12 7: Diagnostic Procedure .....................................................................................................100-04-12 NVH Condition and Symptom Categories .........................................................................100-04-13 Symptom Charts ................................................................................................................100-04-14 Pinpoint Tests ....................................................................................................................100-04-35 Component Tests ...............................................................................................................100-04-49

GENERAL PROCEDURES

Brake Disc Machining .........................................................................................................100-04-55 Powertrain/Drivetrain Mount Neutralizing ...........................................................................100-04-55 Exhaust System Neutralizing ..............................................................................................100-04-55 Wheel Bearing Check .........................................................................................................100-04-56

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within an acceptable range.Noise, Vibration and Harshness (NVH)Glossary of TermsNoise is any undesirable sound, usually unpleasant in

nature. Vibration is any motion, shaking or trembling, Acceleration-Lightthat can be felt or seen when an object moves backAn increase in speed at less than half throttle.and forth or up and down. Harshness is a ride quality

issue where the vehicles response to the road Acceleration-Mediumtransmits sharply to the customer. HarshnessAn increase in speed at half to nearly full throttle,normally describes a firmer than usual response fromsuch as 0-97 km/h (0-60 mph) in approximately 30the suspension system. Noise, vibration andseconds.harshness (NVH) is a term used to describe these

conditions, which result in varying degrees of Acceleration-Heavydissatisfaction. Although, a certain level of NVHAn increase in speed at one-half to full throttle, suchcaused by road and environmental conditions isas 0-97 km/h (0-60 mph) in approximately 20normal. This section is designed to aid in theseconds.diagnosis, testing and repair of NVH concerns.

Acceptable Noise, Vibration and Ambient TemperatureHarshness The surrounding or prevailing temperature.All internal combustion engines and drivelines Amplitudeproduce some noise and vibration; operating in a real

The quantity or amount of energy produced by aworld environment adds noise that is not subject tovibrating component (G force). An extreme vibrationcontrol. Vibration isolators, mufflers and dampershas a high amplitude. A mild vibration has a lowreduce these to acceptable levels. A driver who isamplitude.unfamiliar with a vehicle can think that some sounds

are abnormal when actually the sounds are normal for Backlashthe vehicle type. For example, Traction-LokGear teeth clearance.differentials produce a slight noise on slow turns after

extended highway driving. This is acceptable and has Boomno detrimental effect on the locking axle function. As aLow frequency or low pitched noise oftentechnician, it is very important to be familiar withaccompanied by a vibration. Also refer to Drumming.vehicle features and know how they relate to NVH

concerns and their diagnosis. If, for example, the Bound Upvehicle has automatic overdrive it is important to testAn overstressed isolation (rubber) mount thatdrive the vehicle both in and out of overdrive mode.transmits vibration/noise instead of absorbing it.

Diagnostic TheoryBrakes AppliedThe shortest route to an accurate diagnosis resultsWhen the service brakes are applied with enoughfrom:force to hold the vehicle against movement with thesystem knowledge, including comparison with a transmission in gear.known good system.

system history, including repair history and usage Buffet/Buffetingpatterns. Strong noise fluctuations (less than 1000 Hz) causedcondition history, especially any relationship to by gusting winds. An example would be wind gustsrepairs or sudden change. against the side glass.knowledge of possible sources. Buzzusing a systematic diagnostic method that divides A low-pitched sound (200-5000 Hz) like that from athe system into related areas. bee. Often a metallic or hard plastic humming sound.

The diagnosis and correction of noise, vibration and Also describes a high frequency (200800 Hz)harshness concerns requires: vibration. Vibration feels similar to an electric razor.

a road or system test to determine the exactCambernature of the concern.The angle of the wheel in relation to the true verticalan analysis of the possible causes.as measured looking from the front of the vehicle.testing to verify the cause. Camber is positive when the wheel angle is offset so

repairing any concerns found. that the top of the wheel is positioned away from thea road test or system test to make sure the vehicle.concern has been corrected or brought back to

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ClonkA hydraulic knocking sound. Sound occurs with airpockets in a hydraulic system. Also described ashammering.

Clunk/Driveline ClunkA heavy or dull, short-duration, low-frequency sound.Occurs mostly on a vehicle that is accelerating ordecelerating abruptly. Also described as a thunk.

Coast/DecelerationReleasing the accelerator pedal at cruise, allowing theengine to reduce vehicle speed without applying thebrakes.

Caster Coast/Neutral CoastThe angle of the steering knuckle in relation to the Placing the transmission range selector in NEUTRALtrue vertical as measured looking from the side of the (N) or depressing the clutch pedal while at cruise.vehicle.

Constant Velocity (CV) JointA joint used to absorb vibrations caused by drivingpower being transmitted at an angle.

Controlled Rear Suspension HeightThe height at which a designated vehicle elementmust be when driveline angle measurements aremade.

Coupling ShaftThe shaft between the transfer case and the frontdrive axle or, in a two-piece rear driveshaft, the frontsection.

CPSCycles per second. Same as hertz (Hz).

