BA Falcon Workshop Manual PDF

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
01/2003 2003.0 BA Falcon

(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
01/2003 2003.0 BA Falcon

About this Manual NOTE: Notes are used to provide additional essential
information required to carry out a complete and
Introduction satisfactory repair.
This manual has been written in a format that is As you read through this manual, you will come
designed to meet the needs of Ford technicians across WARNINGS, CAUTIONS and NOTES.
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
This manual provides general descriptions for warning, caution or note only applies to one step, it is
accomplishing service and repair work with tested, placed at the beginning of the specific step (after the
effective techniques. Following them will help assure step number).
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
Special Tools Information, Chassis, Powertrain, Electrical and Body
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
Australia in sequence, the sequence will be identified
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
Appropriate service methods and correct repair taken from a position at the flywheel looking towards
procedures are essential for the safe, reliable the front camshaft pulley.
operation of all motor vehicles as well as the personal Where appropriate, instructions will be given for the
safety of the individual carrying out the work. use of WDS, diagnostic equipment.
This manual cannot possibly anticipate all such Inspection and Verification
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.
Warnings, Cautions and Notes in This Sympton Chart
Manual The symptom chart indicates symptoms, sources and
actions to address a condition.
WARNING: Warnings are used to indicate Pinpoint Tests
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
CAUTION: Cautions are used to indicate that columns: CONDITIONS and
failure to follow a procedure correctly may result DETAILS/RESULTS/ACTIONS.
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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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
The boxed numbers indicate the order in which the be consulted.
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
in multiple pinpoint tests, or if a procedure is too For example caustic soda, sulphuric acid.
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
Test graphics show the measurement or test to be clothing.
performed in a test step. Avoid splashes to the skin, eyes and clothing. Wear
A representative tester graphic is used for voltmeters suitable protective impervious apron, gloves and
and ohmmeters. goggles. Do not breath mists.
If multiple measurements are made in a single Make sure access to eye wash bottles, shower and
graphic, the test leads are drawn with a solid line until soap are readily available for splashing accidents.
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
Samples policy.
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.
Introduction Air Bags - Do’s
do store modules in an upright position.
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards or do keep modules dry.
other risks to health. This subsection lists, do carry modules with the cover side pointing
alphabetically, some of these hazardous operations away from the body.
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
procedures, and the handling of materials, should be do make sure all test equipment is properly
carried out with health and safety in mind. calibrated and maintained.
do wash hands after handling deployed air bags.
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Air Bags - Do Nots Solvent-based Adhesives/Sealers - See

do not store highly flammable material together Solvents
with modules or gas generators.
Follow manufacturers instructions.
do not store gas generators at temperatures
exceeding 80°C. Water-based Adhesives/Sealers
do not store modules upside down. Those based on polymer emulsions and rubber
do not attempt to open a gas generator housing. latexes may contain small amounts of volatile toxic
do not expose gas generators to open flame or and harmful chemicals. Skin and eye contact should
be avoided and adequate ventilation provided during
sources of heat.
use.
do not place anything on top of a module cover.
do not use damaged modules. Hot Melt Adhesives
do not touch a fired module or gas generator for In the solid state, they are safe. In the molten state
at least 10 minutes. they may cause burns and health hazards may arise
do not use any electrical probes on the wiring from the inhalation of toxic fumes.
circuit. Use appropriate protective clothing and a
thermostatically controlled heater with a thermal
Air Conditioning Refrigerant cut-out and adequate extraction.
See also Chlorofluorocarbon, Chemical Materials Resin-based Adhesives/Sealers, for example
Highly flammable, combustible – observe No Smoking Epoxide and Formaldehyde Resin-based
policy.
Mixing should be carried out in well ventilated areas,
Skin contact may result in frostbite. as harmful or toxic volatile chemicals may be
Instructions given by the manufacturer must be released.
followed. Avoid naked lights, wear suitable protective Skin contact with uncured resins and hardeners can
gloves and goggles. result in irritation, dermatitis, and absorption of toxic or
If refrigerant comes into contact with the skin or eyes, harmful chemicals through the skin. Splashes can
rinse 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 eye
solution and should not be rubbed. SEEK MEDICAL contact.
ASSISTANCE IF NECESSARY.
Anaerobic, Cyanoacrylate (super-glues) and
Air Conditioning Refrigerant - Do Nots other Acrylic Adhesives
do not expose refrigerant bottles to sunlight or
Many are irritant, sensitizing or harmful to the skin and
heat. respiratory tract. Some are eye irritants.
do not stand refrigerant bottles upright; when
Skin and eye contact should be avoided and the
filling, hold them with the valve downwards.
manufacturers instructions followed.
do not expose refrigerant bottles to frost. Cyanoacrylate adhesives (super-glues) MUST NOT
do not drop refrigerant bottles. contact the skin or eyes. If skin or eye tissue is
do not vent refrigerant to atmosphere under any bonded, cover with a clean moist pad and SEEK
circumstance. IMMEDIATE MEDICAL ATTENTION. Do not attempt
do not mix refrigerants, for example R12 (Freon) to pull tissue apart. Use in well ventilated areas as
and R134a. vapours can cause irritation to the nose and eyes.
For two-pack systems see Resin-based and
Adhesives and Sealers Isocyanate Adhesives/Sealers.
See also Fire, Chemical Materials Isocyanate (Polyurethane) Adhesives/Sealers
Highly flammable, flammable, combustible – observe
No Smoking policy. See also Resin-based Adhesives
Individuals suffering from asthma or respiratory
Generally should be stored in No Smoking areas.
allergies should not work with or near these materials
Cleanliness and tidiness in use should be observed,
for example disposable paper covering benches; as sensitivity reactions can occur.
should be dispensed from applicators where possible; Over exposure is irritating to the eyes and respiratory
containers, including secondary containers, should be system. Excessive concentrations may produce
labelled appropriately. effects on the nervous system including drowsiness.
In extreme cases, loss of consciousness may result.
Long term exposure to vapour concentrations may
result 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
cases, dermatitis. See also Fire.
Splashes entering the eye will cause discomfort and Splashes to the skin and eyes are extremely irritating.
possible damage. Avoid skin and eye contact as far as possible.
Inhalation vapour hazards do not arise at ambient
Any spraying should preferably be carried out in
temperatures because of the very low vapour
exhaust ventilated booths, removing vapours and pressure.
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory Brazing
protection. See Welding.
Antifreeze Chemical Materials
See 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,
Used in vehicle coolant systems, brake air pressure antifreeze, brake fluids, fuels, oils and grease should
systems, screenwash solutions. always be used with caution and stored and handled
Vapours may be given off from coolant antifreeze with care. They may be toxic, harmful, corrosive,
(glycol) when heated. Avoid breathing these vapours. irritant or highly flammable and give rise to hazardous
fumes and dusts.
Antifreeze may be absorbed through the skin in toxic
or harmful quantities. Antifreeze, if swallowed, can be The effects of excessive exposure to chemicals may
fatal and MEDICAL ATTENTION SHOULD BE be immediate or delayed; briefly experienced or
SOUGHT IMMEDIATELY. permanent; cumulative; superficial; life threatening; or
may reduce life expectancy.
These products must not be used in any cooling or
industrial water system which is connected or linked Chemical Materials - Do’s
to general, food preparation or drinking water
Do carefully read and observe hazard and
supplies.
precaution warnings given on material containers
Asbestos (labels) and in any accompanying leaflets, posters
or 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 and
Breathing asbestos dust may cause lung damage or, clothing as soon as practicable after soiling.
in some cases, cancer. Change heavily soiled clothing and have it
Used in brake and clutch linings, transmission brake cleaned.
bands and gaskets. Ford original production and Do organise work practices and protective
genuine 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 explosion
damp 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 when
any 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 of
and only hand tools or low speed power tools used. spills.
Battery Acids Do store chemical materials according to national
and local regulations.
See also Acids and Alkalis.
Do keep chemical materials out of the reach of
Gases released during charging are explosive. Never children.
use naked flames or allow sparks near charging or
recently charged batteries. Chemical Materials - Do Nots
Make sure there is adequate ventilation. Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
Brake and Clutch Linings and Pads form other toxic or harmful chemicals, give off
See Asbestos. toxic or harmful fumes or become explosive when
mixed together.
Do not spray chemical materials, particularly
G17372 en 01/2003 2003.0 BA Falcon

those based on solvents, in confined spaces, for Cutting

example when people are inside a vehicle.
See Welding.
Do not apply heat or flame to chemical materials
except under the manufacturers instructions. Dewaxing
Some are highly flammable and some may
release toxic or harmful fumes. See Solvents and Fuels (Kerosene).
Do not leave containers open. Fumes given off Dusts
can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than air Powder, dusts or clouds may be irritant, harmful or
and will accumulate in confined areas such as toxic. Avoid breathing dusts from powdery chemical
pits. materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation is
Do not transfer chemical materials to unlabelled
inadequate.
containers.
Fine dusts of combustible material can present an
Do not clean hands or clothing with chemicals.
explosion hazard. Avoid explosive limits and sources
Chemicals, 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 Shock
harmful quantities.
Electric shock can result from the use of faulty
Do not use emptied containers for other materials electrical equipment or from the misuse of equipment
except when they have been cleaned under
in good condition.
supervised conditions.
Make sure that electrical equipment is maintained in
Do not sniff or smell chemical materials. Brief good condition and frequently tested. Faulty
exposure to high concentrations of fumes can be
equipment should be labelled and preferably removed
toxic or harmful.
from the work station.
Chlorofluorocarbons (CFC) Make sure that flexes, cables, plugs and sockets are
not frayed, kinked, cut, cracked or otherwise
There is concern in the scientific community that
damaged.
CFCs and Halons are depleting the upper ozone layer
which filters out harmful ultraviolet radiation. Make sure that electrical equipment and flexes do not
Decreased filtration of ultraviolet radiation may result come into contact with water.
in increases in skin cancer, cataracts and immune Make sure that electrical equipment is protected by
system suppression in humans, as well as decreased the correct rated fuse.
productivity of crops and aquatic systems. Never misuse electrical equipment and never use
CFCs are used primarily as refrigerants in vehicle air equipment which is in any way faulty. The results
conditioning systems and as aerosol propellants. could be fatal.
Halons are used as fire extinguishants. Make sure that the cables of mobile electrical
Ford supports worldwide elimination of CFC usage equipment cannot get trapped and damaged, such as
and 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 are
acceptable substitutes are commercially available. trained in basic First Aid.
Clutch Fluids In cases of electrocution:
switch off the power supply before approaching
See Brake fluids.
the victim.
Clutch Linings and Pads if this is not possible push or drag the victim from
the source of electricity using dry non-conductive
See Asbestos.
material.
Corrosion Protection Materials commence resuscitation if trained to do so.
See also Solvents, Fire. SUMMON MEDICAL ASSISTANCE.
Highly flammable, flammable – observe No Smoking Engine Oils
policy.
See Lubricants and Grease.
These materials are varied and the manufacturers
instructions should be followed. They may contain Exhaust Fumes
solvents, resins or petroleum products. Skin and eye
contact should be avoided. They should only be These contain asphyxiating, harmful and toxic
sprayed in conditions of adequate ventilation and not chemicals and particles such as carbon oxides,
in confined spaces. nitrogen oxides, aldehydes, lead and aromatic
G17372 en 01/2003 2003.0 BA Falcon

hydrocarbons. Engines should be run only under Foams - Polyurethane

conditions of adequate exhaust extraction or general
ventilation and not in confined spaces. See also Fire.
Used in sound and noise insulation. Cured foams
Gasolene (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 be
may be immediate or delayed. harmful to the skin and eyes. Wear gloves and
Diesel engine goggles.
Individuals with chronic respiratory diseases, asthma,
Soot, discomfort and irritation usually give adequate bronchial medical problems, or histories of allergic
warning of hazardous fume concentrations.
diseases should not work in or near uncured
Fibre Insulation materials.
The components, vapours or spray mists can cause
See 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. These
cause skin irritation. This is usually a physical and not materials must be applied with adequate ventilation
a chemical effect. and respiratory protection. Do not remove the
Precautions should be taken to avoid excessive skin respirator immediately after spraying, wait until the
contact through careful organization of work practices vapour/mists have cleared.
and the use of gloves. Burning of the uncured components and the cured
foams can generate toxic and harmful fumes.
Fire Smoking, naked flames or the use of electrical
See also Welding, Foams, Legal Aspects. equipment during foaming operations and until
Many of the materials found on or associated with the vapours/mists have cleared should not be allowed.
repair of vehicles are highly flammable. Some give off Any heat cutting of cured foams or partially cured
toxic or harmful fumes if burnt. foams should be conducted with extraction ventilation.
See also the vehicle Body Repair Manual.
Observe strict fire safety when storing and handling
flammable materials or solvents, particularly near Freon
electrical equipment or welding processes.
See Air Conditioning Refrigerant.
Make sure, before using electrical or welding
equipment, that there is no fire hazard present. Fuels
Have a suitable fire extinguisher available when using See also, Fire, Legal Aspects, Chemicals and
welding or heating equipment. Solvents.
First Aid Avoid skin contact with fuel where possible. Should
contact 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 trained
in 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 irritation
Soiled skin should be washed with soap and water. and absorption from the stomach can result in
In case of cold burns, from alternative fuels, place drowsiness and unconsciousness. Small amounts can
affected area in cool to cold water. be fatal to children. Aspiration of liquid into the lungs,
Individuals affected by inhalation of gases and fumes through vomiting, is a very serious hazard.
should be removed to fresh air immediately. If effects Gasolene dries the skin and can cause irritation and
persist, consult a doctor. dermatitis on prolonged or repeated contact. Liquid in
If liquids are swallowed inadvertently, consult a doctor the eye causes severe smarting.
giving him the information on the container or label. Motor gasolene may contain appreciable quantities of
Do not induce vomiting unless this action is indicated benzene, which is toxic upon inhalation, and the
on the label. concentration of gasolene vapours must be kept very
low. High concentrations will cause eye, nose and
Fluoroelastomer throat irritation, nausea, headache, depression and
See Viton. symptoms of drunkenness. Very high concentrations
will result in rapid loss of consciousness.
G17372 en 01/2003 2003.0 BA Falcon

Make sure there is adequate ventilation when checked for integrity following the specified
handling 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 repair
in the event of vapour build up arising from spillages the fuel must be evacuated using dedicated
in confined spaces. equipment and following the specified procedures.
Special precautions apply to cleaning and
maintenance operations on gasolene storage tanks. Gas Cylinders
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
Gas-oil (Diesel Fuel) are normally stored in cylinders at pressures of up to
138 bar (2000 psi) and great care should be taken in
Combustible. handling these cylinders to avoid mechanical damage
Gross or prolonged skin contact with high boiling point to them or to the valve gear attached. The contents of
gas oils may also cause serious skin disorders each cylinder should be clearly identified by
including skin cancer. appropriate markings.
Cylinders should be stored in well ventilated
Kerosene (Paraffin) enclosures, and protected from ice and snow, or
Used also as heating fuel, solvent and cleaning agent. direct sunlight. Fuel gases, for example acetylene and
Flammable - observe No Smoking policy. propane, should not be stored in close proximity to
oxygen cylinders.
Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing arises if Care should be exercised to prevent leaks from gas
liquid aspiration into the lungs occurs. cylinders and lines, and to avoid sources of ignition.
Liquid contact dries the skin and can cause irritation Only trained personnel should undertake work
or dermatitis. Splashes in the eye may be slightly involving gas cylinders.
irritating. Gases
In normal circumstances the low volatility does not
give rise to harmful vapours. Exposure to mists and See Gas Cylinders.
vapours from kerosene at elevated temperature Gaskets (Fluoroelastomer)
should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there is See Viton.
adequate ventilation.
General Workshop Tools and Equipment
Alternative Fuel
It is essential that all tools and equipment are
Highly flammable. Observe “NO SMOKING” signs. maintained in good condition and the correct safety
Make sure there is adequate ventilation when working equipment is used where required.
on alternative fuelled vehicles. Great care must be Never use tools or equipment for any purpose other
taken to avoid the serious consequences of inhalation than that for which they were designed. Never
in the event of vapour build up in confined spaces. overload equipment such as hoists, jacks, axle and
Inhalation in high concentrations may cause chassis stands or lifting slings. Damage caused by
dizziness, headache, nausea and loss of overloading is not always immediately apparent and
co-ordination. Very high concentrations may result in may result in a fatal failure the next time that the
loss of consciousness. equipment is used.
Contact with liquidified petroleum gas (LPG) or Do not use damaged or defective tools or equipment,
compressed natural gas (CNG) to skin may cause particularly high speed equipment such as grinding
cold burns and may cause frost bite. wheels. A damaged grinding wheel can disintegrate
without warning and cause serious injury.
Long sleeved cotton overalls, steel toe capped safety
boots and rubber neoprene gloves should be worn Wear suitable eye protection when using grinding,
during removal and installation of LPG/CNG fuel chiselling or sand blasting equipment.
system components. Wear a suitable breathing mask when using abrasive
LPG/CNG fuel leaks could cause a fire and be a blasting equipment, working with asbestos-based
hazard to health that can lead to personal injury, materials or using spraying equipment.
illness or even death. Make sure there is adequate ventilation to control
If a leak is detected, under no circumstances attempt dusts, mists and fumes.
to seal the leak by tightening the union/connection
until the fuel in the system or component is
depressurised. Once tightened the system should be
G17372 en 01/2003 2003.0 BA Falcon

High Pressure Air, Lubrication and Oil Wash with soap and water to make sure all oil is
Test Equipment removed (skin cleansers and nail brushes will
help). 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 for
joints and unions. cleaning skin.
Never direct a high pressure nozzle, for example If skin disorders develop, obtain medical advice
diesel 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
Halon handling.
Where there is a risk of eye contact, eye
See CFCs. protection should be worn, for example chemical
Legal Aspects goggles or face shields; in addition an eye wash
facility should be provided.
There are many laws and regulations relating to
health and safety in the use and disposal of materials Environmental Precautions
and equipment in a workshop. Burning used engine oil in small space heaters or
For a safe working environment and to avoid boilers can be recommended only for units of
environmental pollution, workshops should be familiar, approved design. If in doubt check with the
in detail, with the many health and safety laws and appropriate local authority and manufacturer of
regulations within their country, published by both approved appliances.
national and local authorities. Dispose of used oil and used oil filters through
Lubricants and Greases authorized waste disposal contractors or licensed
waste disposal sites, or to the waste oil reclamation
Avoid all prolonged and repeated contact with mineral trade. If in doubt, contact the relevant local authority
oils. 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
Used Engine Oil sewers or drains, or into water courses.
Prolonged and repeated contact with mineral oil will Noise

result in the removal of natural fats from the skin, Some operations may produce high noise levels
leading 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. Adequate
means of skin protection and washing facilities must Noise Insulation Materials
be provided.
See Foams, Fibre Insulation.
Do not employ used engine oils as lubricants or for
any 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,
particularly used engine oils. See also Solvents, Chemical Materials.
Wear protective clothing, including impervious Highly flammable, flammable - observe No Smoking
gloves where practicable. policy
Do not put oily rags into pockets. One Pack
Avoid contaminating clothes, particularly Can contain harmful or toxic pigments, driers and
underpants, with oil. other components as well as solvents. Spraying
Heavily soiled clothing and oil-impregnated should be carried out only with adequate ventilation.
footwear should not be worn. Overalls must be
cleaned regularly. Two Pack
First Aid treatment should be obtained Can also contain harmful and toxic unreacted resins
immediately for open cuts and wounds. and resin hardening agents. The manufacturers
Use barrier creams, applying them before each instructions should be followed. See also Resin-based
work period, to help the removal of oil from the Adhesives and Isocyanate Adhesives and Sealers
skin. under Adhesives and Sealers.
G17372 en 01/2003 2003.0 BA Falcon

Spraying should preferably be carried out in Avoid splashes to the skin, eyes and clothing. Wear
exhausted 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 and
protection. Those doing small scale repair work in the keep containers tightly sealed. Do not use in confined
open workshop should wear air-fed respirators. spaces.
Pressurized Equipment When spraying materials containing solvents, for
example paints, adhesive, coatings, use extraction
See High Pressure Air, Lubrication and Oil Test ventilation or personal respiratory protection in the
Equipment. absence of adequate general ventilation.
Solder Do not apply heat or flame except under specific and
detailed manufacturers instructions.
Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent Sound Insulation
metals (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 Loads
flames should not be used, as they are much hotter
and will cause lead fumes to be produced.
CAUTION: Never improvise lifting tackle.
Some fumes may be produced by the application of
any flame to surfaces coated with grease, and There is always a danger when loads are lifted or
inhalation of these should be avoided. suspended. Never work under an unsupported,
suspended or raised load, for example a suspended
Removal of excess solder should be undertaken with engine.
care, to make sure that fine lead dust is not produced,
which can give toxic effects if inhaled. Respiratory Always make sure that lifting equipment such as
protection may be necessary. jacks, hoists, axle stands and slings are adequate and
suitable for the job, in good condition and regularly
Solder spillage and filings should be collected and maintained.
removed promptly to prevent general air
contamination by lead. Transmission Brake Bands
High standards of personal hygiene are necessary in See Asbestos.
order to avoid ingestion of lead or inhalation of solder
dust from clothing. Underseal
Solvents See Corrosion Protection.
See also Chemical Materials, Fuels (Kerosene), Fire. Viton
For example acetone, white spirit, toluene, xylene, In common with many other manufacturers vehicles,
trichloroethane. some components fitted to the Ford range have
Used in cleaning and dewaxing materials, paints, O-rings, seals or gaskets which contain a material
plastics, resins and thinners. known as ‘Viton’.
Some may be highly flammable or flammable. Viton is a fluoroelastomer, that is a synthetic rubber
Skin contact will degrease the skin and may result in type which contains Fluorine. It is commonly used for
irritation and dermatitis following repeated or O-rings, gaskets and seals of all types. Although Viton
prolonged contact. Some can be absorbed through is the most well known fluoroelastomer, there are
the skin in toxic or harmful quantities. others, including Fluorel and Tecmoflon.
Splashes in the eye may cause severe irritation and When used under design conditions fluoroelastomers
could lead to loss of vision. are perfectly safe. If, however, they are exposed to
temperatures in excess of 400°C, the material will not
Brief exposure of high concentrations of vapours or
burn, but will decompose, and one of the products
mists will cause eye and throat irritation, drowsiness,
formed is hydrofluoric acid.
dizziness, headaches and, in the worst
circumstances, unconsciousness. This acid is extremely corrosive and may be absorbed
directly, through contact, into the general body
Repeated or prolonged exposure to excessive but
system.
lower concentrations of vapours or mists, for which
there might not be adequate warning indications, can O-rings, seals or gaskets which have been exposed to
cause more serious toxic or harmful effects. very high temperatures will appear charred or as a
black sticky substance.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of DO NOT, under any circumstances touch them or the
swallowing. attached components.
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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
affected O-ring, seal or gasket. If they are of natural Oxy-acetylene torches may be used for welding and
rubber or nitrile there is no hazard. If in doubt, be cutting, and special care must be taken to prevent
cautious as the material may be Viton or any leakage of these gases, with consequent risk of fire
fluoroelastomer. and explosion.
If Viton or any other fluoroelastomers have been The process will produce metal spatter and eye and
used, the affected area should be decontaminated skin protection is necessary.
before the commencement of work. The flame is bright, and eye protection should be
Disposable heavy duty plastic gloves should be worn used, but the ultra-violet emission is much less than
at all times, and the affected area washed down using that from arc welding, and lighter filters may be used.
wire wool and a limewater (calcium hydroxide) The process itself produces few toxic fumes, but such
solution to neutralise the acid before disposing of the fumes and gases may be produced from coatings on
decomposed Viton residue and final cleaning of the the work, particularly during cutting away of damaged
area. After use, the plastic gloves should be discarded body parts, and inhalation of the fumes should be
carefully and safely. avoided.
In brazing, toxic fumes may be produced from the
Welding metals in the brazing rod, and a severe hazard may
See also Fire, Electric Shock, Gas Cylinders. arise if brazing rods containing cadmium are used. In
Welding processes include Resistance Welding (Spot this event particular care must be taken to avoid
Welding), Arc Welding and Gas Welding. inhalation of fumes and expert advice may be
required.
Resistance Welding Special precautions must be taken before any welding
This process may cause particles of molten metal to or cutting takes place on vessels which have
be emitted at a high velocity, and the eyes and skin contained combustible materials, for example boiling
must be protected. or steaming out of fuel tanks .
Arc Welding Warning Symbols on Vehicles

This process emits a high level of ultra-violet radiation Decals showing warning symbols will be found on
which may cause arc-eye and skin burns to the various vehicle components.
operator and to other persons nearby. Gas-shielded These decals must not be removed. The warnings are
welding processes are particularly hazardous in this for the attention of owners/operators and persons
respect. Personal protection must be worn, and carrying out service or repair operations on the
screens used to shield other people. vehicle.
CONTACT LENS WEARERS ARE ADVISED TO The most commonly found decals are reproduced
REVERT TO ORDINARY SPECTACLES WHEN ARC below together with an explanation of the warnings.
WELDING as the arc spectrum is believed to emit
microwaves which dry out the fluid between the lens
and the eye. This may result in blindness when the
lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and
skin protection is necessary.
The heat of the welding arc will produce fumes and
gases from the metals being welded, the rods and
from any applied coatings or contamination on the
surfaces being worked on. These gases and fumes
may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
the fumes from the working area may be necessary
particularly in cases where the general ventilation is
poor, or where considerable welding work is
1. Components or assemblies displaying the caution
anticipated. In extreme cases or confined spaces
triangle and open book symbol advise
where adequate ventilation cannot be provided,
consultation of the relevant section of the owners
air-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 conjunction
triangle with the ‘electrified’ arrow and open book with 5 above) warn of the presence of potentially
symbol give warning of inherent high voltages. explosive matter within the immediate vicinity.
Never touch these with the engine running or the
ignition switched on. See Electric Shock in this
subsection.
6. Displaying this symbol warn that children should

not be allowed in the immediate vicinity
unsupervised.
3. Components or assemblies displaying this symbol
give warning that the component contains a White Spirit
corrosive substance. See Acids and Alkalis in this See Solvents.
subsection.
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always
make sure that:
the parking brake is applied or the wheels are
securely chocked to prevent the vehicle moving
forwards or backwards.
the key is removed from key operated hood locks
before any work is carried out around the front of
the vehicle.
if the engine is to be run, there is adequate
ventilation, or an extraction hose to remove
exhaust fumes.
4. Displaying the caution circle with a deleted lighted
match symbol, caution against the use of naked there is adequate room to raise the vehicle and
lights or flames within the immediate vicinity due remove the wheels, if necessary.
to the presence of highly flammable or explosive fender covers are always fitted if any work is to be
liquids or vapours. See Fire in this subsection. carried out in the engine compartment.
G17373 en 01/2003 2003.0 BA Falcon

the battery is disconnected if working on the do not work on the fuel lines or system
engine. components unless the alternative fuel has been
evacuated and the pressure in the system is
CAUTION: When electric arc welding on a reduced to atmospheric, or less
vehicle, always disconnect the generator wiring to do not use anything other than the specified leak
prevent the possibility of a surge of current detector fluid to trace fuel leaks
causing damage to the internal components of the
Be aware of situations that may cause the LPG or
generator.
CNG fuel system to vent off fuel, such as:
If using welding equipment on the vehicle, a
extremely hot days
suitable fire extinguisher is readily available.
parking by a space heater
Alternative Fuel hoisting a vehicle up near a ceiling heater
Only 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.
Failure to follow these instructions may result in Towing the Vehicle
personal injury.
If the odour of liquified petroleum gas (LPG) or WARNING: When the vehicle is being towed
compressed natural gas (CNG) is present in the air in the ignition switch must be in position II (steering
the workshop, warn all persons in the area to: lock released and warning lights illuminated).
extinguish all flames and lighted tobacco. Only then will the steering, turn signal lamps,
horn and stop lamps be operational. Failure to
shut 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,
contact fire control authorities. the gear selector must be in position N (Neutral).
remove the vehicle to a dedicated, ventilated Never tow a vehicle with automatic transmission
area. faster than 30 mph (50 km/h) or further than 30 miles
(50 km). If it is necessary to tow the vehicle a greater
Alternative Fuel — Do’s distance, the drive wheels must be lifted clear off the
ground.
do work on the vehicle in a designated area that
is well ventilated and its access restricted to Alternatively the vehicle can be transported on a low
qualified personnel only loader or a trailer.
install new warning labels to their original Connecting a Slave Battery Using Jumper
locations Cables
if possible always isolate the alternative fuel tank,
run the vehicle on the alternative fuel until it WARNING: If the slave battery has recently
automatically switches to its normal fuel prior to been charged and is gassing, cover the vent plugs
taking the vehicle into the workshop/service area or covers with a damp cloth to reduce the risk of
only use tested and approved components and explosion should arcing occur when connecting
pipes when repairing or servicing LPG and CNG the jumper cables. Failure to follow these
systems instructions may result in personal injury.
Alternative Fuel — Do Nots CAUTION: A discharged battery condition
do not vent off LPG fuel may have been caused by an electrical short
do not use shop air pressure to force LPG fuel circuit. If this condition exists there will be an
from the fuel tank apparently live circuit on the vehicle even when all
normal circuits are switched off. This can cause
do not use paint drying ovens above 40°C for any arcing when the jumper cables are connected.
alternative fuel vehicles. LPG and CNG fuel tanks
should be removed from the vehicles prior to CAUTION: While it is not recommended that
being put into paint drying ovens above 40°C the vehicle is jump started, it is recognized that
do not modify the system or install new this may occasionally be the only practical way to
components with parts not designed for gas mobilize a vehicle. In such an instance the
vehicles discharged battery must be recharged
do not evacuate fuel tanks unless there is repair immediately after jump starting to avoid
that requires removed of the fuel tank permanent damage.
G17373 en 01/2003 2003.0 BA Falcon

Always make sure that the jumper cables are Component Cleaning
adequate for the task. Heavy duty cables must be
used. To prevent ingress of dirt, accumulations of loose dirt
and greasy deposits should be removed before
Always make sure that the slave battery is of the disconnecting or dismantling components or
same voltage as the vehicle battery. The batteries
assemblies.
must be connected in parallel.
Components should be thoroughly cleaned before
Always 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 cleaning
removal of loose dirt with soft or cable brushes
scraping dirt off with a piece of metal or wood
wiping off with a rag
CAUTION: Compressed air is sometimes

‘wet’ so use with caution, especially on hydraulic
systems.
blowing dirt off with compressed air. (Eye
protection must be worn when using this method)
removal of dry dust using vacuum equipment.
This method should always be used to remove
friction lining material dust (asbestos particles)
steam cleaning
WARNING: Make sure that the ends of the
jumper cables do not touch each other or ground WARNING: Most solvents require careful
against the vehicle body at any time while the handling and some are harmful. Refer to Health
cables are attached to the battery. A fully charged and Safety Precautions and to the manufacturers
battery, if shorted through jumper cables, can literature for safety precautions. Failure to follow
discharge at a rate well above 1000 amps causing these instructions may result in personal injury.
violent arcing and very rapid heating of the Various solvents are available which are suitable for
jumper cables and terminals, and can even cause component cleaning. Some components such as
the battery to explode. Failure to follow these brake hydraulic parts and electrical assemblies should
instructions may result in personal injury. be cleaned only with recommended solvents — refer
Always connect the jumper cables in the following to Solvents, Sealers and Adhesives or to the section
sequence: of the manual relevant to the component.
slave battery positive first then vehicle battery Calibration of Essential Measuring
positive Equipment
slave battery negative next and then vehicle
ground at least 12 inches (300 mm) from the WARNING: Failure to follow these
battery 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 essential
Before 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 the
voltage peak when the cables are removed. manufacturers instructions.
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short Solvents, Sealers and Adhesives
the ends of the cables.
Introduction
Do not rely on the generator to restore a discharged
battery. For a generator to recharge a battery, it would
take in excess of eight hours continuous driving with WARNING: Always handle all solvents,
no additional loads placed on the battery. sealers and adhesives with extreme care. Some
contain chemicals or give off fumes which can be
dangerous to health. Always follow the
manufacturers instructions. If in doubt about any
G17374 en 01/2003 2003.0 BA Falcon

substance, particularly a solvent, DO NOT use it.
CAUTION: If in doubt about the suitability of

any proprietary solvent or sealer for a particular
application, contact the manufacturer of the
product for information regarding storage,
handling and application.
The Health and Safety Precautions subsection refers
to some commonly used chemicals and materials,
hazards associated with their use, and safety
measures to be taken. Some of these chemicals may
be included in the following list either in their own right
or as an ingredient in a sealer or adhesive.
General Specifications
Anti-Seize Compound
Ford Spec.
General SAM-1C-9107A
SAM-1C-9107A
Spark plug threads ESE-M1244-A
Sealers
Application Ford Spec. Manufacturer and Identification
For camshaft bearing caps ESK-M4G260-A Loctite 518
For cylinder block WSK-M4G320-A Hylosil 502
For fitting rear lamp assembly WSK-M4G329-ABC
For transmission housing (80 gram can) Finis Code 6 160 443
Adhesives
Application Ford Spec.
PU for windscreen, side and rear glass Finis Code 6 997 259
Road/Roller Testing Engine oil level
Engine coolant level
Road or roller testing may be carried out for various Tires, for correct pressure, compatible types and
reasons and a procedure detailing pre-test checks,
tread patterns, and wear within limits.
through engine starting and stopping, pre-driving
checks, on-test checks to final checks on completion There is sufficient fuel in the tank to complete the
of the test is given overleaf. test.
Unless complete vehicle performance is being All around the engine, transmission and under the
checked, the full road test procedure need not be vehicle for oil, coolant, hydraulic and fuel leaks.
carried out. Instead, those items particularly relevant Make a note of any apparent leaks and wipe off
to the system/s being checked can be extracted. the surrounding areas to make it easier to identify
the extent of the leak on completion of the test.
Pre-Test Checks
Starting the Engine
WARNING: If the brake system hydraulic fluid NOTE: On initial drive away from cold and within the
level is low, pedal travel is excessive or a first 1.5 km (1 mile), do not depress accelerator pedal
hydraulic leak is found, do not attempt to road beyond half travel until the vehicle has attained a
test the vehicle until the reason for the low fluid minimum speed of 25 km/h (15 miles/h). Never
level, excessive pedal travel or hydraulic leak is operate at high engine speed or with the accelerator
found and rectified. pedal at full travel whilst the engine is cold.
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,
lights and steering, should always be carried out The gear lever is in neutral.
before the road or roller test.
G17374 en 01/2003 2003.0 BA Falcon

All instrument gauges (except fuel gauge) read Brake Testing

zero.
With the ignition switched on, check: WARNING: When brake testing, avoid
Ignition controlled warning lights come on. breathing the smoke or fumes from hot brakes,
Engine temperature gauge registers a reading this may contain asbestos dust which is
compatible with the engine temperature. hazardous to health, see Health and Safety
Precautions.
Fuel gauge registers a reading appropriate to the
fuel level in the tank. Avoid brake testing on busy roads where it can cause
inconvenience or danger to other road users.
The operation of the handbrake warning light and
fluid level warning indicator light.
CAUTION: Brake testing which includes
On Road or Roller Test Check: heavy brake applications should not be carried
out with new brake pads/discs or linings/drums
until the components have bedded-in. New brake
CAUTION: If road testing, check the brake friction components will not reach full efficiency
operation while still travelling at low speed before until the bedding-in process is complete.
continuing with the test. If the brakes pull to one
side, or appear to be otherwise faulty, do not Test the brakes at several speeds within the normal
continue with the road test until the fault has been operating range using both light and heavy pedal
found and rectified. pressure. Note any tendency to snatch, pull or drag,
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 to
Initial gear engagement is smooth and there is no pull to one side, or evidence that the brakes are
evidence of clutch drag. binding.
Handbrake control operates smoothly and the After stopping the vehicle (not immediately after a
handbrake releases quickly and completely. period of heavy braking), carefully check the brake
Clutch takes up the drive smoothly, without slip or temperature. A disc which feels hot, or appreciably
judder. hotter than the others, indicates that the brake is
Gear changing is smooth, and there are no binding.
abnormal 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 components
is 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 or
returns to idle correctly. lack of lubrication.
There is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
Steering operation, including power steering
where fitted, is smooth, accurate, not excessively
heavy or with excessive free play or vibration.
Does not pull to one side and self centres
smoothly after cornering.
Speedometer, oil pressure warning lamp, coolant
temperature gauge and tachometer (where fitted)
register the correct readings or operate correctly.
Switches and controls operate smoothly and
positively, warning or indicator lights operate
correctly and the direction indicator control self
cancels when the steering is returned to the
straight ahead position.
Heating and ventilation systems work correctly
and effectively.
Brake operation and efficiency.
G17375 en 01/2003 2003.0 BA Falcon

100-01-1 Identification Codes 100-01-1
SECTION : 100-01 Identification Codes

CONTENTS PAGE
Identification Codes ..............................................................................................................100-01-2
Vehicle Identification Number ..............................................................................................100-01-2
Vehicle Compliance (VC) Label .............................................................................................100-01-5
Emission Decal ....................................................................................................................100-01-6
01/2003 2003.0 BA Falcon

Identification Codes
Vehicle Identification Number
The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is
printed on a label located in the engine compartment or on the driver’s side A-pillar as shown. The VIN
number is also found on the vehicle compliance (VC) label located in the same area.
Typical Identification Plate Locations
Identification Label (engine bay)
G86656 en 01/2003 2003.0 BA Falcon

Identification Label (A-pillar)
G86656 en 01/2003 2003.0 BA Falcon

Body Style Code

BODY TYPE CODE
XT Sedan SW
XT Wagon WA
Futura Sedan SW
Futura Wagon WA
XR Sedan SW
XR Ute CM
GT Sedan SW
Fairmont Sedan SW
Fairmont Wagon WA
Fairmont Ghia Sedan SW
Fairlane Ghia LW
LTD LW
XL Ute CM
XLS Ute CM
Model Code
Body Type Body Style Model Code
Sedan XT 18333
Wagon XT 18363
Sedan Futura 18334
Wagon Futura 18364
Sedan XR 18335
Sedan FMT 18332
Wagon FMT 18332
Sedan FMT Ghia 18338
Sedan Fairlane Ghia 18349
Sedan LTD 18346
Ute XL Tray 45313
Ute XL SSB 45373
Ute XR Tray 45375
Ute XLS Tray 45314
Ute XLS SSB 45374
G86656 en 01/2003 2003.0 BA Falcon

Paint Colour and Code with the Design Rules referred to on the compliance
Colour Code label of the vehicle.
Winter White A1 Such Laws must be complied with at all times.
Failure to do so may result in Substantial Financial
Venom VF
Penalties. Where State/Territory Laws differ from the
Ice Mint Silver EI repair manual procedures, the Laws MUST take
Barossa Reb B7 precedence.
Congo Green DG To ensure continuing compliance it is imperative that
Silhouette ST the engine/emission system is serviced according to
the specified procedure. A typical compliance plate is
Blue Print UU shown below.
Narooma Blue NR
Compliance Plate (engine bay)
Phantom P3
Mercury Silver M7
Blue Pearl CP
Acid Rush RH
Citric Acid JA
Blood Orange HO
Victorian Taxi Yellow 44
Taxi Orange 22
Trim Colour and Code
Colour Code
Stone S1
Warm Charcoal B1
Vehicle Compliance (VC) Label

Australian Design Rules (A.D.R.) reuire vehicle
manufacturere to comply with specific requirements
regarding consumer, environment protection, and
safety devices. A compliance plate is fitted to the
vehicle and this contains codes which relate to
specific design rules in effect at the time of vehicle
manufacture.
Legiclation requires that no alteration be made to a
vehicle that would result in the vehicle not complying
G86657 en 01/2003 2003.0 BA Falcon

Compliance Plate (A-pillar)
Emission Decal
Emission Control Information Decal is affixed to the
underside of the bonnet. Should this decal become
mutilated or unreadable, a new decal must be
obtained and affixed to the vehicla. To ensure
contained compliance it is imperative that the engine
and emission system is serviced according to the
service procedures outlined in this manual.
Should it become necessary to replace a component
which affects vehicle emissions, it is mandatory that
the replacement part be of the same calibration as the
original part.
No circumstances would permit the disconnection,
alteration or modification of any emission related
component on vehicles marketed by Ford Sales
Company of Australia Limited, except in accordance
with the diagnostic, maintenance and repair
procedures specified in the Company’s service
materials.
Any person who removes, modifies or otherwise
renders ineffective any emission control components
fitted to a vehicle could be contravening the relevant
regulations and be guilty of an offence under the
regulations. Any person who owns and/or operates
such a vehicle could also be guilty of an offence
under the regulations.
G86657 en 01/2003 2003.0 BA Falcon

100-02-1 Jacking and Lifting 100-02-1
SECTION : 100-02 Jacking and Lifting

CONTENTS PAGE
Jacking ..................................................................................................................................100-02-2
Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-2
Jacking/Lifting Points - Ute ..................................................................................................100-02-2
01/2003 2003.0 BA Falcon

100-02-2 Jacking and Lifting 100-02-2
Jacking Jacking/Lifting Points - Ute
WARNING: Do not run the engine when

jacking the vehicle. The wheels contacting the
ground could cause the vehicle to move. Failure
to follow these instructions may result in personal
injury.
WARNING: Make sure the jack and jack

stands are correctly located to prevent the vehicle
from falling. Failure to follow these instructions
may result in personal injury.
WARNING: Wheel chocks should be used to

prevent the vehicle from rolling and falling off the
jack. Failure to follow these instructions may 1. The front jacking\lifting point for the ute is on the
result 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
vehicle is only intended to be used in an 2. The rear jacking\lifting point for the ute is on the
emergency for changing a deflated tire. Never use leaf spring hanger bracket.
the service jack to hoist the vehicle for any other
service. Refer to the Owner Guide when using the
jack supplied with the vehicle.
Jacking/Lifting Points - Sedan/Wagon
1. The front jacking\lifting point for sedan and wagon

is on the sill at the point where the rocker
moulding has been cut away to expose the sill.
2. The rear jacking\lifting point for the sedan and
wagon is on the sill at the point where the rocker
moulding has been cut away to expose the sill.
G72676 en 01/2003 2003.0 BA Falcon

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

CONTENTS PAGE
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
01/2003 2003.0 BA Falcon

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

nature. Vibration is any motion, shaking or trembling,
Acceleration-Light
that can be felt or seen when an object moves back
and forth or up and down. Harshness is a ride quality An increase in speed at less than half throttle.
issue where the vehicle’s response to the road
Acceleration-Medium
transmits sharply to the customer. Harshness
normally describes a firmer than usual response from An increase in speed at half to nearly full throttle,
the suspension system. Noise, vibration and such as 0-97 km/h (0-60 mph) in approximately 30
harshness (NVH) is a term used to describe these seconds.
conditions, which result in varying degrees of
dissatisfaction. Although, a certain level of NVH Acceleration-Heavy
caused by road and environmental conditions is An increase in speed at one-half to full throttle, such
normal. This section is designed to aid in the as 0-97 km/h (0-60 mph) in approximately 20
diagnosis, testing and repair of NVH concerns. seconds.
Acceptable Noise, Vibration and Ambient Temperature
Harshness The surrounding or prevailing temperature.
All internal combustion engines and drivelines Amplitude
produce some noise and vibration; operating in a real
world environment adds noise that is not subject to The quantity or amount of energy produced by a
control. Vibration isolators, mufflers and dampers vibrating component (G force). An extreme vibration
reduce these to acceptable levels. A driver who is has a high amplitude. A mild vibration has a low
unfamiliar with a vehicle can think that some sounds amplitude.
are abnormal when actually the sounds are normal for
Backlash
the vehicle type. For example, Traction-Lok®
differentials produce a slight noise on slow turns after Gear teeth clearance.
extended highway driving. This is acceptable and has
Boom
no detrimental effect on the locking axle function. As a
technician, it is very important to be familiar with Low frequency or low pitched noise often
vehicle features and know how they relate to NVH accompanied by a vibration. Also refer to Drumming.
concerns and their diagnosis. If, for example, the
vehicle has automatic overdrive it is important to test Bound Up
drive the vehicle both in and out of overdrive mode. An overstressed isolation (rubber) mount that
transmits vibration/noise instead of absorbing it.
Diagnostic Theory
Brakes Applied
The shortest route to an accurate diagnosis results
from: When the service brakes are applied with enough
force to hold the vehicle against movement with the
system knowledge, including comparison with a transmission in gear.
known good system.
system history, including repair history and usage Buffet/Buffeting
patterns. Strong noise fluctuations (less than 1000 Hz) caused
condition history, especially any relationship to by gusting winds. An example would be wind gusts
repairs or sudden change. against the side glass.
knowledge of possible sources.
Buzz
using a systematic diagnostic method that divides
A low-pitched sound (200-5000 Hz) like that from a
the 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 (200–800 Hz)
harshness concerns requires: vibration. Vibration feels similar to an electric razor.
a road or system test to determine the exact
nature of the concern. Camber
an analysis of the possible causes. The angle of the wheel in relation to the true vertical
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 the
a road test or system test to make sure the vehicle.
concern has been corrected or brought back to
G72678 en 01/2003 2003.0 BA Falcon

Clonk
A hydraulic knocking sound. Sound occurs with air
pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency sound.
Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Coast/Deceleration
Releasing the accelerator pedal at cruise, allowing the
engine to reduce vehicle speed without applying the
brakes.
Caster Coast/Neutral Coast
The angle of the steering knuckle in relation to the Placing the transmission range selector in NEUTRAL
true vertical as measured looking from the side of the (N) or depressing the clutch pedal while at cruise.
vehicle.
Constant Velocity (CV) Joint
A joint used to absorb vibrations caused by driving
power being transmitted at an angle.
Controlled Rear Suspension Height

The height at which a designated vehicle element
must be when driveline angle measurements are
made.
Coupling Shaft
The shaft between the transfer case and the front
drive axle or, in a two-piece rear driveshaft, the front
section.
CPS
Cycles per second. Same as hertz (Hz).
Item Description
1 True vertical Cracks
2 Positive caster A mid-frequency sound, related to squeak. Sound
varies with temperature conditions.
3 Steering axis
Creak
Chatter A metallic squeak.
A pronounced series of rapidly repeating rattling or
clicking sounds. Cruise
Constant speed on level ground; neither accelerating
Chirp nor decelerating.
A short-duration high-pitched noise associated with a
slipping drive belt. Cycle
The process of a vibrating component going through a
Chuckle complete range of motion and returning to the starting
A repetitious low-pitched sound. A loud chuckle is point.
usually described as a knock.
Decibel
Click A unit of measurement, referring to sound pressure
A sharp, brief, non-resonant sound, similar to level, abbreviated dB.
actuating a ball point pen.
Drive Engine Run-Up (DERU) Test
The operation of the engine through the normal rpm
range 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 unbalanced
used for noise and vibration checks. wheel and tyre assemblies can cause wheel shimmy.
Driveline Angles Engine Imbalance

The differences of alignment between the A condition in which an engine’s center mass is not
transmission output shaft, the driveshaft, and the rear concentric to the rotation center, causing excessive
axle pinion centerline. motion.
Engine Misfire
When combustion in one or more cylinders does not
occur or occurs at the wrong time.
Engine Shake
An exaggerated engine movement or vibration that
directly increases in frequency as the engine speed
increases. It is caused by non-equal distribution of
mass in the rotating or reciprocating components.
Flexible Coupling
A flexible joint.
Float
A drive mode on the dividing line between cruise and
Item Description coast where the throttle setting matches the engine
1 Engine speed with the road speed.
2 Driveshaft
Flutter
3 Differential
Mid to high (100-200 Hz) intermittent sound due to air
flow. Similar to a flag flapping in the wind.
Driveshaft
The shaft that transmits power to the rear axle input Frequency
shaft (pinion shaft). In a two-piece driveshaft, it is the The rate at which a cycle occurs within a given time.
rearmost shaft.
Gravelly Feel
Drivetrain A grinding or growl in a component, similar to the feel
All power transmitting components from the engine to experienced when driving on gravel.
the wheels; includes the clutch or torque converter,
the transmission, the transfer case, the driveshaft, Grind
and the front or rear drive axle. An abrasive sound, similar to using a grinding wheel,
or rubbing sand paper against wood.
Drivetrain Damper
A weight attached to the engine, the transmission, the Hiss
transfer case, or the axle. It is tuned by weight and Steady high frequency (200–800 Hz) noise. Vacuum
placement to absorb vibration. leak sound.
Drone Hoot
A low frequency (100-200 Hz) steady sound, like a A steady low frequency tone (50-500 Hz), sounds like
freezer compressor. Also described as a moan. blowing over a long neck bottle.
Drumming Howl
A cycling, low-frequency (20–100 Hz), rhythmic noise A mid-range frequency (200-800 Hz) noise between
often 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
rolling thunder. Hum
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
centerline, so that when the wheel and tyre assembly Hz
spins, 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

Imbalance
Out of balance; heavier on one side than the other. In
a rotating component, imbalance often causes
vibration.
Inboard
Toward the centerline of the vehicle.
Intensity
The physical quality of sound that relates to the
strength of the vibration (measured in decibels). The
higher the sound’s amplitude, the higher the intensity
and vice versa.
Isolate
To separate the influence of one component to Item Description
another. 1 Lateral runout
Knock 2 Radial runout
A heavy, loud, repetitious sound, like a knock on the
door. Rattle
A random and momentary or short duration noise.
Moan
A constant, low-frequency (100–200 Hz) tone. Also Rotary Blade Coupling (RBC)
described as a hum. This part is attached to the rear axle on 4WD
vehicles. It includes an internal hydraulic pump and
Neutral Engine Run-Up (NERU) Test clutch pack to control the torque supplied to the rear
The operation of the engine through the normal rpm axle/wheels. It also has an internal electromagnetic
range with the vehicle standing still and the clutch to lock to the RCB for the 4WD ON mode. This
transmission disengaged. This test is used to identify unit is not to be disassembled and if necessary a new
engine related vibrations. unit must be installed.
Neutralize/Normalize Ring Gear

To return to an unstressed position. Used to describe The large, circular, driven gear in a ring and pinion
mounts. Refer to Bound Up. gearset.
Outboard Road Test

Away from the centerline of the vehicle. The operation of the vehicle under conditions
intended to produce the concern under investigation.
Ping
A short duration, high-frequency sound, which has a Roughness
slight echo. A medium-frequency vibration. A slightly higher
frequency (20 to 50 Hz) than a shake. This type of
Pinion Shaft vibration is usually related to drivetrain components.
The input shaft in a driving axle that is usually a part
of the smaller driving or input hypoid gear of a ring Runout
and pinion gearset. Lateral runout means measuring the movement or
“wobble” of a wheel or tyre at the sidewall. Radial
Pitch runout means measuring the out-of-round of the tyre
The physical quality of sound that relates to its tread surface.
frequency. Pitch increases as frequency increases
and vice versa. Rustling
Intermittent sound of varying frequency (100-200 Hz),
Pumping Feel sounds similar to shuffling through leaves.
A slow, pulsing movement.
Shake
Radial/Lateral A low-frequency vibration (5–20 Hz), usually with
Radial is in the plane of rotation; lateral is at 90 visible component movement. Usually relates to tyres,
degrees to the plane of rotation. wheels, brake drums or brake discs if it is vehicle
G72678 en 01/2003 2003.0 BA Falcon

speed sensitive, or engine if it is engine speed warm. Also, irregular tyre wear patterns in the tyre
sensitive. Also referred to as a shimmy or wobble. tread resulting from wheel-locked skids.
Shimmy Tyre Force Vibration

An abnormal vibration or wobbling, felt as a A tyre vibration caused by variations in the
side-to-side motion of the steering wheel in the construction of the tyre that is noticeable when the
driveshaft rotation. Also described as waddle. tyre rotates against the pavement. This condition can
be present on perfectly round tyres because of
Shudder variations in the inner tyre construction. This condition
A low-frequency vibration that is felt through the can occur at wheel rotation frequency or twice rotation
steering wheel or seat during light brake application. frequency.
Slap Transient
A resonance from flat surfaces, such as safety belt A noise or vibration that is momentary, a short
webbing or door trim panels. duration.
Slip Yoke/Slip Spline Two-Plane Balance

The driveshaft coupling that allows length changes to Radial and lateral balance.
occur while the suspension articulates and while the
driveshaft rotates. Vibration
Any motion, shaking or trembling, that can be felt or
Squeak seen when an object moves back and forth or up and
A high-pitched transient sound, similar to rubbing down.
fingers against a clean window.
Whine
Squeal A constant, high-pitched noise. Also described as a
A long-duration, high-pitched noise. screech.
Static Balance Whistle

The equal distribution of weight around the wheel. High-pitched noise (above 500 Hz) with a very narrow
Statically unbalanced wheel and tyre assemblies can frequency band. Examples of whistle noises are a
cause a bouncing action called wheel tramp. This turbocharger or airflow around an antenna.
condition will eventually cause uneven tyre wear.
Wind Noise
Tap Any noise caused by air movement in, out or around
A light, rhythmic, or intermittent hammering sound, the vehicle.
similar to tapping a pencil on a table edge.
WOT
Thump The acronym wide-open throttle is WOT.
A dull beat caused by two items striking together.
Tick
A rhythmic tap, similar to a clock noise.
Tip-In Moan
A light moaning noise heard during light vehicle
acceleration, usually between 40-100 km/h (25-65
mph).
TIR
The acronym for the total indicated runout is TIR.
Tyre Deflection
The change in tyre diameter in the area where the
tyre contacts the ground.
Tyre Flat Spots

A condition commonly caused by letting the vehicle
stand while the tyres cool off. This condition can be
corrected by driving the vehicle until the tyres are
G72678 en 01/2003 2003.0 BA Falcon

Noise, Vibration and Harshness (NVH)

To assist the service advisor and the technician, a
Write-up Job Aid and an NVH Diagnostic Guide are
included with this material. The Write-up Job Aid
serves as a place to record all important symptom
information. NHV Diagnostic Guide serves as a place
to record information reported on the Write-up Job Aid
as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH
Diagnostic Guide, record the reported findings, then
proceed to each of the numbered process steps to
complete the diagnosis.
G72679 en 01/2003 2003.0 BA Falcon

DIAGNOSIS AND TESTING (Continued)
G72679 en 01/2003 2003.0 BA Falcon

G72679 en 01/2003 2003.0 BA Falcon

1: Customer Interview The engine speed is an important factor in arriving

at a final conclusion. Therefore, connect an
The diagnostic process starts with the customer accurate tachometer to the engine, even if the
interview. The service advisor must obtain as much vehicle has a tachometer. Use a tachometer that
information as possible about the concern and take a has clearly defined increments of less than 50
test drive with the customer. There are many ways a rpm. This ensures an exact engine speed reading.
customer will describe NVH concerns and this will
help minimize confusion arising from descriptive 4: Verify the Customer Concern
language differences. It is important that the concern
Verify the customer concern by carrying out a road
is correctly interpreted and the customer descriptions
are recorded. During the interview, ask the following test, an engine run-up test, or both.
questions: The decision to carry out a road test, an engine
run-up test, or both depends on the type of NVH
When was the concern first noticed?
concern. A road test may be necessary if the
Did the concern appear suddenly or gradually? symptom relates to the suspension system or is
Did any abnormal occurrence coincide with or sensitive to torque. A drive engine run-up (DERU) or a
proceed its appearance? neutral engine run-up (NERU) test identifies noises
Use the information gained from the customer to and vibrations relating to engine and drivetrain rpm.
accurately begin the diagnostic process. Remember, a condition will not always be identifiable
by carrying out these tests, however, they will
2: Pre-Drive Check eliminate many possibilities if carried out correctly.
It is important to do a pre-drive check before road 5: Road Test
testing the vehicle. A pre-drive check verifies that the
vehicle is relatively safe to drive and eliminates any NOTE: It may be necessary to have the customer ride
obvious faults on the vehicle. along or drive the vehicle to point out the concern.
During the road test, take into consideration the
The pre-drive check consists of a brief visual customer’s driving habits and the driving conditions.
inspection. During this brief inspection, take note of
The customer’s concern just may be an acceptable
anything that will compromise safety during the road
operating condition for that vehicle.
test and make those repairs or adjustments before
taking the vehicle on the road. The following is a brief overview of each test in the
order in which it appears. A review of this information
3: Preparing for the Road Test helps to quickly identify the most appropriate process
Observe the following when preparing for the road necessary to make a successful diagnosis. After
test: reviewing this information, select and carry out the
appropriate test(s), proceeding to the next step of this
Review the information recorded on the NVH process.
Diagnostic Guide. It is important to know the
specific concern the customer has with the The Slow Acceleration Test is normally the first
vehicle. test to carry out when identifying an NVH concern,
especially when a road test with the customer is
Do not be misled by the reported location of the
not possible.
noise or vibration. The cause can actually be
some distance away, transferred from another The Heavy Acceleration Test helps to determine if
part of the vehicle. the concern is torque-related.
Remember that the vibrating source component The Neutral Coast Down Speed Test helps to
(originator) may only generate a small vibration. determine if the concern is vehicle speed-related.
This small vibration can in turn cause a larger The Downshift Speed Test helps to determine if
vibration or noise to emanate from another the concern is engine speed-related.
receiving component (reactor), due to contact with The Steering Input Test helps to determine how
other components (transfer path). the wheel bearings and other suspension
Conduct the road test on a quiet street where it is components contribute to a vehicle speed-related
safe to duplicate the vibration or noise. The ideal concern.
testing route is an open, low-traffic area where it The Brake Test helps to identify vibrations or
is possible to operate the vehicle at the speed in noise that are brake-related.
which the condition occurs.
The Road Test Over Bumps helps isolate a noise
If possible, lower the radio antenna in order to that occurs when driving over a rough or bumpy
minimize turbulence. Identify anything that could surface.
potentially make noise or be a source of wind
noise. Inspect the vehicle for add-on items that The Engine Run-Up Tests consist of the Neutral
Run-up Test and the Engine Load Test. These
create vibration/noise. Turn off the radio and the
heating and cooling system blower.
G72679 en 01/2003 2003.0 BA Falcon

tests help to determine if the concern is engine Downshift Speed Test

speed-related.
To carry out this test, proceed as follows:
The Neutral Run-up Test is used as a follow-up
test to the Downshift Speed Test when the Shift into a lower gear than the gear used when
concern occurs at idle. carrying out the Slow Acceleration Test.
The Engine Load Test helps to identify Drive at the engine rpm where the concern
vibration/noise sensitive to engine load or torque. occurs.
It also helps to reproduce engine speed-related The concern is engine speed related if duplicated
concerns that cannot be duplicated when carrying while carrying out this test. This eliminates the
out the Neutral Run-up Test or the Neutral Coast tyres, wheels, brakes and the suspension
Down Test. components as sources.
The Engine Accessory Test helps to locate faulty If necessary, repeat this test using other gears
belts and accessories that cause engine and NEUTRAL to verify the results.
speed-related concerns. Proceed as necessary.
The Vehicle Cold Soak Procedure helps to
identify concerns occurring during initial start-up
Steering Input Test
and when an extended time lapse occurs between To carry out this test, proceed as follows:
vehicle usage. Drive at the speed where the concern occurs,
Slow Acceleration Test while making sweeping turns in both directions.
If the concern goes away or gets worse, the
To carry out this test, proceed as follows: wheel bearings, hubs, U-joints (contained in the
Slowly accelerate to the speed where the reported axles of 4WD applications), and tyre tread wear
concern occurs. Note the vehicle speed, the are all possible sources.
engine rpm and, if possible, determine the Proceed as necessary.
vibration frequency.
Attempt to identify from what part of the vehicle Brake Test
the concern is coming. To carry out this test, proceed as follows:
Attempt to identify the source of the concern. Warm the brakes by slowing the vehicle a few
Proceed as necessary. times from 80–32 km/h (50–20 mph) using light
braking applications. At highway speeds of 89–97
Heavy Acceleration Test km/h (50–60 mph), apply the brake using a light
To carry out this test, proceed as follows: pedal force.
Accelerate hard from 0-64 km/h (0-40 mph). Accelerate to 89–97 km/h (55–60 mph).
Decelerate in a lower gear. Lightly apply the brakes and slow the vehicle to
The concern is torque-related if duplicated while 30 km/h (20 mph).
carrying out this test. A brake vibration noise can be felt in the steering
Proceed as necessary. wheel, seat or brake pedal. A brake noise can be
heard upon brake application and diminish when
Neutral Coast Down Speed Test the brake is release.
To carry out this test, proceed as follows: Road Test Over Bumps
Drive at a higher rate of speed than where the To carry out this test, proceed as follows:
concern occurred when carrying out the Slow
Acceleration Test. Drive the vehicle over a bump or rough surface
one wheel at a time to determine if the noise is
Place the transmission in NEUTRAL and coast coming from the front or the back and the left or
down past the speed where the concern occurs. the right side of the vehicle.
The concern is vehicle speed-related if duplicated Proceed as necessary.
while carrying out this test. This eliminates the
engine and the torque converter as sources. Neutral Engine Run-up (NERU) Test
If the concern was not duplicated while carrying To carry out this test, proceed as follows:
out this test, carry out the Downshift Speed Test
Install a tachometer.
to verify if the concern is engine speed-related.
Increase the engine rpm up from an idle to
Proceed as necessary.
approximately 3,500 rpm while in PARK on front
wheel drive vehicles with automatic transmissions,
or NEUTRAL for all other vehicles. Note the
G72679 en 01/2003 2003.0 BA Falcon

engine rpm and, if possible, determine the If the vibration/noise is duplicated when carrying
vibration frequency. out this test, the belts and accessories are not
Attempt to identify what part of the vehicle the sources.
concern is coming from. If the vibration/noise was not duplicated when
Attempt to identify the source of the concern. carrying out this test, install each accessory belt,
one at a time, to locate the source.
Proceed as necessary.
Vehicle Cold Soak Procedure
Drive Engine Run-Up (DERU) Load Test
To carry out this procedure, proceed as follows:
Test preparations include matching customer
WARNING: Block the front and rear conditions (if known). If not known, document the
wheels, and apply the parking brake and the test conditions: gear selection and engine rpm.
service brake, or injury to personnel can Monitor the vibration/noise duration with a watch
result. for up to three minutes.
Park the vehicle where testing will occur. The
CAUTION: Do not carry out the Engine vehicle must remain at or below the concern
Load Test for more than five seconds or temperature (if known) for 6-8 hours.
damage to the transmission or transaxle can Before starting the engine, conduct a visual
result. inspection under the hood.
Block the front and rear wheels.
Turn the key on, but do not start the engine.
Apply the parking brake and the service brake. Listen for the fuel pump, anti-lock brake system
Install a tachometer. (ABS) and air suspension system noises.
Shift the transmission into DRIVE, and increase Start the engine.
and decrease the engine rpm between an idle to
approximately 2,000 rpm. Note the engine rpm CAUTION: Never probe moving parts.
and, if possible, determine the vibration Isolate the vibration/noise by carefully listening.
frequency. Move around the vehicle while listening to find the
Repeat the test in REVERSE. general location of the vibration/noise. Then,
If the vibration or noise is duplicated when search for a more precise location by using a
carrying out this test, inspect the engine and stethoscope or EngineEAR.
transmission or transaxle mounts. Refer to Idle Noise/Vibration in the Symptom
If the concern is definitely engine speed-related, Chart to assist with the diagnosis.
carry out the Engine Accessory Test to narrow 6: Check OASIS/TSBs/Repair History
down the source.
Proceed as necessary. After verifying the customer concern, check for OASIS
reports, TSBs and the vehicle repair history for related
Engine Accessory Test concerns. If information relating to a diagnosis/repair
is found, carry out the procedure(s) specified in that
information.
WARNING: Block the front and rear If no information is available from these sources, carry
wheels, and apply the parking brake and the out the vehicle preliminary inspection to eliminate any
service brake, or injury to personnel can obvious faults.
result. 7: Diagnostic Procedure
CAUTION: Limit engine running time to Qualifying the concern by the particular sensation
one minute or less with belts removed or present can help narrow down the concern. Always
serious engine damage will result. use the “symptom” to “system” to “component” to
NOTE: A serpentine drive belt decreases the “cause” diagnosis technique. This diagnostic method
usefulness of this test. In these cases, use a divides the problem into related areas to correct the
vibration analyzer, such as the EVA, to pinpoint customer concern.
accessory vibrations. An electronic listening Verify the “symptom”.
device, such as an EngineEAR, will also help to
identify noises from specific accessories. Determine which “system(s)” can cause the
“symptom”.
Remove the accessory drive belts.
If a vibration concern is vehicle speed related,
Increase the engine rpm to where the concern the tyre and wheel rpm/frequency or
occurs. driveshaft frequency should be calculated.
G72679 en 01/2003 2003.0 BA Falcon

If a vibration concern is engine speed related, deceleration. Goto Tire

the engine, engine accessory or engine firing Noise/Vibration.
frequencies should be calculated. Noise varies with wind/vehicle speed
After determining the “system”, use the diagnostic and direction. Goto Air Leak and
tools to identify the worn or damaged Wind Noise.
“components”. Related to engine speed.
Noise varies with engine rpm. Goto
After identifying the “components”, try to find the Engine Noise/Vibration.
“cause” of the failure.
Vibration occurs at a particular speed
Once the concern is narrowed down to a (mph) regardless of engine speed
symptom/condition, proceed to NVH Condition and (rpm).
Symptom Categories.
2. Acceleration
NVH Condition and Symptom Categories Wide open throttle (WOT)
Engine induced contact between
Operating Condition—Vehicle is Not Moving components. Inspect and repair as
1. Static operation necessary.
Noise is continuous throughout WOT.
Noise occurs during part/system functioning. Exhaust system or engine ground out.
Goto Squeak and Rattle. Goto Engine Noise/Vibration.
2. While cranking Light/moderate acceleration
1. Grinding or whine, differential ring gear or Tip-in moan. Engine/exhaust noise.
starter motor pinion noise. Goto Engine Goto Engine Noise/Vibration.
Noise/Vibration. Knock-type noise. Goto Engine
Noise/Vibration.
2. Rattle. Exhaust hanger, exhaust heat shield
Driveline shudder. Goto Driveline
or A/C line noise. Goto Squeak and Rattle. Noise/Vibration.
3. Vibration. Acceptable condition. Engine vibration. Goto Engine
3. At idle Noise/Vibration.
Idle noise. Goto Idle Noise/Vibration. 3. Turning noise. Goto Steering Noise/Vibration.
Idle vibration or shake. Goto Idle 4. Braking.
Noise/Vibration. Clicking sound is signaling ABS is active.
4. During gear selection Acceptable ABS sound.
A continuous grinding/squeal. Goto Brake
1. Vehicle parked on a steep incline. Acceptable Noise/Vibration.
noise. Brake vibration/shudder. Goto Brake
2. Vehicle parked on a flat surface. Goto Noise/Vibration.
Driveline Noise/Vibration. 5. Clutching.
3. Vehicle with a manual transmission. Goto A noise occurring during clutch operation.
Transmission (Manual) and Transfer Case Goto Transmission (Manual) and Transfer
Noise/Vibration. Case Noise/Vibration.
Vibration. Goto Transmission (Manual)
Operating Condition—Vehicle is Moving and Transfer Case Noise/Vibration.
1. Depends more on how the vehicle is operated 6. Shifting
1. Speed-related Noise or vibration condition related to the
Related to vehicle speed transmission (automatic). Goto
Pitch increases with vehicle speed. Transmission (Automatic) Noise/Vibration.
Goto Tire Noise/Vibration. Noise or vibration related to the
Noise occurs at specific vehicle transmission (manual). Goto
speed. A high-pitch noise (whine). Transmission (Manual) and Transfer
Goto Drivline Noise/Vibration. Case Noise/Vibration.
Loudness proportional to vehicle 7. Engaged in four-wheel drive. Goto
speed. Low-frequency noise at high Transmission (Manual) and Transfer Case
speeds, noise and loudness increase Noise/Vibration.
with speed. Goto Driveline
8. Cruising speeds
Noise/Vibration.
Accelerator pedal vibration. Goto Engine
A low-pitched noise (drumming). Goto Noise/Vibration.
Engine Noise/Vibration.
Driveline vibration. Goto Driveline
Vibration occurs at a particular speed
Noise/Vibration.
(mph) regardless of acceleration or
G72679 en 01/2003 2003.0 BA Falcon

A shimmy or shake. Goto Tire

Noise/Vibration.
9. Driving at low/medium speeds
A wobble or shudder. Goto Tire
Noise/Vibration.
2. Depends more on where the vehicle is operated
1. Bump/pothole, rough road or smooth road.
Goto Suspension Noise/Vibration.
Noise is random or intermittent occurring
from road irregularities. Goto Squeak and
Rattle.
Noise or vibration changes from one road
surface to another. Normal sound
changes.
Noise or vibration associated with a
hard/firm ride. Goto Suspension
Noise/Vibration.
Symptom Charts
Symptom Chart — Air Leak and Wind Noise
Condition Source Action

Air leak around door perimeter Loose fit seal. PINCH the seal carrier to improve
retention on the seal flange.
Seal installed incorrectly. REINSTALL the seal.
Door misaligned. REALIGN the door. CHECK door gaps

and fit in the door opening and
ADJUST as necessary.
Scuff plate installed incorrectly. REINSTALL the scuff plate.
Seal or seal push pins damaged. INSTALL a new seal.
Air leak around glass run Door glass misaligned. ADJUST the door glass.
Glass run installed incorrectly. ADJUST the glass run. INSERT foam
in the glass run carrier.
Leak path behind glass run. INSTALL foam rope behind the glass
run.
Glass run channel spread wide. PINCH the glass run channel to
reduce the size of the opening.
Blow-out clip bent or contacting door ADJUST the blow-out clip or INSTALL
glass. a new glass run/blow-out clip molding
assembly.
Glass run damaged. INSTALL a new glass run.
Air leak at inner belt line Belt line seal installed incorrectly on ADJUST the seal. (Do not bend the
flange. flange.)
Belt line seal integrated with door trim REINSTALL the door trim.
installed incorrectly (no glass contact).
No contact with side glass. ADJUST the door glass.

No contact with glass runs at both ADJUST the belt line seal or ADD
ends of belt line seal. foam at the seal ends.
Belt line seal damaged. INSTALL a new seal.
G72679 en 01/2003 2003.0 BA Falcon


Air leak at outer belt line Belt line seal installed incorrectly on ADJUST the seal.
flange (no glass contact).
Belt line seal does not contact the ADJUST the door glass.
glass.
No contact with glass runs at both ADJUST the belt line seal/ADD foam
ends of belt line seal. at the seal ends.
Belt line seal damaged. INSTALL a new seal.

Draft at inner door handle/speaker Hole in watershield. SEAL the hole with a suitable tape.
opening
Watershield misaligned. REALIGN the watershield. INSTALL a

new watershield if the pressure
sensitive adhesive fails.
Exterior door handle seal REALIGN or INSTALL a new seal as
misaligned/damaged. necessary.
Wind noise from exterior rear view Exterior mirror housing misaligned. REALIGN with the edges shingled
mirror correctly and no gaps.
Mirror sail gasket folded/misaligned. REINSTALL with the gasket unfolded

and aligned correctly.
Mirror housing trim cap installed REINSTALL with the edges shingled to
incorrectly. the air flow.
Air leak through mirror housing hinge. Fully ENGAGE the mirror into its
operating position/USE foam to block
the air path through the hinge.
Inner sail trim installed incorrectly. REINSTALL the sail trim/ADJUST the
door trim.
Inner sail gasket/barrier installed REINSTALL the trim cover with the
incorrectly. gasket/barrier aligned correctly.
Air path through wiring bundle/fastener BLOCK the air path(s) with foam/tape.
access holes.
Exposed fastener access hole on INSTALL a new cap if it is missing.
mirror housing/sail.
Air leak around perimeter of fixed Gaps in the sealant bead. APPLY approved sealant.
glass
Air traveling up windshield molding INSTALL foam rope the full length of
along A-pillar. the A-pillar.
Windshield/backlite misaligned or not REINSTALL the windshield/backlite.
installed correctly.
Rear hood seal at base of windshield REALIGN or INSTALL a new seal as
misaligned/damaged. necessary.
Air leak at cowl Cowl gasket misaligned/damaged. REALIGN or INSTALL a new seal as
necessary.
Air leak around liftgate perimeter Loose fit seal. PINCH the seal carrier to improve
retention on the seal flange or INSERT
foam in the carrier.
Seal misaligned. REINSTALL the seal.
Liftgate misaligned. REALIGN the liftgate. CHECK the

liftgate fit in the body opening and
ADJUST as necessary.
Scuff plate misaligned. REINSTALL the scuff plate.
Seal or seal push pins damaged. INSTALL a new seal.
G72679 en 01/2003 2003.0 BA Falcon


Air leak around the liftgate flip window Loose fit seal. PINCH the seal carrier to improve the
perimeter retention to the seal flange.
Seal misaligned. REINSTALL the seal.
Glass misaligned. REALIGN the glass.
Seal damaged. INSTALL a new seal.
Wind noise from antenna Shape of antenna. INSTALL an antenna boot or a spiral
antenna.
Air leak around antenna cable access INSPECT the antenna access hole
hole. grommet. REPAIR as necessary.
Air leak from closed roof opening Seal installed incorrectly. REINSTALL the seal.
panel
Roof opening panel glass/door REALIGN the roof opening panel
misaligned. glass/door.
Roof opening panel damaged. INSTALL a new roof opening panel.

REFER to Section 501-17 .
Buffeting from an open roof opening Wind deflector inoperative/damaged. REPAIR or INSTALL a new wind
panel deflector as necessary. REFER to
Section 501-17 .
Wind deflector height incorrect. ADJUST the wind deflector higher.

Wind noise created by airflow over or Fender splash shield misaligned. REALIGN the fender splash shield.
behind body panels
Body panel misaligned (exposed REALIGN the appropriate body panel.
edge).
Hood misaligned (front margin). CHECK hood gaps and fit. ADJUST
the hood as necessary.
Front grille edge noise. APPLY foam in the hollow areas

behind the louvers.
Wind noise created by grille opening Grille relationship to leading edge on ADJUST the grille opening panel
panel hood. forward to eliminate wind noise.
Sharp edges due to material REMOVE the sharp edges (no
imperfections. damage to visible surface).
Wind noise from air extractor Air extractor housing seated REINSTALL the air extractor housing.
incorrectly.
Air extractor housing or flaps INSTALL a new air extractor.
damaged.
Noise from roof rack Roof rack rails or crossbars loose. TIGHTEN the fasteners.
Roof rack fasteners missing. INSTALL the approved fasteners.

Roof rack crossbars installed REINSTALL the crossbars.
backward.
Roof rack rub strips partially lifting from REAPPLY adhesive or fasteners or
roof. INSTALL new rub strips as necessary.
Roof rack gaskets loose or misaligned. REINSTALL the gasket.

Wind noise from bug shield/exterior Turbulence created by location and REMOVE per customer direction if it is
windshield sun visor shape. a dealer installed option.
G72679 en 01/2003 2003.0 BA Falcon

Symptom Chart — Brake Noise/Vibration

Rattling noise Caliper mounting bolts loose. CHECK the caliper bolts. TIGHTEN to
specifications. REFER to Section
206-03 .
Damaged or worn caliper pins or CHECK the caliper pins and retainers
retainers. for lubrication and correct fit.
LUBRICATE or INSTALL new
components as necessary.
Missing or damaged anti-rattle clips or CHECK the brake pads for missing
springs. clips or broken springs. INSTALL new
components as necessary. REFER to
Section 206-03 .
Loose brake disc shield. TIGHTEN the brake disc shield bolts to
specification. REFER to Section
206-03 .
Clicking noise—with brakes applied ABS hydraulic control unit. Acceptable condition.
with ABS brakes
Squealing noise—occurs on first Disc brake pads. Acceptable condition. Caused by
(morning) brake application humidity and low disc brake pad
temperature.
Squealing noise—a continuous squeal Disc brake pads worn below minimum INSTALL new disc brake pads.
thickness. REFER to Section 206-03 .
Squealing noise—an intermittent Disc brake pads. Acceptable condition.
squeal brought on by cold, heat, water,
mud or snow
Groaning noise—occurs at low speeds Disc brake pads. Acceptable condition.
with brake lightly applied (creeping)
Grinding noise—continuous Disc brake pads worn below minimum INSPECT the brake pads, shoes,
thickness. brake discs and attaching hardware for
damage. REPAIR or INSTALL new
Section 206-03 for front disc brakes or
Section 206-02 for rear disks.
Moaning noise Brake linings contaminated with INSPECT the brake pads and shoes
grease or oil. for contamination. REPAIR or
INSTALL new components as
necessary. REFER to Section 206-03
for front disc brakes or Section 206-04
for rear disks.
Brake vibration/shudder—occurs when Uneven disc or drum wear. Go to PinPoint Test A .
brakes are applied Uneven disc brake pad or lining
transfer.
Suspension components.
Brake vibration/shudder—occurs when Brake drag. INSPECT the brake pads and shoes
the brake pedal is released for premature wear. REPAIR or
INSTALL a new caliper or wheel
cylinder as necessary. REFER to
Section 206-03 for front disc brakes or
Section 206-04 for rear disk brakes.
Symptom Chart—Driveline Noise/Vibration

Axle howling or whine—rear axle or Axle lubricant low. CHECK the lubricant level. FILL the
transfer case axle to specification.
G72679 en 01/2003 2003.0 BA Falcon


Axle housing damage. INSPECT the axle housing for
damage. REPAIR or INSTALL a new
axle as necessary. REFER to Section
205-02 .
Damaged or worn wheel bearings or CHECK for abnormal wheel bearing
axle bearings. play or roughness. REFER to Wheel
Bearing Check in this section.
ADJUST or INSTALL new wheel
bearings as necessary. REFER to
Section 204-01 for front bearings or
Section 204-02 for rear bearings.
Damaged or worn differential ring and INSPECT the ring and pinion ring for
pinion. abnormal wear patterns or broken
teeth. INSTALL a new ring and pinion
as necessary. REFER to Section
205-02 .
Damaged or worn differential side or CHECK for abnormal bearing play or
pinion bearings. roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .
Damaged or worn differential side DISASSEMBLE the differential carrier.
gears and pinion gears. INSPECT the side and pinion gears for
abnormal wear patterns or broken
teeth. INSTALL new gears as
Transfer case housing or internal gear INSPECT the transfer case for
damage or low lubricant. damage. CHECK the lubricant level
and fill transfer case to specification.
REFER to Section 308-07b .
Driveline clunk—loud clunk when Incorrect axle lubricant level. CHECK the lubricant level. FILL the
shifting from reverse to drive axle to specification.
Excessive backlash in the axle or CARRY OUT a total backlash check.
transmission.
Damaged or worn pinion bearings. CHECK for abnormal bearing play or

roughness. INSTALL new bearings as
Damaged or worn universal joints INSPECT the U-joints for wear or
(U-joints). damage. INSTALL new U-joints as
Loose suspension components. INSPECT the suspension for damage

or wear. REPAIR or INSTALL new
Section 204-00 .
Broken powertrain mounts. INSPECT the powertrain mounts.

INSTALL new mounts as necessary.
REFER to Section 303-01a for 2.0L
Zetec engine or Section 303-01b for
3.0L (4V) engine.
Idle speed too high. CHECK for the correct idle speed.
Driveline clunk—occurs as the vehicle Worn driveshaft constant velocity (CV) INSPECT the CV joint and U-joints for
starts to move forward following a stop joint or U-joints with excessive play. a worn condition. INSTALL a new
Driveshaft as necessary. REFER to
Section 205-01 .
Loose rear axle mount. CHECK the axle for loose bolts.
TIGHTEN to specification.
Clicking, popping or grinding—occurs Inadequate or contaminated lubrication CHECK the CV joint boots and joints
while vehicle is turning in the CV joints. for wear or damage. REPAIR or
G72679 en 01/2003 2003.0 BA Falcon


Another component contacting the CHECK the halfshafts and the area
halfshaft. around the halfshafts. REPAIR as
necessary.
Brake components. INSPECT the front brakes for wear or

damage. REPAIR as necessary.
Steering components. INSPECT the drag link, inner and

outer tie-rods or idler arm for wear or
Suspension components. INSPECT the upper and lower ball

joints for wear or damage. REPAIR as
for front ball joints or Section 204-02
for rear ball joints.
Damaged or worn wheel bearings. CHECK for abnormal wheel bearing

play or roughness. REFER to Wheel
Bearing Check in this section.
ADJUST or INSTALL new wheel
bearings as necessary. REFER to
Section 204-01 for front wheel
bearings or Section 204-02 for rear
wheel bearings.
High pitched chattering—noise from Incorrect or contaminated lubricant. CHECK the vehicle by driving in tight
the rear axle when the vehicle is circles (5 clockwise, 5
turning counterclockwise). FLUSH and
REFILL with the specified rear axle
lubricant and friction modifier as
necessary.
Damaged or worn differential DISASSEMBLE the differential
(differential side gears and pinion assembly. INSPECT the differential
gears). case, pin and gears for wear or
damage. REPAIR or INSTALL a new
differential as necessary. REFER to
Section 205-02 .
Buzz—buzzing noise is the same at Damaged or worn tyres. CHECK for abnormal tyre wear or
cruise or coast/deceleration damage. INSTALL a new tyre as
Incorrect driveline angles. CHECK for correct driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .
Rumble or boom—noise occurs at Driveshaft is out-of-balance. CHECK the driveshaft for damage,
coast/deceleration, usually driveshaft missing balance weights or
speed related and noticeable over a undercoating. Using the Driveline
wide range of speeds balancer, CHECK the driveshaft
balance. CARRY OUT a driveline
vibration test. REFER to Section
205-00 . REPAIR as necessary.
U-joints binding or seized. ROTATE the driveshaft and CHECK

for rough operation or seized U-joints.
INSTALL new U-joints as necessary.
Excessive pinion flange runout. CARRY OUT a runout check. REPAIR

as necessary.
Grunting—normally associated with a Driveshaft CV joint binding. CLEAN the CV joint and INSTALL a
shudder experienced during new driveshaft as necessary. REFER
acceleration from a dead stop to Section 205-01 .
Loose rear axle mount bolts or INSPECT the rear suspension and
suspension fasteners axle. TIGHTEN the fasteners to
specification.
G72679 en 01/2003 2003.0 BA Falcon


Howl—can occur at various speeds Incorrect ring and pinion contact, CHECK the ring and pinion and
and driving conditions—affected by incorrect bearing preload or gear bearings for damage. INSPECT the
acceleration and deceleration damage. ring and pinion wear pattern. REFER
to Checking Tooth Contact Pattern and
Condition of the Ring and Pinion
component test in this section.
ADJUST or INSTALL new components
205-02 .
Chuckle—heard at Incorrect ring and pinion contact or by CHECK the ring and pinion for
coast/deceleration—also described as damaged teeth on the coast side of damage. INSPECT the ring and pinion
a knock the ring and pinion. wear pattern. REFER to Checking
Tooth Contact Pattern and Condition
of the Ring and Pinion component test
in this section. ADJUST or INSTALL
new components as necessary.
Knock—noise occurs at various Gear tooth damage to the ring and CHECK the differential case and ring
speeds—not affected by acceleration pinion. and pinion for damage. INSTALL new
or deceleration components as necessary. REFER to
Section 205-02 .
Excessive axle shaft end play CHECK the axle end play using a dial
(vehicles with integral axles). indicator. INSTALL a new axle shaft or
side gears as necessary. REFER to
Section 205-02 .
Scraping noise—a continuous low Worn or damaged pinion bearings. CHECK the pinion bearings. INSTALL
pitched noise starting at low speeds new pinion bearings as necessary.
Driveline shudder—occurs during Rear drive axle assembly CHECK the axle mounts and the rear
acceleration from a slow speed or stop mispositioned. suspension for damage or wear.
REPAIR as necessary.
Loose rear axle bolts. INSPECT the bolts. TIGHTEN the bolt
nuts to specification.
Incorrect or high CV joint operating CHECK vehicle ride height is within
angle. limits. REPAIR as necessary.
Damaged or worn front suspension CHECK for a loose stabilizer bar,
components. damaged or loose strut/strut bushings
or loose or worn ball joints. INSPECT
the steering linkage for wear or
Section 204-00 .
Driveline angles out of specification. CHECK for correct driveline angles.

Section 205-00 .
U-joints binding or seized. ROTATE the driveshaft and CHECK

for rough operation or seized U-joints.
INSTALL new U-joints as necessary.
Binding the driveshaft CV joint. INSPECT the driveshaft shaft CV joint

and coupling shaft for a worn, or
damaged condition. INSTALL a new or
driveshaft assembly as necessary.
Section 205-01 . REPAIR as
necessary.
Loose rear axle bolts. INSPECT the bolts. TIGHTEN the

bolts to specification.
G72679 en 01/2003 2003.0 BA Falcon


Driveline vibration—occurs at cruising U-joints are worn. CHECK for wear or incorrect seating.
speeds INSTALL new driveshaft as necessary.
Worn or damaged driveshaft center CHECK the insulator for damage or
bearing support. wear. ROTATE the driveshaft and
CHECK for rough operation. INSTALL
a new center bearing support as
Loose axle pinion flange bolts. INSPECT the axle pinion flange.
TIGHTEN the pinion flange bolts to
205-01 .
Excessive axle pinion flange runout. CARRY OUT a Runout Check. REFER
to Section 205-01 . REPAIR as
necessary.
Driveshaft is out-of-balance. CHECK the driveshaft for damage,

missing balance weights or
undercoating. CHECK driveshaft
balance. CARRY OUT a driveline
vibration test. REFER to Section
205-01 . REPAIR as necessary.
Binding or damaged driveshaft CV INSPECT the driveshaft CV joint for
joint. wear or damage. INSTALL a new
driveshaft assembly as necessary.
REFER to Section 205-01 . REPAIR
as necessary.
Driveshaft runout. CARRY OUT a runout check. REFER

to Section 205-01 . REPAIR as
necessary.
Incorrect lateral and radial tyre/wheel INSPECT the tyre and wheels.
runout. MEASURE tyre runouts. REPAIR or
Driveline angles out of specification. CHECK for correct driveline angles.

Section 205-00 .
Incorrectly seated CV joint in the front CHECK the outer CV joint for correct
wheel hub. seating into the hub. REPAIR as
for front CV joints or Section 205-05
for rear CV joints.
Symptom Chart — Engine Noise/Vibration

Grinding noise—occurs during engine Incorrect starter motor mounting. INSPECT the starter motor for correct
cranking mounting. REPAIR as necessary.
Starter motor. CHECK the starter motor. REPAIR or

INSTALL a new starter motor as
Incorrect starter motor drive INSPECT the starter motor drive and
engagement. flexplate/flywheel for wear or damage.
If necessary, INSTALL a new starter
motor drive. REFER to Section 303-06
. If necessary, INSTALL a new
flexplate/flywheel. REFER to Section
303-01a for 2.0L Zetec engine or
Section 303-01b for 3.0L (4V) engine.
G72679 en 01/2003 2003.0 BA Falcon


Engine ticking noise Fuel injector. Go to PinPoint Test B .
Fuel line.
Oil pump.
Valve lifter.
Belt tensioner.
Water pump.
Obstruction of cooling fan.
Engine drumming noise—normally Powertrain mount. CARRY OUT Powertrain/Drivetrain
accompanied by vibration Mount Neutralizing in this section.
Damaged or misaligned exhaust INSPECT the exhaust system for
system. loose or broken clamps and brackets,
flex coupling or damper (2.0L Zetec).
CARRY OUT Exhaust System
Neutralizing in this section.
Whistling noise—normally Air intake system. CHECK the air intake ducts, air
accompanied with poor idle condition cleaner, throttle body and vacuum
hoses for leaks and correct fit.
REPAIR or ADJUST as necessary.
Clunking noise Water pump has excessive end play or CHECK the water pump for excessive
imbalance. end play. INSPECT the water pump
with the drive belt off for imbalance.
INSTALL a new water pump as
Alternator has excessive end play. CHECK the generator for excessive
end play. REPAIR or INSTALL a new
alternator. REFER to Section 414-02 .
Pinging noise Exhaust system leak. INSPECT the exhaust system for
leaks. REPAIR as necessary.
Gasoline octane too low. VERIFY with customer the type of

gasoline used. CORRECT as
necessary.
Knock sensor operation. CHECK the knock sensor. INSTALL a

new knock sensor as necessary.
Incorrect spark timing. CHECK the spark timing. REPAIR as

necessary.
High operating temperature. INSPECT cooling system for leaks.

CHECK the coolant level. REFILL as
necessary. CHECK the coolant for the
correct mix ratio. DRAIN and REFILL
as needed. CHECK engine operating
temperature is within specifications.
Foul-out spark plug. CHECK the spark plugs. REPAIR or

INSTALL new spark plugs as
necessary.
Catalytic converter. Acceptable noise.

Knocking noise—light knocking noise, Excessive clearance between the Engine cold and at high idle. Using an
also described as piston slap—noise is piston and the cylinder wall. EngineEAR, pull a spark plug or fuel
most noticeable when engine is cold injector connector until the noise goes
with light to medium away. CARRY OUT a cylinder bore
acceleration—noise disappears as clearance to piston check. INSTALL a
engine warms new piston.
G72679 en 01/2003 2003.0 BA Falcon


Knocking noise—light double knock or Excessive clearance between the INSTALL a new piston or piston pin.
sharp rap sound—occurs mostly with piston and the piston pin.
warm engine at idle or low speeds in
DRIVE—increases in relation to engine
load—associated with poor lubrication
history
Knocking noise—light knocking noise Excessive clearance between the Engine warm and at idle. PULL a
is most noticeable when engine is connecting rod bearings and the spark plug or fuel injector connector
warm—noise tends to decrease when crankshaft. until the noise goes away. INSTALL
vehicle is coasting or in neutral new bearings.
Knocking—deep knocking Worn or damaged crankshaft main CARRY OUT DERU test. CHECK for
noise—noise is most noticeable when bearings. noise with vehicle at operating
engine is warm, at lower rpm and temperature, during medium to heavy
under a light load and then at float acceleration. CHECK at idle with
injector disconnected, noise does not
change. INSTALL new main bearings.
Knocking noise—occurs mostly with Spark plugs. CHECK the spark plug for damage or
warm engine at light/medium wear. INSTALL new spark plugs as
acceleration necessary.
Carbon accumulation in combustion REMOVE carbon from combustion
chamber. chamber.
Whine or moaning noise Air intake system. CHECK the air cleaner and ducts for
correct fit. INSPECT the air intake
system for leaks or damage. REPAIR
303-12 .
Alternator electrical field or bearings. CARRY OUT alternator load test.

REPAIR or INSTALL a new alternator
412-02 .
Drone type noise Exhaust system. CARRY OUT the Exhaust System
Neutralizing in this section. REPAIR as
necessary.
A/C compressor. CHECK for noise with vehicle at

constant speeds. CYCLE the
compressor on and off and listen for a
change in pitch. REPAIR as
Powertrain mounts. CARRY OUT the Exhaust System

Sputter type noise—noise worse when Damaged or worn exhaust system INSPECT the exhaust system for leaks
cold, lessens or disappears when components. or damage. REPAIR as necessary.
vehicle is at operating temperature REFER to Section 309-00 .
Rattling noise—noise from the upper Low oil level. CHECK oil level. FILL as necessary.
engine (valve train)—worse when
engine is cold
Thin or diluted oil. INSPECT the oil for contamination. If

oil is contaminated, CHECK for the
source. REPAIR as necessary.
CHANGE the oil and filter.
Low oil pressure. CARRY OUT an oil pressure test. If

not within specifications, REPAIR as
Worn rocker arms/fulcrums or CARRY OUT a valve train analysis.
followers. INSTALL new valve train components
as necessary. REFER to Section 303.
Worn valve guides. CARRY OUT a valve train analysis.

INSTALL new valve guides as
necessary. REFER to Section 303.
G72679 en 01/2003 2003.0 BA Falcon


Excessive runout of valve seats on the CARRY OUT a valve seat runout test.
valve face. INSPECT the valve face and seat.
INSTALL new valves as necessary.
REFER to Section 303.
Rattling noise—from the bottom of the Loose muffler shields or catalytic CHECK the exhaust system for loose
vehicle converter shields. shields. REPAIR as necessary.
Thumping noise—from the bottom of Exhaust pipe/muffler grounded to CHECK the exhaust system to chassis
the vehicle, worse at acceleration chassis. clearance. CHECK the exhaust system
hangers for damage. REPAIR as
necessary.
Engine vibration—increases intensity Engine out-of-balance. CARRY OUT Neutral Engine Run-up
as engine rpm is increased (NERU) Test. ROTATE the torque
converter, 120° for 3 bolt and 180° for
4 bolt. INSPECT the torque converter
pilot outer diameter to crankshaft pilot
inner diameter.
Engine vibration—is felt with increases Strain on exhaust mounts. CARRY OUT the Exhaust System
and decreases in engine rpm Neutralizing procedure in this section.
Damaged or worn powertrain/drivetrain CHECK the powertrain/drivetrain
mounts. mounts for damage. REPAIR as
necessary.
Engine or transmission grounded to INSPECT the powertrain/drivetrain for
chassis. correct clearances. REPAIR as
necessary.
Engine vibration—vibration felt at all Excessive engine pulley runout. CARRY OUT Engine Accessory Test.
times INSTALL a new engine pulley as
necessary. REFER to Section 303.
Damaged or worn accessory CARRY OUT Engine Accessory Test.
component. REPAIR or INSTALL a new
component as necessary. REFER to
Section 303-05.
Engine vibration—mostly at Combustion instability. CHECK the ignition system. INSTALL
coast/neutral coast—condition new components as necessary.
improves with vehicle accelerating
Engine vibration or shudder—occurs Worn or damaged spark plugs. INSPECT the spark plugs for cracks,
with light to medium acceleration high resistance or broken insulator.
above 56 km/h (35 mph) INSTALL a new spark plug(s) as
necessary.
Plugged fuel injector. REPAIR or INSTALL a new injector as

necessary.
Damaged spark plug wire. INSPECT the spark plug wires for
damage. INSTALL a new spark plug
wire(s) as necessary.
Contaminated fuel. INSPECT the fuel for contamination.

DRAIN the fuel system and refill.
Worn or damaged torque converter. CHECK the torque converter. INSTALL

a new torque converter as necessary.
Symptom Chart—Idle Noise/Vibration

Idle air control (IAC) valve moan — IAC valve is contaminated with oil. GO to Component Tests in this
occurs on throttle tip-out section.
G72679 en 01/2003 2003.0 BA Falcon


Accessory drive belt chirp — occurs at Accessory drive belt worn, or pulley is INSPECT for loose or misaligned
idle or high idle, cold or hot—most misaligned or loose. pulleys. CHECK the drive belt for wear
common occurrence is during humid or damage. INSTALL new pulley(s) or
weather accessory drive belt, as necessary.
Accessory drive bearing hoot — Accessory drive idler or tensioner Go to PinPoint Test C .
occurs at idle or high idle in cold pulley bearing is experiencing stick/slip
temperatures of approximately +4°C between ball bearings and bearing
(+40°F) or colder at first start of the race.
day
Power steering moan — occurs at high High fluid viscosity, or plugged Go to PinPoint Test D .
idle and possibly at idle during the first reservoir screen in power steering
cold start of the day in temperatures of reservoir starves pump causing
approximately -18°C (0°F) or cavitation.
colder—noise can even be a severe
screech for less than one minute in
very cold temperatures of
approximately -29°C (-20°F) or colder
Alternator whine — during high Alternator electrical field noise. CHECK for changes in the noise level
electrical loads at idle or high idle, a while changing electrical loads (such
high pitch whine or moan is emitted as rear defrost, headlamps etc.).
from the alternator CARRY OUT a alternator load test.
REFER to Section 414-00 . If the
system passes the load test, the noise
is from the alternator bearings,
INSTALL new bearings. If the system
fails the load test, INSTALL a new
alternator. REFER to Section 414-02 .
Drumming noise — occurs inside the Exhaust system vibration excites the Go to PinPoint Test E .
vehicle during idle or high idle, hot or body resonances inducing interior
cold—very low-frequency drumming is noise.
very rpm dependent Engine vibration excites the body
resonances inducing interior noise.
Hissing noise — occurs during idle or Vacuum leak or idle air control (IAC) CHECK the air intake system from the
high idle that is apparent with the hood valve flow noise. inlet to each cylinder intake port.
open DISCARD the leaking parts, and
INSTALL a new component.
Automatic transmission buzz or hiss Incorrect driveline angles. CHECK for correct driveline angles.
Section 205-00 .
Worn or damaged main control Using a transmission tester,
solenoids or valves. ACTIVATE the solenoids to duplicate
sound. INSTALL new components as
Manual Transmission Clutch throw-out Worn throw-out bearing. INSTALL a new throw-out bearing.
bearing whine—a change in noise REFER to Section 308-01 .
pitch or loudness while depressing the
clutch pedal
Heating, vacuum and air conditioning Damaged or worn HVAC blower INSTALL a new blower motor. REFER
(HVAC) system chirp — most audible bearing. to Section 412-02 .
inside the vehicle—listen for a change
in noise pitch or loudness while
changing the HVAC system blower
speed
Air conditioning (A/C) clutch ticking — Acceptable noise. LISTEN to the clutch to determine if
occurs when the compressor clutch Incorrect air gap. the noise occurs with clutch
engages engagement. A small amount of noise
is acceptable. If the noise is excessive,
CHECK the A/C clutch air gap.
INSPECT the A/C clutch for wear or
damage. INSTALL a new clutch as
G72679 en 01/2003 2003.0 BA Falcon


Intermittent rattle, or scraping/rubbing Loose exhaust heat shield(s). INSPECT the exhaust system for
noise loose parts using a glove or clamps to
verify cause. REPAIR as necessary.
Wiring, hose or other part interfering INSPECT the accessory drive system
with the accessory drive belt or pulley. closely verifying there is adequate
clearance to all rotating components.
Engine ticking or knocking noise — Piston noise or valvetrain noise (bled Go to PinPoint Test F .
occurs during idle or high idle during down lifter/lash adjuster).
the first cold start of the day
A continuous, speed-dependent rattle Piston noise or valvetrain noise (bled Go to PinPoint Test F .
from the engine — occurs during idle down lifter/lash adjuster).
or high idle during the first cold start of
the day and disappears as the engine
warms up
Idle vibration—a low-frequency Cylinder misfire. Using the diagnostic tool, CHECK the
vibration (5-20 Hz) or mild shake that ignition system. CARRY OUT a
is felt through the seat/floorpan cylinder power test. REFER to Section
303-00 .
Engine or torque converter out of VERIFY the torque converter to
balance. crankshaft pilot clearance is correct,
REPAIR as necessary. RE-INDEX the
torque converter on the flex plate by
120° on a 3-bolt converter or 180° for
a 4-bolt converter. REFER to Section
307-01 . RETEST the vehicle.
Idle vibration—a high-frequency Exhaust system mounts bound up. VERIFY concern occurs at engine
vibration (20–80 Hz) or buzz, that is firing frequency. CHECK that the
felt through the steering wheel or seat exhaust system vibrates at the same
frequency as the engine. ADD 9–14
km (20–30 lb.) to the tail pipe to test,
CARRY OUT Exhaust System
Power steering lines grounded out. INSPECT that the power steering lines
are not contacting the chassis or each
other. REPAIR as necessary.
Engine mounts binding. NEUTRALIZE the powertrain/drivetrain

mounts. CARRY OUT
Powertrain/Drivetrain Mount
Symptom Chart—Squeak and Rattle

Squeak—heard inside the vehicle Insufficient lubrication on the door LUBRICATE the hinge or check strap.
when closing/opening the door hinge or check strap.
Internal door components loose, CHECK the inside of the door.
rubbing or misaligned. TIGHTEN or ALIGN as necessary.
USE the Rotunda Squeak and Rattle
Kit to ISOLATE any rubbing
components.
Squeak—heard inside the vehicle Worn or damaged glass run/channel. REPAIR or INSTALL a new glass
when closing/opening the window run/channel. REFER to Section 501-11
.
Squeak—heard outside of vehicle Exhaust shield rubbing against the CHECK the exhaust system. REPAIR
when closing/opening the door chassis or exhaust pipe. as necessary. REFER to Section
309-00 .
G72679 en 01/2003 2003.0 BA Falcon


Squeak—occurs with initial brake Disc brake pads. Under certain conditions, asbestos free
pedal application pads can generate a squeak noise.
This noise is normal and does not
indicate a concern.
Squeak—a constant noise that occurs Damaged or worn disc brake pads. INSPECT the pads for oil, grease or
with brake pedal applications brake fluid contamination. CHECK for
glazed linings. A brake disc with hard
spots will also cause a squeak type
noise. REPAIR or INSTALL new brake
pads as necessary. REFER to Section
206-03 .
Squeak—noise occurs over bumps or Worn control arm bushings. INSPECT the control arm bushings.
when turning Spray with lubricant and CARRY OUT
a “bounce test” to determine which
bushing. REPAIR as necessary.
REFER to Section 204-01 for front
bushings or Section 204-02 for rear
bushings.
Worn or damaged shock INSPECT the shock absorber for
absorber/strut. damage. CARRY OUT a “bounce test”
to isolate the noise. INSTALL a new
shock absorber/strut as necessary.
REFER to Section 204-01 for front
shock absorber/strut or Section 204-02
for rear shock absorber/strut.
Rattle—heard when closing/opening Loose internal door mechanism, REPEAT the motion or CARRY OUT a
the door or window bracket or attachment. “tap test” to duplicate the noise.
INSPECT the door for loose
components. TIGHTEN loose
components.
Squeak or rattle—heard inside the Misaligned glove compartment ALIGN the glove compartment door.
vehicle over rough roads/bumps door/hinge.
Instrument panel trim loose or INSPECT the instrument panel trim for
misaligned. missing or loose clips or screws.
Loose interior component or trim. CARRY OUT a “touch test”.