Item DescriptionCracks1 True verticalA mid-frequency sound, related to squeak. Sound2 Positive castervaries with temperature conditions.3 Steering axisCreak

Chatter A metallic squeak.A pronounced series of rapidly repeating rattling or

Cruiseclicking sounds.Constant speed on level ground; neither accelerating

Chirp nor decelerating.A short-duration high-pitched noise associated with a

Cycleslipping drive belt.The process of a vibrating component going through a

Chuckle complete range of motion and returning to the startingpoint.A repetitious low-pitched sound. A loud chuckle is

usually described as a knock.Decibel

Click A unit of measurement, referring to sound pressurelevel, abbreviated dB.A sharp, brief, non-resonant sound, similar to

actuating a ball point pen.Drive Engine Run-Up (DERU) TestThe operation of the engine through the normal rpmrange with the vehicle standing still, the brakes

G72678 en 01/2003 2003.0 BA Falcon



applied and the transmission engaged. This test is from side-to-side (wobble). Dynamically unbalancedused for noise and vibration checks. wheel and tyre assemblies can cause wheel shimmy.

Driveline Angles Engine ImbalanceThe differences of alignment between the A condition in which an engines center mass is nottransmission output shaft, the driveshaft, and the rear concentric to the rotation center, causing excessiveaxle pinion centerline. motion.

Engine MisfireWhen combustion in one or more cylinders does notoccur or occurs at the wrong time.

Engine ShakeAn exaggerated engine movement or vibration thatdirectly increases in frequency as the engine speedincreases. It is caused by non-equal distribution ofmass in the rotating or reciprocating components.

Flexible CouplingA flexible joint.

FloatA drive mode on the dividing line between cruise and

Item Description coast where the throttle setting matches the enginespeed with the road speed.1 Engine

2 Driveshaft Flutter3 Differential Mid to high (100-200 Hz) intermittent sound due to air

flow. Similar to a flag flapping in the wind.Driveshaft

FrequencyThe shaft that transmits power to the rear axle inputThe rate at which a cycle occurs within a given time.shaft (pinion shaft). In a two-piece driveshaft, it is the

rearmost shaft.Gravelly Feel

Drivetrain A grinding or growl in a component, similar to the feelexperienced when driving on gravel.All power transmitting components from the engine to

the wheels; includes the clutch or torque converter,Grindthe transmission, the transfer case, the driveshaft,

and the front or rear drive axle. An abrasive sound, similar to using a grinding wheel,or rubbing sand paper against wood.

Drivetrain DamperHissA weight attached to the engine, the transmission, the

transfer case, or the axle. It is tuned by weight and Steady high frequency (200800 Hz) noise. Vacuumplacement to absorb vibration. leak sound.

Drone HootA low frequency (100-200 Hz) steady sound, like a A steady low frequency tone (50-500 Hz), sounds likefreezer compressor. Also described as a moan. blowing over a long neck bottle.

Drumming HowlA cycling, low-frequency (20100 Hz), rhythmic noise A mid-range frequency (200-800 Hz) noise betweenoften accompanied by a sensation of pressure on the drumming and whine. Also described as a hum.ear drums. Also described as a low rumble, boom, or

Humrolling thunder.Mid-frequency (200-800 Hz) steady sound, like a

Dynamic Balance small fan motor. Also described as a howl.The equal distribution of weight on each side of the

Hzcenterline, so that when the wheel and tyre assemblyspins, there is no tendency for the assembly to move Hertz; a frequency measured in cycles per second.

G72678 en 01/2003 2003.0 BA Falcon



ImbalanceOut of balance; heavier on one side than the other. Ina rotating component, imbalance often causesvibration.

InboardToward the centerline of the vehicle.

IntensityThe physical quality of sound that relates to thestrength of the vibration (measured in decibels). Thehigher the sounds amplitude, the higher the intensityand vice versa.

IsolateItem DescriptionTo separate the influence of one component to

another. 1 Lateral runout2 Radial runoutKnock

A heavy, loud, repetitious sound, like a knock on theRattledoor.A random and momentary or short duration noise.

MoanRotary Blade Coupling (RBC)A constant, low-frequency (100200 Hz) tone. Also

described as a hum. This part is attached to the rear axle on 4WDvehicles. It includes an internal hydraulic pump and

Neutral Engine Run-Up (NERU) Test clutch pack to control the torque supplied to the rearaxle/wheels. It also has an internal electromagneticThe operation of the engine through the normal rpmclutch to lock to the RCB for the 4WD ON mode. Thisrange with the vehicle standing still and theunit is not to be disassembled and if necessary a newtransmission disengaged. This test is used to identifyunit must be installed.engine related vibrations.

Ring GearNeutralize/NormalizeThe large, circular, driven gear in a ring and pinionTo return to an unstressed position. Used to describegearset.mounts. Refer to Bound Up.

Road TestOutboardThe operation of the vehicle under conditionsAway from the centerline of the vehicle.intended to produce the concern under investigation.

PingRoughnessA short duration, high-frequency sound, which has aA medium-frequency vibration. A slightly higherslight echo

mki bafalcon workshop manual_2003

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