ELIMINATE the noise by pressing or
pulling on interior trim and
components.
Squeak or rattle—noise with a Damaged or worn sub-frame mounts. INSPECT the upper and lower
vibration concern absorbers for damage or wear.
CHECK the sub-frame for damage.
CHECK the nuts and bolts are
tightened to specifications. TIGHTEN
as necessary.
Symptom Chart—Steering Noise/Vibration

Steering grunt or shudder — occurs Steering gear or power steering hoses. GO to Steering Gear Grunt/Shudder
when turning into or out of a turn at Test component test in this section.
low speeds (temperature sensitive)
Steering System clonk—hydraulic Air in the steering hydraulic system. CHECK for leaks in the system.
knocking sound PURGE the air from the system.
Power steering pump moan — loud Power steering hose grounded out to INSPECT the power steering hoses.
humming noise occurs when the chassis. REPAIR as necessary.
steering wheel is rotated to the stop
position. Produces a 120-600 Hz
frequency that changes with rpm
G72679 en 01/2003 2003.0 BA Falcon


Aerated fluid. CHECK for leaks in the system.
PURGE the air from the system.
Steering gear isolators. INSPECT the isolators for wear or

Low fluid. CHECK the fluid level. REFILL as

necessary.
Power steering pump brackets loose CHECK bolts, brackets and bracket
or misaligned. alignment. TIGHTEN bolts to
specification. REPAIR or INSTALL
new brackets as necessary. REFER to
Section 211-02.
Steering gear clunk — occurs only Steering gear. INSPECT the steering gear for loose
while cornering over a bump (can be mounting bolts. TIGHTEN as
temperature sensitive) necessary. REFER to Section 211-02 .
Feedback (rattle, chuckle or knocking Column intermediate/flexible shaft INSTALL a new intermediate/flexible
noise in the steering gear) — a joints damaged or worn. shaft. REFER to Section 211-04 .
condition where roughness is felt in the
steering wheel when the vehicle is
driven over rough surfaces
Loose, damaged or worn tie-rod ends. TIGHTEN the nuts to specification or

INSTALL new tie-rod ends as
Steering gear insulators or mounting TIGHTEN the bolts or INSTALL new
bolts loose or damaged. bolts as necessary. REFER to Section
211-02 .
Steering column intermediate shaft TIGHTEN the bolts to specification.
bolts are loose.
Steering column damaged or worn. REPAIR or INSTALL a new steering

column as necessary. REFER to
Section 211-04 .
Loose suspension bushings, bolts or INSPECT the suspension system.
ball joints. TIGHTEN or INSTALL new
Section 204-01 for front suspension or
Section 204-02 for rear suspension.
Feedback (nibble at the steering Lateral runout in the tyre or wheel. GO to Pinpoint Test G.
wheel) — a condition where slight
rotational movement is felt in the
steering wheel when the vehicle is
driven over rough or grooved surfaces
Accessory drive belt Loose or worn accessory drive belt. ADJUST or INSTALL a new accessory
squeal/chirp—when rotating the belt as necessary. REFER to Section
steering wheel from stop to stop 303-05 .
Power steering gear hiss Steering column intermediate/flexible REPAIR or INSTALL a new
shaft-to-steering gear is binding or intermediate/flexible shaft as
misaligned. necessary. REFER to Section 211-04 .
Grounded or loose steering column REPAIR as necessary.
boot at the dash panel.
Damaged or worn steering gear input REPAIR or INSTALL a new steering
shaft and valve. gear as necessary. REFER to Section
211-02 .
Steering column rattle Loose bolts or attaching brackets. TIGHTEN the bolts to specifications.
Loose, worn or insufficiently lubricated LUBRICATE or INSTALL new steering
column bearings. column bearings as necessary.
G72679 en 01/2003 2003.0 BA Falcon


Steering shaft insulators damaged or INSTALL new insulators. REFER to
worn. Section 211-04 .
Intermediate/flexible shaft compressed INSTALL a new intermediate/flexible
or extended. shaft. REFER to Section 211-04 .
Steering column squeak or cracks Insufficiently lubricated steering shaft LUBRICATE the steering shaft and
bushings. shaft tube seals.
Loose or misaligned steering column TIGHTEN or ALIGN the steering
shrouds. column shrouds.
Steering wheel rubbing against REPOSITION the steering column
steering column shrouds. shrouds.
Insufficient lubricated speed control LUBRICATE the speed control slip
slip ring. ring.
Upper or lower bearing sleeve out of REPOSITION the bearing sleeves.
position.
Power steering pump noisy Incorrect assembly of components. REPAIR or INSTALL a new power
Imperfections on the outside diameter steering pump as necessary. REFER
or end surface of the power steering to Section 211-02 .
pump rotor.
Damaged or worn power steering
pump rotor splines.
A crack on the inner surface of the
power steering pump cam.
Interference between the power
steering pump rotor and cam.
Damaged or worn power steering
pump rotor and pressure plates.
Power steering pump swish noise Power steering fluid flow into the Acceptable condition.
bypass valve of the pump valve
housing with fluid temperature below
54°C (130°F).
Power steering pump whine noise Aerated fluid. PURGE the air from the system.
REFER to Section 211-00 . CHECK for
a leak in the system.
Damaged power steering pump. REPAIR or INSTALL a new power

steering pump as necessary. REFER
to Section 211-02 .
Damaged valve cover O-ring seal. REPAIR or INSTALL a new power

steering pump as necessary. REFER
to Section 211-02 .
Power steering pump clicking Power steering pump rotor slippers too REPAIR or INSTALL a new power
(mechanical) noise long, excessive rotor slipper-to-slot steering pump as necessary. REFER
clearance or damaged or worn rotor to Section 211-02 .
assembly.
Power steering pump clatter noise Damaged corners on the outside REPAIR or INSTALL a new power
diameter or the power steering rotor or steering pump as necessary. REFER
distorted rotor slipper ring. to Section 211-02 .
Symptom Chart—Suspension Noise/Vibration

Squeak or grunt—noise from the front Front stabilizer bar insulators. Under these conditions, the noise is
suspension, occurs more in cold acceptable. CHECK TSBs.
ambient temperatures—more
noticeable over rough roads or when
turning
Clunk—noise from the front Loose front struts or shocks. INSPECT for loose nuts or bolts.
suspension, occurs in and out of turns TIGHTEN to specifications. REFER to
Section 204-01 .
G72679 en 01/2003 2003.0 BA Falcon


Clunk—noise from the rear Loose rear suspension components. INSPECT for loose or damaged rear
suspension, occurs when shifting from suspension components. REPAIR or
reverse to drive INSTALL new components as
Click or pop—noise from the front Worn or damaged ball joints. CARRY OUT a ball joint inspection.
suspension—more noticeable over INSTALL new control arm as
rough roads or over bumps necessary. REFER to Section 204-01 .
Front suspension noise—a squeak, Steering components. Go to PinPoint Test G .
creak or rattle noise—occurs mostly Loose or bent front struts or shock
over bumps or rough roads absorbers.
Damaged spring or spring mounts.
Damaged or worn control/radius arm
bushings.
Worn or damaged stabilizer bar
bushings or links.
Rear suspension noise—a squeak, Loose or bent rear shock absorbers. Go to PinPoint Test H .
creak or rattle noise—occurs mostly Damaged spring or spring mounts.
over bumps or rough roads Damaged or worn control arm
bushings.
Shudder—occurs during acceleration Rear drive axle assembly CHECK the axle mounts and the rear
from a slow speed or stop mispositioned. suspension for damage or wear.
Incorrect or high CV joint operating CHECK vehicle ride height is within
angle. limits. REPAIR as necessary.
Damaged or worn front suspension CHECK for a loose stabilizer bar,
components. damaged or loose strut/strut bushings
or loose or worn ball joints. INSPECT
the steering linkage for wear or
components as necessary.
Shimmy—most noticeable on Excessive positive caster. CHECK the caster alignment angle.
coast/deceleration—also hard steering CORRECT as necessary. REFER to
condition Section 204-00 .
Symptom Chart—Tyre Noise/Vibration

Tyre noise—hum/moan at constant Abnormal wear patterns. SPIN the tyre and CHECK for tyre
speeds wear. INSTALL a new tyre as
necessary. INSPECT for
damaged/worn suspension
components. CARRY OUT wheel
alignment.
Tyre noise—noise tone lowers as the Out-of-balance tyre. BALANCE the tyre and road test.
vehicle speed is lowered INSTALL a new tyre as necessary.
Tyre noise — ticking noise, changes Nail puncture or stone in tyre tread. INSPECT the tyre. REPAIR as
with speed necessary.
Wheel and tyre—vibration and noise Damaged or worn tyre. Go to PinPoint Test I .
concern is directly related to vehicle
speed and is not affected by
acceleration, coasting or decelerating
Tyre wobble or shudder — occurs at Damaged wheel bearings. SPIN the tyre and CHECK for
lower speeds abnormal wheel bearing play or
roughness. ADJUST or INSTALL new
wheel bearings as necessary. REFER
to Section 204-01 for front bearings or
Section 204-02 for rear bearings.
G72679 en 01/2003 2003.0 BA Falcon


Damaged wheel. INSPECT the wheel for damage.
INSTALL a new wheel as necessary.
Damaged or worn suspension INSPECT the suspension components
components. for wear or damage. REPAIR as
necessary.
Loose wheel nuts. CHECK the wheel nuts. TIGHTEN to

204-04 .
Damaged or uneven tyre wear. SPIN the tyre and CHECK for
abnormal tyre wear or damage.
INSTALL a new tyre as necessary.
Tyre shimmy or shake— occurs at Wheel/tyre out of balance. BALANCE the wheel/tyre assembly.
lower speeds
Uneven tyre wear. CHECK for abnormal tyre wear.

INSTALL a new tyre as necessary.
Excessive radial runout of wheel or CARRY OUT a radial runout test of the
tyre. wheel and tyre. INSTALL a new tyre
204-04 .
Worn or damaged wheel studs or INSPECT the wheel studs and wheels.
elongated stud holes. INSTALL new components as
necessary.
Excessive lateral runout of the wheel CARRY OUT a lateral runout test of
or tyre. the wheel and tyre. CHECK the wheel,
tyre and hub. REPAIR or INSTALL
new components as necessary.
Foreign material between the brake CLEAN the mounting surfaces of the
disc and hub or in the brake disc fins. brake disc and hub. CHECK the brake
disc fins for material.
High speed shake or shimmy—occurs Excessive wheel hub runout. Go to PinPoint Test J .
at high speeds Damaged or worn tyres.
Damaged or worn wheel bearings.
Worn or damaged suspension or
steering linkage components.
Brake disc or drum imbalance.
Symptom Chart—Transmission (Manual) Vibration

Clutch rattling noise—occurs with Flywheel bolts, clutch housing bolts or TIGHTEN the bolts to specifications.
clutch engaged, noise clutch pressure plate bolts loose. CHECK the bolts for damage.
changes/disappears with clutch pedal
depressed
Clutch squeaking noise—noise is Pilot bearing seized or damaged. INSTALL a new pilot bearing. REFER
heard when the clutch is to Section 308-01 .
operated—vehicle moves slowly or
creeps when the clutch is
disengaged—can also be difficult to
shift into first and reverse gear
Clutch squeaking noise—occurs with Worn clutch pedal shaft or bushings. INSPECT the clutch pedal for wear or
clutch pedal depressed/released damage. REPAIR as necessary.
Clutch whirring/rattle noise—occurs Worn, damaged or misaligned clutch INSTALL a new clutch release
when clutch pedal is depressed release bearing. bearing. REFER to Section 308-02 .
G72679 en 01/2003 2003.0 BA Falcon


Clutch grating/grinding noise—occurs Clutch pressure plate fingers bent or INSPECT the clutch pressure plate
when clutch pedal is depressed worn. release fingers. INSTALL a new
pressure plate as necessary. REFER
to Section 308-01 .
Contact surface of clutch release INSTALL a new clutch release
bearing worn or damaged. bearing. REFER to Section 308-01 .
Clutch chatter—a small amount of Clutch engagement. Acceptable operating condition.
noise when clutch pedal is released at
initial take-off
Clutch chatter/grabs—in some cases a Damaged or worn powertrain/driveline INSPECT the powertrain/drivetrain
shudder is felt—occurs with clutch mounts. mounts. INSTALL new mounts as
pedal depressed/released necessary. REFER to Section 308-03 .
Binding or dragging plunger of the CHECK the master and slave cylinder
clutch master cylinder or slave operation. INSPECT the components
cylinder. for damage or wear. INSTALL a new
master or slave cylinder as necessary.
Grease or oil on the clutch disc facing. CHECK the input shaft seal and rear
main oil seal. REPAIR as necessary.
INSTALL a new clutch disc. REFER to
Section 308-03 .
Clutch disc surface glazed or INSPECT the clutch disc surface for a
damaged. glazed, hardened or damage
condition. CARRY OUT a disc check.
INSTALL a new clutch disc as
Damaged or worn clutch pressure INSPECT the clutch pressure plate for
plate. wear or damage. INSTALL a new
clutch pressure plate as necessary.
Flywheel surface damaged or glazed. INSPECT the flywheel for damage or

wear. CARRY OUT a flexplate/flywheel
runout check. INSTALL a new flywheel
303-01a for 2.0L Zetec engine or
Section 303-01b for 3.0L (4V) engine.
Clutch chatter noise—noise when Pilot bearing worn, damaged or not INSPECT the clutch pressure plate
clutch pedal is released at initial correctly aligned in bore. release fingers for uneven wear, clutch
take-off—clutch is hard to engage and components burnt or a seized pilot
disengage bearing. INSTALL a new pilot bearing
308-01 .
Clutch vibration Loose flywheel bolts. Go to PinPoint Test K .

Damaged or loose clutch pressure
plate.
Excessive flywheel runout.
Transmission rattling/clattering Gearshift lever joint worn or damaged. INSTALL a new gearshift lever.
noise—noise at idle or on light REFER to Section 308-06 .
acceleration from a stop—gear
selection difficult
Gearshift lever loose. TIGHTEN the bolts to specification.

Gearshift linkage rods worn or CHECK the linkage bushings for wear.
damaged. INSTALL new linkage rods as
Transmission rattling/clattering Incorrect fluid level or fluid quality. CHECK that the transmission is filled
noise—occurs in neutral or in gear, at to the correct level and with the
idle specified fluid. REFER to Section
308-03 .
G72679 en 01/2003 2003.0 BA Falcon


Transmission rattling/clattering Worn or rough reverse idler gear. CHECK the reverse idler gear.
noise—noise at idle in neutral REPAIR as necessary. REFER to
Section 308-03 .
Rough running engine, cylinder misfire. CHECK the ignition system. CARRY
OUT a cylinder power test. REFER to
Section 303-00 .
Excessive backlash in gears CHECK the gear backlash. ADJUST

308-03 .
Worn countershaft gears. REPAIR as necessary. REFER to

Section 308-03 .
Transmission whine—a mild whine at Rotating gears/geartrain. Acceptable noise.
extreme speeds or high rpm
Transmission whine—a high pitched Transmission gears are worn (high Result of normal gear wear. REPAIR
whine, also described as a squeal mileage vehicle). as necessary. REFER to Section
308-03 .
Mismatched gear sets. INSPECT the gear sets for an uneven

wear pattern on the face of the gear
teeth. REPAIR as necessary. REFER
to Section 308-03 .
Damaged or worn transmission INSPECT the transmission bearings.
bearing. INSTALL new bearings as necessary.
Transmission Gear is cracked, chipped or rough. INSPECT the transmission gears for
growling/humming—noise occurs in damage or wear. INSTALL new gears
the forward gears—the noise is more as necessary. REFER to Section
prominent when the gear is 308-03 .
loaded—the problem gear can be
located as the noise occurs in a
specific gear position
Transmission hissing—noise in neutral Damaged or worn bearings. INSPECT the transmission bearings.
or in forward gears—as bearings wear INSTALL new bearings as necessary.
or break up, the noise changes to a REFER to Section 308-03 .
thumping noise
Transmission Bearings with damaged balls or rollers INSPECT the transmission bearings.
knocking/thudding—noise at low or with pitted and spalled races. INSTALL new bearings as necessary.
speeds in forward gears REFER to Section 308-03 .
Transmission rumble/growl—noise at Incorrect driveline angle. CHECK the driveline angle. REPAIR
higher speeds in forward gears, more as necessary. REFER to Section
pronounced in a coast/deceleration 205-00 .
condition
Driveshaft out of balance or damaged. CHECK the driveshaft for damage,

missing balance weights or
undercoating. Using the EVA, CHECK
the driveshaft balance. CARRY OUT a
driveline vibration test. REFER to
Section 205-01 . REPAIR as
necessary.
Transmission rumble/growl—noise at Damaged or worn transmission CHECK transmission fluid for
all speeds in forward gears, more bearing or gears (high mileage excessive metal particles. REPAIR as
pronounced in a heavy acceleration vehicles). necessary. REFER to Section 308-03 .
condition
Symptom Chart—Transmission (Automatic) Noise/Vibration

Rattle—occurs at idle or at light Damaged engine or transmission CHECK the powertrain/drivetrain
acceleration from a stop mounts. mounts for damage. INSTALL new
mounts as necessary. REFER to 303.
G72679 en 01/2003 2003.0 BA Falcon


A loose front exhaust pipe heat shield. REPAIR or INSTALL a new heat shield
as necessary.
Loose inspection plate or dust cover CHECK for loose bolts. TIGHTEN to
plate. specifications. REFER to Section
307-01 .
Loose flex plate to converter nuts. CHECK for loose nuts. TIGHTEN to
specifications. REFER to Section
307-01 .
Whine—pitch increases with vehicle Damaged or worn low one-way clutch. INSPECT the transmission for wear or
speed—starts in first and second gear, Damaged or worn intermediate damage. REPAIR or INSTALL new
decreases or goes away at higher one-way clutch. components as necessary. REFER to
gears Friction elements. Section 307-01 .
Damaged or worn planetary or sun
gear.
Whine—the pitch changes with engine A worn or damaged accessory drive CARRY OUT the Engine Accessory
speed component. Test. REPAIR or INSTALL new
Section 303-05 .
Incorrect fluid level. CHECK that the transmission is filled

to the correct level. ADD fluid as
Partially blocked filter. INSPECT the filter. CLEAN or

INSTALL a new filter as necessary.
Worn or damaged torque converter. CARRY OUT the torque converter

service and replacement check.
Worn or damaged front pump. INSPECT the front pump. INSTALL a

new front pump as necessary. REFER
to Section 307-01 .
Whine—pitch changes with vehicle Speedometer gears. REPAIR or INSTALL new gears as
speed necessary.
Whine/moan type noise—pitch Damaged engine or transmission CHECK the powertrain/drivetrain
increases or changes with vehicle mount. mounts for damage. CARRY OUT
speed Powertrain/Drivetrain Mount
U-joints worn or damaged. INSPECT the U-joints for wear or

damage. INSTALL new U-joints as
Damaged or worn differential ring and INSPECT the differential ring and
pinion. pinion for damage. CARRY OUT the
Checking Tooth Contact Pattern and
component test in this section.
REPAIR or INSTALL a new differential
ring and pinion as necessary. REFER
to Section 205-02 .
Planetary gears nicked or chipped. CHECK the planetary gears for

damage. INSTALL new components
307-01 .
Whistle—noise is high pitched, Hydraulic pressure in the main control. INSPECT the main control. REPAIR or
constant—changes in pitch with INSTALL new components as
throttle position necessary. REFER to Section 307-01 .
Incorrect band/clutch apply pressure. CARRY OUT the line pressure tests.
REPAIR or INSTALL components as
G72679 en 01/2003 2003.0 BA Falcon


Worn or damaged torque converter. CARRY OUT the torque converter
service and replacement check.
Clunk—occurs when shifting from Damaged powertrain mounts. INSPECT the powertrain mounts for
PARK to a drive or reverse position damage. INSTALL new mounts as
Damaged or worn pinion bearings. CHECK for abnormal bearing play or

roughness. INSTALL new bearings as
Worn driveshaft CV joint. INSPECT the CV joint. INSTALL a

new driveshaft as necessary. REFER
to Section 205-01 .
Worn friction elements or excessive INSPECT the transmission for wear.
clutch pack end plate play. CHECK that all end play and
clearances are within specification.
REPAIR or INSTALL new components
307-01 .
Bump—occurs when shifting from Initial gear engagement. Acceptable condition.
PARK to a drive or reverse
position—similar to Clunk but with no
sound
Buzz or hiss Incorrect driveline angles. CHECK for correct driveline angles.
Section 205-00 .
Worn or damaged main control INSTALL new components as
solenoids or valves. necessary. REFER to Section 307-01 .
Vibration—a high frequency (20–80 Transmission cooler lines grounded CHECK the transmission cooler lines.
Hz) that is felt through the seat or gear out. REPAIR as necessary.
shifter—changes with engine speed
Flexplate to torque converter nuts CHECK the flexplate nuts. TIGHTEN
loose. to specification. REFER to Section
307-01 .
Fluid filler tube grounded out. CHECK the fluid filler tube. REPAIR as
necessary.
Shutter or chatter—occurs with light to Electrical inputs/outputs. CARRY OUT a Torque Converter
medium acceleration from low speeds Vehicle wiring harness. Clutch Operation Test. RUN on-board
or a stop Incorrect inputs/outputs from the diagnostics or self–test. CLEAR the
powertrain control module (PCM), DTCs, ROAD TEST and RERUN
digital transmission range (TR) sensor, on-board diagnostics or self–test.
brake pedal position (BPP) sensor,
throttle position (TP) sensor,
transmission speed sensor (TSS),
output speed shaft (OSS) sensor or
the torque converter clutch (TCC).
Pinpoint Tests system for normal operation. Sometimes, it is
necessary to remove various vehicle components to
The pinpoint tests are a step-by-step diagnostic gain access to the component requiring testing. For
process designed to determine the cause of a additional information, refer to the appropriate section
condition. It may not always be necessary to follow a for removal and installation procedures. Reinstall all
pinpoint test to its conclusion. Carry out only the steps components after verifying system operation is
necessary to correct the condition. Then, test the normal.
G72679 en 01/2003 2003.0 BA Falcon

PINPOINT TEST A : BRAKE VIBRATION/SHUDDER
Test Step Result / Action to Take
A1 ROAD TEST THE VEHICLE—LIGHT BRAKING

Check that the wheel and tyres are correct for the vehicle. Inspect the Yes
tyres for abnormal wear patterns. Go to A4.
Road test the vehicle. Warm the brakes by slowing the vehicle a few No
times from 80–32 km/h (50 to 20 mph) using light braking Go to A2.
applications. At highway speeds of 89–97 km/h (55-60 mph), apply
the brake using a light pedal force.
Is there a vibration/shudder felt in the steering wheel, seat or
brake pedal?
A2 ROAD TEST THE VEHICLE—MODERATE TO HEAVY

BRAKING
Road test the vehicle. At highway speeds of 89–97 km/h (55-60 mph), Yes
apply the brake using a moderate to heavy pedal force. For vehicles with ABS, Go to A3.
For vehicles with standard brakes, Go to A4.
Is there a vibration/shudder?
No
Vehicle is OK. VERIFY condition with customer.
TEST the vehicle for normal operation.
A3 NORMAL ACTUATION OF THE ABS SYSTEM

DIAGNOSIS
During moderate to heavy braking, noise from the hydraulic control Yes
unit (HCU) and pulsation in the brake pedal can be observed. Pedal Go to A5.
pulsation coupled with noise during heavy braking or on loose gravel,
bumps, wet or snowy surfaces is acceptable and indicates correct No
functioning of the ABS system. Pedal pulsation or steering wheel The brake system is operating correctly.
nibble whose frequency is proportioned to the vehicle speed indicates
a concern with a brake or suspension component.
Is the vibration/shudder vehicle speed sensitive?
A4 APPLICATION OF THE PARKING BRAKE
NOTE: Begin at the front of the vehicle unless the vibration or shudder Yes
has been isolated to the rear. Go to A8.
This test is not applicable to vehicles with drum-in-hat type parking No

brakes. For vehicles with drum-in-hat parking brakes, proceed to the Go to A5.
next test. For all other vehicles, apply the parking brake to identify if
the problem is in the front or rear brake. At highway speeds of 89–97
km/h (55-60 mph), lightly apply the parking brake until the vehicle
slows down. Release the parking brake immediately after the test.
Is there a vibration/shudder?
A5 CHECK THE FRONT WHEEL BEARINGS

Check the front wheel bearings. Refer to Wheel Bearing Check in this Yes
section. Go to A6.
Are the wheel bearings OK? No
INSPECT the wheel bearings. ADJUST or
REPAIR as necessary. TEST the system for
normal operation.
G72679 en 01/2003 2003.0 BA Falcon


A6 CHECK THE FRONT SUSPENSION
Check the front suspension for: Yes
broken or loose bolts Go to A7.
damaged springs No
worn or damaged lower control arm bushings REPAIR or INSTALL new components as
loose or rough front bearings necessary. TEST the system for normal
operation.
uneven tyre wear
Are all the suspension components in satisfactory condition?
A7 RESURFACE THE FRONT BRAKE DISCS

Yes
CAUTION: Do not use a bench lathe to machine brake discs. Go to A8.
NOTE: Follow the manufacturer’s instructions to machine the brake No

discs. After machining, make sure the brake disc meets the thickness Vehicle is OK.
specification.
Refer to Brake Disc Machining in this section. Resurface the front

brake discs. Road test the vehicle.
Is the vibration/shudder present?
A8 CHECK THE REAR SUSPENSION

Check the rear suspension for: Yes
broken or loose bolts Go to A9.
damaged or worn springs or spring bushings No
worn or damaged upper and lower control arm bushings REPAIR or INSTALL new components as
worn or damaged trailing arms necessary. TEST the system for normal
operation.
loose or rough rear bearings
uneven tyre wear
Are all the suspension components in satisfactory condition?
A9 RESURFACE THE REAR BRAKE DISC OR DRUM

Yes
CAUTION: Do not use a bench lathe to machine brake discs. CHECK the front suspension for wear or
damage, RESURFACE the front brake discs.
NOTE: Follow the manufacturers instructions to machine the brake discs. TEST the system for normal operation.
After machining, make sure the brake disc meets the thickness
specification. No
Vehicle is OK.
Refer to Brake Disc Machining in this section. Resurface the rear
brake disc or drums. Road test the vehicle.
Is the vibration/shudder present?
PINPOINT TEST B : ENGINE TICKING NOISE
B1 CHECK FOR TICKING NOISE AT THE FUEL RAIL

Disconnect the first fuel line clip. Yes
CHECK for TSB for applicable vehicle. REPAIR
Is the ticking noise gone? as necessary. TEST the system for normal
operation.
No
Go to B2.
G72679 en 01/2003 2003.0 BA Falcon


B2 CHECK FOR TICKING NOISE AT THE FUEL INJECTOR
Using an EngineEAR, listen at the fuel injectors by placing a probe on Yes
each injector. To isolate the faulty injector, disconnect the injector INSTALL a new fuel injector. REFER to Section
electrical connector and listen for the noise. 303-04a for 2.0L Zetec engine or Section
303-04b for 3.0L (4V) engine. TEST the system
Is the fuel injector the source of the ticking noise? for normal operation.
No
Go to B3.
B3 CHECK THE BELT TENSIONER FOR TICKING NOISE

Inspect the front engine accessory drive (FEAD). Check for the belt Yes
tensioner bottoming at end of travel or not at end of stroke. INSTALL a new belt tensioner. REFER to
Section 303-05 . TEST the system for normal
Using an EngineEAR, listen at the belt tensioner. operation.
Is the belt tensioner the source of the noise?
No
Go to B4.
B4 CHECK THE WATER PUMP FOR TICKING NOISE

Using an EngineEAR, listen at the water pump for ticking noise. Yes
INSTALL a new water pump. REFER to Section
Is the water pump the source of the noise? 303-03 . TEST the system for normal operation.
No
Go to B5.
B5 CHECK FOR AN OBSTRUCTION OF THE COOLING FAN

Inspect the cooling fan for obstructions. Yes
REPAIR or INSTALL a new cooling fan. REFER
Check the cooling fan and shroud for wear or damage. to Section 303-03 . TEST the system for normal
Was there an obstruction or does the cooling fan show signs of operation.
damage?
No
Go to B6.
B6 CHECK THE OIL PUMP FOR TICKING NOISE

Check the oil pump using EngineEARs and probe at the oil filter Yes
adapter to verify the oil pump as a source. INSTALL a new oil pump. REFER to Section
303-01a for 2.0L Zetec engine or Section
Is the oil pump the source of the noise? 303-01b for 3.0L (4V) engine. TEST the system
for normal operation.
No
Go to B7.
B7 CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR

CORRECT OPERATION
Check valve lifter/lash adjuster for correct operation, using Yes
EngineEARs. VERIFY customer concern. CONDUCT a
diagnosis of other suspect components.
Are the valve lifters/lash adjusters operating correctly?
No
INSTALL a new valve lifter/lash adjuster(s).
TEST the system for normal operation.
G72679 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT
C1 CHECK THE ACCESSORY DRIVE IDLER AND

TENSIONER PULLEY BEARINGS
Carry out the Vehicle Cold Soak Procedure in this section. Yes
INSTALL a new pulley/idler. REFER to Section
Key in START position.
303-05 . CARRY OUT the Vehicle Cold Soak
Place an EngineEAR probe directly on the pulley center post or bolt to Procedure and TEST the system for normal
verify which bearing is making the noise. operation.
Key in OFF position. No
CONDUCT a diagnosis on other suspect
Is either bearing making the noise?
accessory drive components.
PINPOINT TEST D : POWER STEERING MOAN
D1 CHECK THE POWER STEERING SYSTEM

Go to D2.
Turn the steering wheel while the noise is occurring and listen for No
changes in sound pitch or loudness. CONDUCT a diagnosis on other suspect
accessory drive components.
Key in OFF position.
Does the sound pitch or loudness change while turning the
steering wheel?
D2 VERIFY THE SOURCE

Key in START position. Yes
VERIFY that the supply tube to the pump is
Place an EngineEAR probe near the power steering pump/reservoir
unobstructed. CHECK the fluid condition and
while the noise is occurring. While an assistant turns the steering
level. DRAIN the fluid and REFILL. CARRY OUT
wheel, listen for changes in sound pitch or loudness.
the Vehicle Cold Soak Procedure and TEST the
Key in OFF position. system for normal operation. REFER to Section
211-02 .
Does the sound pitch or loudness change while turning the
steering wheel? No
Normal system operation.
G72679 en 01/2003 2003.0 BA Falcon

PINPOINT TEST E : DRUMMING NOISE
E1 CHECK THE EXHAUST SYSTEM

CARRY OUT Exhaust System Neutralizing in
Increase the engine rpm until the noise is the loudest. Note the engine this section. TEST the system for normal
rpm. operation.
No
Add approximately 9 kg (20 lb) of weight to the exhaust system. Place Go to E2.
the weight at the tailpipe and test.
Increase the engine rpm and listen for the drumming noise. Note the
engine rpm if the noise occurs.
Using a vibration analyzer, determine the amount of vibration that
occurs with the drumming noise.
Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm?
E2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING

Carry out Powertrain/Drivetrain Mount Neutralizing in this section. Yes
Test the system for normal operation. Vehicle is OK. TEST the system for normal
operation.
Is the noise reduced or eliminated?
No
CONDUCT diagnosis of other suspect
components.
PINPOINT TEST F : ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE
F1 CHECK FOR NOISE AT THE VALVE COVERS AND THE

FRONT COVERS (OHC ENGINES)
REMOVE the appropriate cover and INSPECT
Key in START position. for loose, worn/broken components. REPAIR as
necessary. TEST the system for normal
NOTE: For a short-duration ticking noise, multiple engine starts may operation.
be necessary.
Using an EngineEAR, listen closely at the valve covers and the front No
covers by placing the probe near the surface of the valve cover and Go to F2.
then on the surface front cover.
Is the noise source apparent?
F2 CHECK FOR NOISE AT THE CYLINDER BLOCK

REPAIR or INSTALL new components as
Using an EngineEAR, listen closely at the cylinder block by placing a necessary.
probe on or near each freeze plug.
Go to F3.
Is the noise source apparent?
G72679 en 01/2003 2003.0 BA Falcon


F3 CHECK FOR NOISE WHILE DISCONNECTING EACH
FUEL INJECTOR ELECTRICAL CONNECTOR, ONE AT A
TIME
INSTALL a new fuel injector. REFER to Section
Disconnect each fuel injector electrical connector, one at a time, to
decrease piston force and listen for the noise.
303-04b for 3.0L (4V) engine. TEST the system
Key in OFF position. for normal operation.
Is the noise reduced or eliminated? No
INSPECT accessory drive or the transmission as
a possible source.
PINPOINT TEST G : FRONT SUSPENSION NOISE
G1 ROAD TEST THE VEHICLE

Test drive the vehicle. Yes
Go to G2.
During the road test, drive the vehicle over a rough road. Using
ChassisEARs, determine from which area/component the noise is No
originating. The suspension system is OK. CONDUCT a
Is there a squeak, creak or rattle noise? diagnosis on other suspect systems.
G2 INSPECT THE STEERING SYSTEM

Raise and support the vehicle. For additional information, refer to Yes
Section 100-02 . REPAIR the steering system. INSTALL new
components as necessary. TEST the system for
Check the steering system for wear or damage. Carry out a steering normal operation.
linkage test.
Inspect the tyre wear pattern. Refer to Tyre Wear Patterns chart in No
this section. Go to G3.
Are the steering components worn or damaged?
G3 FRONT SHOCK ABSORBER/STRUT CHECK

Check the front shock absorbers/strut mounts for loose bolts or nuts. Yes
TIGHTEN to specifications if loose. INSTALL
Check the front shock absorbers/struts for damage. Carry out a shock
new front shock absorbers/struts if damaged.
absorber check.
Are the front shock absorbers/struts loose or damaged?
No
Go to G4.
G4 CHECK THE FRONT SPRINGS

Check the front spring and front spring mounts/brackets for wear or Yes
damage. REPAIR or INSTALL new components as
Are the front springs or spring mounts/brackets worn or operation.
damaged?
No
Go to G5.
G72679 en 01/2003 2003.0 BA Falcon


G5 CHECK THE CONTROL ARMS/RADIUS ARMS
Inspect the control arm bushings for wear or damage. Yes
REPAIR or INSTALL new components as
Inspect for twisted or bent control arm/radius arm. necessary. TEST the system for normal
Are the control arm/radius arms damaged or worn? operation.
No
Go to G6.
G6 CHECK THE STABILIZER BAR/TRACK BAR

Check the stabilizer bar/track bar bushings and links for damage or Yes
wear. REPAIR or INSTALL new components as
Check the stabilizer bar/track bar for damage. operation.
Check for loose or damaged stabilizer bar/track bar isolators or
brackets. No
Suspension system is OK. CONDUCT diagnosis
Are the stabilizer bar/track bar components loose, worn or on other suspect systems.
damaged?
PINPOINT TEST H : REAR SUSPENSION NOISE
H1 ROAD TEST THE VEHICLE

Test drive the vehicle. Yes
Go to H2.
During the road test, drive the vehicle over a rough road. Using
ChassisEARs, determine from which area/component the noise is No
originating. The suspension system is OK. Conduct a
Is there a squeak, creak or rattle noise? diagnosis on other suspect systems.
H2 REAR SHOCK ABSORBER/STRUT CHECK

Raise and support the vehicle. REFER to Section 100-02 . Yes
TIGHTEN to specifications if loose. INSTALL
Check the rear shock absorber/strut mounts for loose bolts or nuts. new rear shock absorbers/struts if damaged.
Check the rear shock absorbers/struts for damage. Carry out a shock TEST the system for normal operation.
absorber check.
No
Are the rear shock absorbers/struts loose or damaged? Go to H3.
H3 CHECK THE REAR SPRINGS

Check the rear springs and rear spring mounts/brackets for wear or Yes
damage. REPAIR or INSTALL new components as
Are the rear springs or spring mounts/brackets worn or operation.
damaged?
No
Go to H4.
H4 CHECK THE CONTROL ARMS/TRAILING ARMS

Inspect the control arm/trailing arm bushings for wear or damage. Yes
Check for loose control arm/trailing arm bolts. REPAIR or INSTALL new components as
Inspect for twisted or bent control arms/trailing arms.
operation.
Are the control arms/trailing arms loose, damaged or worn?
No
Suspension system is OK. CONDUCT diagnosis
on other suspect systems.
G72679 en 01/2003 2003.0 BA Falcon

PINPOINT TEST I : WHEEL AND TYRE
I1 ROAD TEST THE VEHICLE
NOTE: Wheel or tyre vibrations felt in the steering wheel are most likely Yes
related to the front wheel or tyre. Vibration felt through the seat are most Go to I2.
likely related to the rear wheel or tyre. This may not always be true, but it
can help to isolate the problem to the front or rear of the vehicle. No
The wheel and tyres are OK. CONDUCT a
Test drive the vehicle at different speed ranges. diagnosis on other suspect systems.
During the road test, if the vibration can be eliminated by placing the
vehicle in neutral or is affected by the speed of the engine, the cause
is not the wheels or tyres.
Is there a vibration and noise?
I2 CHECK THE FRONT WHEEL BEARINGS

Check the front wheel bearings. Refer to Wheel Bearing Check in this Yes
section. Go to I3.
Are the wheel bearings OK? No
INSPECT the wheel bearings. ADJUST or
REPAIR as necessary. TEST the system for
normal operation.
I3 INSPECT THE TYRES

Check the tyres for missing weights. Yes
CORRECT the condition that caused the
Check the wheels for damage. abnormal wear. INSTALL new tyre(s). TEST the
Inspect the tyre wear pattern. Refer to the Tyre Wear Patterns chart in system for normal operation.
this section.
No
Do the tyres have an abnormal wear pattern? Go to I4.
I4 TIRE ROTATION DIAGNOSIS

Spin the tyres slowly and watch for signs of lateral runout. Yes
Go to I5.
Spin the tyres slowly and watch for signs of radial runout.
Are there signs of visual runout? No
CHECK the wheel and tyre balance. CORRECT
as necessary. TEST the system for normal
operation.
G72679 en 01/2003 2003.0 BA Falcon


I5 RADIAL RUNOUT CHECK ON THE TIRE
Measure the radial runout of the wheel and tyre assembly. A typical Yes
specification for total radial runout is 1.15mm (0.059inch). Go to I8.
No
Go to I6.
Is the radial runout within specifications?
I6 RADIAL RUNOUT CHECK ON THE WHEEL

Measure the radial runout of the wheel. A typical specification for total Yes
radial runout is 1.14mm (0.045 inch). INSTALL a new tyre. TEST the system for
normal operation.
Is the radial runout within specifications?
No
Go to I7.
I7 CHECK THE HUB/BRAKE DISC OR DRUM PILOT

RUNOUT OR BOLT CIRCLE RUNOUT
Measure the pilot or bolt circle runout. A typical specification for radial Yes
runout is: INSTALL a new wheel. TEST the system for
pilot runout— less than 0.15 mm (0.006 inch) normal operation.
bolt circle runout— less than 0.38 mm (0.015 inch) No

Is the radial runout within specifications? REPAIR or INSTALL new components as
necessary. REFER to 204-01 for the front
suspension or 204-02 for the rear suspension.
G72679 en 01/2003 2003.0 BA Falcon


I8 LATERAL RUNOUT CHECK ON THE TIRE
Measure the lateral runout of the wheel and tyre assembly. A typical Yes
specification for total lateral runout is 2.5mm (0.098inch). Wheel and tyres are OK. CONDUCT diagnosis
No
Go to I9.
Is the lateral runout within specifications?
I9 LATERAL RUNOUT CHECK ON THE WHEEL

Measure the lateral runout of the wheel. A typical specification for Yes
total radial runout is 1.2mm (0.047inch). INSTALL a new tyre. TEST the system for
normal operation.
Is the lateral runout within specifications?
No
Go to I10.
I10 CHECK THE FLANGE FACE LATERAL RUNOUT

Measure the flange face lateral runout. A typical specification for Yes
lateral runout is: INSTALL a new wheel. TEST the system for
hub/brake disc— less than 0.13mm (0.005inch) normal operation.
axle shaft— less than 0.25 mm (0.010 inch) No

Is the lateral runout within specifications? REPAIR or INSTALL new components as
necessary. REFER to Section 204-01 for the
front suspension or Section 204-02 for the rear
suspension.
PINPOINT TEST J : HIGH SPEED SHAKE OR SHIMMY
J1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS

Chock the rear wheels. Yes
INSPECT the wheel bearings. REPAIR as
Raise and support the front end of the vehicle so that the front wheel necessary. TEST the system for normal
and tyre assemblies can spin. Refer to Section 100-02 . operation.
Spin the front tyres by hand.
No
Do the wheel bearings feel rough? Go to J2.
G72679 en 01/2003 2003.0 BA Falcon


J2 CHECK THE END PLAY OF THE FRONT WHEEL
BEARINGS
Check the end play of the front wheel bearings. Yes
Go to J3.
Is the end play OK?
No
ADJUST or REPAIR as necessary. TEST the
system for normal operation.
J3 MEASURE THE LATERAL RUNOUT AND THE RADIAL

RUNOUT OF THE FRONT WHEELS ON THE VEHICLE
Measure the lateral runout and the radial runout of the front wheels on Yes
the vehicle. Go to Pinpoint Test I. Go to J4.
Are the measurements within specifications? No
INSTALL new wheels as necessary and
BALANCE the assembly. TEST the system for
normal operation.
J4 MEASURE THE LATERAL RUNOUT OF THE FRONT

TIRES ON THE VEHICLE
Measure the lateral runout of the front tyres on the vehicle. Go to Yes
Pinpoint Test I. Go to J5.
Is the runout within specifications? No
INSTALL new tyres as necessary and
BALANCE the assembly. TEST the system for
normal operation.
J5 MEASURE THE RADIAL RUNOUT OF THE FRONT

TIRES ON THE VEHICLE
Measure the radial runout of the front tyres on the vehicle. Go to Yes
Pinpoint Test I. BALANCE the front wheel and tyre assemblies.
If any tyre cannot be balanced, INSTALL a new
Is the runout within specifications? tyre. TEST the system for normal operation.
No
Go to J6.
J6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY

Mark the high runout location on the tyre and also on the wheel. Yes
Break the assembly down and rotate the tyre 180 degrees (halfway BALANCE the assembly. TEST the system for
around) on the wheel. Inflate the tyre and measure the radial runout. normal operation.
Is the runout within specifications? No
If the high spot is not within 101.6 mm (4 inches)
of the first high spot on the tyre, Go to J7.
G72679 en 01/2003 2003.0 BA Falcon


J7 MEASURE THE WHEEL FLANGE RUNOUT
Dismount the tyre and mount the wheel on a wheel balancer. Yes
Measure the runout on both wheel flanges. Go to Pinpoint Test I. LOCATE and MARK the low spot on the wheel.
INSTALL the tyre, matching the high spot on the
Is the runout within specifications? tyre with the low spot on the wheel. BALANCE
the assembly. TEST the system for normal
operation. If the condition persists, Go to J8.
No
INSTALL a new wheel. CHECK the runout on
the new wheel. If the new wheel is within limits,
LOCATE and MARK the low spot. INSTALL the
tyre, matching the high spot on the tyre with the
low spot on the wheel. BALANCE the assembly.
TEST the system for normal operation. If the
condition persists, Go to J8.
J8 CHECK FOR VIBRATION FROM THE FRONT OF THE

VEHICLE
Yes
WARNING: If only one drive wheel is allowed to rotate, speed SUBSTITUTE known good wheel and tyre
must be limited to 55 km/h (34 mph) using the speedometer reading, assemblies as necessary. TEST the system for
since actual wheel speed will be twice that indicated on the normal operation.
speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the
drive wheel to hang unsupported can result in tyre disintegration or No
differential failure, which can cause serious personal injury and For front wheel drive vehicles, check the
extensive vehicle damage. driveline components. TEST the system for
normal operation. For rear wheel drive vehicles,
Spin the front wheel and tyre assemblies with a wheel balancer while Go to J9.
the vehicle is raised on a hoist. Feel for vibration in the front fender or
while seated in the vehicle.
Is the vibration present?
J9 CHECK FOR VIBRATION FROM THE REAR OF THE

VEHICLE
Yes
WARNING: If only one drive wheel is allowed to rotate, speed Go to J10.
must be limited to 55 km/h (34 mph) using the speedometer reading,
since actual wheel speed will be twice that indicated on the No
speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the TEST the system for normal operation.
drive wheel to hang unsupported can result in tyre disintegration or
differential failure, which can cause serious personal injury and
extensive vehicle damage.
Chock the front wheels.

Raise and support the rear end of the vehicle so that the rear wheel
and tyre assemblies can spin. Refer to Section 100-02 .
Engage the drivetrain and carefully accelerate the drive wheels while
checking for vibration.
G72679 en 01/2003 2003.0 BA Falcon


J10 CHECK THE DRIVETRAIN
Yes
WARNING: If only one drive wheel is allowed to rotate, speed CHECK/TEST the drivetrain and driveline
must be limited to 55 km/h (34 mph) using the speedometer reading, components. TEST the system for normal
since actual wheel speed will be twice that indicated on the operation.
speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the
drive wheel to hang unsupported can result in tyre disintegration or No
differential failure, which can cause serious personal injury and SUBSTITUTE known good wheel and tyre
extensive vehicle damage. assemblies as necessary. TEST the system for
normal operation.
Remove the rear wheel and tyre assemblies. Refer to Section 204-04
.
Secure the brake drums (if so equipped), by installing wheel hub bolt
nuts, reversed.
Carefully accelerate the drivetrain while checking for vibration.
PINPOINT TEST K : CLUTCH VIBRATION
K1 CHECK ENGINE COMPONENTS FOR GROUNDING
NOTE: Make sure the clutch is the cause of the vibration concern. The Yes
vibration should occur during clutch operation. The clutch can also be REPAIR as necessary. TEST the system for
difficult to engage or disengage. Eliminate all related systems before normal operation.
checking the clutch components.
No
NOTE: Check the driveline angles and driveshaft runout before Go to K2.
disassembling the clutch system. Refer to Section 205-00 for the correct
driveline angle specifications.
Check the powertrain/drivetrain mounts, exhaust manifolds or other

engine components for grounding on the chassis.
Are any mounts or engine components grounded?
K2 CHECK THE ACCESSORY DRIVE BELT

Remove the accessory drive belt. Yes
DIAGNOSE the accessory drive components.
Does the vibration stop with the accessory drive belt removed?
No
Go to K3.
K3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE

BOLTS
Check for loose clutch pressure plate bolts. Inspect the clutch Yes
pressure plate for damage or for material between the pressure plate TIGHTEN the bolts to specifications or if
and flywheel. damaged, INSTALL a new clutch pressure plate.
REFER to Section 308-01 . TEST the system for
Are there any loose bolts or damage? normal operation.
No
Go to K4.
K4 CHECK THE CLUTCH DISC SPRINGS

Check for worn, broken or loose clutch disc springs. Yes
INSTALL a new clutch disc. REFER to Section
Are the clutch springs worn, broken or loose? 308-01 . TEST the system for normal operation.
No
Go to K5.
G72679 en 01/2003 2003.0 BA Falcon


K5 CHECK THE CLUTCH DISC SPLINES
Inspect the clutch disc splines for damage or wear. Yes
INSTALL a new clutch disc. REFER to Section
Is there damage or wear? 308-01 . TEST the system for normal operation.
No
Go to K6.
K6 CHECK THE FLYWHEEL BOLTS

Check for loose flywheel bolts. Yes
TIGHTEN the bolts to specifications. REFER to
Are the bolts loose? Section 308-01 . TEST the system for normal
operation.
No
Go to K7.
K7 CHECK THE FLYWHEEL SURFACE

Inspect the flywheel surface for wear or damage. Check the flywheel Yes
runout. INSTALL a new flywheel. REFER to Section
Is there any damage or excessive wear? 303-01b for 3.0L (4V) engine. TEST the system
No
Clutch system is normal. CONDUCT a diagnosis
Component Tests scored or forcibly damaged gear teeth and is usually

quite audible over the entyre speed range. The
Steering Gear Grunt/Shudder Test second type of ring and pinion noise pertains to the
1. Start and run the vehicle to operating mesh pattern of the gear pattern. This gear noise can
temperature. be recognized as it produces a cycling pitch or whine.
Ring and pinion noise tends to peak in a narrow
2. Set engine idle speed to 1,200 rpm. speed range or ranges, and will tend to remain
CAUTION: Do not hold the steering wheel constant in pitch.
against the stops for more than three to five 1. Raise and support the vehicle. Refer to Section
seconds at a time. Damage to the power 100-02.
steering pump will occur. 2. Drain the axle lubricant. Refer to Section 205-02.
3. Rotate the steering wheel to the RH stop, then 3. Remove the carrier assembly or the axle housing
turn the steering wheel 90 degrees back from that cover depending on the axle type. Refer to
position. Turn the steering wheel slowly in a 15 to Section 205-02.
30 degree arc. 4. Inspect the gear set for scoring or damage.
4. Turn the steering wheel another 90 degrees. Turn
the steering wheel slowly in a 15 to 30 degree
arc.
5. Repeat the test with power steering fluid at
different temperatures.
6. If a light grunt is heard or a low (50-200 Hz)
shudder is present, this is a normal steering
system condition.
7. If a loud grunt is heard or a strong shudder is felt,
fill and purge the power steering system.
Checking Tooth Contact Pattern and
There are two basic types of conditions that will
produce ring and pinion noise. The first type is a howl
or chuckle produced by broken, cracked, chipped,
G72679 en 01/2003 2003.0 BA Falcon

5. In the following steps, the movement of the 8. A high, thick contact pattern that is worn more
contact pattern along the length is indicated as toward the toe.
toward the “heel” or “toe” of the differential ring Tooth contact pattern shown on the drive side
gear. of the gear teeth.
The high contact pattern indicates that the
drive pinion is not installed deep enough into
the carrier.
The differential ring gear backlash is correct,
a thinner drive pinion shim is needed. A
decrease will move the drive pinion toward
the differential ring gear.
Item Description
1 Heel
2 Toe
6. Apply a marking compound to a third of the gear
teeth on the differential ring gear. Rotate the
differential ring gear several complete turns in
both directions until a good, clear tooth pattern is 9. A high, thin contact pattern that is worn toward
obtained. Inspect the contact patterns on the ring the toe.
gear teeth. Tooth contact pattern shown on the drive side
7. A good contact pattern should be centered on the of the gear teeth.
tooth. It can also be slightly toward the toe. There The drive pinion depth is correct. Increase the
should always be some clearance between the differential ring gear backlash.
contact pattern and the top of the tooth.
Tooth contact pattern shown on the drive side
of the gear teeth.
G72679 en 01/2003 2003.0 BA Falcon

10. A contact pattern that is worn in the center of the

differential ring gear tooth toward the heel.
of the gear teeth.
The low contact pattern indicates that the
drive pinion is installed too deep into the
carrier.
The differential ring gear backlash is correct.
A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the

differential ring gear tooth toward the heel.
of the gear teeth.
The pinion gear depth is correct. Decrease
the differential ring gear backlash.
G72679 en 01/2003 2003.0 BA Falcon

Tyre Wear Patterns and Frequency Calculations

Tyre Wear Chart
G72679 en 01/2003 2003.0 BA Falcon

Wheel and tyre NVH concerns are directly related to

vehicle speed and are not generally affected by
acceleration, coasting or decelerating. Also,
out-of-balance wheel and tyres can vibrate at more
than one speed. A vibration that is affected by the
engine rpm, or is eliminated by placing the
transmission in NEUTRAL is not related to the tyre
and wheel. As a general rule, tyre and wheel
vibrations felt in the steering wheel are related to the
front tyre and wheel assemblies. Vibrations felt in the
seat or floor are related to the rear tyre and wheel
assemblies. This can initially isolate a concern to the
front or rear.
Careful attention must be paid to the tyre and wheels.
There are several symptoms that can be caused by
damaged or worn tyre and wheels. Carry out a careful
visual inspection of the tyres and wheel assemblies.
Spin the tyres slowly and watch for signs of lateral or
radial runout. Refer to the tyre wear chart to
determine the tyre wear conditions and actions.
For a vibration concern, use the vehicle speed to
determine tyre/wheel frequency and rpm. Calculate
tyre and wheel rpm and frequency by carrying out and
following:
Measure the diameter of the tyre.
Record the speed at which the vibration occurs.
Obtain the corresponding tyre and wheel rpm and
frequency from the Tyre Speed and Frequency
Chart.
If the vehicle speed is not listed, divide the
vehicle speed at which the vibration occurs by
16 (km/h (10 mph). Multiply that number by
16 km/h (10 mph) tyre rpm listed for that tyre
diameter in the chart. Then divide that number
by 60. For example: a 40 mph vibration with
835 mm (33 in) tyres. 40 ÷10 = 4. Multiply 4
by 105 = 420 rpm. Divide 420 rpm by 60
seconds = 7 Hz at 40mph.
Tyre Speed and Frequency Chart

Tyre Diameter Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz
mm (inch) @ 16 km/h (10 @ 80 km/h (50 @ 97 km/h (60 @ 113 km/h (70
mph) mph) mph) mph)
483 (19) 182 910/15 1092/18 1274/21
508 (20) 173 865/14 1038/17 1211/20
533 (21) 165 825/14 990/16 1155/19
560 (22) 158 790/13 948/16 1106/18
585 (23) 151 755/13 906/15 1057/18
610 (24) 145 725/12 870/14 1015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
G72679 en 01/2003 2003.0 BA Falcon

Tyre Diameter Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz Tyre RPM/Hz
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12
G72679 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Using the match marks, mount the brake disc

Brake Disc Machining on the hub.
12. Install the caliper.
CAUTION: Do not install brake discs that are 13. Install the tyre and wheel assembly.
less than the minimum thickness specified. Do
not machine a brake disc below the minimum 14. Test the system for normal operation.
thickness specification.
Powertrain/Drivetrain Mount
1. Check wheel bearing end-play and correct as
necessary.
Neutralizing
2. Remove the tyre and wheel. 1. Raise and support the vehicle. For additional
NOTE: Begin at the front of the vehicle unless the information, refer to Section 100-02.
vibration has been isolated to the rear. 2. Loosen, but do not remove, the
powertrain/drivetrain mount fasteners.
3. Remove the brake caliper.
3. Lower the vehicle.
4. Inspect the brake linings. Install new brake linings
if below specification. For additional information, 4. Move the vehicle in forward and reverse 0.6-1.2
refer to the appropriate brake section. meters (2-4 ft).
5. Measure and record the brake disc thickness. CAUTION: Do not twist or strain the
Install a new brake disc if the thickness after powertrain/drivetrain mounts.
machining will be at or below specification. The 5. Raise and support the vehicle.
specification is stamped on the brake disc. Do not
machine a new brake disc. 6. Tighten the powertrain/drivetrain mount fasteners.
6. For vehicles with a two-piece hub and brake disc 7. Lower the vehicle.
assembly: 8. Test the system for normal operation.
Match-mark before disassembly.
Exhaust System Neutralizing
Remove the brake disc.
Using a die grinder with a mild abrasive WARNING: Exhaust gases contain carbon
(Scotch Brite® type), remove any rust or monoxide, which is harmful to health and
corrosion from the hub and brake disc potentially lethal. Repair exhaust system leaks
mounting surfaces. immediately. Never operate the engine in an
Align the match-marks and reinstall the brake enclosed area. Failure to follow these instructions
disc on the hub. may result in personal injury.
7. Using the special tool, machine the brake discs.
Follow the manufacturer’s instructions. After WARNING: Exhaust system components are
machining, make sure the brake disc still meets hot. Failure to follow these instructions may result
the thickness specification. in personal injury.
NOTE: Neutralize the exhaust system to relieve strain
CAUTION: Do not use a bench lathe to on mounts which can be sufficiently bound up to
machine brake discs. transmit vibration as if grounded.
NOTE: The depth of cut must be between 0.10
and 0.20 mm (0.004 and 0.008 inch). Lighter cuts 1. Raise and support the vehicle. For additional
will cause heat and wear. Heavier cuts will cause information, refer to Section 100-02.
poor brake disc surface finish.
CAUTION: Make sure the system is
8. Using a dial indicator, verify that the brake disc warmed up to normal operating temperature,
lateral runout is now within specification. as thermal expansion can be the cause of a
9. Remove the special tool hub adapter. strain problem.
10. Remove any remaining metal chips from the 2. Loosen all exhaust hanger attachments and
machining operation. reposition the hangers until they hang free and
straight.
11. For vehicles with a two-piece hub and brake disc
assembly: 3. Loosen all exhaust flange joints.
Remove the brake disc from the hub. 4. Place a stand to support the muffler parallel to the
vehicle frame with the muffler pipe bracket free of
Remove any remaining metal chips from hub stress.
and brake disc mounting surfaces and from
the ABS sensor. 5. Tighten the muffler connection.
Apply a high temperature anti-seize lubricant
to the mounting surfaces.
G72682 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES (Continued)
6. Tighten all the exhaust hanger clamps and 3. Grip each front tyre at the top and bottom and
flanges (tighten the exhaust manifold flange joint move the wheel inward and outward while lifting
last). the weight of the tyre off the front wheel bearing.
Verify there is adequate clearance to prevent
grounding at any point in the system. Make
sure that the catalytic converter and heat
shield do not contact the frame rails.
After neutralization, the rubber in the exhaust
hangers should show some flexibility when
movement is applied to the exhaust system.
With the exhaust system installed securely
and cooled, the rear hanger should be angled
forward.
8. Test the exhaust system for normal operation.
Wheel Bearing Check

4. If the tyre and wheel (hub) is loose on the spindle,
1. Raise the vehicle until the front tyres are off the does not rotate freely, or has a rough feeling
floor. when spun, install a new wheel hub.
Make sure the wheels are in a straight
forward position.
2. Spin the tyre by hand to check the wheel bearings
for roughness.
NOTE: Make sure the wheel rotates freely and
that the brake pads are retraced sufficiently to
allow free movement of the tyre and wheel
assembly.
G72682 en 01/2003 2003.0 BA Falcon

204-00-1 Suspension System — General Information 204-00-1
SECTION : 204-00 Suspension System — General

Information
CONTENTS PAGE
Suspension System — General Information ..........................................................................204-00-2
Front Wheel Alignment ........................................................................................................204-00-2
Rear Wheel Alignment .........................................................................................................204-00-4
Suspension System — General Information ..........................................................................204-00-5
Inspection and Verification ...................................................................................................204-00-5
Symptom Chart ....................................................................................................................204-00-5
Shock Absorbers ..................................................................................................................204-00-8
GENERAL PROCEDURES
Toe Adjustment ......................................................................................................................204-00-9
Front Wheel Alignment ..........................................................................................................204-00-9
Toe & Steering Wheel Spoke Adjustments ............................................................................204-00-9
Front Wheel Lock Angle Adjustment .....................................................................................204-00-9
Upper & Lower Ball Joint Inspection ......................................................................................204-00-9
XR Rear Camber Adjustment ................................................................................................204-00-9
RLCA (Rear Lower Control Arm) to Subframe Cambolt Adjustment .....................................204-00-9
01/2003 2003.0 BA Falcon

Suspension System — General where necessary at kerb height.

Information NOTE: When checking ute and wagon front caster it
is important that the rear ride height is correct. This
Front Wheel Alignment can be achieved by ensuring the vehicle unladen.
Suggested method and sequence for checking The following charts show wheel alignment data for
steering wander or drift the various models.
1. Check and adjust tyre pressures to specification. Toe settings are provided in degrees.
Make sure the vehicle is loaded evenly so ride
heights are relatively even side to side.
2. Check all wheel bearings, steering mechanisms
and suspension joints are to specification. Adjust,
repair or replace as required.
3. Check tyres for uneven wear patterns especially
the inner edges compared to the outer edges.
Rotate tyres front to rear if required.
4. Road test vehicle on a level road surface and
note direction and extent of steering pull or drift.
Ensure prevailing crosswinds are not a factor.
5. If pull of drift is confirmed check the wheel
alignment and confirm that the vehicle is within
specification.
Wheel Alignment Equipment/Maintenance

It is extremely important the wheel alignment
equipment used is periodically checked and
recalibrated to ensure vehicle readings are both
accurate and repeatable. Please consult your
equipment supplier for advice as to how and when the
periodic checking and recalibration should occur.
Regular checking and calibration of wheel alignment
equipment is essential with the current generation of
wheel alignment machines.
NOTE: See text for XR camber adjustment.
NOTE: Ute and Wagon rear alignment can not be
adjusted.
NOTE: Camber and castor figures will vary depending
on the vehicle ride height. The ride height will alter
depending on the how heavily the vehicle is loaded,
the way the load is distributed, the amount of fuel in
the tank and accessories fitted eg: bulbar. The lower
the vehicle the more negative the camber value
becomes and the more positive the castor value
becomes.
NOTE: Toe in is shown as a + (positive) value while
toe out is shown as a - (negative) value. It is
preferable to measure vehicles in degrees. Data is for
reference only.
NOTE: With correct tyre pressures the ride height is
measured vertically from the exact centre of the wheel
to the underside of the guard lip (refer figure).
Measure all four corners of the vehicle and locate the
appropriate ride height in the left hand column in both
table: 1 for front the suspension and table: 2 for the
rear suspension. Then select the appropriate
alignment values for each corner of the vehicle and
confirm if vehicle is within specification. Adjust toe
G22340 en 01/2003 2003.0 BA Falcon

Front Wheel Alignment

Sedan / Wagon
Ride Camber Castor Total Toe at kerb height
Height Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °
Variation ° Variation
350 -1.91 -1.41 -0.91 0.7 7 7.50 8 0.7
360 -1.66 -1.16 -0.66 0.7 6.9 7.40 7.9 0.7
370 -1.44 -0.94 -0.44 0.7 6.8 7.30 7.8 0.7
380 -1.23 -0.73 -0.23 0.7 6.69 7.19 7.69 0.7 -0.02 0.08 0.18
390 -1.07 -0.57 -0.07 0.7 6.59 7.09 7.59 0.7
400 -0.92 -0.42 -0.08 0.7 6.48 6.99 7.48 0.7
410 -0.81 -0.31 -0.19 0.7 6.38 6.88 7.38 0.7
420 -0.72 -0.22 -0.28 0.7 6.27 6.77 7.27 0.7
XR Sedan
340 -1.52 -1.02 -0.52 0.7 7.32 7.82 8.32 0.7
350 -1.22 -0.72 -0.22 0.7 7.21 7.71 8.21 0.7
360 -0.95 -0.45 0.05 0.7 7.10 7.60 8.10 0.7
370 -0.71 -0.21 0.29 0.7 6.99 7.49 7.99 0.7 0.06 0.16 0.26
380 -0.50 0.00 0.50 0.7 6.88 7.38 7.88 0.7
390 -0.33 0.17 0.67 0.7 6.77 7.27 7.77 0.7
400 -0.17 0.33 0.83 0.7 6.65 7.15 7.65 0.7
Ute
370 -1.24 -0.74 -0.24 0.7 6.81 7.31 7.81 0.7
380 -1.05 -0.55 -0.05 0.7 6.7 7.20 7.7 0.7
390 -0.88 -0.38 -0.12 0.7 6.59 7.09 7.59 0.7 -0.02 0.08 0.18
400 -0.73 -0.23 -0.27 0.7 6.48 7.99 7.48 0.7
410 -0.62 -0.12 -0.38 0.7 6.38 7.88 7.38 0.7
420 -0.54 -0.04 -0.46 0.7 6.27 6.77 7.27 0.7
XR Ute, XLS Ute with standard sports suspension

340 -1.92 -1.42 -0.92 0.7 5.70 6.20 6.70 0.7
350 -1.63 -1.13 -0.63 0.7 5.56 6.06 6.56 0.7
360 -1.37 -0.87 -0.37 0.7 5.43 5.93 6.43 0.7
370 -1.13 -0.63 -0.13 0.7 5.30 5.80 6.30 0.7 0.06 0.16 0.26
380 -0.93 -0.43 0.07 0.7 5.18 5.68 6.18 0.7
390 -0.76 -0.26 0.24 0.7 5.06 5.56 6.06 0.7
400 -0.61 -0.11 0.39 0.7 4.93 5.43 5.93 0.7
G22340 en 01/2003 2003.0 BA Falcon

Rear Wheel Alignment

Sedan
Ride Height Camber Total Toe at kerb height
Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °
Variation °
350 -1.96 -1.71 -1.46 0.5
360 -1.76 -1.51 -1.26 0.5
370 -1.57 -1.32 -1.07 0.5
380 -1.38 0.13 -0.88 0.5 0.14 0.24 0.34
390 -1.19 -0.94 -0.69 0.5
400 -1 -0.75 -0.50 0.5
410 -0.81 -0.56 -0.31 0.5
420 -0.61 -0.36 -0.11 0.5
NOTE: Sedan camber settings cannot be adjusted,
for reference only.
XR Sedan
Ride Height Camber Total Toe at kerb height
Min. ° Opt. ° Max. ° Max. Min. ° Opt. ° Max. °
Variation °
340 -1.35 -1.10 -0.85 0.5
350 -1.14 -0.89 -0.64 0.5
360 -0.95 -0.70 -0.45 0.5
370 -0.75 -0.50 -0.25 0.5 0.06 0.16 0.26
380 -0.56 -0.31 -0.06 0.5
390 -0.37 -0.12 0.13 0.5
400 -0.18 0.07 0.32 0.5
G22340 en 01/2003 2003.0 BA Falcon

Suspension System — General these symptoms are also common to suspension

frame, and wheel and tyre troubles. For this reason,
Information be sure that the cause of a concern is in the steering
gear or linkage before adjusting, repairing, or
Inspection and Verification replacing any of the steering parts.
NOTE: Table 1 lists various steering gear and linkage
trouble symptoms and possible causes. Several of
Symptom Chart

Jerky Steering Power Steering Fluid Level Low Leak Remove/Repair as required
Glazed, Loose or Broken Power
Steering Pump Belt
Air in Power Steering System
Binding Front Suspension Ball Joints
or Steering Linkage
Loose, Worn, or Damaged Steering
Linkage or Connections
Loose Steering Gear Mountings
Incorrect Steering Gear Adjustment
Incorrect Brake Adjustment
Incorrect Front Wheel Bearing
Adjustment
Wheel Out of Balance
Obstruction Within Steering Gear
Loose Steering Loose, Worn, or Damaged Steering Remove/Repair as required

Adjustment
Hard Steering and/ or Loss of Power Incorrect Tyre Pressure Remove/Repair as required
Assist Tyre Sizes Not Uniform
Power Steering Fluid Level Low Leak
Steering Pump Belt
Lack of Lubrication
Obstruction in Power Steering Lines
or Steering Linkage
Insufficient Steering Pump Pressure
Incorrect Front Wheel Alignment
Excessive Wear of Steering Pump
Internal Parts
Steering Gear Valve Sleeve or Seals
Worn
Hard Turning When Stationary Incorrect Tyre Pressure Remove/Repair as required

Tyre Sizes Not Uniform
Steering Pump Belt
Lack of Lubrication
or Steering Linkage
Worn
G22341 en 01/2003 2003.0 BA Falcon


Steering and Suspension Noises Power Steering Fluid Level Low Leak Remove/Repair as required
Sagging or Broken Spring
Steering Pump Belt
Broken Rear Spring Tie Bolts (Wagon)
Lack of Lubrication
Loose or Weak Shock Absorber
Loose or Worn Suspension Arm
Bushings
or Steering Linkage
Adjustment
Bent Rear Axle Housing
Internal Parts
Shimmy or Wheel Tramp Incorrect Tyre Pressure Remove/Repair as required

Bushings
Adjustment
Out-of-Round Wheel
Pull to One Side Incorrect Tyre Pressure Remove/Repair as required

Overloaded or Unevenly Loaded
Vehicle
Rear Spring Tie Bolt Off Centre
(Wagon/Ute)
Rear Spring Front Hanger Mislocated
(Wagon/Ute)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Frame or Underbody Out of Alignment
Worn
G22341 en 01/2003 2003.0 BA Falcon


Side- to- side Wander Incorrect Tyre Pressure Remove/Repair as required
Vehicle
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Body Sway or Roll Incorrect Tyre Pressure Remove/Repair as required

Tyre Squeel on Turns Incorrect Tyre Pressure Remove/Repair as required

Bent Spindle Arm
Bent Spindle
Binding or Poor Recovery Incorrect Tyre Pressure Remove/Repair as required

Lack of Lubrication
or Steering Linkage
Worn
Abnormal or Irregular Tyre Wear Incorrect Tyre Pressure Remove/Repair as required

Vehicle
(Wagon/Ute)
(Wagon/Ute)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Out-of-Round Wheel
G22341 en 01/2003 2003.0 BA Falcon


Sag at One Wheel Incorrect Tyre Pressure Remove/Repair as required
Vehicle
Bushings
Hard or Rough Ride Incorrect Tyre Pressure Remove/Repair as required

Vehicle
Lack of Lubrication
Bushings
or Steering Linkage
Out-of-Round Wheel
Rear Suspension Misalignment (Dog- Rear Spring Tie Bolt Off Centre Remove/Repair as required
Tracking) (Wagon/Ute)
(Wagon/Ute)
Bushings
Shock Absorbers Hand Test
On Vehicle Tests 1. With the shock absorber removed from the
vehicle, hold the shock absorber such that it is in
1. Grasp the vehicle bumper bar and bounce the a vertical position, as it would be installed in the
corner of the vehicle up and down. If the shock vehicle. Fully compress and extend the shock
absorbers are in serviceable condition the vehicle absorber unit three times to bleed the shock
will settle to it’s original position within two absorber. Compress the unit and observe that the
bounces after the bumper is released. piston rod extends under it’s own internal gas
2. Check the shock absorber to be sure that it is pressure. There should be a smooth movement of
securely and properly installed on the vehicle. the shock absorber rod over the complete stroke
Check the shock absorber mounting bushes and as the shock extends. Any noticeable slowing of
body insulators for damage and / or wear. the rod, loss of movement or drag, especially as
Replace any defective body insulators and tighten the piston rod nears the top of its stroke, will
attachments to the specified torque. If wear or indicate low internal gas pressure, loss of shock
damage is visible on shock absorber mounting fluid or faulty internal valve operation.
bushes, the entire shock absorber should be 2. Extend and compress the shock as fast as
replaced. possible, using as much travel of the shock as
3. Check the compression rubbers or bumpers fitted possible. The action of the shock should become
on the shock rod for signs of damage. Replace if smooth and uniform throughout each stroke. It is
necessary. normal for the shock to have higher resistance to
4. Inspect the shock absorber for evidence of fluid extension than compression. Faint fluid "swishing"
leakage. It is important to be sure that any fluid noises are also normal during extension and
observed is from the shock absorber and not from compression of the shock.
any other source. 3. If the action is smooth, but the shock absorbers
5. If the leakage is severe, replace the shock are suspected of being weak, repeat Step 2 on a
absorber if leakage. (Some evidence of fluid new shock absorber or on the mating shock
weepage on the shock body is not considered absorber fitted to the opposite side of the vehicle.
harmful to the shock provided that the on-vehicle Compare the results of both tests.
and hand tests described below are acceptable).
G22341 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Toe Adjustment Front Wheel Lock Angle Adjustment

1. Toe is the inward point of both front wheels at the 1. When the inside wheel is turned 20°, the turning
front. The checking and optimum resetting toe-in angle of the outside wheel should be specified in
in specifications are specified in the Description the Description and Operation section.
and Operation section. 2. If the turning angles are incorrect or uneven when
2. Check the toe with the steering wheel in the compared with the figures obtained on the other
straight-ahead position. lock, first check the toe. If this is correct, examine
3. On vehicles with power steering, the steering the tie rods which should be approximately the
wheel must be in the straight-ahead position when same length. It they are appreciably different (i.e.
the engine is switched off. 3.0mm) the turning angles will be adversely
affected. It should be noted that minor differences
4. If it is necessary to again move the steering wheel
in tie rod length are acceptable and, in fact,
on a power steering vehicle the engine must be
sometimes necessary to compensate for
restarted. production tolerances in the build up of the
5. Measure the angle of each front wheel from the suspension and steering assembly.
straight-ahead position and add the angles
3. If the toe and the tie rod lengths are satisfactory
together. examine the tie rods for distortion. The tie rod ball
Front Wheel Alignment joints should also be checked for wear or
looseness.
1. The Caster, Camber and King Pin Inclination
angles are set in production and are not Upper & Lower Ball Joint Inspection
adjustable.
1. Raise the vehicle.
2. The tie rods, part of the steering rack assembly,
2. Grasp the tyre at the top and bottom and try to
are adjustable for length to permit the setting of move it in and out.
Toe and wheel lock angles.
3. There should be no perceptible movement in
3. Do not attempt to carry out alignment checks
either joint. If movement is detected in either joint,
without first making a preliminary check of the that joint should be replaced.
serviceability of the front end components.
Toe & Steering Wheel Spoke XR Rear Camber Adjustment

Adjustments 1. Measure ride height. Refer to wheel Alignment
charts in this section for ride heights vs. camber.
NOTE: Check the steering wheel spoke position when Select appropriate camber setting.
the front wheels are in the straight-ahead position. If
2. Complete RLCA (Rear Lower Control Arm) to
the spoke is not in its correct position, it can be subframe cam bolt adjustment (set Toe).
corrected while toe is being adjusted.
3. With toe set and locked in position, adjust left
1. Clean and lubricate the exposed threads on the camber to specification using the cambolt.
tie-rods. Loosen the clips on the outer ends of the 4. Adjust the right camber to specification using the
rack bellows and ensure that the bellows are free
cambolt.
on the tie-rods.
5. Re-adjust left camber if necessary. Tighten both
2. Hold the tie-rod and loosen the lock nut on each nuts to the specified torque (126 ± 24 Nm).
rod.
NOTE: Both rods have right hand threads. 6. Take care during the above procedure to ensure
the brake hose bracket is located correctly.
3. Adjust toe-in. If the steering wheel spokes are in
their correct position, lengthen or shorten both RLCA (Rear Lower Control Arm) to
rods equally to obtain correct toe. If the steering Subframe Cambolt Adjustment
wheel spoke is not in its correct position, make
the necessary rod adjustments to obtain correct 1. Loosen both bolts and adjust as required to reach
toe and steering wheel spoke alignment. spesified toe.
4. When the toe and steering wheel spoke alignment 2. Tighten both nuts to the specified torque
are both correct tighten the lock nut on each rod. (105 ± 10 Nm).
5. Position each tie-rod end ball joint at the centre of
its articulation and tighten the clips on the rack
bellows.
G22346 en 01/2003 2003.0 BA Falcon

204-01-1 Front Suspension 204-01-1
SECTION : 204-01 Front Suspension

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................204-01-2
Front Suspension ...................................................................................................................204-01-3
Suspension ..........................................................................................................................204-01-3
Front Suspension ...................................................................................................................204-01-4
REMOVAL AND INSTALLATION
Lower Control Arm .................................................................................................................204-01-5
Lower Control Arm Ball Joint .................................................................................................204-01-5
Upper Control Arm .................................................................................................................204-01-6
Upper Control Arm Ball Joint .................................................................................................204-01-7
Stabilizer Bar ..........................................................................................................................204-01-8
Stabilizer Bar Centre Bushing (Front or Rear Bar) ...............................................................204-01-8
Stabilizer Bar Link Bushing ....................................................................................................204-01-9
Lower Arm Bushing ................................................................................................................204-01-9
Lower Arm - Large Bushing .................................................................................................204-01-11
Upper Arm Bushing ..............................................................................................................204-01-11
Front Wheel Spindle and Hub ..............................................................................................204-01-13
Spring and/or Shock Absorber Assembly ............................................................................204-01-15
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Torque Specifications
Description Nm
Upper Arm to Mounting Bracket 50
Upper Arm Mounting Bracket to Body 35
Lower Control Arm to Sub-frame 115
Shock Absorber to Upper Attachment 35
Shock Absorber to Lower Control Arm 80
Spring Seat to Body 35
Ball Joint to Spindle 90
Stabilizer Bar Bracket 35
Stabilizer Bar Link Nuts 55
Wheel Bearing Nut 300
Wheel Nut 125
Brake Caliper to Spindle 115
G48690 en 01/2003 2003.0 BA Falcon

Front Suspension Item Description

4 Bracket Assy
Suspension 5 Insulator
The suspension is so designed that it allows an 6 Shock Absorber Frt
individual wheel to compensate for changes in the 7 Arm & Shaft Assy Frt Susp Upr
road’s surface level without considerably affecting the
8 Bolt Hex M14
opposite wheel. Each wheel is independently
connected to the frame and body by a spindle, ball 9 Nut M14
joint assemblies, and upper and lower control arms. 10 Arm Assy Frt Susp Lwr
The control arms are specifically designed and 11 Nut M10 Flange
positioned to allow the steering spindle to move in a
prescribed three dimensional arc. The front wheels 12 Spring Frt Susp Coil
are held in proper relationship to each other by two tie 13 Nut
rods that are connected to the steering rack and to Side roll of the suspension is controlled by a spring
the spindles. steel stabilizer bar. It is mounted in rubber bushings
Coil chassis springs are mounted between the spring held to the frame side rails by brackets.
housings on the front end sheet metal and the spring The ends of the stabilizer are connected to the lower
seats that are integral with the shock absorber body. control arms. Rubber grommets at these connections
Ride control is provided by double, direct acting shock provide flexibility and ride features.
absorbers mounted inside the coil springs and
The upper control arm is attached to the body through
attached to the lower control arms by bolts. The upper
isolating rubber bushings connected to brackets that
portion of each shock absorber extends through the are bolted to the body.
dual path shear mount and is secured with two
grommets, two grommet retainers, and a nut. The upper ball joint is a press fit into the upper control
arm, and the stud is fitted into the upper control end of
the spindle forging. A nylok nut and bolt clamps the
spindle to the ball joint.
The lower ball joint is a press fit into the lower arm,
and secures to the lower end of the spindle forging by
a tapered stud and nylok nut.
The inner ends of the lower control arms have
pressed in bushings and are attached to the cross
members by a single bolt through each bushing.
The suspension mounting points are all rubber
insulated to minimise the transmission of road noise
and vibration to the vehicle body.
Compliance in the lower arm bushes permits the
wheel a small amount of fore and aft movement and
so reduce the shock loading on the steering linkage
when the wheel hits a sudden irregularity in the road
surface.
Item Description
1 Nut
2 Washer
3 Insulator
G48691 en 01/2003 2003.0 BA Falcon

Front Suspension
Refer to Section 204-00.
G48797 en 01/2003 2003.0 BA Falcon

Lower Control Arm 7. Lower the vehicle and tighten the pivot bolts and
shock absorber bolt with the vehicle at curb
Special Tools attitude.
E9332
Removal
1. Raise the vehicle and support it under the body
rails.
2. Remove the wheel.
3. Loosen the ball joint nut. Using Tool No. E9332
free the taper. Remove the nut.
4. Disconnect the stabilizer bar link.
5. Loosen the hardware securing the front
crossmember and lower the crossmember
sufficiently to allow the front boss of the arm to be
withdrawn.
6. Remove the shock absorber bolt.
Item Description
7. Remove the control arm pivot bolts and remove
1 Arm Assy Frt Susp Lower
the arm.
2 Nut Lock
Installation
3 Spindle Assy Frt Wheel
1. Fit the lower arm to the crossmembers.
2. Install but do not tighten the pivot bolts. Lower Control Arm Ball Joint
3. Install the shock absorber bolt from the rear and
install the washer and a new nut on the strut. Do Special Tools
not tighten either at this time.
204-236
4. Position the ball joint stud in the spindle. Tighten
with new nylok nut.
5. Install the wheel.
6. Tighten the hardware securing the front
crossmember.
204-230
Removal
NOTE: Eye protection must be worn during the
following procedures.
1. Place small end of Installer/Remover tool
204-236-Item 3 over shaft of ball joint.
2. Place Receiver 204-236-Item 2 above lower
control arm.
G48693 en 01/2003 2003.0 BA Falcon

REMOVAL AND INSTALLATION (Continued)
3. Using a hydraulic press, push ball joint out using 5. Press home using a hydraulic press using 6.5
6 tonne removal force. tonne installing force.
Item Description Item Description

1 Receiver 204-236-Item 2 1 An appropriate plate to support hydraulic
2 204-236-Item 3 ram
2 204-230-Item 8
Installation
3 Receiver 204-230-Item 3
1. Carefully remove rubber boot & retaining ring prior
to installation.
Upper Control Arm
2. Place ball joint into position in casting.
3. Place large end of installer/remover 204-230-Item Removal
8 over butt of ball joint. 1. Raise the vehicle and support it under the body
4. Place receiver 204-230-Item 3 under lower control rails.
arm. 2. Remove the wheel.
3. Separate the upper ball joint from the upper arm.
Tie the spindle to prevent it from failing away from
the body and straining the brake hose.
4. Remove the four nuts securing the upper arm
brackets to the suspension tower and remove the
assembly from the vehicle.
5. Remove the two bolts and the bracket assemblies
from the control arm.
Installation
1. Position the bracket assemblies on the upper arm
and loosely install new prevailing torque nuts.
2. Position the control arm on the suspension tower
and install and tighten the attaching nuts.
G48693 en 01/2003 2003.0 BA Falcon

3. Attach the ball joint to the spindle, tighten the 2. Using a hydraulic press with two tonne approx.
clamp joint. Remove the spindle tie. force push out ball joint using tool 204-229-2,
4. Install the wheel and lower the vehicle. small diameter down.
5. With the vehicle at curb attitude tighten the
spindle pivot bolts to specification.
Item Description
1 Arm Assy Frt Susp Upper
2 Receiver Bolt
3 Spindle Assy
4 Nut
Upper Control Arm Ball Joint

Special Tools
204-229
Item Description
1 204-229-Item 2
2 Ball Joint
3 204-229-Item 1 Receiver
Removal 4 Upper Control Arm
NOTE: Eye protection must be worn during the Installation
following procedures.
1. Remove rubber boot from the new ball joint,
1. Place receiver 204-229-Item 1 large diameter ensuring not to damage the boot or retainer ring
facing up, under upper arm casting. clip.
2. Position ball joint over control arm.
3. Place receiver 204-229-Item 1, small end up,
under upper arm casting.
4. Using a hydraulic press push ball joint home with
tool 204-229-Item 2 large end facing down.
G48695 en 01/2003 2003.0 BA Falcon

5. Reinstall protective rubber boot and retainer ring 3. Fit the bolt and nut securing the shock absorber
clip. to the lower arm.
4. Fit the upper ball joint stud to the spindle and fit
the clamp bolt and nut.
5. Fit the insulators and brackets supporting the
stabilizer bar to the siderails ensuring that the bar
is cenrally located.
6. Attach the ends of the bar links, ensuring that the
insulators are correctly positioned.
7. Fit the wheel and lower the vehicle.
Item Description
1 204-229-Item 2
2 Upper Control Arm
3 204-229-Item 1 Receiver
4 Ball Joint with Boot Removed
Stabilizer Bar
Stabilizer Bar Centre Bushing (Front
Removal
or Rear Bar)
1. Raise the vehicle supporting the body by the
side-rails. Removal
2. Disconnect the stabilizer bar from each link. NOTE: Damage to suspension and/or steering
Remove the retaining brackets. components may occur if care is not exercised when
3. Remove the wheel and disconnect the upper ball positioning hoist adaptors or jacks when lifting the
joint stud from the spindle. vehicle. Do not allow contact with the steering linkage.
4. Remove the shock absorber lower bolt. 1. Raise the vehicle on a hoist positioning the
5. Move the shock absorber to allow the end of the suspension in the curb load position.
stabilizer bar to be brought rearwards past it. 2. Remove the hardware and brackets attaching the
6. Remove the stabilizer bar. centre section of the stabilizer bar.
Installation 3. Remove the insulators from the bar.
1. Place one end of the bar into position. Installation
2. Move the other side shock absorber to allow that 1. Position the insulators on the front bar. Position
end of the bar to be brought into position in front the insulator on the rear bar.
of the shock absorber.
G48695 en 01/2003 2003.0 BA Falcon

2. Ensure that the links on each end of the bar are Scenario 1-Replacement of small bush only
located at approximately the same angle relative
1. Clamp lower control arm in vice using soft jaws
to the centre line of the vehicle and install the
with both bushes at top.
attaching brackets.
3. Lower the vehicle. 2. Apply a graphite grease to forcing screw thread
before usage.
Stabilizer Bar Link Bushing 3. Screw the holding nut fully onto the forcing screw
204- 230-Item 5.
Removal
1. Raise the vehicle on a hoist positioning the
suspension in the curb load position.
2. Remove the nut, washers, spacer, insulators and
link bolt attaching the ends of the stabilizer bar.
Item Description
1 Locating collar 204-230-Item 8
2 204-230-Item 9
3 Forcing screw 204-230-Item 5
Installation 4 Holding Nut
1. Install the bolt, washers, insulators, spacer and 5 204-230-Item 10 Orient anvil so stamping
nut as illustrated. Ensure that the insulators are is to top (this positions eccentric hole)
correctly located in the respective mounting holes.
4. Slide large bush anvil 204-230-Item 10 onto the
2. Lower the vehicle. threaded end of forcing screw.
Lower Arm Bushing 5. Orient large bush anvil so part no stamping is on
top.
Special Tools 6. Position assembly over the inside end of large
bush.
204-230
7. Place locating collar 204-230-Item 8 over
assembly.
8. Place small hole in small bush tool 204-230-Item
9 over forcing screw spigot.
9. Slide locating collar over small bush tool
204-230-Item 9 to prevent assembly slipping
Removal during use.
NOTE: Three scenarios exist for the replacement of 10. Screw out holding nut to remove slack.
lower control arm bushes. They are: 11. With suitable spanners, clamp holding nut and
turn forcing screw using its hexagonal section
scenario 1 - replacement of the small bush only, until small bush is removed.
scenario 2 - replacement of the large bush only, NOTE: Beware, the unit will collapse as the bush
scenario 3 - replacement of both bushes. is removed.
Refer to the applicable scenario numbers. Removal
Scenario 1 - Replacement of small bush only Scenario 2-Replacement of large bush only
NOTE: If both bushes are to be removed then remove 1. Apply a graphite grease to Forcing Screw thread
small bush first. before usage.
G48699 en 01/2003 2003.0 BA Falcon

2. Screw the Holding Nut fully on to the Forcing Scenario 3-Replacement of both large and small
Screw (204-230-Item 5). bushes
1. First follow procedure to remove small bush.
2. Slide Small Bush Anvil (204-230-Item 3) on the
threaded end of Forcing Screw (204-230-Item 5).
3. Slide Small Bush Anvil (204-230-Item 3) on the

threaded end of Forcing Screw.
4. Orient eccentric hole in Small Bush Anvil so part
stamping ‘UP’ is on Top.
3. Place narrow end of Small Bush Anvil Locator
5. Position assembly over the inside end of Small (204-230-Item 4) in to empty small bush socket.
Bush.
4. Orient Small Bush Anvil so stamping ‘UP’ is on
6. Place Locating Collar (204-230-Item 1) over Top.
assembly.
5. Position assembly over the exposed end of Small
7. Place small hole in Large Bush Tool Bush Anvil Locator.
(204-230-Item 2) over Forcing Screw spigot.
6. Place Locating Collar (204-230-Item 1) over
assembly.
7. Place small hole in Large Bush Tool
(204-230-Item 2) over Forcing Screw spigot.
Item Description
1 Locating collar 204-230-Item 1
2 204-230-Item 2
3 Forcing screw 204-230-Item 5 Item Description
4 Holding Nut 1 Locating collar 204-230-Item 1
5 204-230-Item 3 Orient anvil so stamping is 2 204-230-Item 2
to top (this positions eccentric hole) 3 Forcing screw 204-230-Item 5
8. Slide Locating Collar over Large Bush Tool to 4 Holding Nut
prevent assembly slipping during use. 5 204-230-Item 3 Orient anvil so stamping is
9. With suitable spanners, clamp Holding Nut and to top (this positions eccentric hole)
turn Forcing Screw using its hexagonal section
8. Slide Locating Collar over Large Bush Tool to
until large bush is removed.
prevent assembly slipping during use.
Removal
9. With suitable spanners, clamp Holding Nut and
NOTE: If both bushes are to be removed then remove turn Forcing Screw using its hexagonal section
small bush first. until large bush is removed.
G48699 en 01/2003 2003.0 BA Falcon

Lower Arm - Large Bushing 3. Place the shaft of the installer 204-230-Item 8 into
the bush.
Special Tools
204-230
Installation
Large bush
1. Position large bush in arm orientating keyway
along central access of arm.
NOTE: Large bush keyway must be positioned ±
5° from centreline of control arm. Item Description
1 Installer 202-230-Item 8
2 Small Bush
4. Using a hydraulic press and suitable “V” blocks
place a steel plate over the installer and press the
bush home (2.5-3 tonne req’d).
CAUTION: Always wear safety glasses and

try to protect your body by placing yourself at the
side of the press frame during operation or use a
transparent ballistic nylon protective blanket
1230PB.
Upper Arm Bushing

Item Description Special Tools
1 Installer 204-230-Item 1
204-228
2 Large Bush
2. Place the open side of the installer 204-230-Item
2 onto the bush.
3. Place receiver 204-230-Item 10 under the arm,
cup upwards.
4. Using a hydraulic press on the installer press the Removal
bush home (2.5-3 tonne req’d). NOTE: For introduced at AV Falcon are different
Installation bushes in front of arm to rear of arm. Front bushes
Small bush are visually different & are voided around the
circumference.
1. Position small bush in arm.
NOTE: Eye protection must be worn during the
2. Place the receiver 204-230-Item 3 cup upward following procedures.
onto the shaft of the installer 204-230-Item 8.
G48701 en 01/2003 2003.0 BA Falcon

1. Support receiver tool 204-228-Item 1 under bush. 3. Insert mandrel 204-228-Item 2 into bush sleeve.
Insert aligning bush 204-228-Item 3 into bottom of
receiver. Proceed to push bush out until it
releases itself from the upper arm casting.
Item Description
1 Upper control arm
Item Description
2. Press receiver tool 204-228-Item 1 onto bush until 1 Mandrel 204-228-Item 2
it supports on casting. 2 Aligning bush 204-228-Item 3
Installation
NOTE: Insert voided bush into forward housing in
arm. Insert non-voided bush into rear housing in arm.
1. Place receiver tool 204-228-Item 1 under upper
control arm.
2. Insert aligning bush 204-228-Item 3 into receiver.
3. Insert reducing bush tool 204-228-Item 4 on top of
upper control arm.
4. Insert suspension bush onto mandrel
204-228-Item 2 and insert into reducing bush.
5. Lubricate bush in soapy water.
Item Description
1 Upper control arm
G48701 en 01/2003 2003.0 BA Falcon

6. Insert bush until bush is correctly inserted into Item Description

upper control arm. 4 Aligning bush 204-228-Item 3
NOTE: Correct insertion can be viewed by cutouts 5 Reducing bush 204-228-Item 4
in receiver. Bush should be central to the control
arm.
Front Wheel Spindle and Hub
Removal
1. Raise the vehicle and support it under the body
rails.
2. Remove the wheel.
3. Remove the brake caliper from the spindle and
suspend it so that there is no strain on the brake
hose.
4. Remove the hub and disc from the spindle.
5. Loosen the tie rod end nut and using a taper
breaker free the stud taper. Remove the nut and
detach the tie rod end from the spindle.
6. Loosen the nuts on the spindle ball joint studs and
free the tapers using a taper breaker.
7. Remove the bolt and nut securing the upper ball
joint stud and move the stud out of the spindle.
8. Remove the nut from the lower ball joint stud and
remove the spindle from the vehicle.
Installation
1. Locate the lower ball joint stud into the spindle
and attach the nut.
2. Locate the upper ball joint stud into the spindle
and fit the clamp bolt and nut.
3. Torque the nuts to specification.
4. Install the tie rod end in the spindle. Torque the
nut.
5. Install the hub and disc on the spindle. Torque nut
Item Description to specification.
6. Install the brake caliper.
1 Mandrel 204-228-Item 2
7. Install the wheel and lower the vehicle.
2 Upper control arm
G48702 en 01/2003 2003.0 BA Falcon

Item Description
1 Nut M14x2
2 Bolt and Retainer
3 Arm Assembly Front Susp. Lower
4 Nut Lock
5 Spindle Assembly
6 Nut 3/8-24 UNF
7 Stabilizer Bar Link
8 Nut
9 Front Stabilizer Bar
10 Bolt M8x26
11 Stab. Bar Mounting Bracket
Item Description
1 Hub & Bearing Assy Frt Brake
2 Nut & Washer Assy
3 Seal Frt Wheel Hub
4 Spindle Assy Frt Wheel
G48702 en 01/2003 2003.0 BA Falcon

Spring and/or Shock Absorber Installation

Assembly 1. Ensure that the bumpstop, washer and dirtshield
fitted are correctly fitted onto the shock absorber;
Removal compress the spring in the spring compressor and
1. Remove the coolant bottle or the air cleaner box assemble the shock absorber into it.
depending upon which side is to be removed. 2. Set the stop of the shock absorber spring seat,
against the spring lower end, fit the upper spring
seat insulator and rotate it’s stop against the
upper end of the spring. Fit the spring cap with
any of the three studs at the specified angle
relative to the centre line of the shock absorber
assembly to lower control arm mounting bolt
(lower spring seat stop end).
3. Assemble the dual path shear mount and nut onto
the shock absorber piston rod.
4. Partly release the spring compressor and torque
the nut to specification whilst preventing the
spring cap from rotating by use of a soft lever (eg:
piece of wood) against two of the three studs.
5. Fully release the spring compressor.
Item Description 6. Install the shock absorber/spring assembly into
the vehicle. The lower spring tail is to be to the
1 Shock Absorber Ftr front on LHS and to the rear on RHS. Take care
2 Bolt Hex Hd M14 not to damage boot of the lower ball joint, or the
3 Nut M14 ABS wire (where fitted) and loosly fit one of the
4 Arm Assy Frt Susp Lwr nuts supporting the assembly to suspension
tower.
2. Remove the two of the three nuts securing the 7. Fit the shock absorber lower mounting bolt and
shock absorber/sprlng assembly to the loosely fit the nut.
suspension tower and loosen the third nut. NOTE: Bolt thread must point towards the front of
3. Raise the vehicle - supporting it under the body the vehicle.
rails.
8. Fit the upper ball joint stud to the spindle; fit the
4. Remove the wheel and separate the upper ball clamp bolt and nut. torque the nut.
joint stud from the spindle.
9. Fit the two remaining nuts securing the upper
5. Remove the shock absorber lower mounting bolt. spring seat cap to the tower.
6. Remove the third nut supporting the shock 10. Fit the wheel.
absorber/spring assembly to the suspension
tower, gently ease down the lower arm and 11. With the vehicle weight on it’s wheels, torque the
remove the assembly, taking care to ensure that shock absorber lower mounting hardware and the
the shock absorber lower brackets do not damage three nuts on the suspension tower, to
the dust boot of the lower ball joint. Also take care specification.
not to damage the ABS wire (where fitted).
7. Install the shock absorber/spring assembly onto
the spring compressor and compress the spring to
relieve the tension from the shock absorber piston
rod.
WARNING: Do not attempt to separate the
spring from the shock absorber until the
spring is restrained by the use of a spring
compressor.
8. Remove the nut, dual path shear mount and
spring seat insulator from the shock absorber
piston rod and withdraw the shock absorber.
9. Release the tension from the spring if the spring
is to be changed.
G48703 en 01/2003 2003.0 BA Falcon

Item Description
1 Nut
2 Washer
3 Insulator
4 Bracket Assy
5 Insulator
6 Spring Frt Susp Coil
7 Shock Absorber Assy Frt
8 Nut
Item Description
1 2A Crossmember
2 2B Crossmember
3 Nut Nyloc M12
G48703 en 01/2003 2003.0 BA Falcon

204-02a-1 Rear Suspension — IRS 204-02a-1
SECTION : 204-02a Rear Suspension — IRS

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................204-02a-2
Rear Suspension — IRS ......................................................................................................204-02a-3
Components .......................................................................................................................204-02a-3
Inspection and Verification ...................................................................................................204-02a-6
Stabiliser Bar ......................................................................................................................204-02a-6
Diagnosis ...........................................................................................................................204-02a-6
GENERAL PROCEDURES
FPV Cam bolt adjustment ....................................................................................................204-02a-7
RLCA to subframe cam adjustment .....................................................................................204-02a-7
Upper Control Arm Assembly (UCA) ...................................................................................204-02a-8
Front Lower Control Arm Assembly (FLCA) ........................................................................204-02a-9
Rear Lower Control Arm Assembly (RLCA) ......................................................................204-02a-10
Knuckle ..............................................................................................................................204-02a-13
Rear Lower Control Arm (RLCA) park brake cable bracket ..............................................204-02a-15
Abutment bracket ...............................................................................................................204-02a-15
Control Blade .....................................................................................................................204-02a-16
Shock Absorber .................................................................................................................204-02a-17
Spring and Upper Spring Insulator ....................................................................................204-02a-18
Stabiliser bar ......................................................................................................................204-02a-20
Upper Stabiliser Bar Insulator ............................................................................................204-02a-21
Jounce Bumper ..................................................................................................................204-02a-22
Body Brace ........................................................................................................................204-02a-22
IRS Module ........................................................................................................................204-02a-23
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Stabiliser Bar Specifications

Description Specification
Stabiliser bar diameter: 18 ± 0.2mm
Stabiliser bar diameter: 19 ± 0.2mm
Stabiliser bar/droplink M10 X 1.25 flanged head
attachment nut: nut / Zinc plated
Stabiliser bar/droplink M10 X 1.25 flanged head
attachment bolt: bolt / Zinc plated
Description Nm
Nut - M12 - RLCA to Subframe 105 ± 15
Bolt - M12 - Diff Blade to Diff 88 ± 17
Bolt - M16 - Front Diff Bush (subframe) 140 ± 28
to Diff
Nut - M14 - RLCA to Knuckle 140 ± 28 *
Nut - M14 - FLCA to Subframe 140 ± 28 *
Nut - M14 - UCA to Subframe 140 ± 28 *
Nut - M12 - FLCA to Knuckle 126 ± 24
Nut - M12 - UCA to Knuckle 126 ± 24
Bolt - M14 - Diff Rear Cover to 200 ± 40
Subframe
Bolt - M14 - Diff Rear Cover to 200 ± 40
Subframe with Mass Damper
Nut - M24 - Wheel End Pacnut 325 ± 25
Bolt - M12 - Caliper to Knuckle 103 ± 16
Screw - M8 - Stabiliser Bar Bracket to 25 ± 5
Subframe
Nut - M10 - Stabiliser Bar Droplink to 25 ± 5
RLCA
Nut - M10 - Stabiliser Bar Lower 52.5 ± 2.5
Attachment
Screw - M8 - Abutment Bracket to 25 ± 5
Knuckle
Screw - M6 - ABS Sensor to Knuckle 10.4 ± 2
Nut - M10 - Body Brace to Subframe 50 ± 9.5
Screw - M12 - Control Blade to 88 ± 17
Knuckle
Bolt - M14 - Shock Absorber to 121 ± 18
Knuckle
Shock Absorber to Upper Mount 70
(upper bolt)
Nut - M12 - Subframe to Body (rear 108 ± 17
spring area)
Nut - M12 - Subframe to Body (front 108 ± 17
area of subframe)
Nut - M12 - Control Blade to Body 100
Bolt - M10 - Body Brace to Body 50 ± 9.5
Bolt - M10- Vee Brace to Subframe 108 ± 17
(rear diff bush mount frame)
* Torque at ride height.
G765430 en 01/2003 2003.0 BA Falcon

Rear Suspension — IRS
The Independent Rear Suspension (IRS) design is press-fitted rubber bush in the lower control arm. At
based on three control arms attached to the subframe the other end the droplink also has a press fitted
and knuckle. The Rear Lower Control Arms (RLCA) rubber bush for the attachment to the stabiliser bar.
seat the base of the spring and also allow for The stabiliser bar and droplink can be replaced
adjusting wheel alignment. Torque is transmitted to individually or altogether as an assembly if necessary.
the wheels via a centrally located differential and two
independent halfshafts. The design allows for
servicing on either side of the module. Alternatively,
the entire module may be removed from the vehicle.
Components
Wheel Knuckle Assembly
carries the wheel hub.
carries the brake caliper assembly.
carries the parkbrake assembly.
carries the ABS sensor.
carries the shock absorber.
is supported by three arms and a knuckle support
blade each side.
Item Description
Stabiliser Bar Assembly 1 Droplink
The stabiliser bar assembly consists of the stabiliser 2 Stabiliser Bar
bar and two droplinks. The assembly is attached to 3 Attachment Bolt
the subframe with two brackets with rubber d-blocks.
4 Attachment Nut
The droplink serves as a linkage between the lower
control arm and the stabiliser bar. The droplink has a
spigot at one end, which is bolted inside the
G765431 en 01/2003 2003.0 BA Falcon

Upper Control Arm Assembly (UCA) Front Lower Control Arm Assembly (FLCA)
Assembly consists of a forged arm with a rubber bush Assembly consists of a stamped arm with rubber
on the subframe end and a cross axis ball joint bushes on the subframe end and a CABJ on the
(CABJ) on the Wheel Assembly end. Wheel Assembly end.

1 Bushing 1 Nut FLCA to Subframe
2 Nut-UCA to Subframe 2 FLCA without Bushing
3 UCA without Bushing 3 Bolt-FLCA to Knuckle
4 Bolt-UCA to Knuckle 4 Cross Axis Ball Joint (CABJ)
5 Nut-UCA to Knuckle 5 Nut-FLCA to Knuckle
6 Cross Axis Ball Joint (CABJ) 6 Bolt-FLCA to Subframe
7 Bolt-UCA to Subframe 7 Bushing - Upper Inner
Rear Lower Control Arm Assembly (RLCA)

Assembly consists of a stamped arm with rubber
bushes on the subframe end and a CABJ on the
wheel assembly end. A cam bolt fixes the RLCA to
the subframe.
G765431 en 01/2003 2003.0 BA Falcon

Item Description
1 Cam Washer
2 Nut RLCA to Subframe
3 Bolt RLCA to Knuckle
4 Cross Axis Ball Joint (CABJ)
5 Nut RLCA to Knuckle
6 Rear Lower Control Arm RLCA
7 Bolt RLCA to Subframe
8 Cam Washer
9 Bush - Lower Inner
Control Blade Assembly

Assembly consists of a stamped blade with a rubber
bush on the end connecting to the body and is
retained by 3 bolts at the knuckle end.
G765431 en 01/2003 2003.0 BA Falcon

4. Inspect rubber bush for damage.

Inspection and Verification
Stabiliser Bar
1. Inspect the stabiliser bar for signs of corrosion,
deep scoring or cracks, which can dramatically
reduce the fatigue life of the stabiliser bar.
Replace if necessary.
2. Check the stabiliser bar for permanent
deformation. This can be checked by laying the
stabiliser bar on a flat bench as shown in figure
below. Measure the height of the eyes from the
bench and they should be within 4mm from each
other. Do not attempt to heat the stabiliser bar
and bend the eyes into position, as doing so will
affect the fatigue properties of the material.
Replace if necessary.
NOTE: The droplink and its rubber bush must be Diagnosis
replaced as a unit. 1. Inspect the droplink for signs of corrosion or deep
scoring which can dramatically reduce the life of
the product. Replace if necessary.
2. Check the integrity of the press-fit for the rubber
bushes in the droplinks. Measure the distances
shown in the figure below. If the measurements
are outside the tolerances shown the press-fit has
probably worked itself loose under excessive
loads. If the facilities are available, the integrity of
the press-fit can also be checked by applying a
3kN (300kg) load to the bush. The bush should be
capable of taking the load without slipping. Do not
attempt to refit the rubber bushes into the
droplinks. Replace if necessary.
3. Inspect the rubber bush for any signs of tearing or
the failure of the bond from the steel sleeves in
3. Inspection of press fit. the region shown in the figure above. Replace if
necessary.
G765432 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
FPV Cam bolt adjustment

Refer to section Section 204-00.
RLCA to subframe cam adjustment

Refer to section Section 204-00.
G765434 en 01/2003 2003.0 BA Falcon

Upper Control Arm Assembly (UCA)
6. Loosen and remove UCA-subframe nut.

7. Remove UCA-subframe bolt.
Item Description 8. Slide UCA free.
1 Bushing Installation
2 Nut-UCA to Subframe 1. Locate UCA in subframe as shown.
3 UCA without Bushing 2. Attach UCA-subframe bolt and loosely attach
4 Bolt-UCA to Knuckle UCA Subframe nut.
5 Nut-UCA to Knuckle NOTE: Bolt head faces the front of the module.
6 Cross Axis Ball Joint (CABJ) 3. Set the suspension to the correct ride height.
7 Bolt-UCA to Subframe Refer to Section 204-00.
4. Locate UCA into knuckle attachment point with
Removal UCA-knuckle bolt and loosely attach
1. Hoist vehicle and remove rear wheels. Refer to UCA-Knuckle nut.
Section 100-02. NOTE: Bolt head faces the front of the module.
2. Remove IRS module. Refer to IRS Module in this
5. Torque UCA-knuckle bolt and UCA-knuckle nut to
section.
126 ± 24 Nm.
3. Set the suspension to ride height. Refer to
Section 204-00.
4. Loosen and remove UCA-knuckle nut.
5. Remove UCA-knuckle bolt.
G765435 en 01/2003 2003.0 BA Falcon

6. Torque UCA-subframe bolt and UCA-Subframe 2. Set suspension to design height with springs
nut to 140 ± 28 Nm. installed. Refer to Section 204-00. Support wheel
ends under the knuckle positions and under
RLCAs as indicated.
3. Remove nut on FLCA bolt to knuckle.
4. Remove nut on FLCA bolt to subframe.
7. Install the IRS module back into the vehicle. Refer

to IRS Module in this section.
Front Lower Control Arm Assembly

(FLCA) 5. Remove both FLCA-knuckle and FLCA-subframe
bolts.
6. Slide FLCA free.
Item Description
1 Nut FLCA to Subframe Installation
2 FLCA without Bushing 1. Locate FLCA to subframe.
3 Bolt-FLCA to Knuckle NOTE: The FLCA should be oriented so that the
4 Cross Axis Ball Joint (CABJ) CABJ fits to the knuckle, that the face with the
"REAR" label faces the rear of the module and
5 Nut-FLCA to Knuckle that the upper and lower flanges face the rear of
6 Bolt-FLCA to Subframe the module.
7 Bushing - Upper Inner 2. Fit nut to bolt loosely.
Removal NOTE: Ensure bolt head faces the rear of the
1. Hoist vehicle and remove rear wheels. Refer to module. This is the only bolt head that faces the
Section 100-02. rear of the vehicle.
3. Set suspension to ride height. See Section
204-00.
G765436 en 01/2003 2003.0 BA Falcon

4. Locate FLCA to knuckle and fit nut to bolt loosely. Removal

NOTE: Ensure bolt head faces the front of the 1. Hoist vehicle so that the wheels are fully
module. supported.
2. Set suspension to ride height. See Section
204-00.
3. Remove rear wheels.
4. Disconnect Control Blade from Wheel End
Assembly.
5. Torque FLCA-knuckle bolt to 126 ± 24 Nm.

6. Torque FLCA-subframe bolt to 140 ± 28 Nm.
7. Attach wheels and lower vehicle.
CAUTION: Care should be taken when
removing transmission jack from under RLCA 5. Remove Knuckle-RLCA bolt.
due to the high compressive force in the
spring.
Rear Lower Control Arm Assembly

(RLCA)
6. Disconnect Stabiliser Bar links by removing

nut/washer.
Item Description
1 Cam Washer
2 Nut RLCA to Subframe
3 Bolt RLCA to Knuckle
4 Cross Axis Bolt Joint (CABJ)
5 Nut RLCA to Knuckle
6 Rear Lower Control Arm RLCA
7 Bolt RLCA to Subframe
8 Cam Washer
9 Bush - Lower Inner
G765436 en 01/2003 2003.0 BA Falcon

7. Loosen bolts connecting Stabiliser Bar brackets to 11. Lower jack slowly and rotate RLCA downwards.
Subframe.
12. Remove spring and Spring Insulators when spring

8. Rotate stabiliser bar away from RLCA, and becomes fully extended.
towards Control Blade.
9. Unclip park brake cable from RLCA park brake CAUTION: Springs have high spring rate
cable bracket. and extreme care should be taken when
releasing jack.
NOTE: Wheel-ends must be supported at the
knuckle in the two indicated positions so that
halfshafts are not over-articulated.
13. Remove RLCA Cam bolt assembly.
10. Loosen RLCA Cam bolt assembly at subframe

attachment.
14. Slide RLCA downward from vehicle.
G76555 en 01/2003 2003.0 BA Falcon

Installation 6. Locate and loosely fit RLCA-knuckle bolt. Ensure

bolt head faces the front of the module, and that
1. Ensure that park brake cable and stabiliser bar
the nut is fully closed over the bolt shank.
links are positioned away from the RLCA position
within module.
2. Locate RLCA and locate RLCA cam bolt
assembly through RLCA bush and subframe.
7. Attach Control Blade to knuckle using new Control

Blade-knuckle bolts.
NOTE: Replace Control Blade-Knuckle bolts as
they are a 1 use only item.
3. Position upper spring insulator and spring into
position on subframe. Position lower spring
insulator onto RLCA.
4. While holding spring and insulators in position,
rotate RLCA upward into position.
8. Torque RLCA-knuckle bolt to 140±28Nm.

9. Torque Control Blade-Knuckle bolts to 88±17Nm.
10. Adjust RLCA Cam bolt as necessary (see below)
and torque to 105 ± 15 Nm.
5. Insert jack underneath RLCAs. Extend jack so 11. Clip park brake cable into RLCA cable bracket.
that spring is compressed and return the
halfshafts to a horizontal position.
G76555 en 01/2003 2003.0 BA Falcon

12. Rotate stabiliser bar and insert stabiliser bar links

into RLCA. Complete stabiliser bar assembly as
detailed later in this section.
6. Lower transmission jack from ride height so that

springs are fully extended. Support wheel-ends at
the knuckle in the two indicated positions so that
13. Attach wheels and lowere vehicle. halfshafts are not over-articulated.
Knuckle
Removal
1. Secure wheel/hub to prevent halfshaft rotation
loosen axle pac nuts from halfshafts.
NOTE: Pac nuts are substantially torqued.
2. Hoist vehicle with wheels fully supported. Refer to
Section 100-02.
3. Set vehicle to ride height (Refer to Section
204-00) and remove rear wheels.
4. Unbolt ABS sensor.
5. Disconnect Control Blade and remove from
Knuckle.
7. Release park brake. Disconnect park brake cable
from knuckle mount.
Item Description
1 Hand Brake Cable
2 Retaining Spring Clip
G76540 en 01/2003 2003.0 BA Falcon

8. Detach abutment brackets from knuckle. Refer However, halfshafts and control arms must be
later in this section. adequately supported so that they remain
horizontal.
9. Detach caliper and rotor. Refer to Section 206-00.

10. Disconnect shock absorbers from knuckle. Installation
11. Loosen and remove UCA-knuckle nut, 1. Set the suspension to ride height. Refer to
FLCA-knuckle nut, and RLCA-knuckle nut. Section 204-00.
1. FPV Vehicles 2. Position knuckle assembly over halfshaft (with
Loosen nut from UCA to knuckle and remove halfshaft supported horizontally). Replace axle
Cam bolt and washer. FLCA-knuckle and pac nut and torque to 50Nm.
RLCA-knuckle connections are as for the 3. Locate FLCA to knuckle using FLCA-knuckle bolt
standard IRS module. and nut.
12. Remove axle pac nut, UCA-knuckle bolt, 4. a) Locate UCA to knuckle using UCA-knuckle bolt
FLCA-knuckle bolt and RLCA-knuckle bolt. and nut.
b) Insert Cam bolt into Cam slot on FPV knuckle.
5. Locate RLCA to knuckle using RLCA-knuckle bolt
and nut.
NOTE: This may require the adjustment of the
spring height, via the jack attached to the RLCA,
in order to position the RLCA groove over the
knuckle.
6. Torque RLCA-knuckle nut to 140 ± 28 Nm.
7. Torque FLCA-knuckle bolt to 126 ± 24 Nm.
8. Torque UCA-knuckle bolt to 126 ± 24 Nm.
NOTE: Torquing of bolts should be done with the
vehicle at ride height.
1. FPV Vehicles
Item Description Adjust Camber on UCA-knuckle as required
1 Upper Control Arm Nut and Bolt connection prior to the torque of the Cam bolt.
For more information, see Section 204-00.
2 Axle Pac Nut
9. Secure wheel/hub to prevent halfshaft rotation
3 Rear Lower Control Arm Nut and Bolt when torquing axle nut.
4 Lower Shock Absorber Bolt 10. Torque axle nuts to 325 ± 25 Nm.
5 Front Lower Control Arm Nut and Bolt 11. Fit ABS sensor. See Section 206-09.
13. Remove knuckle from halfshaft in a horizontal 12. Fit abutment brackets.
direction. 13. Attach park brake cable to Banksia lever on
NOTE: Knuckles must be removed in a direction knuckle.
parallel to the halfshafts to avoid damage to the
teeth on the halfshaft and knuckle splines.
NOTE: After removal of knuckle(s), the
suspension may be extended from ride height, to
allow springs to extend to uncompressed height.
G76540 en 01/2003 2003.0 BA Falcon

14. Fit Control Blade to knuckle. 3. Remove park brake cable bracket by squeezing
the wire ends together using wide-grip pliers or
equivalent.
15. Replace wheels. Release jack supporting the

suspension and slowly lower vehicle weight onto
the wheels. Installation
1. Attach park brake cable bracket to RLCA by
Rear Lower Control Arm (RLCA) park squeezing ends together and inserting into two
brake cable bracket holes on the RLCA.
Removal
1. Hoist vehicle (Refer to section 100-02) to obtain
access to IRS module.
2. Unhook park brake cable from RLCA cable
bracket.
2. Clip park brake cable onto RLCA bracket.
3. Ensure that park brake cable is fitted correctly to

all attachment points as given in park brake cable
procedure.
Abutment bracket
Removal
1. Release park brake.
G76542 en 01/2003 2003.0 BA Falcon

2. Hoist vehicle and remove rear wheels. See Installation

Section 100-02.
1. Locate abutment brackets with two abutment
3. Disconnect abutment bracket v-clip. bracket-knuckle bolts per side.
4. Disconnect park brake cable from attachment
point on knuckle and feed cable through abutment
bracket.
2. Torque bolts to 25 ± 5 Nm.

3. Locate park brake cable through abutment
bracket and attach to Banksia lever on inside of
Item Description knuckle assembly.
1 Hand Brake Cable
5. Loosen abutment bracket-knuckle bolts - 2 per
side.
6. Remove bolts and release abutment brackets.
Item Description
1 Hand Brake Cable
4. Attach park brake cable to abutment bracket
using v-clips.
5. Ensure park brake cable routing and adjust park
brake cable as required. See Section 206-05.
Control Blade
Removal
1. Hoist vehicle so that the wheels are fully
supported. See Section 100-02.
2. Set vehicle to design height. For more
information, see Section 204-00.
G76542 en 01/2003 2003.0 BA Falcon

4. a) Detach ABS cable from attachment point Installation

beneath the rear seat. 1. Set vehicle to ride height. See Section 204-00.
b) Remove both ferntree clips from the control
2. Locate knuckle support arm to knuckle with 3
blade.
c) Feed the ABS cable through the hole in the bolts each side.
control blade. NOTE: The flanges of the knuckle support arms
face inwards on the vehicle.
3. Fit knuckle support arm-chassis mounting bolts.
NOTE: The transmission jack used to set design
height may require adjustment to correctly align
the knuckle support arm with the chassis
mounting points.
4. Torque knuckle support arm-knuckle bolts to
between 85-100Nm and torque knuckle support
arm-chassis mounting bolts.
5. Feed ABS cable through hole in knuckle support
arm. Attach ferntree clip to ABS cable and clip to
knuckle support arm. Connect ABS cable to
attachment point at front of knuckle support arm.
5. Disconnect Control Blade from chassis mounts.
6. Hoist vehicle and remove rear wheels. Allow Shock Absorber
spring to extend to uncompressed length and
support wheel ends at this length. Removal
7. Disconnect control blade from chassis mounting 1. Disconnect brake hose from support bracket.
points. 2. With the vehicle on the ground, remove the upper
shock absorber bolt by gaining access through
the wheel arch gap directly above the rear tyre.
3. Hoist vehicle slowly. Refer to Section 100-02.
Shock absorber will drop with the lower control
arm. Watch for spring dislodgment.
4. Remove lower shock absorber attachment bolt.
5. Maneuver the shock absorber from the vehicle.
WARNING: Never attempt to remove the
shock absorber from the fully installed
position by removing the upper or lower bolts
when the vehicle is raised on a hoist. This
may cause the wheel to drop suddenly
resulting injury.
8. Disconnect Control Blade from knuckle by Installation
loosening and removing knuckle support 1. Install the shock absorber to the vehicle and
arm-knuckle bolts - 3 per side. loosely install the lower mounting bolt.
2. Begin to lower the vehicle from hoist, stopping the
hoist and guiding the upper shock absorber into
the upper bracket where necessary. Do not guide
the shock absorber whilst the hoist is in operation.
Ensure rear spring is not dislodged. Lower the
hoist until the shock absorber upper mount is
aligned with the bracket hole.
3. Install the upper shock absorber bolt. Lower the
vehicle completely (if not already) and tighten
both the upper and lower bolts to the specified
torque.
4. Reconnect the brake hose to bracket.
NOTE: Shock absorber hand tests are detailed in
section Section 204-00.
9. Remove knuckle support arm.
G76544 en 01/2003 2003.0 BA Falcon

Spring and Upper Spring Insulator 5. Remove links from RLCA and rotate stabiliser bar
towards the front of the vehicle.
Removal
1. Hoist vehicle, remove rear wheels and set
suspension to ride height. For further information,
see Section 204-00.
2. Disconnect park brake cable from knuckle.
Item Description
1 Hand Brake Cable
3. Unclip cable from RLCA cable clips.
6. Loosen RLCA-knuckle nuts and remove

RLCA-knuckle bolts.
4. Loosen and remove stabiliser bar link nuts and

washers.
7. Loosen RLCA-subframe nut.
G76544 en 01/2003 2003.0 BA Falcon

8. By slowly extending the transmission jack, lower 3. Connect RLCA to knuckle by loosely fitting bolt
the RLCA to extend the spring. and nut.
NOTE: Ensure bolt head faces front of vehicle.
9. Remove spring and insulators as necessary.

Installation 4. Torque RLCA to knuckle to 140Nm.
1. With vehicle hoisted and RLCA-subframe 5. Rotate stabiliser bar links through RLCAs and
connection loose, insert spring insulators and attach nut and washer. Torque nut to 15-20Nm.
spring.
NOTE: The flat end of spring faces the subframe
and the curved end of the spring faces the RLCA.
2. Insert transmission jack underneath RLCAs.
Extend jack to slowly compress spring and return
suspension to design height.
6. Adjust RLCA-subframe cam bolt as required. See

Section 204-00.
7. Attach wheels to knuckles. Lower jack under

RLCAs while returning the vehicle weight to its
own wheels.
CAUTION: Ensure that the vehicle is well
supported on its own wheels before
completely removing the jack.
G76544 en 01/2003 2003.0 BA Falcon

Stabiliser bar 5. Undo stabiliser bar link-RLCA nuts and

disconnect stab bar.
6. Unclip stabiliser bar bushes from the stabiliser

Item Description bar.
1 Stabiliser Bar Link Insulator 7. Undo bolt/nut from stabiliser bar link to stabiliser
2 Drop Link bar.
3 Stabiliser Bar Lower Bolt 8. Remove link.
4 Stabiliser Bar Installation
5 Stabiliser Bar Insulator 1. Locate stabiliser bar link to stabiliser bar.
6 Stabiliser Bar Mounting Bracket Stabiliser bar links should be positioned on the
outside of the stabiliser bar.
7 M8 Screw - Stabiliser Bar Bracket to
Subframe 2. Connect bolt/nut from stabiliser bar link to
stabiliser bar loosely.
8 M10 - Stabiliser Bar Lower Attachment
3. Locate stabiliser bar bushes to stabiliser bar.
9 Stabiliser Bar Bush
4. Locate stabiliser bar links through insulators on
Removal RLCAs. Affix stabiliser bar to RLCAs by loosely
1. Hoist vehicle and remove rear wheels. fitting stabiliser bar link-RLCA nut/washer.
NOTE: Support knuckles to ensure halfshafts are
not over-articulated.
2. Loosen stabiliser bar link-RLCA nuts.
3. Loosen stabiliser bar bracket bolts and remove
from the subframe.
4. Remove stabiliser bar bush brackets.
G76544 en 01/2003 2003.0 BA Falcon

5. Locate stabiliser bar bush brackets to stabiliser 3. Loosen bolts connecting stabiliser bar brackets to
bar bushes. Locate the stabiliser bar brackets to subframe.
the subframe using bracket-subframe bolts.
4. Rotate stabiliser bar and links away from RLCA

6. Torque stabiliser bar bush brackets to subframe towards knuckle support arms.
to between 20Nm and 30Nm. 5. Reach into rear of module over the top of RLCA.
7. Torque stabiliser bar link to RLCA to between Remove stabiliser bar insulator.
20Nm and 30Nm.
8. Torque stabiliser bar link bolt to stabiliser bar.
NOTE: Module should be supported on its own
wheels with halfshafts horizontal before torquing
stabiliser bar links.
Upper Stabiliser Bar Insulator

Removal
1. Hoist vehicle and set to ride height. For more
information, see Section 204-00.
2. Disconnect stabiliser bar links by removing
nut/washer connecting link to RLCA.
Installation
1. Locate and fit upper stabiliser bar insulator by
compressing the insulator with a screwdriver and
using a twisting motion.
NOTE: Two grooved steps of the stabiliser bar
insulator should be inserted into the RLCA.
2. Rotate stabiliser bar and insert stabiliser bar links
into RLCA. Complete stabiliser bar assembly as
detailed in stabiliser bar installation procedure.
G76547 en 01/2003 2003.0 BA Falcon

Jounce Bumper 2. Torque subframe-body brace nut to 50 ± 9.5 Nm.

3. Torque chassis-body brace bolt to 50 ± 9.5 Nm.
Removal
1. Hoist vehicle so that access is available to the
suspension module.
NOTE: The vehicle should be supported on its
wheels so that the halfshafts remain horizontal
(i.e. design height). Unclip jounce bumper from
upper subframe.
Installation
1. With vehicle hoisted, locate jounce bumper and
plug on subframe above RLCA.
Body Brace
Removal
1. Loosen subframe-body brace bolt.
2. Loosen chassis-body brace connection.
3. Remove subframe-body brace and chassis-body
brace bolts. Disconnect body brace.
Installation
1. Locate body brace to subframe and chassis using
respective bolts. Body brace should be fixed so
that standard hole is fitted to the module subframe
and the slotted hole is fitted to vehicle chassis.
NOTE: Body brace should be oriented with
flanged ends higher than the middle section of the
body brace.
G76547 en 01/2003 2003.0 BA Falcon

IRS Module Special Tool(s)

IRS alignment pins
Special Tool(s) 204-478
IRS module remover and
installer cradle
502-006
General
Removal 3. Replace 1 wheel nut to retain rear rotors.

1. Using a 2 post hoist (note position). 4. Remove rear seat bottom cushion.
G76549 en 01/2003 2003.0 BA Falcon

5. Unplug both ABS connector and push out 11. Remove loctite from bolts.
grommet and connect through the floor sheet
metal.
6. Remove both brake calipers and secure up out off
the way. Beware not to kink brake hose.
Item Description
1 Constant Velocity Joint
2 Differential Flange
7. Raise vehicle on hoist. 3 Bolt
8. Remove the rear intermediate exhaust mounting
12. Disconnect the rear hand brake cables.
rubber from the LH side of vehicle.
13. Disconnect the differential breather hose.

9. Mark rear drive shaft CV and diff flange. If the
vehicle is fitted with drive shaft balance weight,
number them and their corresponding location
before removing them.
10. Unbolt and drive shaft from diff flange.
G76549 en 01/2003 2003.0 BA Falcon

14. Remove IRS braces (note orientation). 18. Remove the 2 nuts forward of the springs on the
subframe.
15. Remove the 4 nuts retaining the front bush off the
Trailing Arms to the body. 19. Loosen (crack) the 2 nuts reward of the springs
on the subframe.
16. Remove the bolt at the rear of the differential.

20. Loosen (crack) both lower shock absorber bolts.
21. Fit the IRS module removal and installation cradle
502-006.
17. Remove the 2 bolts on the front off the IRS

module (in front of the springs).
Item Description
1 Front Location Bosses
2 Front Tabs
3 Rear Pins
1. Locate the 2 front bosses of the SST 502-006
into the IRS subframe
G76549 en 01/2003 2003.0 BA Falcon

2. Tighten the rear pins 25. Move the trolley jack under the IRS module SST
3. Engage the 2 front tabs and tighten with a and take up the weight of the IRS. Do not lift the
spanner vehicle off of the hoist.
26. Remove the remaining 2 nuts (rearward of the

springs) on the subframe.
22. Lower the vehicle until the knuckle is approx 1

foot above the ground.
27. Lower the IRS using the trolley jack. The front
23. Using a trolley jack take up the load of the bush off the trailing arms may need some help
spring/shocker and remove the shocker lower bolt coming away from the studs using a breaker bar.
lower jack slowly.
28. Raise the vehicle on the hoist.
NOTE: It is important that the knuckle be
supported by the jack to avoid having the spring & Installation
half shaft fall-out. 1. Unbolt and remove the IRS sensors.
24. Repeat step 23 for the other side.
G76549 en 01/2003 2003.0 BA Falcon

2. Remove the Control Blades. 8. Place the larger of the two location pins SST
204-478 in the left hand alignment hole and
tighten the rearward nut.
3. Move the IRS into the approximate position under

the vehicle. The IRS should just be clear of the
ground. Don’t have the Jack fully raised. 9. Place the smaller of the two location pins SST
204-478 in the right hand alignment hole and
4. Lower the vehicle until the chassis stud for tighten the rearward nut.
attaching the IRS are approx 1" off of the IRS
module.
5. Raise the IRS Module locating the 4 studs (Don’t
lift the vehicle off of the hoist).
6. Install the 4 nut each side of the rear springs.
10. Place the larger of the two location pins in the left
hand alignment hole and tighten the forward nut.
G76549 en 01/2003 2003.0 BA Falcon

11. Place the smaller of the two location pins in the 15. Replace the Y braces. Apply thread-locker (ie.
right hand alignment hole and tighten the forward loctite) to both nuts and bolts. Note the
nut. orientation.
12. Torque all 4 nuts. 16. Put the hand brake cable back. Refer to Section
13. Install and torque the 2 bolts in the front of the 206-05.
IRS module.
17. Reconnect the tail shaft. Apply thread-locker (ie.

14. Install and torque the bolt in the rear of the loctite) to all bolts. Make sure that if weights were
differential to the chassis. present on disassembly that they are return to
there original position.
G76549 en 01/2003 2003.0 BA Falcon

18. Reconnect the differential breather tube. 22. Using a jack raise the knuckle to align the top bolt
hole of the knuckle and the Control Blade. You
may need to pull the knuckle forward.
19. Install the nuts that fix the Trailing Arms to the
Body/Chassis and torque the nuts to specification.
23. Now replace the middle and then the lower bolt.
Some manipulation of the knuckle height may be
require to align the bolt hole.
24. Torque all 3 Trailing Arm bolts.
25. Refit the shock absorber into position and torque
the bolts. Use a jack to hold the knuckle into
place.
20. Replace the exhaust mounting rubber.
26. Bolt the ABS sensor back into position.
21. Lower the vehicle to approx 300mm off the

ground.
G76549 en 01/2003 2003.0 BA Falcon

27. Push the ABS connector plug back through the

sheet metal and engage the grommet correctly.
28. Reinstall the rear brake caliper. Refer to Section

206-04.
29. Repeat steps 22 to 28 for the other side.
30. Refit the wheels.
31. Connect the ABS plugs.
32. Refit the rear seat base.
G76549 en 01/2003 2003.0 BA Falcon

204-02b-1 Rear Suspension — Beam Axle 204-02b-1
SECTION : 204-02b Rear Suspension — Beam Axle

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................204-02b-2
Rear Suspension — Beam Axle ..........................................................................................204-02b-3
Ute & Wagon Rear Suspension .........................................................................................204-02b-3
Shock Absorbers ................................................................................................................204-02b-4
Rear Suspension .................................................................................................................204-02b-5
GENERAL PROCEDURES
Ride Height Procedure .........................................................................................................204-02b-6
Wheel Balancing ..................................................................................................................204-02b-6
Hoisting Instructions .............................................................................................................204-02b-6
Shock Absorber — Ute/Wagon ............................................................................................204-02b-7
Leaf Spring — Ute/Wagon ...................................................................................................204-02b-7
Leaf Spring Front Eye Bushing — Ute ................................................................................204-02b-7
Leaf Spring Front Eye Bushing — Wagon ...........................................................................204-02b-7
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Rear Hanger Bracket to Body 50
Spring Shackle to Rear hanger and 120
Spring
Rear Shock Absorber to Upper 70
Mounting Bracket
Rear Shock Absorber Upper Mounting 35
Bracket to Body
Rear Shock Absorber to Rear Spring 40
Plate
Rear Spring to Rear Axle U-bolt, Nut 60
Wheel Nut 125
Rear Spring to Rear Spring Front 105
Hanger
G478919 en 01/2003 2003.0 BA Falcon

Rear Suspension — Beam Axle spring is suspended from the underbody side rail by a
hanger at the front and shackle at the rear. The upper
Ute & Wagon Rear Suspension end of each shock absorber is mounted to a bracket
in the underbody. The lower end is mounted to the
3/4 tonne & 1/2 tonne (Sports suspension) spring clip plate.
Ute and Wagon The springs and shock absorbers control the up and
Two spring pads integral with the axle housing rest on down movement of the rear axle and wheels as
a spring plate and rubber insulator. These are located required by changes in the road surface. They also
on two leaf-type springs. The axle housing is fastened cushion road shocks.
to the springs by U-bolts, spring plates and nuts. Each

1 Nut (Wagon only) 15 Shock absorber
2 Nut 16 Shock absorber bracket
3 Bump stop 17 Plate assy. RR Spring
4 Bolt 18 Nut
5 U bolt 19 Nut
6 Nut 20 Insulator
7 Bushing 21 Nut
8 Bushing 22 Leaf spring
9 Rear spring bracket hanger 23 Bolt Hex HD Washer ½ 13x6
10 Nut 24 Insulator
11 Shackle 25 Retaining bracket
12 Bolt 26 Bolt (Wagon only)
13 Bolt 27 Pinion nose bump stop (Wagon only)
14 Bolt
G478920 en 01/2003 2003.0 BA Falcon

1 Tonne Ute
The rear suspension layout differs from, 3/4 tonne &
1/2 tonne (Sports suspension) ute only by the deletion
of the rubber insulator between the spring pads and
the spring plate.

1 Nut 18 Bolt
2 Bump stop 19 Bolt
3 Bolt 20 Bush
4 U bolt 21 Leaf Spring eye
5 Nut 22 Leaf spring bushing
6 Bushing 23 Nut
7 Bushing 24 Bush
8 Rear spring bracket hanger 25 Nut
9 Nut Shock Absorbers
10 Shackle
All vehicles are equipped with hydraulic gas
11 Bolt pressurised shock absorbers of the direct-acting type
12 Bolt and are non-adjustable and non-refillable, and cannot
13 Bolt be repaired.
14 Shock absorber
WARNING: Under no circumstances should
15 Shock absorber bracket the shock absorbers be pierced or heated.
16 Plate assy. RR Spring Before replacing a shock absorber, check the action
17 Nut of the shock absorbers.
G478920 en 01/2003 2003.0 BA Falcon

Rear Suspension
Refer to, Section 204-00.
G478921 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Ride Height Procedure

Loading Reqirements
1. Full tank of fuel.
2. Cooling system filled.
3. Crankcase oil at full.
4. Spare wheel and tyre stowed in design position.
5. Front seat one notch forward from rearmost
position.
Measuring Procedure
1. Position vehicle on level surface as loaded above.
2. Bounce the front and rear of the vehicle up and
down approximately 50 mm in each direction.
3. With the parking brake disengaged, push the
vehicle rear end at the centre of the rear bumper
evenly down, approximately 25 mm, and release
slowly.
4. With appropriate instruments measure from the
fender opening eyebrow to the wheel centreline
on both sides and record these measurements.
5. Raise the vehicle rear end at the centre of the
rear bumper evenly, approximately 25 mm, and
release slowly.
6. Repeat item 4.
7. Average the above measurements for each side
and record as rear ride heights left and right.
NOTE: Ride height specifications for coil springs are
base on springs that have settled in operation. When
are fitted a further 6 mm for coil springs and 15 mm
for leaf springs may be added to the maximum
allowable height. Ride height is also dependent on the
options fitted to a base vehicle and the quantity of fuel
carried.
Wheel Balancing
NOTE: Refer to the instructions provided with the
Wheel Balancer.
Hoisting Instructions
NOTE: Damage to suspension and/or steering
components may occur if care is not exercised when
positioning hoist adaptors or jacks when lifting the
vehicle. Do not allow contact with the steering linkage.
G478922 en 01/2003 2003.0 BA Falcon

Shock Absorber — Ute/Wagon 2. Position the upper insulator pad and the bracket
to the spring. Lift the rear end of the spring, locate
Removal the insulator bracket to the rear axle and install
1. Raise the vehicle on a hoist supporting it under the bushings and the shackle plate and pin
the body side-rails. Position a jack under the axle assemblies. Install the nuts finger tight.
to ensure that the axle breather hose and the 3. Position the lower insulator pad to the spring and
brake hose are not stretched. the upper insulator bracket.
2. Remove the nut securing the shock absorber 4. Install the U-bolts, spring plate and the attaching
lower mounting to the U-bolt plate and disconnect nuts.
this lower mounting. 5. Place stands beneath the rear axle and lower the
3. Remove the bolt from the shock absorber upper vehicle to the curb load position.
mounting, and rotate the shock absorber and 6. Install the lower shock absorber mounting.
remove.
7. Tighten the front hanger and the rear shackle lock
Installation nuts.
1. With the vehicle raised and supported under the 8. Where the RH spring has been removed attach
body rails, fit the shock absorber and upper the exhaust system.
mounting bolt. 9. Remove the stand and lower the vehicle.
2. Fit the shock absorber lower mounting stud to the
U-bolt plate. Leaf Spring Front Eye Bushing — Ute
3. Lower the vehicle to the ground and torque the
hardware to specification. Removal
1. Remove the spring as previously described.
Leaf Spring — Ute/Wagon 2. Using suitable adaptors press the old bush from
the spring eye.
Removal
3. Press the new bush into the spring eye.
1. Raise the vehicle on an underbody support hoist.
4. Install the spring as previously described.
2. Place a stand beneath the rear axle and lower the
hoist sufficient to remove the weight of the rear
axle from the shock absorber. Disconnect the
lower end of the shock absorber from the spring
plate, and push the shock absorber clear of the
work area.
3. Raise the hoist and support the rear axle on the
stand.
4. Remove the nuts from the U-bolts: then, remove
the plate and insulator (where fitted).
5. Remove the nut from the front hanger bolt.
6. Remove the nuts, the rear shackle plate and pin
assemblies and the shackle bushings. Lower the
rear end of the spring.
7. Remove the upper insulator and spring plate from Installation
the spring. 1. Install by reverse procedure.
8. When removing the RH side spring detach the 2 NOTE: Torque nuts to specification with the
rear exhaust system supports and lower the suspension in curb load position.
muffler to enable the front hanger bolt to be
removed. 2. Where necessary attach exhaust system.
9. Remove the front hanger bolt and remove the rear 3. Lower vehicle.
spring.
Leaf Spring Front Eye Bushing —
Installation
Wagon
1. Position the spring front eye in the front hanger
and (from the inboard side) insert the bolt through Removal
the hanger and the bushing. Install the lock nut on 1. Remove the spring as previously described.
the bolt and tighten finger tight.
2. Using suitable adaptors press the old bush from
the spring eye.
G478928 en 01/2003 2003.0 BA Falcon

3. Press the new bush into the spring eye.

NOTE: The bush must be installed with the void
toward the front of the spring and flange at the
inboard side of the spring.
4. Install the spring as previously described.
Installation
1. Install by reverse procedure.
NOTE: Torque nuts to specification with the
suspension in curb load position.
2. Where necessary attach exhaust system.
3. Lower vehicle.
G478928 en 01/2003 2003.0 BA Falcon

204-04-1 Wheels and Tyres 204-04-1
SECTION : 204-04 Wheels and Tyres

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................204-04-2
Wheels and Tyres ..................................................................................................................204-04-3
Wheels .................................................................................................................................204-04-3
Tyres ....................................................................................................................................204-04-3
Safety Precautions ..............................................................................................................204-04-3
Wheels and Tyres .................................................................................................................204-04-4
Symptom Chart ....................................................................................................................204-04-5
Component Tests .................................................................................................................204-04-6
GENERAL PROCEDURES
Straightening Wheels, Rims or Components .........................................................................204-04-8
Wheel and Tyre Assembly Balancing ...................................................................................204-04-8
Wheel ....................................................................................................................................204-04-9
Tyre ........................................................................................................................................204-04-9
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Wheel Nuts 135
G43320 en 01/2003 2003.0 BA Falcon

Wheels and Tyres Correct tyre pressure and driving techniques have an
important influence on tyre life. Heavy cornering,
Wheels excessively rapid acceleration and unnecessary sharp
braking, increase tyre wear.
The road wheels are of the double safety rim type. To equalize tyre wear, the tyres should be rotated at
They may be steel or aluminium according to the
recommended intervals.
model variant. It is essential that correct wheel nuts
are used at all times.
WARNING: Never run the engine with one
Steel Wheels wheel off the ground, for example, when changing
a tyre. The wheel(s) resting on the ground could
Steel wheels are fitted with wheel covers that must be cause the vehicle to move. Failure to follow these
removed to access the wheel nuts. instructions may result in personal injury.
The wheel nuts are conventional conical nuts.
WARNING: The tyre and wheel must always
Aluminium Wheels be correctly matched. It is very important to
The aluminium wheels are protected against corrosion determine the size of each component before any
by a special coating. Care must be taken when either assembly operations commence. Failure to adhere
replacing a tyre or fitting wheel balance weights not to to these instructions can result in an explosive
chip or score this protective coating. separation and cause serious bodily injury or
death.
Tyres
Radial tyres are fitted as standard equipment to all WARNING: Aftermarket aerosol tyre sealants
models. For tyre data refer to the decal attached to are extremely flammable. Always question the
the lock face of the right hand front door. customer to make sure these products have not
been used. Failure to follow these instructions
Tyre Care may result in personal injury.
It is essential that the recommended inflation
pressures are always maintained. Radial ply tyres WARNING: Aftermarket wheel assemblies
may appear underinflated at the correct may not be compatible with the vehicle. Use of
recommended pressures.This is normal and they incompatible wheel assemblies can result in
should never be inflated beyond the recommended equipment failure and possible injury. Use only
pressures. approved wheel assemblies. Failure to follow
these instructions may result in personal injury.
Tyre Pressures
WARNING: Use only wheels and wheel nuts
The tyre pressures quoted are cold pressures. In this
that have been designed for the vehicle.
context, the tyre temperature is considered ‘hot’ after
Aftermarket wheels or wheel nuts may not fit or
extended motoring at speed. Under certain extreme
function correctly. Failure to follow these
conditions of operation, a tyre may require up to one
instructions may result in personal injury.
hour at rest before it can be considered ‘cold’.
Tyre Wear WARNING: Always wear safety goggles or a
face shield when performing any work with the
If irregular wear is noticed, check the wheel bearings tyre and wheel assemblies. Failure to follow these
and front suspension ball joints for excess play and instructions may result in personal injury.
also check the front suspension geometry.
Safety Precautions CAUTION: Reduce the air pressure as much
as possible by pushing the valve core plunger in
prior to removing the valve core. Avoid working in
WARNING: Do not mix different types of tyres a position in which the face or body is directly
on the same vehicle such as radial, bias, or over a tyre in which there is pressure.
bias-belted tyres except in emergencies
(temporary spare usage), because vehicle When carrying out any inspection or repair
handling may be seriously affected and may result procedures on wheels and tyres, follow the preceding
in loss of control. Failure to follow these safety precautions.
Factory-installed tyres and wheels are designed to
operate satisfactorily with loads up to and including
full-rated load capacity when inflated to recommended
inflation pressures.
G43321 en 01/2003 2003.0 BA Falcon

Wheels and Tyres It is mandatory to use only the tyre sizes

recommended on the tyre chart attached to the
Inspection and Verification vehicle. Larger or smaller tyres can damage the
vehicle, affect driveability, and require changing the
speedometer calibration. Make sure wheel size and
WARNING: Do not balance the wheels and offsets match those recommended for the tyre in use.
tyres while they are still mounted on the vehicle.
Possible tyre disintegration or differential failure 1. Inspect for signs of uneven wear that can indicate
can result, causing serious injury and extensive a need for balancing, rotation, suspension
component damage. Use off-vehicle wheel and alignment, or damaged steering components.
tyre balancer only. Failure to follow these 2. Check tyres for:
instructions may result in personal injury. cuts
Be sure to follow the warnings when carrying out stone bruises
inspection and verification.
abrasions
Road Test blisters
Verify the customer concern by carrying out a road embedded objects
test on a smooth road. If any vibrations are apparent, 3. Tread wear indicators are moulded into the
refer to Section 100-04. bottom of the tread grooves. Install a new tyre
To maximize tyre performance, inspect for signs of when the indicator bar becomes visible.
incorrect inflation and uneven wear, which can
Match Mounting Tyres
indicate a need for balancing, rotation, or a
suspension alignment. Match mounting is a technique used to reduce radial
Correct tyre pressure and driving techniques have an runout. Excessive runout is a source of vibration,
important influence on tyre life. Heavy cornering, shimmy and poor handling concerns. Use the
excessively rapid acceleration and unnecessary sharp following steps to reduce radial runout:
braking increase tyre wear. 1. Mark the wheel at the same point as the mark
Replacement tyres should follow the recommended: previously made when measuring the tyre runout.
tyre sizes 2. Dismount the tyre and remount it 180 degrees on
the wheel so the original mark on the tyre is
speed rating
opposite the mark on the wheel.
load range
3. Inflate the tyre to specification.
tyre construction type
4. Measure the radial runout with Radial Runout
Use of any other tyre size or type may seriously Gauge at the center of the tread face. If the radial
affect: runout is reduced to acceptable guidelines, the
ride tyre can be used. If the radial runout remains
handling excessive, check the wheel runout.
speedometer/odometer calibration Tyre Drift Diagnosis
vehicle ground clearance Drift is the deviation of the vehicle from a straight path
tyre clearance between the body and chassis on a level road with no pressure on the steering
wheel bearing life wheel. Drift can be caused by:
brake cooling incorrect wheel alignment
Wheels need to be replaced when: dragging brakes
bent incorrect/uneven tyre pressure
dented defective tyres
cracked If defective tyres are suspected in a drift condition,
use the following steps to determine the defective
heavily corroded
tyre:
leaking
1. Rotate the two front tyres. For additional
they have elongated wheel hub bolt holes information, refer to Wheel and Tyre in this
they have excessive lateral or radial runout section.
Wheel and tyre assemblies are attached by five wheel 2. Road test the vehicle. If the vehicle drifts to the
nuts opposite direction, one of the front tyres is at fault.
G43322 en 01/2003 2003.0 BA Falcon

3. Rotate the two front tyres back to their original 5. Road test the vehicle. If the drift is corrected,
position. install a new rear tyre. If the drift remains, install a
4. Rotate one of the front tyres with its new front tyre on the opposite side of the vehicle.
corresponding rear tyre on the same side of the
vehicle.
Symptom Chart

Tyres show excess wear on edge of Underinflated tyres. ADJUST the tyre pressure.
tread
Vehicle overloaded. RETURN vehicle —NOTIFY the

customer of overload condition.
Incorrect wheel alignment. SET the alignment to specification.

REFER to Section 204-00.
High-speed cornering. RETURN vehicle — NOTIFY the

customer of cause of condition.
Incorrect tyre rotation ADVISE the customer of intervals.

condition. ROTATE tyres.
Tyres show excess wear in center of Overinflated tyres. ADJUST the tyre pressure.
tread
Other excessive/uneven tyre wear Improper tyre pressure. ADJUST the tyre pressure.
problems
Worn or damaged suspension REFER to Section 204-00.
components.
Incorrect tyre/wheel usage. INSTALL the correct tyre and wheel

combination.
Damaged, loose, or leaking shock TIGHTEN or INSTALL new shock
absorbers or struts. absorbers as necessary.
Incorrect wheel alignment. SET to specification. REFER to

Section 204-00.
Wheel and tyre assembly out of BALANCE the wheel and tyre
balance. assembly.
Excessive lateral or radial runout of REFER to Component Tests in this
wheel or tyre. section.
Tyres need rotating. ADVISE the customer of the condition.

ROTATE the tyres.
Wheel mounting is difficult Incorrect application or mismatched FOLLOW the manufacturer’s

parts, including lug bolts and wheel specifications.
nuts.
Corroded, worn or damaged parts. CLEAN or INSTALL new parts as

necessary.
Wobble or shimmy Worn or damaged wheel bearings. REFER to Section 204-00.

Loose or damaged suspension REFER to Section 204-00.
components.
Bent or damaged wheel. INSTALL a new wheel as necessary.

Wheel and tyre assembly out of BALANCE the wheel and tyre
balance. assembly.
Damaged tyre. INSTALL a new tyre as necessary.
Loose wheel nuts. TIGHTEN to specification. Refer to

Wheel and Tyre in this section.
G43322 en 01/2003 2003.0 BA Falcon


Vehicle vibrations Driveline. REFER to Section 100-04.
Wheel and tyre assembly out of
balance.
High-speed shake Wheel hub face/pilot/bolt circle runout. REFER to Section 100-04.
Wheel and tyre assembly out of
balance.
Damaged or worn wheel bearings.
Damaged or worn suspension/steering
linkage.
Driveline.
Brake discs/imbalance.
Damaged wheel nuts Loose wheel assembly. INSTALL new wheel nuts. Refer to
Overtightened wheel nuts. REMOVE the wheel nuts. INSPECT

for damage. INSTALL new
components as necessary. Refer to
Frozen wheel nuts Corrosion or galling. If the corrosion is slight, BRUSH away
the corrosion with a wire brush. If the
corrosion is excessive, INSTALL new
wheel studs and wheel nuts. REFER
to Section 204-01 (front) or Section
204-02 (rear). If the condition persists,
LUBRICATE the first three threads of
each wheel stud with a graphite-based
lubricant
CAUTION: Do not allow the

lubricant to get on the cone
seats of the stud holes or on the
cone angles of the wheel nuts.
Overloading. REDUCE the load weight.
Component Tests Tyre Runout
Tyre and Wheel Runout Measure radial and lateral runout at the positions
shown in the illustration. Runout should not exceed
Before checking runout, and to avoid false readings specifications.
caused by temporary flat spots in the tyres, check
runout only after the vehicle has been driven far
enough to warm the tyres.
Excessive radial and lateral runout of a wheel and tyre
assembly can cause roughness, vibration, wheel
tramp, tyre wear, and steering wheel tremor.
The extent of the runout is measured with a radial
runout gauge. All measurements are made on the
vehicle with the tyres inflated to recommended
inflation pressures.
Wheel Runout
Measure radial and lateral wheel runout at the
positions shown on the illustration. Runout should not
exceed specifications. Note that the tyre has been
removed.
G43322 en 01/2003 2003.0 BA Falcon

G43322 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Straightening Wheels, Rims or

Components
NOTE: Do not heat wheels in an attempt to soften
them for straightening to repair damage. The special
alloy used in these wheels is heat-treated.
Uncontrolled heating from welding affects the
properties of the material.
Do not weld the wheels for any reason.
Wheel and Tyre Assembly Balancing

1. Wheel and tyre assemblies should be dynamically
balanced. The wheel centre should be mounted
and located on a 70.45 to 70.50 mm diameter
spigot and clamped against the mounting plate via
the wheel stud holes, (i.e. as on a vehicle).
2. When balancing wheels note that the weights are
different on alloy and steel wheels.
3. Clip-on weights are to be used where the wheel
has a lip on the flange to accept a clip-on weight,
otherwise stick-on weights are to be used. For
stick on weights, the thickness of the lead weight
plus the adhesive should not exceed 4.5mm.
NOTE: It is important that only the correct balance
weights are used.
Item Description
1 Steel wheel weights
2 Aluminium wheel weights
G43323 en 01/2003 2003.0 BA Falcon

Wheel 3. Stand the wheel and tyre upright with the tyre
inner bead in the drop centre well at the
Removal bottom of the wheel. Insert the tyre iron
1. Remove the wheel cover by inserting the small between the bead and the edge of the wheel
end of a wheel nut removal tool inside the outer rim, and pry the wheel out of the tyre.
edge of the cover and progressively prying off the Installation
cover (steel wheels only). 1. If a used tyre is being installed remove all dirt
2. Loosen the wheel nuts one turn. from the tyre. If a tyre is being mounted to the
3. Raise the vehicle until the tyre clears the floor. original wheel, check the tyre bead seat on the
rim for imperfections and rectify same before
4. Remove the wheel nuts and the centre cap installing the tyre. If a new tyre or wheel is being
(where fitted). installed coat a new valve with lubricant and
Installation position the valve to the wheel. Use a valve
1. Clean all dirt from the hub. replacing tool to seat the valve in the rim.
2. Position the wheel on the hub. Install the wheel 2. Apply lubricant to the sealing surface on both tyre
centre cap (where fitted) on the wheel bolts. beads and wheel. With the outer side of the wheel
up, install the beads one at a time over the wheel
3. Install the wheel nuts and tighten them alternately
rim, by using a rubber mallet or a tyre mounting
in order to draw the wheel evenly against the hub.
machine.
4. Lower the vehicle to the floor, and tighten the
3. Remove the valve core and give the tyre a few
nuts.
quick bursts of air to seal the beads.
5. Position the wheel cover recess for the valve,
symmetrically around the valve and using a 4. If the beads do not seal, hold the beads against
the rim by positioning a tyre mounting band over
rubber mallet gently knock the cover onto the
the tyre. If a mounting band is not available, tie a
wheel, hitting on the outer edge. (Steel wheels
only.) tourniquet of heavy cord around the
circumference of the tyre. Tighten the cord with a
Tyre tyre iron. Centre the tyre on the wheel with a
rubber mallet. Repeat item 3. Remove the
Removal mounting band.
NOTE: When fitting a new tubeless tyre, a new 5. Install the valve core then inflate the tyre to 275
snap-in valve should also be fitted. The valve is made kPa pressure to seat the beads against the rim
to last the life of the tyre, but beyond that time fatigue flanges.
of the valve body rubber is likely to impair the air-seal 6. Check to see that the bead positioning rings (rings
at the rim hole. on the side walls near the rim) are evenly visible
NOTE: The tyre can be demounted or mounted on a just above the rim flanges all the way around the
machine. A machine should always be used on tyre. If the rings are not even, deflate the tyre
aluminium alloy wheels. completely and inflate it again.
7. When the rings are properly positioned, deflate
NOTE: Be sure that outer side of the wheel is the tyre to the recommended pressure.
positioned upward. It is acceptable to use tyre irons
on steel wheels using the following procedure. 8. Dynamically balance the wheel and tyre
assembly.
1. Remove the valve cap and core, and deflate the
tyre completely.
2. With the bead loosening tool, break loose the tyre
beads from the wheel.
3. Remove the wheel weights (if fitted).
1. With the outer side of the wheel upward,
insert two tyre irons about 200 mm apart
between the tyre outer bead and the wheel
rim. Use only tyre irons with rounded edges or
irons designed for demounting tubeless tyres.
2. Lever the tyre bead over the wheel rim with
one iron and hold it in this position. Pry the
rest of the bead over the rim with the other
iron. Take small "bites" with the iron around
the tyre in order to avoid damaging the NOTE: Ensure correct rotational direction when fitting
sealing surface of the tyre bead. a directional tyre to a rim.
G43326 en 01/2003 2003.0 BA Falcon

205-00-1 Driveline System — General Information 205-00-1
SECTION : 205-00 Driveline System — General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-00-2
Driveline System ....................................................................................................................205-00-3
General Specifications .........................................................................................................205-00-3
Run in ...................................................................................................................................205-00-5
Towing ..................................................................................................................................205-00-5
Oil Changes ........................................................................................................................205-00-5
Driveline System ....................................................................................................................205-00-5
In Vehicle Diagnostics ..........................................................................................................205-00-5
Symptom Chart ....................................................................................................................205-00-5
Bearing Noise .......................................................................................................................205-00-7
Gear Tooth Contact Pattern Check .....................................................................................205-00-7
Shim and Backlash Changes ...............................................................................................205-00-8
Driveline Vibration ................................................................................................................205-00-9
Limited Slip Differentials (M78 & M86) ...............................................................................205-00-9
Inspection after Removal & Dismantling ............................................................................205-00-10
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Refer to, Specifications and Special Tools of Section
205-02 for all Torque Specifications.
G77665 en 01/2003 2003.0 BA Falcon

Driveline System Conventional M86 differentials are not fitted with a

metal tag. For LSD units, a metal tag marked
General Specifications “SPIN RESISTANT DIFF. USE APPROVED
LUBRICANT ONLY” is attached under the filler
M78 & M86 IRS (Sedan) plug on the rear cover.
M78 IRS M78 & M86 Beam Axle (Wagon & Ute)
M78 Beam axle
M86 IRS
M86 Beam axle
A label identifying the drive unit assembly part

number, serial number, final drive ratio and model is
fixed to the carrier casting. Two different model final A label identifying the beam axle assembly part
drive units are used in sedan vehicles: number, serial number, and final drive ratio is fixed to
the axle tube adjacent to the carrier.
1. M78 final drive units are fitted with 3.23 or 3.45
7.75" (197mm) diameter gear sets, with or without Two different model beam axles are used on wagon
LSDs. All M78 final drive units should be filled and utility vehicles:
with synthetic oil as per Section 205-02 1. M78 beam axles are fitted with 3.23 or 3.45 7.75"
Specifications. Conventional M78 differentials are (197mm) diameter gear sets, with or without ABS
fitted with a metal tag marked “HIGH and with or without LSDs. All M78 beam axles
PERFORMANCE. USE APPROVED LUBRICANT should be filled with synthetic oil as per Part 4-5
ONLY” that is attached under the filler plug on the Specifications. Conventional M78 differentials are
rear cover. For Limited Slip Differentials (LSD) fitted with a metal tag marked “HIGH
units, the metal tag is marked “LSD - HIGH PERFORMANCE. USE APPROVED LUBRICANT
PERFORMANCE. USE APPROVED LUBRICANT ONLY” that is attached under the filler plug on the
ONLY”. rear cover. For LSD units, the metal tag is marked
2. M86 final drive units are fitted with 3.23 or 3.46 “LSD - HIGH PERFORMANCE. USE APPROVED
8.6" (220mm) diameter gear sets, with or without LUBRICANT ONLY”.
LSDs. M86 final drive units are fitted to all sedan 2. M86 beam axles are fitted with 3.23 or 3.46 8.6"
vehicles powered by a V8 or turbo I6 engine. All (220mm) diameter gear sets, with or without ABS
M86 final drive units should be filled with mineral and with or without LSDs. M86 axles are fitted to
oil as per Section 205-02 Specifications. 1 tonne rated utilities, and all vehicles powered by
G77666 en 01/2003 2003.0 BA Falcon

a V8 or turbo I6 engine. All M86 beam axles over-running of the cones; such a condition or sound
should be filled with mineral oil as per Part 4-5 does not indicate failure of the unit.
Specifications. Conventional M86 differentials are
not fitted with a metal tag. For LSD units, a metal Run in
tag marked “SPIN RESISTANT DIFF. USE
It is recommended that the vehicle is driven
APPROVED LUBRICANT ONLY” is attached
conservatively for the first 1500kms from new, and
under the filler plug on the rear cover.
that towing is avoided during this period. This allows
NOTE: Upgrading the lubricating oil to synthetic type the final drive to bed in correctly and helps assure
is recommended for vehicles fitted with a M86 final satisfactory final drive component life. During the
drive unit where the vehicle will be regularly used for run-in period, the vehicle should be driven at normal
towing. Refer to, Specifications of Section 205-02 for road speeds (within the posted limits) as final drive
the recommended synthetic lubricant. loading not vehicle speed is of primary importance.
These axle types are a hypoid type of unitised carrier Towing
construction. The two pinion differential case and the
drive pinion are mounted in opposed taper roller Ensure that the vehicle is fitted with a Ford approved
bearings in the carrier. Differential bearing preload tow pack, and that the towing limits for the particular
adjustment is provided by the screw adjusters. Pinion vehicle as designated by Ford and relevant State
bearing preload is regulated by a collapsible spacer regulatory bodies are adhered to. The final drive must
and adjusted using the pinion nut. be filled to the correct level with the correct type of oil
Torque is transferred from the propshaft to the final to ensure satisfactory performance while towing.
drive assembly via the constant velocity type Overheating can occur where low oil level or the
companion flange that is splined to the hypoid pinion. wrong type of lubricant is used.
The torque is then transferred from the pinion through Oil Changes
the ring gear, differential case, differential pinion cross
shaft, differential pinions and side gears to the If the vehicle is going to be used for towing on a
constant velocity joint halfshafts for conventional regular basis, or occasional heavy towing, an oil
differentials. Halfshaft end play is pre-set and is not change after run-in is recommended. Note that this is
adjustable. Oil seals are located between the not part of regular scheduled vehicle maintaince.
haflshafts and the screw adjusters.
M78 Limited Slip Differentials (LSDs), the differential
case houses two cone type clutches behind the side
gears. These cones are splined to the halfshafts, their
tapered faces bearing on the differential case. Thrust
springs pre-load the gears and cones, forcing the
tapered face of the cones into contact with the
differential case. The partial locking action due to the
spring load on the cones is automatically increased by
the inherent separating forces between the side gears
and pinion. This locking action directs a portion of the
driving force to the wheel with the least traction.
M86 LSDs transfer torque in a similar manner as M78
LSDs, except that a multiplate oil bath type design is
utilised where alternate plates are splined to the
differential case and side gear. Compressive
preloading of the plates provides frictional resistance
to rotation, providing torque transfer to the rear wheel
with the least traction.
With a conventional differential, when the rear wheels
are under extreme unbalance tractive conditions, such
as one wheel on dry road and the other in mud or ice,
wheel spin will occur if over acceleration is attempted.
However, with the limited slip differential, when the
tendency for wheel spin occurs, the friction generated
between the cones and the differential case (M78) or
between the friction plates (M86) transfers a portion of
the driving torque to the non-spinning wheel.
NOTE: (For M78 LSDs) In the event of continued
spinning a whirring sound is produced due to
G77666 en 01/2003 2003.0 BA Falcon

Driveline System practical speed in top gear to 110 kilometres per hour
(or maximum legal speed), noting any noises and the
In Vehicle Diagnostics speeds at which they occur. Release the accelerator
and without using the brakes allow the vehicle to lose
For other than obvious mechanical failures, careful speed, again noting noise and speed. Next, allow the
tests should be made to locate final drive troubles vehicle to coast to rest from 110 kph with the
since noises from engine, transmission and wheels transmission in neutral position. Any noises common
may all be attributed to the final drive. A suggested to earlier tests may be eliminated, as the final drive is
test routine is as follows:- Ensure that the axle not under load in these conditions. Engine noise is
lubricant is correct and at the correct level. Drive at gauged by gradually accelerating the engine with the
low speed until thoroughly familiar with vehicle noises vehicle at rest. Noises not eliminated at this stage are
by which time the rear axle assembly should have most probably final drive gear noise.
warmed up. Accelerate gradually from the lowest
Symptom Chart
Symptom Chart
Rear Wheel Noise (Beam Axles) Worn brake rotor. Replace/Repair as required
Wheel bolts loose.
Brinnelled or scored bearings.
Insufficient lubrication.
Bent axle shaft or wheel.
Dragging brakes.
Axle shaft retainer plate loose.
Tyre defective.
Damaged or worn C.V. joints (IRS).
G77667 en 01/2003 2003.0 BA Falcon


Final Drive Noise Bearing noise is usually fairly constant Replace/Repair as required
throughout the entire speed range and
of a pitch that increases in proportion
to vehicle speed.
NOTE: Final drive noises fall into two
categories: Gear Noise and Bearing
Noise.
Gear noise is of a periodic nature
being produced at various speeds on
drive, float, coast and cruise
conditions. If the pinion and ring gear
have been set up with too little
backlash a continuous whine may be
produced.
NOTE: Gear noise is most commonly
caused by:
Incorrect mesh of gear teeth (i.e.
incorrect pinion head positioning shim
or backlash setting shims).
Scored gear teeth - usually the result
of incorrect lubricant type or level.
End play in bearings.
Bruised or chipped teeth.
Excessive runout of pinion head or ring
gear backface.
Ring gear creeping on differential
housing resulting from ring gear bolts
loosening - noise from this source
usually appears as a sharp metallic
sound when shifting from reverse to
first gear.
NOTE: Bearing Noise is usually
caused by worn bearings and can be
the result of:
Contaminants in the lubricant.
Incorrect preload setting.
Bearings incorrectly mounted - e.g. dirt
trapped behind abutment faces during
assembly.
Rear Axle Shaft Breakage (Beam Abnormal clutch operation. Replace/Repair as required
Axle) Bent axle tubes/half shafts.
Excessive vehicle loads.
Overheating of Final Drive Assembly Lubricant level incorrect. Replace/Repair as required

Incorrect lubricant type.
Incorrect run-in procedure.
Loss of Lubricant Lubricant level too high. Replace/Repair as required

Breather malfunction.
Damaged or worn oil seals.
Rear cover bolts / filler plug loose.
Rear cover flange distorted.
Rear cover gasket/sealant damaged or
incorrectly applied.
Split cover or tubes (beam axles).
Incorrect type of lubricant - can cause
foaming.
Loose drain plug, or sealant not
replaced on drain plug at refitting.
G77667 en 01/2003 2003.0 BA Falcon


Excessive Backlash Worn axle shaft or halfshaft splines. Replace/Repair as required
Loose wheel nuts.
Loose universal or constant velocity
propshaft joint flange mountings.
Excessive backlash in either the
differential or hypoid gears.
Bearings worn or incorrectly adjusted.
Worn or loose constant velocity
halfshaft joints (IRS).
Bearing Noise 2. Increasing backlash moves the drive gear away
from the pinion:
Defective bearings can produce a whine that varies in
Drive pattern moves slightly higher and
proportion to vehicle speed. This will help distinguish
toward the heel.
between bearing and/or gear noise.
1. Pinion bearing noise can be identified as a Coast pattern moves higher and toward the
heel.
constant grinding noise. Pinion bearings are
rotating at a higher speed than differential side 3. Thicker pinion shim with the backlash constant
bearings or axle shaft bearings. The noise is most moves the pinion closer to the driver gear.
noticeable during light acceleration between 30 to Drive pattern moves deeper on the tooth
40 km/h. (flank contact) and slightly toward the toe.
2. Wheel bearing noise may be confused with rear Coast pattern moves deeper on the tooth
axle noise. To differentiate between wheel toward the heel.
bearings and rear axle, drive the vehicle on a 4. Thinner pinion shim with the backlash constant
smooth road at a medium low speed. With traffic moves the pinion further from the drive gear:
permitting, turn the vehicle sharply right and left. If
noise is caused by wheel bearings, the noise will Drive pattern moves toward the top of the
increase on the defective bearings because of tooth (face contact) and toward the heel.
side loading. Coast pattern moves toward the top of the
3. Side bearings will produce a constant grinding tooth and slightly toward the toe.
noise of a slower nature than pinion bearing, (side If the patterns are not correct, make the changes as
bearing noise cannot be determined by the wheel indicated.
bearing test), but will be of a similar frequency as When the pattern is correct, remove the marking
axle shaft bearings. compound from the gear teeth. Regardless of all
previous measurements and other factors, the tooth
Gear Tooth Contact Pattern Check contact pattern must be correct for successful rear
Paint the gear teeth with suitable gear marking axle operation.
compound. Wrap a cloth around the drive shaft to act
as a brake. Rotate the ring gear back and forth (use a The Ideal Tooth Pattern
box wrench on the drive gear attaching bolts for a The ideal tooth pattern is not a rigid standard but
lever) until a clear tooth contact pattern is obtained merely a general rule. In general, desirable tooth
(approximately 4 ring gear rotations in both patterns should have the following characteristics:
directions).
The drive pattern should be fairly well centred on
After diagnosing the tooth pattern, make the the tooth.
appropriate adjustments as explained in the following
pages. Drive and coast patterns indicating changes The coast pattern should be centred on the tooth
but may be slightly toward the toe.
required to obtain the correct operating position of the
gears is illustrated in the “ideal tooth contact pattern Some clearance between the pattern and the top
on ring gear” diagram. The movement of tooth contact of the tooth is desirable.
patterns with changes in gear location can be There should be no hard lines where the pressure
summarised as follows: is high.
1. Decreasing backlash moves the drive gear closer The individual gear set need not conform exactly to
to the pinion: the ideal pattern in order to be acceptable.
Drive pattern (convex side of gear) moves Characteristic differences between individual gear
slightly lower and toward the toe. sets will result in patterns that are acceptable yet
different from those illustrated.
Coast pattern (concave side of gear) moves
lower and toward the toe.
G77667 en 01/2003 2003.0 BA Falcon

Ideal Tooth Contact Pattern on Ring Gear
Acceptable Pattern Faulty gear set.

The drive pattern shown was rolled on a hunting-type Shim and Backlash Changes
gear set. Since each pinion tooth came into contact
with each ring gear tooth, the pattern is a result of the The patterns shown are typical of gear sets that have
combined tooth contacts. Therefore, the pattern is either an incorrect backlash or an incorrect shim
uniform from tooth to tooth. adjustment. Since each gear set rolls a characteristic
pattern, the patterns shown should be considered as
Acceptable Gear Tooth Contact Pattern typical only and should be used as a guide rather than
a rigid standard. The drive pattern is rolled on the
convex side of the tooth, and the coast pattern is
rolled on the concave side.
Unacceptable Pattern
An erratic tooth pattern on a hunting gear set
indicates gear set runout and is caused by one of the
following conditions:
Foreign matter between differential hemisphere
gear locating base and back face of crown wheel.
G77667 en 01/2003 2003.0 BA Falcon

Typical Gear Tooth Contact Patterns Indicating Shim or Backlash Change
Driveline Vibration 2. Chock the front wheels.

3. Raise the rear of the vehicle, remove one rear
For information regarding driveline, Refer to Section
205-01. wheel and attach the Special Tool No. E6662.
4. Lower the rear of the vehicle to simulate normal
Limited Slip Differentials (M78 & M86) ride height (ie. For IRS, lower arms should be
horizontal to the ground).
Cone Chatter
5. Place the transmission in neutral and release the
When encountering complaints of limited slip cone park brake.
chatter, the vehicle should be warmed up for 10
minutes and then driven in tight circles (slightly less 6. Ensure that there is no brake drag affecting wheel
rotation.
than full steering lock), five times clockwise and five
times anti-clockwise at approximately 10 km/h to allow 7. Attach a torque meter to the special tool, and
lubricant to work in between the cone friction rotate the axle.
surfaces. The torque required to rotate the axle shaft for a used
M78 L.S.D. unit should be between 50 and 130 Nm.
If the chatter persists, drain the lubricant, refill the axle
with the specified lubricant and repeat the aforesaid Reading should be steady within 10 Nm.
procedure. It may be necessary to drive the vehicle The torque required to rotate the axle shaft for a used
10-20 km before re-evaluating to allow the new M86 L.S.D. unit should be between 50 and 130 Nm.
lubricant to take affect. Should chatter still be evident, Reading should be steady within 10 Nm.
dismantling of the differential for further inspection
and repair will be necessary. A whirring sound due to
over-running of the cones is no indication of LSD unit
failure.
In Vehicle Limited Slip Differential Torque Testing

To test the Limited Slip Differential (LSD) for correct
operation proceed as follows:
1. Drive vehicle 10 km to warm up axle oil.
G77667 en 01/2003 2003.0 BA Falcon

Drive Pinion Flange

Check the flange mating face for damage and wear.
The end of the flange contacting the bearing cone and
the seal surface must be free from surface
imperfections like burrs and scoring.
Carrier Casting
Make sure that the differential bearing bores are
smooth and the differential bearing preload spacer
abutment faces are not damaged.
Differential Case
Carefully examine the case bearing hubs for damage.
The bearing assemblies will fail if they do not seat
If the torque required to continuously rotate the wheel against the shoulder on the hubs correctly.
is outside the specification check the differential for
improper assembly and/or rework. Limited Slip Differential (LSD)
For M78 LSDs, thoroughly clean and dry all parts and
Inspection after Removal & Dismantling check the following:
Thoroughly clean all parts. Always use new solvent The cone seats in the case should be smooth and
when cleaning bearings. Oil the bearings immediately free from excessive scoring. Slight grooves or
after cleaning to prevent rusting. Inspect the parts for scratches are permissible and normal.
any major defects. Clean the inside of the case, The land surfaces of the cones will duplicate the
particularly the oil ports, before rebuilding and case surface condition. Excessive wear or
installing. Inspect individual parts as outlined below. damaged cone surfaces will necessitate renewal
Hypoid and Differential Gears of the cone and casing.
The pattern taken during dismantling should help in Inspect thrust springs for damage. Replace where
judging if the gears can be re-used. Worn gears necessary.
cannot be rebuilt to correct a noisy condition. Gear Check the thrust blocks for excessive wear.
scoring is the result of excessive shock loading or the Replace where necessary.
use of an incorrect lubricant. Scored gears must be For M86 LSDs, thoroughly clean and dry all parts and
replaced. Examine the teeth and thrust surface of the check the following:
differential gears. The LSD plates and disc must be in good
NOTE: Check the fit of the side gear hubs in the case condition. If any one member of either stack
on M78 conventional differentials. Wear on the hub of shows evidence of excessive wear or scoring, the
the side gear can cause a “chuckling” noise known as complete stack is to be replaced on both sides of
“chuckle” when the vehicle is driven at low speeds. the assembly.
Wear on splines, thrust surfaces, or thrust washers Side and pinion gears should be checked for
can contribute to excessive driveline backlash. extreme wear and possible cracks. The external
teeth of the side gear, which retain the concentric
Bearings groove discs, should also be checked for wear or
cracks.
Check bearing cups for rings, scores, galling or erratic
wear patterns. Pinion bearing cups must be solidly If replacement of one gear is required due to
seated. Check by attempting to insert a 0.05 mm wear, etc., then both side gears, pinion mate
feeler between the cups and the bottom of their bores. gears, and washers are to be replaced.
If excessive wear is evident on the cross pin, it
The cone and roller assemblies on the differential
should be replaced.
case and the rear cone and roller on the pinion should
be checked before being removed from the differential If wear is evident on any one of the clutch retainer
case or pinion. When these cones and rollers have clips, all four clips must be replaced.
been removed the cones and rollers and their If scoring, wear or metal pick-up is evident on the
respective bearing cups should be discarded. When machined surfaces of the differential case, then
revolved in the cups, bearing rollers must turn without replacement of the case is necessary.
roughness. Examine the roller ends for wear.
Stepwear on the roller ends indicates the bearing
preload was incorrect or the rollers were slightly
misaligned.
G77667 en 01/2003 2003.0 BA Falcon

205-01-1 Driveshaft 205-01-1
SECTION : 205-01 Driveshaft

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-01-2
Driveshaft ...............................................................................................................................205-01-3
Universal Joints ......................................................................................................................205-01-3
Driveshaft ...............................................................................................................................205-01-4
Symptom Chart ....................................................................................................................205-01-5
GENERAL PROCEDURES
Take — Off Shudder ..............................................................................................................205-01-6
Driveshaft Assembly ..............................................................................................................205-01-7
DISASSEMBLY AND ASSEMBLY
Flex Joint Replacement .........................................................................................................205-01-8
Universal Joint Replacement .................................................................................................205-01-8
Centre Bearing Replacement .................................................................................................205-01-9
CV Joint Replacement .........................................................................................................205-01-10
01/2003 2003.0 BA Falcon

205-01-2 Driveshaft 205-01-2
SPECIFICATIONS
Two Piece General Specifications

Constant velocity joint Supplied in CV Kit
grease
Constant velocity joint 262 Loctite
loctite for bolts
Two Piece Torque Specifications
Description Nm
Centre bearing bolts (x2) 36 (±7)
Constant velocity joint bolts (x6) 72 (±13)
Flexible coupling nuts / bolts (x6) 77
End yoke lock nut (x1) 157 (±20)
Single Piece Torque Specifications
Description Nm
Single piece U/J comp 82.5 (±7.5)
G96420 en 01/2003 2003.0 BA Falcon

205-01-3 Driveshaft 205-01-3
Driveshaft
The driveshaft is the means of transferring power from
the engine to the differential in the rear axle and then
to the rear wheels. The two piece Drive shaft in
corporates a flex coupling (with slip flange) centre
bearing, a universal joint and a constant velocity joint
with the ability to plunge. The single piece Drive shaft
incorporates two Universal joint mounted at each end.
The plunging CV (two piece) (& to some degree, the
slip splines) allows lateral movement of the driveshaft
components & assembly as the diff moves up & down.
CAUTION: All driveshafts are balanced. If the

vehicle is to be undercoated, cover the driveshaft
to prevent application of the undercoating
material.
Universal Joints
The single center joint is:
a lubed-for-life design that requires no periodic
lubrication.
equipped with nylon thrust washers, located at the
base of each bearing cup, which control end play,
position the needle bearings and improve grease
movement.
G96422 en 01/2003 2003.0 BA Falcon

205-01-4 Driveshaft 205-01-4
Driveshaft
Driveline Vibrations
Characteristics of driveline vibrations:
high frequency.
worse on acceleration or rapid deceleration.
usually described as a ‘droning’ noise.
often more noticeable from the rear seat of the
vehicle.
Driveline vibrations can originate from wear of
bearings or damage to the driveshaft.
Damage and wear may produce vibrations due to the
fact that the components will be rotating on a centre
other than the centre of balance.
Driveshaft Inspection
Driveshaft Runout
The driveshaft runout is measured at the centre of the
shaft and at 130 mm from the weld at each end.
NOTE: Be careful not to offset shaft at centre bearing.
Maximum Runout Specification

Driveshaft in vehicle . . . . . . Not Recommended
Driveshaft mounted on centres . . . . 0.42 (Ends)
0.35 (Middle) mm
Driveshaft Balance
The driveshaft balance specification is 9 gm. cm at
3200 rpm. The light side is marked with yellow paint
on the rear yoke.
G96423 en 01/2003 2003.0 BA Falcon

205-01-5 Driveshaft 205-01-5
Symptom Chart
Symptom Chart
Driveline vibration Axle flange and driveshaft yellow paint Remove/Repair as required.
marks not aligned.
Undercoating or other foreign material
on shaft.
Universal joint strap/flange bolts loose.
Universal joints worn, or lack of
lubricant.
Universal joint locating clip faces of
pinion flange damaged.
Broken rear spring centre bolt.
Broken rear spring.
Rear springs not matched (sagged to
one side).
Driveshaft damaged (bent) or out of
balance (missing balance weights).
Bearing cups improperly seated in
pinion flange.
Pinion flange run out.
W orn or dry PCV.
Eng/Trans/Diff mounts worn.
Flex coupling/coupling bolts worn.
Flex coupling bolts loose.
Centre bearing bracket bolts loose.
T/OFF Shudder Coupling Bolts misallignment in Z. See General Procedures "Take-Off
Shudder"
U-Joint Noise Universal joint strap/flange bolts loose. Remove/Repair as required.
W orn U-joints.
G96423 en 01/2003 2003.0 BA Falcon

205-01-6 Driveshaft 205-01-6
GENERAL PROCEDURES
Take — Off Shudder UJ Side view Angle (in Actual shim required
degrees) (front shaft (mm)
NOTE: Take off shudder is characterised by a angle - rear shaft angle)
driveline vibration (felt in the driver / passenger seats), -1.9° 5
which peaks and abates between 15 - 25kph under
heavy throttle applications. It is due to the -1.8° 4
misalignment of the centre bearing bracket in the ’Z’ -1.7° 4
(vertically) direction. -1.6° (Optimal U/J angle) 3
1. To eliminate take off shudder, follow the steps -1.5° 3
outlined below: -1.4° 2
Check engine/transmission/diff mounts for -1.3° 2
condition and correct location. If OK then -1.2° 1
proceed to next step.
-1.1° 1
With vehicle on hoist, remove existing shims
(if any) and re-torque bolts up to the floor brkt -1.0° 0
mounting surface. -0.9° 0
Using an Inclinometer, take the front and rear
shaft angles.
NOTE: Use the same inclinometer in the
same orientation for each shaft, failing to do
this will result in inaccurate measurements.
Determine the resultant angle by subtracting
the front shaft angle from the rear shaft angle
(ie front shaft angle - rear shaft angle).
Use look-up table below to determine shim
size required.
Loosen CB bolts, and assemble correct
determined shims, re-torque bolts to 36Nm
(±7Nm).
Using an Inclinometer, take the front and rear
shaft angles.
NOTE: Use the same inclinometer in the
same orientation for each shaft, failing to do
this will result in inaccurate measurements.
Check if front and rear resultant angle is at
the optimal figure (-1.6°).
Take vehicle for short run on safe roads and
do two WOT runs to 25kph to verify fix.
UJ Side view Angle (in Actual shim required

degrees) (front shaft (mm)
angle - rear shaft angle)
-3.0 10
-2.9 10
-2.8 9
-2.7 9
-2.6° 8
-2.5° 8
-2.4° 7
-2.3° 7
-2.2° 6
-2.1° 6
-2.0° 5
G96424 en 01/2003 2003.0 BA Falcon

205-01-7 Driveshaft 205-01-7
Driveshaft Assembly Installation

1. If the seal installed on the end of the transmission
NOTE: If assembling or disassembling any part of the extension housing is damaged in any way, install
driveshaft asy then either a driveshaft or system a new seal.
re-balance is recommended. 2. Lubricate the slip spline with transmission
NOTE: Before disassembly mark location (and lubricant. Install the slip spline on the transmission
weight) of clip on balance weights (if fitted). output shaft.
Re-assemble in original position. 3. Match the alignment marks and locate the CV
joint, bolts and balance weights to the companion
NOTE: Before disassembly check if Centre Bearing flange and CV bolts. Torque 72Nm (+/- 13Nm).
shims are present and retain for re-assembly.
4. Locate the center bearing bracket on the body.
NOTE: The driveshaft rear CV and the pinion flange Torque to 36Nm (+/- 7Nm).
of the axle have yellow paint alignment marks that are
assembled as close together as possible. If these are
not visible, mark the CV and the flange so that they
may be installed in their original positions.
Removal
Item Description
1 Flex
2 Driveshaft
3 Centre bearing assembly
4 Universal joint
5 Driveshaft
6 CV assembly
7 Differential assembly
8 Bolt
9 transmission assembly
1. Locate Jack or transmission stand at centre
bearing to support before removal.
2. Disconnect the rear CV joint from the pinion
flange.
3. Disconnect the Centre-Bearing closing bracket
from the body. Pull the driveshaft toward the rear
of the vehicle until the front Flex Coupling slip
spline clears the transmission extension housing
and the seal.
NOTE: To prevent oil loss and ingress of foreign
material plug the extension housing with a
mainshaft dust cover or slip flange.
G96425 en 01/2003 2003.0 BA Falcon

205-01-8 Driveshaft 205-01-8
Flex Joint Replacement Universal Joint Replacement

Disassembly and Assembly NOTE: Procedure can be used for single piece slip
NOTE: To maintain driveline balance, mark the slip yoke/tube yoke removal as well.
flange in relation to the Driveshaft so that they may be
installed in their original positions. External Clip Type U-Joint
NOTE: The arrows molded into the flex coupling must

always be pointing to the slip or tube flange arms.
Otherwise premature failure of the component will
occur.
Item Description
1 Driveshaft
2 Slip yolk assembly
3 Snap ring
1. Remove the retaining bolts from the flex joint to 4 Bearing
shaft and flex joint to slip flange. 5 Driveshaft
2. Replace flexible coupling, ensuring arrows 6 U-joint assembly
(moulded in flex rubber) are pointing to the slip or
7 Nut
tube flange arms and locate spigot to shaft.
Reinstall new nuts and bolts (from service kit) and
Torque to 77 Nm. Disassembly
NOTE: If there is any damage to alignment bush NOTE: To maintain drive line balance, mark the
on slip flange then replace slip flange. relation of the slip yoke and the pinion flange on the
axle, with the shaft so that they may be installed in
their original positions.
1. Remove the clips that retain the bearings in the
yoke. Apply penetrating oil to the bearing cups to
assist removal if required.
2. Using a “G” clamp and suitable adaptors, or
similar equipment, press on one of the bearing
cups so as to drive the opposite bearing from the
yoke.
NOTE: All hardware must be correctly installed
and torqued to specification.
G96426 en 01/2003 2003.0 BA Falcon

205-01-9 Driveshaft 205-01-9
DISASSEMBLY AND ASSEMBLY (Continued)
3. Remove the bearing from the spider, rotate the Centre Bearing Replacement
shaft 180° and remove the second bearing.
Detach the yoke from the shaft. NOTE: To maintain driveline balance, mark the
relation of the Universal joint end yoke to front and
rear shafts so that they may be installed in their
original position.
NOTE: Do not use impact/rattle gun on centre bearing
bolts as you will run the risk of stripping the thread in
the nut located inside the body.
NOTE: It is important to keep and replace original CB
shims.
Disassembly and Assembly
4. Repeat this procedure to remove the bearings

from the yoke and rear of the shaft.
Assembly
1. Position the spider in the yoke. Lift the spider to
one side of the yoke and locate a bearing cup on
the spider. While holding the spider in the bearing
press the bearing into the yoke until the clip can
be installed on the bearing. Install the clip.
2. Rotate the yoke 180° and install the other bearing
while holding the spider into the bearing to
prevent the needle rollers from being dislodged.
The bearing cups are fitted with plastic pads that Item Description
impart a preload on the ends of the spider. These 1 Shims
pads must be compressed by use of a “G” clamp 2 Centre bearing bracket assembly
or vice. Tap the yoke to seat the clip previously
fitted and install the remaining clip. 3 Bolt
3. Repeat this procedure to install the remaining 1. Remove Universal joint as directed.
bearings in the shaft. 2. Remove locking nut retaining end yoke flange to
drive shaft, press off end yoke from front shaft.
3. Press Centre Bearing from shaft and Replace.
4. Press fit end yoke and new lock nut and torque to
157Nm (+/- 20Nm).
NOTE: Careful not to apply force to other race of
bearing.
G96428 en 01/2003 2003.0 BA Falcon

205-01-10 Driveshaft 205-01-10
CV Joint Replacement 4. Using bearing puller (tool number ?) press CV

joint from shaft.
NOTE: To maintain balance mark all bolts and 5. Remove boot from shaft.
weights in reference to the companion flange.
Assembly
Disassembly 1. Inspect boot for damage and/or holes.
2. Take care whilst sliding boot onto stub shaft. A
small amount of CV joint grease may be used as
a lubricant.
3. Place metal sealing gasket inside boot can, keep
bolt holes aligned.
4. Press CV onto stub shaft using unique tool (tool
number ?), push on CV joint inner race. Ensure
double grooves on CV joint body are toward the
boot can.
5. Seat retainer circlip.
6. Pack joint with 60g of lubricant (supplied with CV
kit) throughout cage and races.
7. Seat CV boot can onto CV joint body, ensuring
bolt, and metal sealing gasket hole alignment, and
Item Description relieve any twist in the boot.
1 CV 8. Remove backing and place self-adhesive cork
2 Companion flange gasket (supplied with CV kit) into stepped recess
3 Bolt on CV joint face, aligning bolt holes. Placing bolts
through CV Joint as a guide to gasket alignment.
Gasket alignment is critical to sealing integrity.
9. Seat rear can onto CV again ensuring bolt holes
are aligned.
10. Clamp boot in location as shown in figure.
11. Bolts to be torqued to 72Nm (+/- 13Nm). Opposite
bolts to be torqued until all reach spec.
Item Description
1 Stub Shaft
2 Boot Clamp
3 Boot Asy
4 Grease
5 Steel Gasket
6 CV Joint Asy
7 Cork Gasket
8 Circlip
9 Grease Cover
1. Follow steps to remove drive shaft.
2. Remove end cap from CV joint, grease can and
remove retaining clip.
3. Using a hammer and soft punch remove the boot
can forwards from the CV joint.
G96429 en 01/2003 2003.0 BA Falcon

205-02A-1 Rear Drive Axle / Differential — Beam Axle 205-02A-1
SECTION : 205-02A Rear Drive Axle / Differential —

Beam Axle
CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................205-02A-2
Rear Drive Axle / Differential — Beam Axle ........................................................................205-02A-3
Beam Axle Final Drive Identification ..................................................................................205-02A-3
Conventional Differential ....................................................................................................205-02A-3
Limited Slip Differential ......................................................................................................205-02A-3
Differential Assembly and Pinion Bearings .......................................................................205-02A-4
Wheel Bearings .................................................................................................................205-02A-4
Rear Drive Axle / Differential — Beam Axle ......................................................................205-02A-12
GENERAL PROCEDURES
In Vehicle Inspection .........................................................................................................205-02A-14
Beam Axle Oil Change .....................................................................................................205-02A-14
Flange Runout Check ........................................................................................................205-02A-15
In Vehicle Torque Check ...................................................................................................205-02A-15
Limited Slip Differential — M78 & M86 Check .................................................................205-02A-15
Limited Slip Differential Torque Check ..............................................................................205-02A-16
Limited Slip Differential — M86 Inspection for Wear .........................................................205-02A-16
Limited Slip Differential — M78 .........................................................................................205-02A-17
IN-VEHICLE REPAIRS
Pinion Oil Seal Replacement .............................................................................................205-02A-18
Axle Shaft Assembly ..........................................................................................................205-02A-19
M86 Limited Slip Differential ..............................................................................................205-02A-20
Axle Housing and Differential Assembly ...........................................................................205-02A-21
Rear Axle Wheel Bearing and Seal Replacement .............................................................205-02A-24
Differential and Drive Pinion ..............................................................................................205-02A-26
Differential Bearing Preload Spacer Selection ..................................................................205-02A-27
Drive Pinion Position — Shim Selection ............................................................................205-02A-28
Drive Pinion and Bearings .................................................................................................205-02A-29
Differential Installation and Backlash Check .....................................................................205-02A-30
Differential Case — Conventional Type M78 and M86 .....................................................205-02A-30
01/2003 2003.0 BA Falcon

SPECIFICATIONS
General Specifications Description Specification

Description Specification Backlash between ring gear 0.13 to 0.18 mm
Rear Axle Lubrication and pinion.
(Level with bottom of filler plug hole with vehicle at Backlash variation between 0.05 mm max.
curb height.) teeth.
Model 78 Maximum ring gear run out 0.13 mm
CONVENTIONAL (assembled)
Grade SAE 90 Hypoid Limited slip differential torque
Ford Specification ESW-M2C108-A Model 78 New: 80-140 Nm
Capacity 1.70 litre (cone clutch type) Used: 50-130 Nm
LIMITED SLIP Model 86 New: 100-300 Nm
Grade SAE 90 EP (plate clutch type) Used: 50-150 Nm
Ford Specification ESW-FM2C-1006-B Torque Specifications
Capacity 1.60 litre + 100ml Description Nm
Sturaco 7098 Ring gear bolts (L.H. Thread) 140
Additive
Bearing cap bolts 55
Model 86
Differential case bolts (L.S.D.) 40
CONVENTIONAL
Rear cover bolts 30
Grade Mobilube SHC ID
Axle bearing retainer plate bolts 45
Ford Specification ESZ-FM2C190-A
Spring ’U’ bolt nuts (Wagon) 60
Capacity 1.9 litre
* Track arms to body 75
LIMITED SLIP
* Track arms to pivot link 75
Grade Mobilube SHC ID
* Pivot link to axle housing cover 15
Ford Specification ESZ-FM2C190-A
* Suspension arms to axle housing 75
Capacity 1.86 litre + 40ml
Duraphos Mobil * Suspension arms to body 75
M3022 * Shock absorber to spring plate 75
BEARING PRELOADS Caliper to bracket pin nuts 20
New Bearings Nm Splash shield screws 10
Differential Shock absorber to spring plate nut 45
— Measured without axle 0.6-1.9 Stabiliser bar clamp bolt 20
shafts or pinion Universal joint bolts 10
Pinion Vent - Rear axle housing 15
— With oil seal 1.5-2.1 Pinion flange nut —
— Without oil seal 1.5-1.9 Filler Plug 30
Used Bearings Drain Plug 30
Differential * Items marked thus are to be tightened with the
— Measured without axle 0.4-1.1 vehicle in the curb load position.
shafts or pinion
Pinion
— With oil seal 0.7-1.2
— Without oil seal 0.7-1.0
ADJUSTMENTS
Pinion bearing preload Collapsible spacer
adjustment.
Differential bearing preload Selective spacer
adjustment.
Pinion depth of mesh Selective shim
adjustment.
G98770 en 01/2003 2003.0 BA Falcon

Rear Drive Axle / Differential — Beam Limited Slip Differential

Axle This axle is a hypoid type of unitised carrier
Beam Axle Final Drive Identification drive pinion are mounted in opposed tapered roller
A label identifying the beam axle assembly part bearings in the carrier. Differential bearing preload
number, serial number, and final drive ratio is fixed to adjustment is provided by varying shim thicknesses
the axle tube adjacent to the rear cover. behind the bearing cups. Pinion bearing preload is
regulated by a collapsible spacer and adjusted using
Two different model beam axles are used on wagon the pinion nut.
and utility vehicles:
Torque is transferred from the propshaft to the final
1. M78 beam axles are fitted with 3.23 or 3.45 7.75" drive assembly via the companion flange that is
(197mm) diameter gear sets, with or without ABS splined to the hypoid pinion. Torque is then
and with or without LSD’s. All M78 beam axles transferred from the pinion through the ring gear,
whould be filled with lubricant as per the differential case, differential pinion cross shaft,
Specifications. M78 LSD differentials are fitted differential pinions and side gears to the axle shafts.
with a metal tag marked "SPIN RESISTANT DIFF.
USE APPROVED LUBRICANT ONLY". For M78 Limited Slip Differentials (LSDs), the
differential case houses two cone type clutches
2. M86 beam axles are fitted with 3.23 or 3.46 8.6" behind the side gears. These cones are splined to the
(220mm) diameter gear sets, with or without ABS axle shafts, their tapered faces bearing on the
and with or without LSD’s. M86 axles are fitted to differential case. Thrust springs pre-load the gears
all vehicles powered by a V8 or turbo I6 engine. and cones, forcing the tapered face of the cones into
All M86 beam axles should be filled with lubricant contact with the differential case. The partial locking
as per the Specifications. Conventional M86 action, due to the spring load on the cones is
differentials are fitted with a metal tag marked automatically increased by the inherent separating
"HIGH PERFORMANCE. USE APPROVED forces between the side gears and pinion. This
LUBRICANT ONLY". For LSD units, a metal tag locking action directs a portion of the driving force to
marked "LSD - HIGH PERFORMANCE. USE the wheel with the greatest traction.
APPROVED LUBRICANT & FRICTION
MODIFIER" is attached under the filler plug on the M86 LSDs transfer torque in a similar manner as M78
rear cover. LSDs, except that a multiplate oil bath type design is
NOTE: Upgrading the lubricating oil to synthetic type differential case and side gear. Preloading of the
is recommended for vehicles fitted with a M86 beam plates provides frictional resistance to rotation,
axle where the vehicle will be regularly used for providing torque transfer to the rear wheel with the
towing. Refer to Specifications section for the greatest traction.
recommended synthetic lubricant.
The axle shafts are mounted using tapered roller
Conventional Differential bearings and held by retainer plates at the outer ends
of the axle housing. Axle shaft end play is pre-set and
This axle is a hypoid type of unitised carrier is not adjustable. Oil seals are located between the
construction. The two pinion differential case and the retainer plates and the bearing.
drive pinion are mounted in opposed tapered roller With the conventional differential, when the rear
bearings in the carrier. Differential bearing preload wheels are subject to highly unbalanced tractive
adjustment is provided by varying shim thicknesses conditions such as one wheel on dry road and the
behind the bearing cups. Pinion bearing preload is other in mud or ice, wheel spin will occur if over
regulated by a collapsible spacer and adjusted using acceleration is attempted. However, with the limited
the pinion nut. slip differential, when the tendency for wheel spin
Torque is transferred from the propshaft to the final occurs, the friction generated between the cones and
drive assembly via the companion flange that is the differential case (M78) or between the friction
splined to the hypoid pinion. The torque is then plates (M86) transfers a portion of the driving torque
transferred from the pinion through the ring gear, to the non-spinning wheel.
differential case, differential pinion cross shaft, NOTE: (For M78 LSDs) In the event of continued
differential pinions and side gears to the axle shafts spinning a whirring sound is produced due to
for conventional differentials. over-running of the cones; such a condition or sound
The axle shafts are mounted using tapered roller does not indicate failure of the unit.
bearings and held by retainer plates at the outer ends
of the axle housing. Axle shaft end play is pre-set and
is not adjustable. Oil seals are located between the
retainer plates and the bearing.
G98771 en 01/2003 2003.0 BA Falcon

Differential Assembly and Pinion

Bearings
This bearing is a single row, pre-set tapered roller
bearing capable of accepting thrust loads and radial
loads in any combination.
The tapered roller bearing consists of four basic parts:
the cup or outer race, the cone or inner race, the
tapered rollers which roll freely between the cup and
cone, and the cage which serves as a retainer to
maintain the proper spacing between the tapered
rollers grouped around the cone.
Wheel Bearings
This bearing is a single row, pre-set tapered roller
bearing capable of accepting thrust loads in either
direction and radial loads in any combination.
The tapered roller bearing consists of five basic parts:
the cup or outer race, the cup rib ring, the cone or
inner race, the tapered rollers which roll freely
between the cup and cone, and the cage which
serves as a retainer to maintain the proper spacing
between the tapered rollers grouped around the cone.
When the bearing is manufactured, the cup and rib
ring are bonded together with an adhesive to facilitate
bearing handling and installation. Since the cup and
rib ring are clamped together in the axle housing,
there is no need for a permanent bond. When the
bearing is serviced the cup will usually be separated
from the rib ring.
Item Description
1 Cup
2 Cup rib ring
3 Rollers
4 Cone
5 Cage
G98771 en 01/2003 2003.0 BA Falcon

M86 Beam Rear Axle Assembly
G98771 en 01/2003 2003.0 BA Falcon

Item Description
1 Axle & brake retaining bolt (8 off)
2 Park brake assembly
3 Inner bearing retainer
4 Axle shaft oil seal
5 Axle shaft wheel bearing
6 Outer bearing retainer
7 ABS tone wheel
8 Wheel Stud (5 off each side)
9 Axle shaft
10 Differential bearing cap bolts (4 off)
11 Differential bearing caps (2 off)
12 Carrier and tube assembly
13 Filler plug & gasket
14 Drain Plug
15 Lubricant tag
16 Rear cover
17 Differential position shim
18 Differential bearing (cup and cone)
19 Ring gear bolt (8 off)
20 Differential case
21 Rear pinion bearing (cup & cone)
22 Pinion position shim
23 Collapsible preload control spacer
24 Front pinion bearing (cup & cone)
25 Pinion oil seal
26 Companion flange assembly
27 Pinion nut
28 Hypoid gearset (Ring gear & pinion)
29 Load level bracket
30 Park brake cable clips (2 off)
31 Rear cover bolts
G98771 en 01/2003 2003.0 BA Falcon

M78 Beam Rear Axle Assembly
G98771 en 01/2003 2003.0 BA Falcon

Item Description M86 Conventional Differential Assembly

1 Axle & brake retaining bolt (8 off)
2 Park brake assembly
3 Inner bearing retainer
4 Axle shaft oil seal
5 Axle shaft wheel bearing
6 Outer bearing retainer
7 ABS tone wheel
8 Wheel Stud (5 off each side)
9 Axle shaft
10 Differential bearing cap bolts (4 off)
11 Differential bearing caps (2 off)
12 Carrier and tube assembly
13 Filler plug & gasket
14 Drain Plug
15 Lubricant tag
16 Rear cover
17 Differential position shim
18 Differential bearing (cup and cone)
19 Ring gear bolt (8 off)
20 Differential case
21 Rear pinion bearing (cup & cone)
22 Pinion position shim
23 Collapsible preload control spacer
24 Front pinion bearing (cup & cone)
25 Pinion oil seal Item Description
26 Companion flange assembly 1 Case
27 Pinion nut 2 Differential pinion thrust washer
28 Hypoid gearset (Ring gear & pinion) 3 Differential Pinion
29 Load level bracket 4 Side gear thrust washer
30 Park brake cable clips (2 off) 5 Side gears
31 Rear cover bolts 6 Differential shaft
7 Lock pin
G98771 en 01/2003 2003.0 BA Falcon

M78 Conventional Differential Assembly
Item Description
1 Case
2 Differential pinion thrust washer
3 Differential Pinion
4 Side gear thrust washer
5 Side gears
6 Differential shaft
7 Lock pin
G98771 en 01/2003 2003.0 BA Falcon

M86 Limited Slip Differential Assembly
Item Description
1 Case
2 Side Gear
3 Pinion mate spherical washers
4 Retainer Clip
5 Clutch Disc
6 Clutch Plate
7 Differential Shaft
8 Differential Pinion
9 Roll pin
G98771 en 01/2003 2003.0 BA Falcon

M78 Limited Slip Differential Assembly
Item Description
1 Case
2 Cone
3 Spring washer
4 Differential Pinion thrust washer
5 Differential Pinion Gears
6 Lock pin
7 Side Gear thrust washer
8 Side Gears
9 Differential Shaft
G98771 en 01/2003 2003.0 BA Falcon

Rear Drive Axle / Differential — Beam Special Tool(s)

Axle Knife edge puller
205-410 (1123)
Special Tool(s)
Differential Housing Spreader
E9255
Installer drive pinion rear

bearing
205-411 (E3C10AER)
Adaptors differential Housing

Spreader
E9040
Jaw remover differential side
bearing
205-410 (E1673H15)
Kit drive pinion setting gauge

205-406 (E9300A)
Installer differential side bearing

spline axle
205-412 (E3C25)
Press bolster
205-408 (E1673MT)
Installer differential side bearing

28 spline axle
205-412 (E9277)
Push - Puller, includes 6 ¼"

(158mm) legs
205-408 (927)
Base plate remove replace axle
bearing
888-300 (E1721)
Stepped plug-remover
differential side brg.
666-777 (E1673C16)
Remove installer axle bearing
and bearing retainer
(Alternate)
Jaw remover drive pinion rear

bearing
205-408-01(E1673A15)
G98772 en 01/2003 2003.0 BA Falcon

Special Tool(s) Special Tool(s)

Installer drive pinion oil seal IRS wheel bearing and hub
205-414 (E9055) remover installer
205-446
Kit - installer drive pinion IRS differential plugs

bearing cups 205-294
666-500 (E9271)
LSD torque check tool Constant velocity boot clamp

888-200 (7372) remover
666-000 (E6662B) 205-343
Half shaft removal tool

205-465
LSD spline alignment

205-415 (E9293)
Remover drive pinion bearing

cup
205-415 (E9293)
Remover pinion/flange
(E9258B)
Companion flange holder
777-111 (EN1205B)
G98772 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
In Vehicle Inspection 9. If no obvious defect is noted, check the gear tooth

contact. Paint the gear teeth with suitable gear
NOTE: The differential case assembly and the drive marking compound, such as a Henkel 39SY201
pinion should be inspected before they are removed Yellow Gear Marking Compound or similar.
from the housing. These inspections can help to find Too dry a mixture cannot be pressed out from
the cause of the trouble and to determine the between the teeth. Wrap a cloth around the
corrections needed. companion flange to act as a brake. Rotate the
Removal ring gear back and forth (use a box wrench on the
drive gear attaching bolts for a lever) until a clear
1. Raise the vehicle on a hoist. tooth contact pattern is obtained (approximately
2. Check for any external oil leaks. Note location and three full revolutions in both directions).
replace oil seals, gaskets or breather hoses as NOTE: A mixture that is too wet will run and
required to fix the leak(s). smear.
3. Drain the lubricant by carefully removing the lower 10. Certain types of gear tooth contact patterns on
cover bolt which is the drain plug. the drive gear indicate incorrect adjustment. Noise
Clean the area immediately around the rear cover caused by incorrect adjustment can often be
of all loose dirt and contaminates. corrected by re-adjusting the gears. Typical
NOTE: When replacing the drain plug, clean the patterns and the necessary corrections are
thread of old thread sealant (Loctite Dri-Loc 202 explained in Section 308-03.
or similar) and reapply to ensure that the plug 11. Gear tooth runout can sometimes be detected by
seals correctly. an erratic pattern on the teeth. However, a dial
4. Remove the rear cover. Scrape the rear cover indicator should be used to measure the runout of
gasket off the carrier cover mounting surface, the back face of the ring gear, as shown. This
making sure that no dirt is allowed to enter the runout should not exceed 0.13 mm.
carrier housing. Ring Gear Runout Check (Typical)
5. Wipe the lubricant from the internal working parts,
and visually inspect the parts for wear or damage.
6. Rotate the gears to see if there is any roughness
that would indicate defective bearings or chipped
gears. Check the gear teeth for scoring or signs of
abnormal wear.
7. Check the differential case and the drive pinion for
end play.
8. Set up dial indicator and check points around
drive gear. Backlash should be 0.10 to 0.18 mm
at tightest point.
Ring Gear Backlash Check (Typical)
Beam Axle Oil Change

1. Raise the vehicle so that it remains completely
level.
2. Remove the bottom rear cover flanged bolt from
the beam axle to drain oil.
NOTE: It is preferable to drain the oil while it is
warm so that any wear debris can drain out more
easily.
3. Apply thread sealant compound (eg. Loctite
Dri-Loc 211 or 202) to the cover bolt, refit and
tighten to 23-31 Nm.
4. Remove the lubrication tag, gasket and filler plug
located on the rear cover.
5. Fill the beam axle with the appropriate lubricant
(Refer to Specifications section).
6. Check the condition of the filler plug gasket to
ensure proper oil sealing function of filler plug.
G98773 en 01/2003 2003.0 BA Falcon

7. Replace lubrication tag, gasket and filler plug and Limited Slip Differential — M78 & M86
Check
Flange Runout Check
CAUTION: Never place the transmission in
1. Raise the vehicle on a hoist with the wheels
gear with the engine running when only one wheel
unsupported. Disconnect the drive shaft from the
of a limited slip differential equipped vehicle is
drive pinion flange after marking the drive shaft
raised. The vehicle might drive itself off the jack
and pinion flange to ensure correct radial
and cause demage or injury.
positioning on re-assembly. (Refer Section
205-01.) 1. The LSD construction permits differential action
when required for turning comers and transmits
2. Using a dial indicator mounted in the carrier
equal torque to both wheels when driving straight
housing, check the mounting face runout and the
ahead. However, when one wheel tries to spin
radial runout of the drive pinion flange. Refer to
due to leaving the ground, a patch of ice, etc., the
Specifications section for applicable runout limits.
clutch packs automatically provide more torque to
In Vehicle Torque Check the wheel which is not trying to spin.
2. The LSD differential resists wheel spin on bumpy
1. To test the Limited Slip Differential (LSD) for roads and provides more pulling power when one
correct operation proceed as follows: wheel tries to slip. In many cases of differences in
Drive vehicle 10 km to warm up axle oil. traction, pulling power will be automatically
Chock the front wheels. provided until both wheels start to slip.
Raise the rear of the vehicle, remove one rear 3. In diagnosis of vehicle operators’ complaints, it is
wheel and attach the Special Tool No. important to recognise two things:
E6662B. 1. If, with unequal traction, both wheels slip, the
Lower the rear of the vehicle to simulate LSD has done all it can possibly do.
normal ride height. 2. In extreme cases of differences in traction, the
Place the transmission in neutral and release wheel with the least traction may spin after
the park brake. the LSD has transferred as much torque as
Ensure that there is no brake drag affecting possible to the non-slipping wheel.
wheel rotation. 4. If noises or roughness, such as chatter, are
Attach a torque meter to the special tool, and present during cornering, the probable cause is
rotate the axle. incorrect or contaminated lubricant (Refer
Specification section for recommended axle
2. The torque required to rotate the axle shaft for a lubricants and additive). Before any differential is
used LSD unit is detailed in the Specifications removed and disassembled for chatter
section. complaints, the correctness of lubricant can and
should be determined.
5. To confirm the problem, warm up the axle for ten
(10) kms under normal driving conditions and then
make a minimum of ten (10) figure 8 turns. If the
unit chatters then replace the axle lubricant with
new lubricant. If after changing the lubricant and
repeating the above figure 8 procedure, the
chatter continues, a complete lubricant drain,
flush and refill is required.
6. The following procedure is recommended to
ensure flushing the system of old lubricant.
1. Warm the axle lubricant for ten (10) kms
under normal driving conditions.
2. Drain lubricant while warm.
3. If the torque required to continuously rotate the
wheel is outside the specification check the 3. Refill axle with specified Limited Slip
differential for improper assembly and/or rework. Differential lubricant and/or additive.
4. Drive the vehicle for approximately ten (10)
kms, making at least ten (10) figure 8 turns to
flush the old lubricant out of the differential.
G98776 en 01/2003 2003.0 BA Falcon

5. Repeat Steps 2, 3, and 4. 2. Side gears and pinion mate gears — The gear
6. It is possible that slight chatter, requiring teeth of these parts should be checked for
additional vehicle operation may remain after extreme wear and possible cracks. The external
Step 5. If chatter still persists after one teeth of the side gear, which retain the concentric
hundred (100) kms of vehicle operation, or groove discs, should also be checked for wear or
remains severe after Step 5 above, cracks.
disassembly and repair will be necessary. 3. If replacement of one gear is required due to
Follow procedures for disassembly and wear, etc., then both side gears, pinion mate
assembly as illustrated in the manual. gears, and washers are to be replaced.
Limited Slip Differential Torque Check 4. Cross Pin - If excessive wear is evident, the cross
pin should be replaced.
1. Clamp Special Tool or an axle shaft in a vice with 5. Clutch Retainer Clips — If wear is evident on any
approximately 75mm of the splined end extending one of the retainer clips, all four clips must be
above the vice jaws. replaced.
2. Place the differential unit on its end with the 6. Differential Case — If scoring, wear or metal
flange section above the cap section. Place over pick-up is evident on the machined surfaces, then
the extended tool/ axle shaft spline. replacement of the case is necessary.
3. Install the remaining part of Special Tool or an
axle shaft, into the flange section of the case.
4. Using Special Tool E6662 check that the torque
required to continuously rotate the side gears is
as per the values listed in the Specifications.
Item Description
1 Concentric groove disc
2 Radial groove plate
Item Description
1 Tool E6662-LSO Torque check
2 Axle shaft bearing
4 Axle shaft
NOTE: LSD units that operate smoothly but with
excessively low torque should be checked as per the
Inspection for Wear sections.
Limited Slip Differential — M86

Inspection for Wear
1. Plates and discs — If any one member of either
stack shows evidence of excessive wear or
scoring, the complete stack is to be replaced on
both sides.
G98776 en 01/2003 2003.0 BA Falcon

Item Description
1 Plate
2 Disc
3 Dished spacer
4 Side gear

LSD units that operate smoothly but with excessively
low torque should be checked as follows.
With the limited slip differential unit fully dismantled
examine the parts for wear and general condition. If
the cone surfaces have a mirror like finish, then the
following rework procedure should be followed. If the
cone surfaces are scored then components should be
replaced and the normal set up procedure followed as
in the repair manual.
1. Mark the cones to ensure they are reassembled
to the original differential cases.
2. Using P800 grade wet and dry abrasive paper,
rub the tapered surfaces in the differential
direction by hand, in order to remove the glazed
coating from the surfaces. Give the surfaces a
final rub using oil on the wet and dry to produce a
fine finish. The abrasive paper must be rubbed
around the surfaces in a uniform manner to avoid
creating hollows in the cone surfaces.
3. Thoroughly clean debris from all components.
4. Use new spring washers.
5. Prior to reassembly coat all surfaces with an
approved LSD lubricant.
6. Reassemble.
7. Check friction torque of unit as in the Torque
Check procedure.
G98781 en 01/2003 2003.0 BA Falcon

IN-VEHICLE REPAIR
Pinion Oil Seal Replacement 7. Continue to tighten the nut until the marks
previously made on the pinion flange and the nut
NOTE: Refer to Special Tools in this section. are in alignment to re-establish the pinion bearing
preload.
Removal
8. Install the driveshaft with the marking on the drive
1. Raise the vehicle on a hoist. Disconnect the drive shaft and the pinion flange in alignment. (Refer to
shaft from the drive pinion flange after marking Section 205-11.)
the drive shaft and pinion flange to ensure correct
radial positioning on re-assembly. (Refer to 9. Check axle lubricant level and top up if necessary
Section 205-01.) with specified lubricant.
2. Mark the pinion flange and the pinion nut to 10. Remove the vehicle from the hoist.
establish bearing preload on re-assembly.
3. Hold the pinion flange using tool EN1205B and
remove the self locking nut. As Loctite is used on
the pinion nut, the torque required to release the
nut will be greater than 200Nm.
4. Place a drain pan beneath the pinion housing.
5. Mark the ends of the pinion shaft and a pinion
flange spline for correct re-alignment during
installation.
6. Clean the pinion bearing housing around the oil
seal to remove loose dirt and oil so that it does
not fall into the front of the carrier housing during
the removal or replacement procedure.
7. Remove the pinion flange using tool number
E9258B. Under no circumstances should a Item Description
hammer be used. 1 Oil seal installation Tool E9055
8. Remove the pinion oil seal by carefully prying it 2 Drive pinion oil seal
out with a suitable tool.
Installation
NOTE: All hardware must be correctly installed and
torqued to specification.
1. Check the mating splines on the pinion shaft and
pinion flange for burrs and if necessary clean up
with fine crocus cloth. Wipe the flange and shaft
clean. Remove any Loctite thread locking
compound from the pinion nut of flange thread.
2. Clean the oil seal seat. The lubricant return
passage in the axle housing must be clear.
3. Lubricate the seal lips and the outside diameter
with oil and install the seal, using the correct
special tool. Seal location is from flush to 0.25
mm below the machined carrier face.
4. Align the pinion flange spline mark with the pinion
shaft spline mark and start the flange onto the
pinion splines by hand. A smear of lubricant on
the pinion splines will assist in installation.
5. Install the pinion nut onto the pinion thread
(without Loctite) and wind the nut down to pull the
flange onto the pinion spline until no axial end
play can be detected by hand in the pinion
assembly. Remove the pinion nut.
6. Apply Loctite 262 Liquid Threadlocker to the
pinion thread and reinstall the nut, tightening to
100Nm.
G98782 en 01/2003 2003.0 BA Falcon

Axle Shaft Assembly

Removal
1. Raise the vehicle and remove the road wheel.
(Refer to Section 100-02.)
2. Disconnect the park brake cable from the park
brake and remove from axle. (Refer to Section
206-05.)
Remove the caliper.
Remove ABS sensor (if ABS fitted).
Remove the disc from the axle flange.
NOTE: If ABS is fitted, take care not to damage
tone wheel.
3. Working through the access hole in the axle
flange using an allen key to remove the four
bearing retainer plate bolts.
4. Withdraw the axle shaft and bearing assembly.
NOTE: The bearing cup typically may be loose in
the axle housing or may fall out on axle
disassembly. Friction surfaces of brake parts must
be kept contamination free.
Item Description
1 Seal
2 Bearing assembly
3 Bearing retaining collar
4 Axle housing
5 Brake anchor bracket
Item Description 6 Bearing retaining plate
1 Score - M6 7 Tone wheel (ABS)
2 Shield Installation
3 Bolt - M12 NOTE: All hardware must be correctly installed and
4 Caliper torqued to specification.
5 Rotor NOTE: Friction surfaces of brake parts must be kept
6 Asle Assy. contamination free.
1. If the bearing cup was previously removed install
the bearing cup in the axle housing.
NOTE: A new bearing should always be used if
the axle oil seal, retaining collar, retaining plate or
tone wheel have been replaced. Ensure that the
cup back face is seated against the back shoulder
in the housing. The bearing must be lubricated
with axle lubricant before installation. Also, apply
a film of MIC75B Grease to the outside diameter
of the seal prior to installation. Refer to Rear Axle
Bearing And Seal Replacement section for how to
service the axle assembly once removed from the
tube housing.
G98783 en 01/2003 2003.0 BA Falcon

2. Start the splined end of the shaft into the 3. Remove cover plate screws, cover plate. Clean
differential and start the bearing cone assembly sealant from cover faces.
and seal into the housing.
3. Line up the retaining plate to the retaining plate
bolts and push the axle into the housing as far as
possible.
4. Start the bolts onto the tube flange holes and
tighten to finger tight only. Then tighten the bolts
to 20 Nm in a diagonal sequence. The bolts
should be tightened in such a manner to assure
that the seal and bearing cone assembly are
drawn evenly against the cup in the housing.
Refer to Specifications section for tightening
torque required on retaining plate bolts.
5. Install the disc on the axle flange.
Install the brake caliper.
Route the park brake cable and connect to park 4. Remove differential bearing caps. Note letters
brake. (Refer to Section 206-05.) stamped on the bearing caps and the cover face
Replace ABS sensor (if fitted). of the housing. Letters are to correspond in
6. Replace the road wheel and lower the vehicle. horizontal and vertical positions. This is very
7. Tighten the wheel nuts. (Refer to Section 204-04.) important at time of assembly.
8. Check the park brake adjustment. (Refer to
Section 206-05.)
M86 Limited Slip Differential

Special Tool(s)
Spreader
E9255
Indicator Set or Equivalent 5. Mount spreader to housing. Locate a dial indicator

Removal with a magnetic base on cover face as shown.
Locate tip of indicator on housing as shown.
NOTE: On Dana Spicer axles it is recommended that
the complete axle assembly be removed from the 6. Set dial indicator at zero ("0"). Turn forcing screw
vehicle when it becomes necessary to remove the of spreader until indicator records .015" (.38 mm).
M86 LSD from the housing.
CAUTION: Do not spread carrier in
1. Remove wheels, brake drums, brake backing excess of 015" (.38 mm).
plate screws and axle shafts. Brake backing 7. Remove Indicator.
plates can normally be wired to frame without
loosening the hydraulic brake line connection at
the wheel cylinder if desired. Use caution to avoid
damage to brake line.
2. Remove axle assembly and place in rack or stand
to serve as a holding device.
G98783 en 01/2003 2003.0 BA Falcon

8. Remove differential using two pry bars as shown.

Use caution to avoid damage to ring and pinion. It
will not be necessary to remove the differential
bearings at this time, however, the bearing cups
should be marked or tagged to indicate from
which side of the case they were removed. After
differential case has been removed, remove
spreader.
Axle Housing and Differential

Assembly
Removal
1. Loosen the rear wheel nuts.
2. Raise the vehicle and support it on the axle.
3. Remove the rear wheels.
4. Detach the shock absorbers from the spring
plates as follows. (Refer to Section 204-02B.)
5. Support the vehicle on the underbody. (Refer to
Section 100-02.)
6. Mark the relationship of the driveshaft and the

pinion flanges and disconnect the driveshaft from
the pinion flange. (Refer to Section 205-01.)
7. Detach the park brake cable from the drum (park)
brake and remove from rear axle
Remove the calipers and suspend from the
underbody. Leave the hydraulic lines attached.
Remove the discs.
Remove ABS sensor (if ABS fitted).
Remove the splash shields. (Refer to Section
206-04.)
Remove the axle shafts as described in this Part.
NOTE: Do not strain the brake lines and/or hoses.
G98785 en 01/2003 2003.0 BA Falcon

8. Remove the ’U’ bolts, spring plates and the lower

spring insulator. (Refer to Section 204-02B.)
9. Remove the axle housing from the vehicle.
10. Drain the oil from the axle housing through an
axle tube.
Installation
1. Position the axle housing on the springs. Ensure
that the insulators are correctly located on the
springs. Install the ’U’ bolts, lower insulator,
spring plate and ’U’ bolt nuts. (Refer to Section
204-02B.)
2. Install the axle shafts as described in this Section.
3. Install the splash shields.
Item Description
4. Install ABS sensor (if ABS fitted).
Install the discs. 1 Screw (Torque to 6Nm)
Install the calipers. 2 Tube - Rear axle housing vent
Route the park brake cable and connect to rear 3 Clip
drum (park) brake.
4 Screw
5. Align the marks on the driveshaft and the pinion
flanges and connect the driveshaft. (Refer to 5 Clip
Section 205-01.) 6 Clamp
6. Raise the rear axle and install the lower shock 7 Tube assy. - Brake fluid
absorber to the spring plate (Refer to Section
204-02B.). Install the rear wheels.
7. With the vehicle in the curb load position fill the
axle to the bottom of the filler plug hole with the
correct oil.
CAUTION: Use of unspecified lubricant
may lead to premature gear failure.
8. Lower the vehicle and tighten the wheel nuts.
9. Check park brake adjustment. (Refer to Section
206-05.)
Item Description
1 Screw - M6
2 Shield
3 Bolt - M12
4 Caliper
5 Rotor
6 Axle Assy.
G98785 en 01/2003 2003.0 BA Falcon

G98785 en 01/2003 2003.0 BA Falcon

Rear Axle Wheel Bearing and Seal 3. The bearing cone assembly should not be pulled
from the axle shaft unless:
Replacement
1. The seal is to be replaced.
NOTE: Refer to special tools in this section. 2. The retaining plate has to be replaced due to
NOTE: When a bearing is replaced a complete damage or distortion.
assembly must be installed. Bearings are 3. The bearing is to be replaced.
manufactured with a built-in adjustment of 0.25 to 4. A used bearing assembly should have all parts
0.53 mm "bench" end play or axial clearance. This completely covered with rear axle oil prior to
"bench" end play is reduced when the bearing is re-installation into the axle housing. Quarter fill the
pressed on the axle shaft. The final assembled end cavity between the seal lips with grease.
play on the shaft of 0.04 to 0.5 mm is dependent on
the dimensions of the interference fit between the Disassembly
cone and the axle shaft. The standard recommended 1. Remove the retaining collar. This can be easily
cone fit is 0.025 to 0.055 mm tight. The cups are a achieved by drilling a 6 mm hole in the outside
snug fit in the housing. Used bearings may have a diameter of the collar to a depth approximately
maximum of 0.7 mm end play. three-quarters of the thickness of the collar. Do
not drill all the way through the collar as the drill
could damage the axle shaft, necessitating
replacement of the shaft. After drilling the
retaining collar, position a chisel across the drilled
hole and strike sharply to break the collar.
Support the shaft on the collar opposite the drilled
hole.
NOTE: Retaining collars are not reusable after
having once been installed and must be scrapped
after removal even if some removal method is
used which does not cause obvious damage to
the collar.
2. Slide the retaining plate and seal toward the axle
flange.
3. Using special tools, press the bearing from the
Item Description shaft. The special tools support the bearing
1 Cup behind the bearing cone face and prevent
2 Cup rib ring damage to the bearing and the seal surface of the
shaft.
3 Rollers
NOTE: Do not heat or cut the bearing assembly
4 Cone as damage to the axle shaft will result.
5 Cage
4. Likewise, using special tools, press the tone
1. The bearing is held on the shaft by the wheel from the shaft being careful to avoid
interference fit of the bearing cone and the damaging the tone wheel location diameter shaft
retaining collar. The cup and rib ring are clamped surface.
together in the axle housing through the seal by
the retaining plate. The axle seal wipes on the Assembly
rotating axle shaft and at the same time functions 1. When installing new bearings, new seals and
as a static seal to prevent lubricant from escaping retaining collars must be used.
between the housing and seal outside diameter.
2. Check the retaining plate for damage or distortion
2. It is important to note that the seal also acts as a with a straight edge. If the plate is distorted,
"spacer" in the clamp up of the bearing in the axle replace it.
housing. It is imperative that the specified seal is
3. Clean the axle shaft, ensuring that there are no
used.
burrs or nicks on the tone wheel location diameter
surface, bearing seat, seal surface, cone backing
shoulder and chamfer leading to the seal seat.
Sharp edges or nicks on the chamfer leading to
the seal surface will damage the seal lips during
installation of the seal on the shaft. To avoid
damage to the wheel studs, place the axle shaft
flange face on a support.
G98786 en 01/2003 2003.0 BA Falcon

4. Using Special Tools, press the tone wheel onto 9. Install a new retaining collar on the axle shaft and
the axle shaft so that it is seated hard against the press it down to ensure it is in contact with the
flange shoulder. bearing cone assembly.
NOTE: Ensure that the large access hole in the 10. Press the bearing and the retaining collar on the
tone wheel is aligned with the large access hole in axle shaft simultaneously using the relevant
the axle shaft flange before pressing to ensure special tool. Apply sufficient load to assure the
tool access for installation of the retaining plate proper seating of all parts. Check for proper
bolts during reassembly of the axle shaft seating of the bearing cone assembly against the
assembly into the tube assembly is maintained. shaft shoulder and the retaining collar against the
Refer to Figure for tone wheel orientation for cone face by using feeler gauges.
pressing. Check for proper seating of the tone NOTE: When pressing the bearing and retaining
wheel on the axle shaft by checking with feeler collar on to the axle shaft, be sure all faces of the
gauges. installation tubes are square, parallel and free
5. Install the retaining plate on the axle shaft, from any burrs. Installing the retaining collar in a
ensuring that it is positioned with the clamping skewed manner can reduce its holding ability by
face of the plate towards the bearing. Apply as much as 50%.
grease to the cavity between the seal lips and
carefully slide the seal into position on the seal
seat. When installed, the outer face of the seal
must be toward the axle flange.
6. Do not wash a new bearing prior to installation.
The new bearing has protective grease that
provides initial lubrication until the rear axle
lubricating oil reaches the bearing.
If the new bearing has to be washed for any
reason, it must then be completely lubricated with
rear axle oil prior to installation.
Item Description
1 Tool E1721 - Remove/Installer axle
bearing and bearing retainer (Collar)
2 Seal
3 Bearing Item Description
4 Bearing retainer (Collar) 1 Seal
7. Place the lubricated bearing on the axle shaft 2 Bearing Assembly
ensuring the cup rib ring is facing toward the axle 3 Bearing Retaining Collar
flange and that the bearing is in hard contact with 4 Axle Housing
the axle shaft shoulder. 5 Brake Anchor Bracket
8. Clean the journal diameter of any grease that may 6 Bearing Retaining Plate
have been left on the shaft during the pressing of
the bearing. 7 Tone Wheel (ABS)
G98786 en 01/2003 2003.0 BA Falcon

Differential and Drive Pinion 3. Refer to General Procedures for Inspection before
removal.
NOTE: Refer to special tools in this section. 4. Identify the bearings, caps and remove the
bearing cap bolts and bearing caps.
Disassembly 5. Use the differential housing special spreading tool
NOTE: All hardware must be correctly installed and to facilitate the removal of the differential case,
torqued to specification. bearings and spacers. Spread the carrier the
minimum amount which will allow the removal of
1. Remove the axle shafts as described previously in
the differential assembly. Usually 0.1 to 0.2 mm
this Section.
will be adequate. (Spread is measured across the
2. Loosen the cover plate attaching bolts and drain carrier adjacent to the bearings.)
the oil. The lowest cover bolt is a drain plug.
Remove the cover plate. CAUTION: Under no circumstances
should the carrier be spread more than 0.5
mm.
6. Mark the relationship of the driveshaft and the
pinion flanges and disconnect the driveshaft.
7. Mark the relationship of the pinion flange to the
pinion shaft. Hold the pinion flange and remove
the pinion nut.
8. Remove the pinion flange.
9. With a soft-faced hammer, drive the pinion out of
the front bearing cone and remove it through the
rear of the carrier casting.
10. Drive the pinion flange seal and the bearing cone
out of the carrier casting.
11. If the pinion bearing cups are to be replaced,
remove them from the carrier using the special
tool.
NOTE: It is essential to renew the cups one after
the other so that in each Instance the other cup
serves as a guide for the replacer tool.
12. If the pinion rear bearing cone and roller is to be
replaced, lubricate the pinion shaft and remove
the bearing cone from the pinion. Discard the
bearing whenever it has been removed from the
pinion.
Item Description
1 Tool E9255 - Differential housing spreader
2 Tool E9255 - Adaptor Differential housing
spreader
G98787 en 01/2003 2003.0 BA Falcon

Item Description
1 Tool - Push/puller with legs
2 Tool - Stepped plug
3 Tool - Knife edge puller
Differential Bearing Preload Spacer

Selection
NOTE: Refer to special tools in this section.
NOTE:
1. Select any two spacer washers and place one
against each of the differential bearing cups.
Place the cups on the bearing cones and install
the differential assembly in the carrier. When
installed, there should be a small amount of end
play.
2. With the differential held firmly against one side of
the carrier, use a feeler gauge on each side of the
centre line of the case to measure the end play
between the cup and the spacer. Rotate the
carrier to seat the bearing with the feeler gauges
in position, and check to see that the end play has
not been increased by this procedure. Remove
the assembly and measure the spacers.
Item Description
G98788 en 01/2003 2003.0 BA Falcon

3. To establish the thickness of the spacers 12. Remove the assembly from the carrier using the
required:- Total the thickness of the two spacers - spreader. If the preload is correct, tie the selected
Add the gap measured with the feeler gauges. spacers to the bearing cups to have them
Add 0.15 mm when using new bearings or 0.1 available for use in determining gear backlash. If
mm when using used bearings to preload the correct preload is not obtained, a variation of
bearings. 0.025 mm on spacers will alter preload 8 N for
4. Select two spacers, each half the thickness of the new bearings and approx. 4 N for used bearings.
value determined in Step 3. Repeat steps 5-12.
5. Fit the carrier spreader adaptors and the spreader Drive Pinion Position — Shim
to the carrier, together with a dial indicator
positioned over the carrier differential opening, as Selection
close as possible to the centre line of the axle NOTE: The drive pinion and ring gear set
shafts. This may be done by using a pilot stud identification marking (number 5K-25) is the matching
screwed into the side bearing lower stud hole, number that appears on both the drive pinion and the
with the dial indicator plunger in contact with the ring gear. When a new gear set is being installed in
opposite side of the carrier opening. an axle, be sure that the same matching number
6. Use the spreader to expand the case until the appears on both the drive pinion and the ring gear.
differential assembly with bearings and selected
spacers will fit into the carrier. A spread of 0.25 to
0.3 mm is usually sufficient. Under no
circumstances should the carrier be spread
more than 0.50 mm.
7. The differential assembly, with bearing cups and
selected spacers held against the bearing cones,
may now be fitted to the carrier, after removing
the dial indicator.
8. Release and remove the spreader tool leaving
adaptors in position.
9. Fit the bearing cups in their original positions,
tightening the bolts to 55 Nm torque.
10. Rotate the differential assembly at least six full
turns to seat the bearing rollers in the bearing
cups. Pinion/Ring Gear Identification
11. Check the preload using a spring balance.
Measure the tension required to revolve the
assembly when a string is wrapped around the
differential case on the larger diameter, just
behind the drive gear. Balance readings must be
within the following limits: New bearings 25 ± 10
N. Used bearings 13 ± 5 N. These balance
readings are equivalent to the preload torques in
the Specifications.
NOTE: The ring gear and pinion are manufactured

within a tolerance of a specified distance. On the end
of each pinion, there is marked a plus (+) number, a
minus (-) number, or a zero (0) number which
indicates the best running position for each particular
gear set. This dimension is controlled by the
shimming behind the rear pinion bearing cup. When
the shim thickness is decreased, the pinion gear is
moved away from the ring gear. When the shim
thickness is increased, the pinion is moved closer to
the ring gear. A positive (+) number on the drive
G98788 en 01/2003 2003.0 BA Falcon

pinion means that a thinner shim should be installed increments from .008 to .030 in (0.2 to 0.75
to move the pinion gear away from the ring gear. A mm
negative (-) number means that a thicker shim should NOTE: The marking on the pinion is in
be used to move the drive pinion closer to the ring Imperial measurement.
gear.
5. Remove the tools from the carrier.
To select the correct shim thickness follow these
steps: 6. Remove the rear pinion bearing cup from the
housing.
NOTE: Lubricate all differential parts with the
recommended rear axle lubricant, before they are Drive Pinion and Bearings
installed.
NOTE: Refer to special tools in this section.
NOTE: The exact same rear pinion bearing that is to
be used in the vehicle, is to be installed when using NOTE: All hardware must be correctly installed and
the dummy pinion. torqued to specification.
1. Install the front and rear pinion bearing cups into 1. Place the pinion rear bearing cone on the pinion
the axle housing. Fit the pinion bearing cone and shaft. Press the bearing against the pinion shaft
rollers to the dummy pinion tool. Install the shoulder.
dummy pinion to the axle housing. Fit the pinion 2. Install the shims (previously established), between
front cone and roller to the dummy pinion. Install the rear bearing cup and the housing and install
the tool thrust collar and the nut to the dummy the new cups using the Special Tool. Make sure
pinion. the cups are properly seated in their bores. If a
0.025 mm feeler gauge can be inserted between
a cup and the bottom of its bore at any point
around the cup, the cup is not properly seated.
2. Tighten the nut until a bearing preload of 1.4 to

2.4 Nm (new bearing), 0.7 to 1.2 Nm (used
bearing) is achieved while rotating the dummy
pinion back and forth to ensure correct seating of
Item Description
the bearing rollers.
1 Tool - E3C10AER Installer Drive pinion
3. Position the depth gauge cylinder in the carrier rear bearing
and fit the bearing caps, tightening lightly.
2 Bearing cone and roller
4. Determine the size of pinion shim that will pass
between the depth gauge and the dummy pinion 3 Drive pinion
head. Examine the drive pinion installation 3. Lubricate the pinion rear bearing with axle
marking. The size of the pinion shim should then lubricant.
be altered as follows:
4. Position the pinion in the carrier and install a new
A positive (e.g. +0.002 inch) marking means collapsible pinion spacer.
that this pinion has to be set at this number of
5. Lubricate the front pinion bearing and install the
thousandths of an inch further from the drive
gear, i.e. a shim this amount thinner must be bearing onto the pinion while supporting the
pinion under the head.
used.
6. Lubricate the seal lips and the seal outside
A negative (e.g. - 0.002 inch) marking means
that a shim this size thicker must be used. A diameter, and install the seal from flush to 0.25
mm below the carrier surface.
zero (0) marking indicates that the shim
selected with the gauge is the correct one for
this carrier/pinion combination. Position shims
are available in .001 in (0.025 mm)
G98790 en 01/2003 2003.0 BA Falcon

7. Install the pinion flange and nut. Tighten the nut Differential Case — Conventional Type
while rotating the pinion backwards and forwards
to seat the bearings. Check the bearing preload
M78 and M86
frequently while tightening the nut. Tighten the nut NOTE: Refer to special tools in this section.
until the specified bearing preload is achieved. 1.4
Nm to 2.4 Nm with new bearings. 0.7 Nm to 1.2
Disassembly
Nm with used bearings.
NOTE: If the preload is exceeded the collapsible 1. Remove the bolts that attach the ring gear to the
spacer must be replaced. differential case.
CAUTION: All axles use LH thread ring
Differential Installation and Backlash gear bolts - identified by L on bolt head. Press
Check the ring gear from the case or tap it off with a
softfaced hammer.
NOTE: All hardware must be correctly installed and
2. With a suitable drift, drive out the differential
torqued to specifications.
pinion cross shaft retainer pin.
1. Install the differential assembly with the tentatively 3. For M78 use a soft drift to separate the two piece
selected spacers in the carrier, following the differential case.
procedure in Differential Bearing Preload Spacer
4. Drive out the differential pinion cross shaft from
Selection steps 4 to 9 inclusive.
the larger section of the case. Lift the pinion gears
2. Measure the backlash as detailed in this section. and thrust washers from the case.
Measure the backlash on several teeth around the
5. Remove the side gears and thrust washers from
ring gear to find the minimum position. Backlash
each section of the case.
here should be 0.13 to 0.18 mm. If the backlash is
not within the range, decrease the thickness of 6. Remove the differential bearings. Discard
one differential bearing spacer and increase the bearings whenever they have been removed from
other by the same amount. The amount of change the carrier.
of each spacer is approximately equal to the 7. For inspection after removal and dismantling refer
amount of change required to correct the to Section 204-02b.
backlash reading. It is most important that the
total thickness of both spacers be the same after Assembly
backlash adjustment as before, so that correct NOTE: All hardware must be correctly installed and
preload is retained. torqued to specification.
3. Check the gear tooth contact pattern as detailed 1. Lubricate all the differential parts with the
in Section 308-03. recommended rear axle lubricant, before
4. Fit the rear cover to the carrier using silicone installation.
rubber sealant. Fit the park-brake cable clips. On 2. Place the side gear thrust washers over the side
Wagon models fit the protection bracket to the gear journals.
differential cover.
5. Install the axle shafts as described in this Section.
6. Align the marks on the driveshaft and pinion
flanges and connect the driveshaft. (Refer to
Section 205-01.)
7. With the vehicle in the curb load position fill the
axle to the bottom of the filler plug hole with the
correct lubricant.
Item Description
2 Tool - Stepped plug
G98790 en 01/2003 2003.0 BA Falcon

3. Position a side gear in the larger section of the 6. For the cone/ side gear sub-assemblies, slide the
differential case. cone off the splines on the side gear, this will
4. Position the two differential pinions and the thrust reveal one thrust washer and two spring washers.
washers in the large section of the case. NOTE: Ensure the mating cone, side gear, thrust
5. Drive the pinion cross shaft into position. Ensure washer and spring washers are not interchanged
that the retainer pin hole is in line with the hole in with components of the other cone/ side gear
the case. Take care not to damage the differential sub-assembly.
pinion thrust washers. 7. For inspection after removal refer to the General
6. Drive the pinion locking pin through the differential Procedures.
case and pinion shaft. Ensure the pin does not
protrude from the underside of the larger Assembly
differential case. NOTE: All hardware must be correctly installed and
7. Install the second side gear and thrust washer in torqued to specification (see Specifications section).
the smaller section of the case. 1. Lubricate all the differential parts with the
8. Holding the side gear in position through the case recommended rear axle lubricant before
bore, push the two sections of the case together installation.
locating on the retaining pin. Rotate the side gear,
2. Place a side gear face down. Slide two spring
if necessary, to ensure that the gear and pinions washers onto the gear’s splines with the convex
are meshing correctly. side facing up. Next, slide one side gear thrust
9. Place the ring gear in position on the case. Install washer onto the splines. Finally, slide a cone face
and torque the bolts. down over the gear splines.
10. Press the differential side bearings onto the case 3. Clamp an axle shaft in a vice with approximately
journals. 75mm of the splined end extending above the
vice jaws.
Limited Slip Differential — M78 4. Place the cap section of the differential case, with
the interior facing upwards, over the extended
NOTE: Refer to special tools in this section. tool/ axle shaft spline.
5. Place the assembled cone/ gear sub-assembly
Disassembly
face up into the differential case.
1. Place the assembly in a vice equipped with
6. Install the pinion shaft locking pin into the pinion
copper jaws.
shaft seat on the differential case.
2. Remove the bolts holding the cap and flange
7. Install the pinion shaft, together with the pinions
sections of the differential case together and
and thrust washers, onto the locking pin and the
separate the sections.
differential case.
NOTE: Ensure the cone/ side gear
sub-assemblies are not interchanged during 8. Assemble the remaining cone/ side gear
reassembly of the differential. Mark the mating sub-assembly, as per Step 2, and place face up
cone/ side gear and the corresponding side of the into the flange section of the differential case.
differential case with a daub of paint. 9. Bring the cap and flange sections of the case
together, insert two case bolts in opposite holes
3. Remove the cone/ side gear sub-assembly from and tighten the bolts evenly to 40Nm.
the flange section of the case.
10. Install the axle shaft, into the flange section of the
4. Remove the differential pinion shaft/ pinion gears/ case.
thrust washers and the pinion shaft locking pin
from the cap section of the case. 11. Using Special Tool E6662 check that the torque
required to continuously rotate the side gears is
5. Remove the remaining cone/ side gear between 50 and 130Nm.
sub-assembly from the cap section of the case.
12. Remove the tools or axle shaft from the assembly
and install the remaining case bolts.
NOTE: If the tool or axle shaft binds in the spline,
a light tap with a hammer may be necessary.
G98793 en 01/2003 2003.0 BA Falcon

Disassembly
1. Place one of the axle shafts, which was removed
from the assembly, into a vise. Tighten shaft in
vise firmly. The spline end of the shaft is not to
exceed 2.750" (69.85 mm) above the top of the
vise. This will prevent the shaft from fully entering
into the side gear and causing interference with
the step plate during disassembly of the pinion
mate gears, etc. Caution should be used that the
vise jaws do not locate on axle splines or any
machined surfaces.
Item Description
1 Tool E6662 - LSD torque check
2 Axle shaft bearing
4 Axle shaft
2. Place a few shop towels over vise to prevent any

damage during disassembly of ring gear:
Assemble the differential on the axle shaft with
the ring gear screw heads up. Assembling the
differential onto the shaft will serve as a holding
device to remove the ring gear and to
disassemble the internal parts of the case.
Remove the ring gear screws.
NOTE: LSD units that operate smoothly but with

excessively low torque should be checked as follows.
With the limited slip differential unit fully dismantled
examine the parts for wear and general condition. If
the components appear in good condition and the
cone surfaces have a mirror like finish, then the
following rework procedure should be followed. If the
cone surfaces are scored then the components
should be replaced and the normal set up procedure
followed as in the repair manual.

Tool Kit #C-4487
Special Tool(s)
Tool Kit
C-4487
G98793 en 01/2003 2003.0 BA Falcon

3. Remove ring gear. It will be necessary to remove 6. It is recommended that when referring to the
the ring gear to allow clearance for the removal of Trac-Lok, obtain the complete part number and
the cross pin. Tap ring gear with rawhide hammer build date. To do this it will be necessary to wipe
to free it from case. off the lubricant from the case.
NOTE: It is recommended that on spicer axles 7. Reposition differential case onto axle shaft as
whenever the ring gear screws are removed they shown. Remove the two snap rings from the cross
are to be replaced with new ones. pin. Use two screwdrivers and push the rings free
from the cross pin. Place a shop towel behind the
case to prevent the snap rings from flying out of
the case.
Snap Ring Retained Version
4. Remove differential case from the axle shaft and

remove ring gear.
5. All Spicer Trac-Loks are identified with a
manufacturing date and the complete part number
stamped on the barrel of the case. If the axle 8. For roll pin retainer version, use a small drift to
assembly is equipped with a Trac-Lok Limited Slip remove the roll pin retaining the cross shaft.
Differential a special tag will be located on the Roll Pin Retained Version
bottom right hand side of the cover plate
specifying the use of limited slip lubricant.
In this figure the Trac-Lok is identified with 0.125"
(3.17 nim) high numbers stamped on the case.
For example:
The number 1-21-77A is the manufacturing or

build date of the Trac-Lok and is interpreted
as follows. The first number is the month,
second number is the day of the month, third
number is the year, the letter is the shift. For
example: Jan. 21, 1977 first shift. The number
stamped above the manufacturing date is the
complete Trac-Lok assembly part number.
G98794 en 01/2003 2003.0 BA Falcon

9. Remove the cross pin. Use a hammer and punch 11. Lubricate threads of threaded adapter and forcing
as shown to remove the cross pin from the case. screw.
10. Assemble the adapter plate into the bottom side 12. Assemble threaded adapter into top side gear.
gear. Apply a small amount of grease to the Thread forcing screws into threaded adapter until
centering hole of the adapter plate. Tool it becomes centered into adapter plate.
#C-4487-1 (adapter plate). Use a small screwdriver, position it in slot of
threaded adapter. This will prevent the
adapter from turning. Tools #C-4487-3
(threaded adapter), C-4487-2 (forcing screw).
13. Torque forcing screw until it becomes slightly

tight. This will collapse the Belleville plates and
allow a loose condition between the side gears
and pinion mate gears.
G98794 en 01/2003 2003.0 BA Falcon

14. Remove both pinion mate spherical washers. Use 18. Remove top side gear and clutch pack. Keep the
a shim stock of .030" (.76 mm) thickness or an stack of plates and discs intact in exactly the
equivalent tool to push out the spherical washers. same position while they are being removed.
15. Relieve the tension of the Belleville springs by
loosening the forcing screw.
16. Insert small O.D. end of turning bar into cross pin
hole of case. Pull on bar and the case will rotate
until the pinion mate gears can be removed from
opening.
NOTE: It might be necessary to adjust the forcing
screw slightly to allow the case to rotate. Tool
#C-4487-4 (turning bar).
19. Remove the case from the axle shaft. Turn case
with the flange or ring gear side up and allow the
step plate, side gear and clutch pack to be
removed from the case. Remove the retainer clips
from both clutch packs to allow separation of the
plates and discs. Keep the stack of plates and
discs exactly as they were removed.
Assembly
1. Prior to assembly, prelubricate each disc and
17. Hold top clutch pack with one hand and remove plate with Friction Modifier by presoaking for a
tools. It might be necessary to hold threaded minimum of 20 minutes.
adapter with screwdriver.
2. After assembly into carrier housing, fill axle
assembly with the proper amount and specified
lubricant, refer to Specifications section.
G98794 en 01/2003 2003.0 BA Falcon

3. Prelubricate the thrust face of the side gears and

the plates and discs.
7. Reposition case on bench as shown. Assemble

the adapter plate into the side gear. Apply a small
4. Assemble plates and discs in exactly the same amount of grease into the centering hole of the
position as they were removed, regardless of step plate.
whether they are new parts or the original parts.
Be sure lubricant that is used is of the specified
lubricant.
NOTE: Your unit may be equipped with the new
design limited slip disc and plates or your
replacement unit may contain them. If so follow
directions below. The new design can be
identified by a smooth surface. Olderdesigns have
radial grooves in plates and discs.
5. Assemble the retainer clips to the ears of the
plates. Make sure both clips are completely
assembled or seated onto the ears of the plates.
8. Assemble the other clutch pack and side gear as

shown. Make sure the clutch pack stays
assembled to the side gear splines, and that the
retainer clips are completely seated into the
pockets of the case.
6. With the differential case positioned as shown,

assemble the clutch pack and side gear into the
case. Make sure the clutch pack stays assembled
to the side gear splines, and that the retainer clips
are completely seated into the pockets of the
case. To prevent pack from falling out of the case,
it will be necessary to hold them in place by hand
while repositioning case on bench. 9. Hold the clutch pack in position and insert the
threaded adapter into top side gear, insert forcing
screw. Tighten forcing screw into bottom plate.
This will hold both clutch packs in position.
G98794 en 01/2003 2003.0 BA Falcon

10. With tools assembled into the case, position case 15. For snap ring retained versions, be sure the snap
onto the axle shaft by aligning the splines of the ring grooves of the cross pin shaft are exposed to
side gear with those of the shaft. allow assembly of the snap rings. Assemble snap
rings.
11. Loosen forcing screw slightly. Assemble both

pinion mate gears as shown. Hold gears in 16. Remove case from axle shaft. Assemble ring gear
position by hand. to case. Line up the ring gear screw holes with
12. While holding gears in place, insert turning bar those of the case.
into case. Pull on bar to rotate case allowing NOTE: Use new ring gear screws. Assemble new
gears to turn. Make absolutely sure that the holes ring gear screws finger tight.
of the pinion mate gears are in alignment with
holes of the case.
13. Prelubricate spherical washers. Torque forcing

screw until it is tight. This will collapse the
Belleville plates and allow clearance between
gears. Assemble spherical washers into case.
Use a small screwdriver to push washers into
place.
CAUTION: Be sure the holes of the
washers and gears are lined up exactly with
those of the case.
14. Remove tools.
G98794 en 01/2003 2003.0 BA Falcon

17. For roll pin retainer version, use a small drift to 19. Reposition case onto axle shaft as shown. Torque
replace the roll pin that retains the cross shaft. screws alternately and evenly. Torque grade 8
screws to 45-65 lb. ft. (61-88 Nm).
NOTE: If grade 9 screws are used (special for
high strength), torque 75-85 Lb. Ft. (102-115 Nm).
20. Mount spreader onto housing. Locate a dial

indicator with a magnetic base on cover face as
shown. Locate tip of indicator on housing as
shown. Set dial indicator at zero. Turn forcing
screw of spreader until indicator records .015"
(.38 mm).
CAUTION: Do not spread housing over
.015"
18. When roll pin bottoms out, stake (peen) a little

metal over the edges in two places 180’ degrees
apart.
21. Remove dial indicator.

22. Prelubricate differential bearings with the specified
lubricant. Assemble differential bearing cups to
differential cones.
23. Install differential assembly into housing. Make
sure teeth of ring gear are meshed with those of
pinion.
24. Use a rawhide hammer to seat differential
assembly into cross bore of housing. Care should
be taken to avoid nicking the teeth of the ring gear
and pinion during assembly.
25. Remove spreader.
G98794 en 01/2003 2003.0 BA Falcon

26. Install bearing caps. Make sure the letters

stamped on the caps correspond with those
stamped on the housing in horizontal and vertical
position.
NOTE: Torque cap screws to 70-90 Lb. Ft.
(96-122 Nm).
27. The cover face of the carrier and the flat surface
of the rear cover must be free from any oil of
foreign material. Fit the rear cover to the carrier
using silicone rubber sealant.
NOTE: Ensure that the sealant bead is laid on the
inside of the cover screw holes. The bead is not
to pass through the holes or outside of the holes.
G98794 en 01/2003 2003.0 BA Falcon

205-02B-1 Independent Rear Suspension — Full Floating Axle 205-02B-1
SECTION : 205-02B Independent Rear Suspension

— Full Floating Axle
CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................205-02B-2
Description And Operation ..................................................................................................205-02B-4
Drive Unit Identification ......................................................................................................205-02B-4
Drive Unit Differential .........................................................................................................205-02B-4
Conventional Differential ....................................................................................................205-02B-4
Limited Slip Differential ......................................................................................................205-02B-4
Diff and Pinion Bearings ....................................................................................................205-02B-4
M78 & M86 IRS (Sedan) ...................................................................................................205-02B-4
GENERAL PROCEDURES
Drive Unit Oil Change ..........................................................................................................205-02B-8
In Vehicle Torque Check .....................................................................................................205-02B-8
Differential Case Preload Setting ........................................................................................205-02B-8
Backlash and Tooth Contact Setting ...................................................................................205-02B-8
IN-VEHICLE REPAIRS
Pinion Oil Seal Replacement ...............................................................................................205-02B-9
Half Shaft ...........................................................................................................................205-02B-10
Drive Unit Assembly ..........................................................................................................205-02B-10
Differential Assembly .........................................................................................................205-02B-10
Inner Axle Shaft Seal Replacement ..................................................................................205-02B-11
Pinion & Pinion Bearings ...................................................................................................205-02B-11
Drive Pinion Selection — Shim Selection ..........................................................................205-02B-12
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Backlash variation 0.05 mm max.
Rear Axle Lubrication between teeth.
(Level with bottom of filler plug hole with vehicle at Maximum ring gear run 0.13 mm
curb height.) out (assembled)
Model 78 Limited slip differential Selective shim
CONVENTIONAL adjustment. (separate
cone type)
Grade SAE 90 Hypoid
Limited slip differential Non adjustable
Ford Specification ESW-M2C108-A
(integral cone type)
Capacity 1.70 litre Limited slip differential torque
LIMITED SLIP
New: 80-140 Nm
Grade SAE 90 EP
Used: 50-130 Nm (Separate
Ford Specification ESW-FM2C-1006-B cone type)
Capacity 1.60 litre + 100ml 45-130 Nm (Integral cone
Sturaco 7098 Additive type)
Model 86 To be constant within 6
CONVENTIONAL Nm (continuously
Grade Mobilube SHC ID rotating)
Ford Specification ESZ-FM2C190-A General Specifications
Capacity 1.9 litre Item Specification
LIMITED SLIP Spring Rate
Grade Mobilube SHC ID E169 SWB 28N/mm
Ford Specification ESZ-FM2C190-A E169 XR and FPV 38 N/mm
Capacity 1.86 litre + 40ml E169 SFLPG 32 N/mm
Duraphos Mobil M3022 E169 Fairmont Ghia 30 N/mm
BEARING PRELOADS
E169 Heavy Duty 32 N/mm
BEARING PRELOADS
E169 Sport SFLPG 34 N/mm
New Bearings Nm E169 T Series TBA
Differential
E169 LWB 28 N/mm
— Measured without axle 1.1-2.8
Design Load
shafts or pinion
E169 SWB 4800 N
Pinion
E169 XR and FPV 4140 N
— With oil seal 1.4-2.4
E169 SFLPG 5576 N
— Without oil seal 1.4-2.0
E169 Fairmont Ghia 4660 N
Used Bearings
E169 Heavy Duty 5860 N
Differential
E169 Sport SFLPG 5145 N
— Measured without axle 0.5-1.4
shafts or pinion E169 T Series TBA
Pinion E169 LWB 5400 N
— With oil seal 0.7-1.2 Design Height 5400 N
— Without oil seal 0.7-1.0 E169 SWB 190 mm
ADJUSTMENTS E169 XR and FPV 201 mm
Pinion bearing preload Collapsible spacer E169 SFLPG 190 mm
adjustment. E169 Fairmont Ghia 190 mm
Differential bearing Selective spacer E169 Heavy Duty 190 mm
preload adjustment. E169 Sport SFLPG 190 mm
Pinion depth of mesh Selective shim E169 T Series TBA
adjustment.
E169 LWB 190 mm
Backlash between ring 0.13 to 0.18 mm
gear and pinion.
G567879 en 01/2003 2003.0 BA Falcon

SPECIFICATIONS (Continued)
Description Nm
Ring gear bolts (L.H. Thread) 140
Bearing cap bolts 55
Differential case bolts (L.S.D.) 40
Rear cover bolts 30
Axle bearing retainer plate bolts 45
Spring ’U’ bolt nuts (Wagon) 60
* Track arms to body 75
* Track arms to pivot link 75
* Pivot link to axle housing cover 15
* Suspension arms to axle housing 75
* Suspension arms to body 75
* Shock absorber to spring plate 75
Caliper to bracket pin nuts 20
Splash shield screws 10
Shock absorber to spring plate nut 45
Stabiliser bar clamp bolt 20
Universal joint bolts 10
Vent - Rear axle housing 15
Pinion flange nut — Tighten to achieve —
specified bearing pre-load
Filler Plug 30
Drain Plug 30
Screw Adjusters (IRS) — Tighten to —
achieve differential bearing preload
Final drive assy rear mounting bolt 200 ± 40
Final drive assy front mounting bolt 140 ± 28
* Items marked thus are to be tightened with the
vehicle in the curb load position.
G567879 en 01/2003 2003.0 BA Falcon

Description And Operation Torque is transferred from the drive shaft to the rear
axle assembly via the companion flange which is
Drive Unit Identification splined to the hypoid pinion. The torque is then
transferred from the pinion through the ring gear,
A label identifying the drive unit assembly part differential case, pinion spider, differential pinions and
number, model, serial number, and final drive ratio is side gears to the axle shafts. The differential case
fixed to the carrier casting. houses two cone type clutches which are integrated
IRS final drive units (3.23 or 3.45:1) have a 7 3/4 inch with side gears. These cones are splined to the axle
(189.9 mm) diameter ring gear. shafts, their tapered faces bearing on the differential
case.
CAUTION: IRS drive units use a synthetic Thrust springs pre-load the gears/cones, forcing the
lubricant that is not compatible with standard tapered face of the cones into contact with the
polyacrylic pinion seals. Viton pinion seals must differential case. The partial locking action, due to the
be used in this axle. spring load on the cones is automatically increased by
A metal tag carrying the words ’HIGH the inherent separating forces between the side gears
PERFORMANCE USE APPROVED LUBRICANT and pinion. This locking action directs portion of the
ONLY’ is attached under the filler plug for LSD. A driving force to the wheel with the greater traction.
Decal is also attached to the right hand front door When the rear wheels are under extreme unbalance
hinge pillar. (LSD only). tractive conditions, such as one wheel on dry road
and the other in mud or ice, with the conventional
Drive Unit Differential differential, wheel spin will occur if over acceleration is
The drive unit should be removed from the vehicle for attempted. However, with the limited slip differential,
overhaul. Before disassembling the unit the following when the tendency for wheel spin occurs, the friction
inspection should be carried out: generated between the cones and the differential
1. Remove the rear cover, clean and visually inspect case transfers portion of the driving force to the
the moving parts for chipped or scuffed surfaces. non-spinning wheel. in the event of continued
spinning a whirring sound is produced due to
NOTE: The differential bearing lock plates are over-running of the cones; such a condition or sound
removed when the ABS location mounts are does not indicate failure of the unit.
removed.
Axle shaft end play is pre-set and is not adjustable.
2. Use a torque wrench to check the ring gear bolt Oil seals are located between the inner axle shafts
and pinion flange nut torques. and the screw adjusters.
3. Check the run-out and backlash. Refer to Section
205-00. Diff and Pinion Bearings
4. Carry out the Gear Tooth Contact Pattern Check Construction design is a single row, pre-set tapered
outlined in Section 205-00. roller bearing capable of accepting thrust loads in
either direction and radial loads in any combination.
Conventional Differential The tapered roller unit type bearing consists of five
The four pinion gear split differential case and the basic parts: the cup or outer race, the cup rib ring, the
drive pinion are mounted in opposed taper roller cone, or inner race, the tapered rollers which roll
bearings in the carrier. Differential bearing preload freely between the cup and cone, and the cage which
adjustment is provided by the screw adjusters Pinion serves as a retainer to maintain the proper spacing
bearing preload is provided by a collapsible spacer. between the tapered rollers grouped around the cone.
Torque is transferred from the drive shaft to the drive When the bearing is manufactured, the cup and rib
unit assembly via the companion flange which is ring are bonded together with an adhesive to facilitate
splined to the hypoid pinion. The torque is then bearing handling and installation. Since the cup and
transferred from the pinion through the ring gear, rib ring are clamped together in the axle housing,
differential case, differential pinion cross shaft, there is no need for a permanent bond. When the
differential pinions and side gears to the axle shafts. bearing is serviced the cup will usually be separated
from the rib ring.
Axle shaft end play is pre-set and is not adjustable.
Oil seals are located between the inner axle shafts M78 & M86 IRS (Sedan)
and the screw adjusters.
NOTE: A label identifying the drive unit assembly part
Limited Slip Differential number, serial number, final drive ratio and model is
fixed to the carrier casting.
The four pinion gear split differential case and the
drive pinion are mounted in opposed taper roller Two different model final drive units are used in sedan
bearings in the carrier. Differential bearing preload vehicles:
adjustment is provided by the screw adjusters. Pinion M78 final drive units are fitted with 3.23 or 3.45
bearing preload is provided by a collapsible spacer. 7.75" (197mm) diameter gear sets, with or without
G567880 en 01/2003 2003.0 BA Falcon

LSDs. All M78 final drive units should be filled to rotation, providing torque transfer to the rear wheel
with synthetic oil as per Part 4-5 Specifications. with the least traction.
Conventional M78 differentials are fitted with a With a conventional differential, when the rear wheels
metal tag marked "HIGH PERFORMANCE. USE are under extreme unbalance tractive conditions, such
APPROVED LUBRICANT ONLY" that is attached as one wheel on dry road and the other in mud or ice,
under the filler plug on the rear cover. For Limited wheel spin will occur if over acceleration is attempted.
Slip Differentials (LSD) units, the metal tag is However, with the limited slip differential, when the
marked "LSD - HIGH PERFORMANCE. USE tendency for wheel spin occurs, the friction generated
APPROVED LUBRICANT ONLY". between the cones and the differential case (M78) or
M86 final drive units are fitted with 3.23 or 3.46 between the friction plates (M86) transfers a portion of
8.6" (220mm) diameter gear sets, with or without the driving torque to the non-spinning wheel.
LSDs. M86 final drive units are fitted to all sedan NOTE: For M78 LSDs: In the event of continued
vehicles powered by a V8 or turbo I6 engine. All spinning a whirring sound is produced due to
M86 final drive units should be filled with mineral over-running of the cones; such a condition or sound
oil as per Part 4-5 Specifications. Conventional does not indicate failure of the unit.
M86 differentials are not fitted with a metal tag.
For LSD units, a metal tag marked "SPIN
RESISTANT DIFF. USE APPROVED
LUBRICANT ONLY" is attached under the filler
plug on the rear cover.
NOTE: Upgrading the lubricating oil to synthetic type
is recommended for vehicles fitted with a M86 final
drive unit where the vehicle will be regularly used for
towing.
This axle is a hypoid type of unitised carrier
drive pinion are mounted in opposed taper roller
bearings in the carrier. Differential bearing preload
adjustment is provided by the screw adjusters. Pinion
bearing preload is regulated by a collapsible spacer
and adjusted using the pinion nut.
Torque is transferred from the propshaft to the final
drive assembly via the constant velocity type
companion flange that is splined to the hypoid pinion.
The torque is then transferred from the pinion through
the ring gear, differential case, differential pinion cross
shaft, differential pinions and side gears to the
constant velocity joint halfshafts for conventional
differentials.
Halfshaft end play is pre-set and is not adjustable. Oil
seals are located between the haflshafts and the
screw adjusters.
M78 Limited Slip Differentials (LSDs), the differential
case houses two cone type clutches behind the side
gears. These cones are splined to the halfshafts, their
tapered faces bearing on the differential case. Thrust
springs pre-load the gears and cones, forcing the
tapered face of the cones into contact with the
differential case. The partial locking action due to the
spring load on the cones is automatically increased by
the inherent separating forces between the side gears
and pinion. This locking action directs a portion of the
driving force to the wheel with the least traction. M86
LSDs transfer torque in a similar manner as M78
LSDs, except that a multiplate oil bath type design is
differential case and side gear. Compressive
preloading of the plates provides frictional resistance
G567880 en 01/2003 2003.0 BA Falcon

M78 IRS Drive Unit
G567880 en 01/2003 2003.0 BA Falcon

M86 IRS Drive Unit
G567880 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Drive Unit Oil Change Differential Case Preload Setting

1. Raise the vehicle so that it remains level. 1. Hold the differential case in position while
2. Remove the bottom rear cover flanged bolt from inserting screw adjusters until the differential is
the drive unit to drain oil. supported by the bearings. Use special tool
NOTE: It is preferable to drain the oil while it is 205-463 to fit the screw adjusters.
warm so that any debris can drain out more
easily.
3. Refit the cover bolt and tighten to 23-31 Nm.
4. Remove the lubrication tag, gasket and filler plug
(located on the left-hand side of the drive unit
housing ahead of the axle shaft).
5. Fill drive unit with 1.6 litres of the appropriate
lubricant.
6. Check the condition of the gasket to ensure
proper oil sealing function of filler plug.
7. Replace lubrication tag, gasket and filler plug and
In Vehicle Torque Check 2. Rotate the differential several times to seat

bearings while the screw adjusters are being
Torque Testing
tightened.
1. To test the Limited Slip differential for correct 3. Measure the bearing preload.
operation proceed as follows:
4. Tighten the screw adjusters until the bearing
1. Drive vehicle 10 km to warm up axle oil. preload is within the required range. Record the
2. Raise one rear wheel and attach the Special torque required on the screw adjusters to obtain
Tool No. E6662. the required preload.
3. Place the transmission in neutral and release
the park brake.
Backlash and Tooth Contact Setting
4. Ensure that there is no brake drag affecting 1. Replace the differential assembly using the
wheel rotation. spacers selected earlier.
5. Chock the front wheels. 2. Ensure that the pinion nut and bearing cap bolts
are tightened to the specified torque.
6. Attach a torque meter to the special tool, and
rotate the axle. 3. Check the backlash on the ring gear as described
in Section 205-00.
4. If backlash is excessive decrease the size of the
spacer on the pinion side of the ring gear and
increase the gear side spacer by the same
amount by turning the screw adjusters. If the
backlash is insufficient increase the size of the
spacer on the pinion side and decrease the size
of the spacer on the ring gear side by the same
amount by turning the screw adjusters.
NOTE: The total thickness of both spacers should
not change.
5. Recheck the tooth contact pattern as described in
Section 205-00.
6. Make necessary adjustments until tooth contact is
7. The torque required to rotate the axle shaft for appropriate.
a used L.S.D. unit should be between 50 and 7. Replace/Install new seals and silicone sealant
130 Nm. Reading should be steady within 6 that are not already in place.
Nm. 8. Install rear cover and torque to specification.
8. If the torque required to continuously rotate
the wheel is outside the specification check
the differential for improper assembly and/or
rework.
G567881 en 01/2003 2003.0 BA Falcon

IN-VEHICLE REPAIR
Pinion Oil Seal Replacement 3. Lubricate the seal lips and the outside diameter
with oil and install the seal, using the special tool.
Removal Correct seal location is from flush to 0.25 mm
below the carrier surface.
CAUTION: Axles on vehicles with V8 or I6HO 4. Align the pinion flange spline mark with the pinion
engines use a synthetic lubricant that is not shaft spline mark and install the flange with a
compatible with standard polyacrylic pinion seals. smear of lubricant on the splines. Tighten the nut
Viton pinion seals must be used in this axle. until the marks previously made on the pinion
Synthetic seals must not be soaked or washed in flange and the nut are in alignment re-establishing
cleaning solvents. the pinion bearing preload.
1. Raise the vehicle on a hoist. Disconnect the drive 5. Install the driveshaft with the marking on the drive
shaft from the drive pinion flange after marking shaft and the pinion flange in alignment.
the drive shaft and pinion flange to ensure correct
positioning on reassembly. 6. Check axle lubricant level and top up if necessary
with specified lubricant.
2. Mark the pinion shaft and the pinion flange to
ensure correct positioning on reassembly. Mark 7. Remove the vehicle from the hoist.
the pinion flange and the pinion nut to establish
bearing preload on reassembly.
Item Description
1 Oil Seal Tool E9055
2 Drive Pinion Oil Seal
3. Hold the pinion flange using tool EN1205B and
remove the self locking nut.
4. Place a drain pan beneath the pinion housing.
5. Mark the ends of the pinion shaft and the pinion
flange spline for correct re-alignment during
installation.
6. Clean the pinion bearing housing around the oil
seal.
7. Remove the pinion flange using tool number
E9258B. Under no circumstances should a
hammer be used.
8. Remove the pinion oil seal by prying it out with a
suitable tool.
Installation
NOTE: Refer to, Section 205-00 for Special Tool(s).
1. Check the splines on the pinion shaft and pinion
flange for burrs and if necessary clean up with
fine crocus cloth. Wipe the flange and shaft clean.
2. Clean the oil seal seat. The lubricant return
passage must be clear.
G567885 en 01/2003 2003.0 BA Falcon

Half Shaft 3. Remove the differential assembly.
Removal and Installation

Refer to section 205-05.
Drive Unit Assembly

Removal
1. Remove knuckle assembly, refer to Section
204-02a.
2. Remove Rear Drive Halfshafts, refer to Section
205-05.
3. Remove IRS Module, refer to Section 204-02a.
4. Unclip handbrake cables.
5. Remove breather tube.
6. With the Drive Unit Assembly supported, remove Item Description
the front and rear support bolts. 1 Tool-Push/Puller with Legs
2 Tool-Stepped Plug
3 Tool-Knife Edge Puller
Installation
1. Installation procedure is the reverse of the
Removal procedure.
NOTE: Ensure all bolts are torqued to
specifications.
Differential Assembly
1. Remove the rear cover, ABS mounts and screw
adjuster lock plates.
2. Remove the screw adjusters using special service
tool 205-463.
G567892 en 01/2003 2003.0 BA Falcon

Inner Axle Shaft Seal Replacement surface of the axle shafts on which the seal runs and
remove any nicks or burrs. Should this surface be
Disassembly irreparable, a new half shaft should be fitted. Examine
1. Drain lubricant from unit via bottom cover bolt. the housing bore and remove any nicks and burrs.
2. Remove the half shafts from the assembly. Refer 1. Lubricate the seal lips and the outside diameter
to ’Half Shaft’ in this section. and install. The seal is to be seated on the screw
3. Clean around the seal area ensuring there is no adjuster.
ingress of dirt into the axle shaft needle roller 2. Install the half shafts ensuring that the splines do
bearing. not come into contact with the seal lips. Refer to
4. Carefully remove the seal. ’Half Shaft’ in this section.
3. Shafts should withstand a pull out force of 1200N.
Assembly 4. Check lubricant level, top up as required.
NOTE: Before installation of a new seal examine the
Pinion & Pinion Bearings 6. A pinion depth adjusting shim is installed

between the rear pinion bearing cup and the
Disassembly and Assembly axle housing. Discard damaged shims.
1. Carry out the following procedure with the
differential assembly removed:
1. Mark the relationship of the companion
flange. Hold the companion flange and
remove the pinion nut.
2. Remove the companion flange.
3. With a soft hammer, drive the pinion out of
the front bearing cone and remove it through
the rear of the carrier casting.
4. Drive the pinion seal and the bearing cone out
of the carrier casting.
5. If the pinion bearing cups are to be replaced,
remove them from the carrier using the
special tool.
NOTE: It is essential to renew the cups one
after the other so that in each instance the
other cup serves as a guide for the replacer
tool.
G567889 en 01/2003 2003.0 BA Falcon

7. In the pinion rear bearing cone and roller is to Pinion & Ring Gear Identification
be replaced, lubricate the pinion shaft and
remove the bearing cone from the pinion.
Drive the bearing whenever it has been
removed from the pinion.
Item Description
1 Tool-Push/Puller with Legs
2 Tool-Knife Edge Puller
Drive Pinion Selection — Shim

Selection
NOTE: The drive pinion and ring gear set
identification marking (e.g. number 5K-25) is the
matching number that appears on both the drive
pinion and the ring gear. When a new gear set is
being installed in an axle, be sure that the same
matching number appears on both the drive pinion
and the ring gear.
1. The ring gear and pinion are manufactured within

a tolerance of a specified distance. On the end of
each pinion, there is etched a plus (+) number, a
minus (-) number, or a zero (0) number which
indicates the best running position for each
particular gear set. This dimension is controlled by
the shimming behind the rear pinion bearing cup.
2. When the shim thickness is decreased, the pinion
gear is moved away from the ring gear. When the
shim thickness is increased, the pinion is moved
closer to the ring gear.
G567889 en 01/2003 2003.0 BA Falcon

3. A positive (+) number on the drive pinion means

that a thinner shim should be installed to move
the pinion gear away from the ring gear. A
negative (-) number means that a thicker shim
should be used to move the drive pinion closer to
the ring gear.
4. Lubricate all differential parts with the
recommended rear axle lubricant, before they are
installed.
5. To select the correct shim thickness follow these
steps:
NOTE: The exact same rear pinion bearing that is
to be used in the vehicle, is to be used when
using the dummy pinion.
1. Install the front and rear pinion bearing cups
into the axle housing.
2. Fit the pinion bearing cone and rollers to the
dummy pinion tool. Install the dummy pinion
to the axle housing. Fit the pinion front cone
and roller to the dummy pinion. Install the tool
thrust collar and the nut to the dummy pinion.
3. Tighten the nut until a bearing preload of 1.4
to 2.4 Nm (new bearing), 0.7 to 1.2 Nm (used
bearing) is achieved while rotating the dummy
pinion back and forth to ensure correct
seating of the bearing rollers.
4. Position the depth gauge cylinder in the
carrier and fit the bearing caps, tightening
lightly. Determine the size of pinion shim that
will pass between the depth gauge and the
dummy pinion head. Examine the drive pinion
installation marking. The size of the pinion
shim should then be altered as follows:- A
positive (e.g. +0.002 inch) marking means
that this pinion has to be set at this number of
thousandths of an inch further from the drive
gear, i.e. a shim this amount thinner must be
used. A negative (e.g. - 0.002 inch) marking
means that a shim this size thicker must be
used. A zero (0) marking indicates that the
shim selected with the gauge is the correct
one for this carrier/pinion combination.
Position shims are available in .001 in (0.025
mm) increments from .008 to .030 in (0.2 to
0.75 mm).
NOTE: The marking on the pinion is in
Imperial measurement.
5. Remove the tools from the carrier.
6. Remove the rear pinion bearing cup from the
housing.
G567890 en 01/2003 2003.0 BA Falcon

205-05-1 Rear Drive Halfshafts 205-05-1
SECTION : 205-05 Rear Drive Halfshafts

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-05-2
Rear Drive Halfshafts .............................................................................................................205-05-3
Halfshaft Handling ................................................................................................................205-05-3
Rear Drive Halfshafts .............................................................................................................205-05-4
Halfshaft .................................................................................................................................205-05-5
Halfshaft Joint ........................................................................................................................205-05-6
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Constant Velocity Joint ESP-MIC207-A
Grease (High Temp)
E43Z-19590-A
Description Nm
Ball joint nuts 115
Knuckle bolt 115
Rear axle wheel hut nut 290
G86420 en 01/2003 2003.0 BA Falcon

Rear Drive Halfshafts
CAUTION: An inspection of the outer and

inner boots is necessary so that if damage or
grease leakage is evident, installation of a new
halfshaft can take place immediately. Continued
operation with damage or grease leakage will
result in CV joint wear and noise due to
contamination and loss of the CV joint grease.
1. Inboard and outboard CV joints connect to a
splined shaft. A circlip stopper holds the cross
groove inboard race assembly (inboard CV joint)
together.
2. An axle circlip (4B422) retains the splined inboard
CV joint to the differential side gear. Install a new
axle circlip each time the halfshaft is removed
from the vehicle.
3. A rear axle wheel hub nut secures the side shaft
assembly (interconnecting shaft and outboard CV
joint) the rear hub. Install a new rear axle wheel
hub nut each time the halfshaft is removed from
the vehicle.
Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft

only by the inboard or outboard CV joint.
CAUTION: Do not over-angle the CV joints.
CAUTION: Damage will occur to an

assembled inboard CV joint if it is over-plunged
outward from the joint housing.
CAUTION: Never use a hammer to remove or

install the halfshafts.
CAUTION: Never use the halfshaft assembly

as a lever to position other components. Always
support the free end of the halfshaft.
CAUTION: Do not allow the boots to contact

sharp edges or hot exhaust components.
CAUTION: Handle the halfshaft only by the

interconnecting shaft to avoid pull-apart and
potential damage to the CV joint.
CAUTION: Do not drop assembled halfshafts.

The impact will cut the boots from the inside
without evidence of external damage.
Handle all halfshaft components carefully during
removal and installation procedures.
G86421 en 01/2003 2003.0 BA Falcon

Rear Drive Halfshafts

For additional information, refer to Section 205-00.
G96423 en 01/2003 2003.0 BA Falcon

Halfshaft
Removal
1. Disconnect park brake cable, ABS sensor, brake
caliper and rotor and knuckle assembly (Refer to
Section 204-02a Rear Suspension Knuckle
Removal).
2. Holding the halfshaft securely remove by applying

an axial load.
CAUTION: Never use a hammer to
remove or install halfshaft.
CAUTION: Handle the halfshaft only by
the interconnecting shaft to avoid pull-apart
and potential damage to the CV joint.
Installation
1. Refit the halfshaft using the reverse of the
removal procedure taking care not to
over-articulate the CV joints.
G96424 en 01/2003 2003.0 BA Falcon

Halfshaft Joint 4. Slide the inboard halfshaft boot off the inboard CV
joint housing.
Special Tool(s)
CV Boot Clamp Installer
205-343 (9T95P-3514-A)
Disassembly V8 Inboard
1. Remove the halfshaft. Refer to Section 205-02b.
2. Secure the halfshaft and constant velocity (CV)
joint in a vice using protective jaw covers.
5. If reinstalling the original inner joint, mark the
inner joint and the halfshaft to make sure of
correct installation.
3. Remove the inboard halfshaft boot clamp. The V8

inboard joint has only one large boot clamp. Refer
to Section 205-02b.
6. Spread the retainer and using a hammer and
punch separate the halfshaft from the inboard
joint housing by tapping on the inner race.
G96425 en 01/2003 2003.0 BA Falcon

7. Remove and discard the bearing retainer circlip. There are at least two methods to achieve
The retainer should have remained with the inner this - refer to following illustrations.
race during the removal process.
2. Slide the outboard boot back out of the way

8. Remove the inboard halfshaft boot from the exposing the CV joint.
halfshaft.
Disassembly V8 Outboard and I6 Inboard &
Outboard
1. Remove the two outboard halfshaft boot clamps.
There is a small and large boot clamp associated
with this boot.
G96425 en 01/2003 2003.0 BA Falcon

3. If reinstalling the original CV joint, mark the 2. Install the inboard halfshaft boot. This is most
outboard CV joint and halfshaft to make sure of easily achieved by inserting the large opening
correct installation. from the outboard end. And sliding the boot along
the shaft to the other side.
4. Use a soft-face hammer to separate the outboard

CV joint by gently tapping it off the halfshaft. 3. Replace the inboard joint retainer ring. A retainer
5. Remove the halfshaft retainer-circlip and discard. on the shaft is not required.
6. Slide the outboard halfshaft boot off the halfshaft.
Assembly V8 Inboard
1. Lubricate the inboard and outboard CV joint with
joint grease.
G96425 en 01/2003 2003.0 BA Falcon

4. Use a soft-face hammer to install the inboard CV 2. Position the halfshaft boot.
joint by gently tapping it onto the halfshaft.
3. Install the snap ring.

5. Remove any excess grease on the mating
surfaces and slide the inboard halfshaft joint boot
forward onto the inboard CV joint.
6. Remove any excess air trapped in the inboard
halfshaft boot using a cloth covered screwdriver
after adjusting the outboard halfshaft boot
spacing.
4. Using a soft face hammer, install the halfshaft on

the joint.
7. Ensure that the small end of the boot is positioned

as shown in adjacent picture - that is, such that
the small end is located in the groove in the shaft
and that the shape of the shaft adjacent to the
boot is as shown.
8. The air pressure within the boot is self -adjusting
for this type of boot.
Assembly V8 Outboard and I6 Inboard & Outboard
1. Slide the small boot clamp onto the shaft.
5. Position the halfshaft boot.
G96425 en 01/2003 2003.0 BA Falcon

6. Ensure that the small end of the boot is positioned

as shown in adjacent picture - that is, with one of
the small grooves visible.
7. Remove any excess air trapped in the halfshaft

boot using a cloth covered screwdriver after
adjusting the halfshaft boot spacing.
8. Using the special tool, install two new joint boot
clamps. The outboard joint has an ABS rotor
attached as shown.
9. Install the halfshaft. Refer Section 205-02b.
G96425 en 01/2003 2003.0 BA Falcon

206-00-1 Brake System — General Information 206-00-1
SECTION : 206-00 Brake System — General

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-00-2
Brake System .........................................................................................................................206-00-4
Load Proportioning Valve 1 Tonne Ute ................................................................................206-00-5
Brake System .........................................................................................................................206-00-6
Symptom Chart ....................................................................................................................206-00-7
Components Tests ...............................................................................................................206-00-9
GENERAL PROCEDURES
Hydraulic System Bleeding ..................................................................................................206-00-11
Manual System Bleeding .....................................................................................................206-00-11
System Pressure Bleeding ...................................................................................................206-00-11
Service Precautions .............................................................................................................206-00-12
Changing Brake Fluid ..........................................................................................................206-00-12
Brake Pedal Clearance Check .............................................................................................206-00-12
Caliper ..................................................................................................................................206-00-12
Brake System Leak Check ...................................................................................................206-00-13
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Surface Finish (Ra) 0.13-3.2 µm
Lining wear limit (above 1.0 mm (0.040 in) Balance 54 gcm
backing plate or rivets ) Rotor (Rear)
Lubricants Type Cast Iron - Solid
High Performance ESA-M6C25-A Diameter 0.05 mm
SUPER DOT 4 Brake 303 mm
Fluid
Thickness (New) 16.2 mm
High Temperature Nickel ESE-M12A4-A
Max. Runout
Anti-Seize Lubricant
F6AZ-9L494-AA Thickness Variation 0.018 mm
Disc Brakes Min. Thickness Refaced 14.5 mm
(overall)
Brake disc maximum run 0.035 mm (0.001 in)
out Brake Face Surface 0.13-3.2 µm
Finish (Ra)
Brake disc maximum 0.009 mm (0.0004 in)
thickness variation Park Brake Bore Surface 0.13-3.2 µm
Brake Booster Finish (Ra)
Max. Park Brake drum 190.4 mm
Dual Diaphragm 230 mm
diameter
Diameter
Master Cylinder Disc Pads
Material JBUF85FF
Type PBR Dual Line
Brake Pedal Height
Main Bore Diameter 23.8 mm
Fast Fill Bore Diameter 31.75 mm Minimum height without 25 mm
fluid in system and
Min. Total Stroke 32.52 mm master cylinder Bottomed
Split Point (non EBD 3/4 Tonne Ute with prop out
only) valve = 2.5mPa ABS System
1 Tonne Ute with prop System and motor 8.7V
valve (Load levelling dropout threshold
valve fitted to this varient)
Fuse 30A
= 0MPa
Warning lamp 1.2W
Displacement (min.) Primary - 9.0 cc
Secondary - 5.12 cc Current draw - motor 50A
(under load)
Caliper(Front)
Front Wheel Sensor 1.65 kOhm ± 0.2 kOhm
Type PBR Twin Piston
’Collette’ Caliper Resistance
Rear Wheel Sensor 1.65 kOhm ± 0.2 kOhm
AI Head Bore Diameter 2 x 42.0 mm
Resistance
Caliper(Rear)
Type PBR Single Piston Torque Specifications
’Collette’ Caliper Description Nm
Bore Diameter 40.5 mm Brake master cylinder tube fitting, front 18
Rotor (Front) Brake master cylinder tube fitting, rear 18
Type Cast Iron - Ventilated Caliper bleeder screw, rear 20
Diameter 298 mm Caliper bleeder screw, front 20
Thickness (New) 28 mm Master cylinder bleeder screw 8-18
Max. Runout 0.035 mm Cruise control switch 14-20
Thickness Variation 0.009 mm Master Cylinder to Booster 15
Min. Thickness Refaced 26.0 mm Booster to Dash panel 19 - 24
(overall) Brake Tube Nuts 12
Min. Thickness Refaced Brake Line Connector to Rear Axle 25
(individual) Housing
Braking Surfaces 3.2 mm Brake Hose to Caliper 30
G17359 en 01/2003 2003.0 BA Falcon

Description Nm
Splash Shield to Rear Anchor Bracket 10
Front Caliper Mounting Bolts 115 ± 17
Rear Caliper Mounting Bolt 68-92
Park Brake Control to Body 25
Park Brake Equalizer Nut 15
Pressure Differential Switch (where 1.8
fitted)
Proportioning Piston Hex. Fitting 25
Wheel Nuts 140
Cable Bracket Nuts 8
Reservoir Attaching Bolt 4
Secondary Piston Stop 8
Modulator Nuts to Bracket 15
Brake Pipe Tube Nuts (modulator) 13
Wheel Speed Sensor Screws 9
Pump Motor earth strap screw 12
NOTE: All Hydraulic Lines must be tightened to the
specified torque and be free from leakage.
G17359 en 01/2003 2003.0 BA Falcon

Brake System
Component Locator
G17360 en 01/2003 2003.0 BA Falcon

Item Description When the vehicle carries its maximum load, the piston
is postioned so that fluid can flow unresticted through
1 Brake master cylinder and booster
the sensing valve to the rear wheel calipers.
assembly
2 Pedal box
3 Rear disc brake assembly
4 Front disc brake assembly
5 Anti-lock electronic control module
The vehicle is equipped with a vacuum-assisted
power braking system. For additional information,
refer to Section 206-07.
The braking system is a front-to-rear split hydraulic
system. For additional information, refer to Section
206-06.
The front brakes utilize a dual-piston brake caliper
and disc brake system. For additional information,
The rear brakes utilize a single piston caliper and disc
brake system with the parking brake assembly located
inside the drum and hat-type brake disc. For
additional information, refer to Section 206-04.
The parking brake system is a shoe and drum system
that is located inside the drum and hat-type rear brake
discs. For additional information, refer to Section
206-05.
A 4-wheel anti-lock brake system (4WABS) is
standard. For additional information, refer to Section
206-09.
Load Proportioning Valve 1 Tonne Ute
The load proportioning valve regulates the rear brake
system hydraulic pressure and is located at the rear of
the vehicle.
The load proportioning piston is positioned by the use

of two springs. the static spring applies a constant
force on the piston while the sensing torsion spring
applies a variable force depending on the axle load.
When the vehicle is lightly loaded the sensing torsion
spring has its maximum effect. The total force on the
piston and plunger is greatest. This force postions the
load sensing piston to restrict the flow of fluid through
the outlet port to the rear brakes.
G17360 en 01/2003 2003.0 BA Falcon

Brake System Rotor Wear and Runout

Remove the wheel to inspect the rotor.
Special Tool(s)
Check the rotor for scoring. Minor scores need not
Vacuum Pump be removed. If the rotor is excessively scored,
416-D002 (D95L-7559-A) or refinish it in accordance with the Specifications or
equivalant replace the rotor.
When checking front rotor runout, be sure to take
the wheel bearing end play into account. Remove
the rotor if necessary.
Front wheel bearing end play is critical and must
be within specifications.
Inspection and Verification To check the rear rotor run-out either apply a load
to the end of the axle shaft to remove the end
WARNING: Brake fluid contains polyglycol float in the bearing or remove the axle shaft and
ethers and polyglycols. Avoid contact with eyes. rotor assembly from the housing and check the
Wash hands throughly after handling. If brake run-out by mounting the axle on its centres.
fluid contacts eyes, flush eyes with running water Clamp a dial indicator to the caliper housing so
for 15 minutes. Get medical attention if irritation that the stylus contacts the braking surface of the
persists. If taken internally, drink water and rotor approximately 32 mm from the outer edge
induce vomiting. Get medical attention for a front rotor or 3mm from the outer edge for a
immediately. Failure to follow these instructions rear rotor.
may result in personal injuiry.
Rotate the rotor and take an indicator reading. If
the total lateral run-out exceeds 0.08 mm for a
CAUTION: Do not spill brake fluid onto
front rotor or 0.05 mm for a rear rotor, resurface
painted surfaces. If spilled, wipe it up
or replace the rotor.
immediately.
Refer to Specifications section for refinishing
NOTE: Always check the fluid level in the brake
specifications. Refer to Section 206-03 or Section
master cylinder before carrying out the test
206-04 for information regarding rotor
procedures. If the fluid level is not above the MIN line,
replacement.
add High Performance Motor vehicle brake fluid
meeting Ford specification ESZ-M6C55-A or Disc Thickness Variation
equivalant Super DOT4 fluid.
This is the variation in thickness between the two
NOTE: Prior to carrying out any diagnosis, verify that braking surfaces of the rotor measured
the brake warning indicator is functional. Apply the circumferentially.
parking brake. If the brake warning indicator does not Disc thickness variation may cause a pulsating pedal
illuminate, refer to Brake fail warning light component or noisy operation.
test.
Two methods may be used to measure thickness
NOTE: The primary indicators of brake system variation.
concerns are a change in the feeling through the A micrometer can be used to measure the rotor
brake pedal, the brake warning indicator, and the thickness at 12 points approximately 30 degrees apart
brake fluid level. If a problem exists, refer to the and 25 mm from the outer edge of the rotor.
following diagnosis guide.
The other method is to mount the rotor on a precision
Pad Wear lathe designed for machining disc brake rotors. Attach
two dial indicators, one each side of the rotor, so that
Remove the wheel to inspect the pads. Refer the stylus of each indicator contacts the rubbing
Warning under Service Precautions. surface approximately 25 mm from the outer edge of
If a lining has worn to a thickness of 1.0 mm at the rotor.
any one of three measuring locations or if there is Zero both indicators and rotate the rotor while
more than 3 mm taper from end to end replace all watching both dials. If the total readings of both
(4) pad assemblies on both front or both rear indicators exceed the specified limit for thickness
wheels to maintain even braking. Refer to Section variation, the rotor must be refinished or replaced.
206-03 or Section 206-04 for replacement of
parts.
G17361 en 01/2003 2003.0 BA Falcon

Rotor Thickness and Refinishing Rear Disk Brake Resurfacing Limits

Measure the thickness of the rotor to determine if it is
within the specifications.
Use a disc brake lathe to refinish the disc brake
rotors. Refer to Specifications for the remainder of the
refinishing specifications.
Front Disk Brake Resurfacing Limits
Symptom Chart
Symptom Chart

Excessive effort needed to depress Brake pedal binds at pivot INSTALL a new brake pedal
brake pedal or has a rough or raspy or
sticky feel
Brake booster CHECK the brake booster and REFER

to the Booster Section.
Return Booster spring damaged or CHECK the brake booster and REFER
incorrectly positioned to the Booster Section.
Worn or damaged brake pedal INSTALL a new brake pedal.
Foreign object caught in brake pedal CHECK the brake pedal.
Brake pedal does not return freely Weak or broken Booster return spring CHECK the brake booster and REFER
Foreign object caught in brake pedal CHECK the brake pedal.

No response from the brake lights Unconnected light switch CHECK the connection between the
when the brake pedal is pressed light switch and the light.
Faulty brake switch flag INSTALL a new brake pedal.
Incorrect position of the light switch CHECK the light switch. REPLACE or
CHANGE light switch.
No response from the cruise control Unconnected cruise switch CHECK the connection between the
when the brake pedal is pressed cruise switch and the cruise control.
Faulty brake switch flag INSTALL a new brake pedal.
Incorrect position of the cruise switch CHECK the cruise switch. REPLACE
or CHANGE cruise switch.
G17361 en 01/2003 2003.0 BA Falcon


No deceleration when the brake pedal Connection between the Booster rod CHECK connection
is pressed and the brake pedal PUT the booster rod in the cantilever
pin of the brake pedal if the booster
rod is not connected to the cantilever
pin of the brake pedal.
CHECK Booster clip, CHANGE it if
necessary.
Faulty booster CHECK the brake booster and REFER

Discomfort on Brake pedal Brake pedal pad worn or loose CHECK brake pedal pad and
CHANGE it if necessary.
Padal feel Brake Pedal Not Returning on Release Go to PinPoint Test B
Excessive Pedal Travel Braking System Diagnosis. Refer to

Section 206-00.
"Raspy" feel Go to PinPoint Test B
Pedal Binding at Pivot Go to PinPoint Test A
Pedal Pad Worn Replace Brake Pedal Pad. Refer to

Section 206-00.
Obstruction at Pedal Go to PinPoint Test B
Poor braking efficiency Faulty Brake Booster Braking System Diagnosis. Refer to
Section 206-00.
Brake Disc Pads Worn Refer to Section 206-03 and Section

206-04.
Booster Rod Disconnected Go to PinPoint Test ???

Vacuum Poor, Leaking or Braking System Diagnosis. Refer to
disconnection at the Brake Booster Section 206-00.
Cruise control not turning off when Brake Master Cylinder Leaking / Faulty Braking System Diagnosis. Refer to
brake applied Section 206-00.
Cruise Control Switch Faulty / Plug Go to PinPoint Test D
Disconnected
Stop Lamp Switch Faulty / Plug Go to PinPoint Test C
Disconnected
Adjustable brake pedal Cannot Adjust Pedals Go to PinPoint Test E
Faulty Memory Go to PinPoint Test E
Pedal "Step Over" Height Incorrect Go to Section 310-02, Pinpoint test 5

& 6.
Stop lamp switch Stop Lamp Switch Faulty Go to PinPoint Test C
Symptom Chart-(For adjustable pedal box only)

Unable to adjust the brake pedal Unconnected Adjustment motor CHECK the connection between the
motor and the MSC
Disengaged adjustment cable in the RECONNECT adjustment cable
brake pedal
Faulty Potentiometer (Memory Pedal REPLACE potentiometer
Box Only)
Faulty memory settings (Memory RESET memory
Pedal Box Only)
G17361 en 01/2003 2003.0 BA Falcon


Incorrect step over between brake Incorrect-adjustment Refer to disassembly and assembly
pedal and accelerator pedal instructions: Indexing pedals ( Section
206-06)
NOTE: Do not stall through accelerator transmission. and brake chatter. For each of the symptoms
encountered, check and eliminate the causes. To
Components Tests check for brake chatter or surge apply the brakes
lightly from approximately 80 km/h.
Brake Booster
If the preliminary tests show that the booster is
With the transmission in neutral, stop the engine and inoperative or if a hard pedal condition exists the
apply the parking brake. Depress the service brake trouble may be caused by vacuum leakage.
pedal several times to exhaust all vacuum in the Disconnect the vacuum line at the booster, remove
system. Then, depress the pedal and hold it in the the vacuum manifold and check valve assembly and
applied position. Start the engine. If the vacuum look for a sticking or faulty check valve. Check all
system is operating the pedal will tend to fall away vacuum connections for leakage or obstruction. Check
under foot pressure and less pressure will be required all hoses for a leaking or collapsed condition. Repair
to hold the pedal in the applied position. If no action is or replace as necessary.
felt, the vacuum booster system is not functioning. If the trouble persists, replace the vacuum booster.
Refer to the Diagnosis Guide. The booster is not a serviceable item and if found
For booster removal and installation procedures refer defective must be replaced.
to Section 206-07. Brake Master Cylinder
For cleaning and inspection refer to the following
pages in this part.
CAUTION: The braking system should be
Brake Fail Warning Light Test filled with a special high boiling point (280°C)
brake fluid which must not be contaminated with
Turn the ignition key to the ignition ON position, ordinary brake fluid. Ensure only approved brake
the warning lamp should not illuminate. If the lamp fluid is used (refer Specifications section).
illuminates a defect exists in the system and may
be: Brake fluid is hygroscopic, which means that it takes
in moisture from the air. Water-affected brake fluid
a pressure differential in the hydraulic system. has a reduced boiling point. The heat generated by
a defective differential valve switch (where repeated heavy braking causes the fluid to boil at a
fitted). lower temperature, resulting in loss of braking. The
grounded switch wires. water also helps corrosion start in the braking system.
The brake fluid must be replaced at least every two
Turn the key to the START position, the lamp
years if the brakes are to remain fully effective.
should illuminate while the key is held in this
position. If the lamp does not light check the bulb If brake fluid is spilt on paintwork, the affected area
and wiring for defects. must be washed down with cold water immediately.
Road Test
The vehicle should be road tested only if the brakes
will safely stop the vehicle. Apply the brakes at a
speed of 40- 50 km/h to check for any of the trouble
symptoms listed in the Diagnosis Guide with the
exception of those resolved in the preliminary tests
G17361 en 01/2003 2003.0 BA Falcon

Pressure Differential Valve (where fitted)

To Centralize
After any repair or bleeding of the brake systems the
pressure differential valve will centre itself
automatically when pressure is applied to the brake
pedal. The warning light switch is self setting.
Item Description
1 Reservoir Cover
2 Diaphram
3 Reservoir Chamber
To Check Fluid Level

To check the level of the brake fluid in the master
cylinder, visually inspect the fluid level in the
transparent plastic reservoirs, without removing the
reservoir cover.
The fluid level should be within the maximum and
minimum marks on the Right Hand side of the
chamber. The fluid level will decrease gradually as the
linings wear. Any rapid change in fluid level should be
investigated immediately.
To reduce the possibility of fluid contamination, the
reservoir cover should be removed only when
absolutely necessary. To remove the cover, first clean
all dirt from around the cover. Refill to the maximum
level mark.
Prior to installing the master cylinder cover ensure
that the diaphragm gasket is correctly positioned in its
original form in the reservoir cover.
The cover should be fitted so that lettering on cover is
the correct way when viewed from the right hand side
of vehicle.
Use only the specified brake fluid or equivalent.
G17361 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Hydraulic System Bleeding Repeat this procedure at the wheel

cylinder/caliper on the opposite side. Refill the
1. When any part of the hydraulic system has been master cylinder reservoir after each wheel
disconnected for repair or replacement, air may cylinder/caliper is bled and install the master
get into the system and cause spongy pedal cylinder cover and diaphragm seal.
action. Bleed the hydraulic system after it has
If the front brake system is to be bled, repeat
been properly connected to be sure that all air is
steps 1-5 at the left front brake caliper and
expelled. Press the pedal several times and check ending at the right front brake caliper.
for leakage.
Be sure that the caliper pistons are returned
2. The hydraulic system can be bled manually or
to their normal positions and that the pad
with pressure bleeding equipment. assemblies are properly seated by depressing
3. Bleed the longest line first on the individual the brake pedal several times until normal
system being serviced. pedal travel is established.
NOTE: Clean all dirt from the master cylinder
reservoir cover before removing the cover. The cover System Pressure Bleeding
should be fitted so that lettering on cover is the 1. The bleeder tank should contain enough new
correct way when viewed from the right hand side of Brake Fluid to complete the bleeding operation.
the vehicle. Never exceed 340 kilopascals pressure.
Do not mix low temperature brake fluids with the 2. The tank should be charged with 70 to 200
specified fluid. Never re-use brake fluid which has kilopascals of air pressure.
been drained from the hydraulic system.
When the bleeding operation is completed the WARNING: Ensure the adaptor is
reservoir should be filled to the MAX FLUID LEVEL clamped securely to reservoir before applying
mark on the R.H. side of the reservoirs. Be sure the pressure.
diaphragm type gasket is properly positioned in the 3. Install the pressure bleeder adaptor tool to the
master cylinder cover and is positioned in the master cylinder and attach the bleeder tank hose
configuration as shown in Section 206-06 prior to to the fitting on the adaptor.
installation. If brake fluid is split on the paintwork the 4. Master cylinder pressure bleeder adaptor tools
affected area must be washed with water can be obtained from the various manufacturers
immediately. of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing
Manual System Bleeding the adaptor.
NOTE: When bleeding brakes do not pump the pedal. If the rear wheel calipers are to be bled,
position a ring spanner on the bleeder fitting
1. The front and rear hydraulic brake systems are on the left wheel caliper. Attach a bleeder
individual systems and are bled separately. tube to the bleeder fitting. The end of the tube
During the complete bleeding operation, DO NOT should fit snugly around the bleeder fitting.
allow the reservoir to run dry.
Open the valve on the bleeder tank to admit
To bleed the rear brake system, position a pressurised brake fluid to the master cylinder
suitable ring spanner on the bleeder fitting on reservoir.
the wheel cylinder/ caliper. Attach a drain tube
to the bleeder fitting. The end of the tube Submerge the free end of the tube in a
should fit snugly around the bleeder fitting. container partially filled with clean brake fluid,
and loosen the bleeder fitting.
Submerge the free end of the tube in a
container partially filled with clean brake fluid. When air bubbles cease to appear in the fluid
Route the tube upwards from the nipple to the at the submerged end of the bleeder tube,
container, which should be positioned higher close the bleeder fitting and remove the tube.
than the nipple. Loosen the bleeder fitting Repeat steps 3 to 7 at the right rear brake.
approximately 3/4 of a turn. Repeat steps 4 to 7, starting at the left front
Push the brake pedal down slowly through its caliper and ending at the right front caliper.
full travel. Close the bleeder fitting, then return When the bleeding operation is completed,
the pedal slowly to the full release position. close the bleeder tank valve and remove the
Wait 5 seconds then repeat this operation tank hose from the adaptor fitting.
until air bubbles cease to appear at the
Be sure that the caliper pistons are returned
submerged end of the bleeder tube.
to their normal positions and that the pad
When the fluid is completely free of air assemblies are properly seated by depressing
bubbles, close the bleeder fitting and remove the brake pedal several times until normal
the bleeder tube. pedal travel is established.
G17364 en 01/2003 2003.0 BA Falcon

Remove the Pressure Bleeder Adaptor Tool. 2. No brake pedal clearance adjustment is required
or provided for. With the brake master cylinder
Service Precautions outlet lines disconnected and the brake pedal fully
1. Do not attempt to clean or restore brake fluid, oil depressed, the centre of the top surface of the
or grease soaked brake pads. When brake pedal pad should be 25 mm from the floor
contaminated pads are found, brake pads must surface.
be replaced in complete axle sets. 3. If the pedal height is below specification make the
2. Check the brake hoses for signs of softening, necessary repairs.
cracking, leaks or abrasions. Replace them if
necessary.
3. If the vehicle caliper parts show signs of
overheating are present when relining brakes, the
wheel calipers should be disassembled and
inspected for wear and dirt and an overhaul kit
installed, thus avoiding future problems.
WARNING: Under no circumstances
should compressed air blow off be used to
clean brakes and associated components.
Breathing in dust from the pads is a health
hazard. Remove dust and dirt with the rotunda
brake vacuum (4-0009) or equivalent or the
rotunda brake parts washer (65-0016) or
equivalent. Caliper
4. If a piston is removed from a master cylinder or 1. Check the caliper attaching bolts torque. Torque
caliper for any reason the piston seals must be them to specification, if required.
replaced.
2. Visually check the caliper. If the caliper housing is
All foreign material must be kept off braking leaking it should be replaced. If a seal is leaking
surfaces and associated components. the caliper must be disassembled and new seals
Handling of components should be done in a installed. If a piston is seized in the bore and upon
way to avoid deformation, nicking or disassembly is found to be scored it must be
scratching of brake pads or braking surfaces. replaced. If the caliper is found to be distorted or
damaged or if the cylinder bores are excessively
Changing Brake Fluid scored or worn replace the caliper assembly.
NOTE: Do not allow the reservoirs to empty. Refer to Warning under Service Precautions.
1. If this procedure is adhered to, air will not enter 3. Wash all parts with methylated spirits and dry with
the system and the time taken to change the fluid compressed air or lint free cloth.
will be kept to a minimum. 4. Blow out the caliper bore and all drilled passages
Proceed in the same manner and order as for with compressed air.
bleeding the system using a transparent bleed 5. Inspect the piston for scoring, pitting, corrosion or
tube attached to a bleed screw and a glass areas where the chrome plating has worn off. If
jar. Refer to Brake Bleeding in this section. any damage is present replace the piston. Black
Pump out most, but not all, of the fluid in the stains, caused by the seal, will do no harm.
reservoirs. 6. Inspect the caliper bore for scoring, pitting,
Top up the reservoirs with new unused fluid. corrosion or damage and replace the caliper if any
of these factors are present. The caliper must not
Ensure the reservoirs are kept topped up. be honed.
When new fluid is seen in the transparent
tube, continue to bleed for two full strokes of 7. Inspect all other components and replace if wear
the pedal and close the bleed screw. or damage exists.
Repeat the procedure at each bleed screw in 8. The calipers must not be interchanged from one
turn. side to the other. When the caliper is installed on
its proper side the bleeder screw will be at the top
Top up the reservoir and road test vehicle. of the piston bore.
Brake Pedal Clearance Check 9. Refer to Section 206-03 or Section 206-04 for
detailed Caliper replacement information.
1. The brake system is designed to permit full stroke
of the master cylinder when the brake pedal is
fully depressed.
G17364 en 01/2003 2003.0 BA Falcon

Brake System Leak Check

1. Check the brake fluid level. If the fluid level is
below the MIN line on the brake master cylinder
reservoir add the necessary amount of High
Performance SUPER DOT 4 brake fluid meeting
Ford Specification ESA-M6C25-A or SUPER DOT
4 equivalent.
2. Inspect the (1) brake line nuts and the (2) brake
master cylinder reservoir for fluid leaks.
3. Inspect the brake lines and hoses for fluid leaks.

4. Inspect the rear disk brake caliper for leaks.
5. Inspect the front disk brake calipers for leaks.
6. If a hydraulic leak is detected, refer to Section
206-06.
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206-03-1 Front Disk Brake 206-03-1
SECTION : 206-03 Front Disk Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-03-2
Front Disc Brake ....................................................................................................................206-03-3
Disc Pad Running Clearance ...............................................................................................206-03-4
Wear Adjustment ..................................................................................................................206-03-4
Rotor ....................................................................................................................................206-03-4
Front Disc Brake ....................................................................................................................206-03-5
Brake Pads ............................................................................................................................206-03-6
Front Brake Hose ...................................................................................................................206-03-7
Brake Caliper Body ................................................................................................................206-03-7
Brake Disc ..............................................................................................................................206-03-8
Brake Caliper .........................................................................................................................206-03-9
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Minimum brake disc 26.0
thickness(discard
thickness)
Fluid
Brake fluid ESZ-M6C55-A
Lubricant
High melting point grease Dow Corning 44/Niglube
Rx2
Pad
Material JBUF85FF
Lining wear limit 1.0mm
Description Nm
Brake hose bolts 30
Disc brake caliper bolts 115
Brake hose banjo bolt 12-14
Caliper body bolt 98-132
G96750 en 01/2003 2003.0 BA Falcon

Front Disc Brake

Front Disc Brake Components
Item Description hydraulic seal between the piston and the cylinder
wall.
1 Front Disc Caliper Assembly
The top of the piston is machined to accept a sealing
2 Front Wheel Knuckle
dust boot. The outside diameter of the boot is
3 Brake Line Bracket captured by a recess in the top of the cylinder bore
4 Caliper Retaining Bolt x 2 and the piston. The inside diameter of the boot fits
5 ABS Sensor and Elec. Cable into the groove which is machined in the piston. The
piston is precision ground and chrome plated steel,
6 ABS Sensor Retaining Bolt giving it a very hard and durable surface. The use of
7 Wheel Hub and Tone Wheel abrasives or any attempt to re-machine the piston will
8 Brake Disc Rotor destroy the required surface finish.
9 Front Spinle Nut The sliding caliper feature automatically compensates
for lining wear. The abutment bracket is rigidly fixed to
10 Front Hub Cap Seal
the steering knuckle while the housing slides within
The dual piston hydraulic disc brake caliper is the abutment bracket by means of two guide pins
constructed from a single casting which contains two bolted to the housing.
piston bores in the inboard section of the casting.
(Inboard refers to the side of the casting which is Each caliper contains two pad assemblies. They are
constructed of a stamped metal shoe with the lining
nearest the centreline of the vehicle when the caliper
integrally moulded to the shoe.
is mounted.)
The fluid inlet hole and bleeder valve hole are When the brake pedal is applied, brake fluid is
displaced into the cylinders moving the pistons
machined into the inboard section of the caliper and
outward. This action forces the inner pad and lining
connect directly to the piston bores. Each cylinder
contains a piston and seal. assembly against the rotor. The resultant reaction
forces the caliper housing and outboard pad assembly
The seal has a square section, and is located in a inward against the rotor. The resultant forces of the
groove which is machined in the cylinder bore. It fits pads on the rotor are equal. Braking torque is
around the outside diameter of the piston to provide a transferred from the outer brake pad abutments
G96751 en 01/2003 2003.0 BA Falcon

through the caliper housing into the abutment bracket. Guide Pin Adjustments
Braking torque from the inner brake shoe is taken
directly into the abutment bracket.
When the brake pedal is released the seal retracts the
piston into the cylinder and the caliper housing slides
outward releasing the brake.
Disc Pad Running Clearance
Piston Adjustment
Brakes Applied
Item Description
1 Pad Abutment Bracket
2 Guided pin and boot assembly
3 Guide pin bolt
4 Piston
5 Piston dust boot
6 Pad abutment shim
7 Pads
Item Description The figure above shows the guide pin installation.
1 Piston Seal Distorted Running clearance - the caliper head moves back and
2 Caliper Housing forth on low friction guide pins. These guide pins and
3 Piston intended to accommodate disc runout and bearing
float. If friction in the guide pin slide is high, instead of
Brakes Released the caliper head sliding back and forth, the disc will
knock the piston into the head, causing a spongy
pedal on subsequent applications.
Wear Adjustment
Pad wear is taken up during brake application as
follows:
by the piston sliding past the seal to a new
position.
by movement of the caliper head on the slide pin.
Rotor
The cast iron disc is of the ventilated rotor-type and is
separated from the front hub.
Item Description
1 Piston Seal Relaxed
2 Piston
3 Caliper Housing
The figures above show what happens to the pistons
and the seals during usage. The piston seals perform
the self-adjusting action. When the pistons are
pushed out by hydraulic pressure the piston seals
distort. When the hydraulic pressure is relieved the
seals relax and drag the pistons in, creating a disc to
pad running clearance.
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Front Disc Brake

Refer to Section 206-00
G96752 en 01/2003 2003.0 BA Falcon

Brake Pads 3. Using (G-clamps as shown), tighten until each

piston bottoms on each bore.
Removal NOTE: Ensure that one end of the G-clamp rests
on (or is adjacent to) the brake hose attaching
WARNING: Although original equipment pad bolt head, and the other against the outer pad.
material is asbestos free. If non genuine pads are
DO NOT exert excess force on the clamps as
used, the following applies:
damage to steel pistons may result.
Asbestos fiber dust may be present on brake
and clutch assemblies and is hazardous to
health if inhaled.
Brake and clutch assemblies should be
cleaned using a vacuum cleaner
recommended for use with asbestos fibers
such as a brake/clutch/service vacuum. The
bag must be labeled per OSHA instructions,
sealed, and the trash hauler notified as to the
bag’s contents.
If the vacuum suitable for asbestos is not
available, cleaning should be done wet. If dust
generation is still possible, technicians should
wear goverment-approved toxic dust purifying
respirators. Failure to follow these
instructions may result in personal injury. Item Description
1. Clean and remove master cylinder reservoir cap. 1 Pad Abutment Bracket
Loosen front brake line connection at the master
cylinder, allowing fluid to bleed into a container 2 Guided pin and boot assembly
until master cylinder reservoir is one-third full. Re 3 Guide pin bolt
tighten line connection and replace master 4 Piston
cylinder cap. 5 Piston dust boot
WARNING: Brake fluid will damage 6 Pad abutment shim
paintwork. 7 Pads
NOTE: Do not completely remove brake line or
empty the reservoir or it will be necessary to 4. Using a suitable size open-end spanner to hold
bleed the system. the lower guide pin (7), remove and discard the
guide pin bolt (3).
NOTE: Discard the fluid removed. DO NOT NOTE: Old bolts must not be re-used, as they are
RE-USE. vital safety components that have a micro
NOTE: Removal of the fluid is necessary to encapsulated adhesive on the bolt thread.
prevent reservoir overflow when the caliper piston 5. Disengage brake hose grommet from bracket
is pushed back in its bore during pad attached with caliper mounting bolt.
replacement.
6. Swing caliper housing about the existing guide pin
2. With vehicle raised evenly on a hoist or jack until housing is clear of pads.
stands, mark relationship of wheel to hub and 7. Remove worn pads (7&8) from abutment bracket
remove the front wheels. (7) and inspect condition of brake disc. Discard
Using wheel nuts secure rotor to hub during work. end abutment shims (6).
NOTE: If more than one brake requires service,
work on only one brake at a time. Pad 8. Check guide pins for free movement in abutment
assemblies, must always be replaced in both bracket. If there is restriction of movement,
brakes. replace guide pins and/or guide pin boots.
Including high lube grease.
9. Clean any dirt from both the piston face, which
contacts the inner pad, and the caliper head area
that contacts the outer pad.
10. Inspect caliper assembly for fluid leaks or
damage.
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Installation
Front Brake Hose
1. Replace end abutment shims (6) in abutment
bracket (1), ensuring they are secure and clear of Removal
the rotor being careful not to bend them.
2. Install the inner (7) and outer (8) pads to the
abutment bracket (1), against the inner and outer
surface of the brake disc respectively.
3. Lower the brake calliper housing, ensuring that:
the piston boots (4&5) do not get caught
between the piston and inner pad (7).
4. Install and tighten the new guide pin bolt (3) to the
correct torque specification.
NOTE: Do not wedge anything between the
guide pin hex and the caliper as it could cause
incorrect alignment of the free sliding of the
caliper relative to the anchor plate.
5. Refit brake hose grommet to bracket attached to
caliper bracket, as previously positioned. Item Description
6. Replenish the brake fluid in the master cylinder 1 Clip
with fresh specified fluid. 2 Brake tube connector
7. Pump the brake pedal several times to position 3 Banjo bolt
the pad assemblies. 4 Grommet
8. Check for fluid leakage at all connections under
1. Remove banjo bolt and washers.
pedal pressure.
2. Remove grommer from hose positioning bracket.
9. Re-check fluid level in master cylinder reservoir.
3. Disconnect the brake tube connector.
10. Remove wheel nuts.
4. Remove clip (4).
11. Reinstall wheels, aligning marks made prior to
removal and remove jack stands or lower hoist. 5. Remove hose assembly.
12. Tighten wheel, securing nuts to the specified Installation
torque. 1. Install banjo bolt and new washers. Torque to
13. Road test vehicle and make several light specification.
60-0km/h stops to seat the linings. (The vehicle 2. Install grommet into hose positioning bracket.
may pull slightly to one side for the first few 3. Install hose into body bracket and install clip.
applications. This is normal until linings are NOTE: Ensure hose is engaged to bracket prior to
seated).. fitment of banjo bolt. Check routing for correct
clearance on completion.
4. Connect brake tube and torque to specification.
5. Bleed as outlined in procedure.
Brake Caliper Body

Removal
1. Raise and support the vehicle to ensure it is
stable and secure. Mark the relationship of the
wheel and the rotor and remove wheel.
2. Place a drain tray beneath caliper assembly.
Loosen and remove attaching bolt and hose end.
Discard washers and plug caliper body inlet port
and hose end to prevent contamination or fluid
loss.
G96755 en 01/2003 2003.0 BA Falcon

3. Disconnect hose. Discard copper sealing rings. 2. Remove the caliper assembly from the spindle
and the rotor, as previously described in this
section. If the caliper does not require servicing, it
is not necessary to disconnect the brake hose.
Position the caliper out of the way, and support it
with a wire to avoid damaging the caliper or the
hose. Handle the rotor, linings and caliper
assemblies carefully to avoid deformation, nicking,
scratching or contamination.
3. Remove the rotor from hub.
Installation
1. Position the rotor on the axle flange.
NOTE: Ensure that all mounting surfaces are
clean and free from contamination which could
cause possible disc runout.
Installation 2. Mount the caliper assembly on the spindle

1. Assemble caliper body to abutment bracket (1) by following the Disc Brake Caliper Assembly
securing upper guide pin using a new guide pin Installation procedure in this section.
bolt (3). 3. Install the wheel.
2. Lower the brake caliper housing, ensuring that:
1. the piston boots (4&5) do not get caught
between the piston and inner pad (7).
3. Install and tighten the new guide pin bolt (3) to the
correct torque specification.
NOTE: Ensure hose is engaged to bracket prior to
fitment of banjo bolt. Check routing for correct
NOTE: Do not wedge anything between the guide
pin hex and the caliper as it could cause incorrect
alignment of the free sliding of the caliper relative
to the anchor plate.
4. Reconnect new brake hose, using new, dry,
sealing washers. Tighten attaching bolt to the
correct torque specification ensuring hose routing
is removed.
5. Bleed brake system, refer to Brake system Bleed
in this section.
Brake Disc
Removal
1. Remove the wheel and tyre from the hub.
G96755 en 01/2003 2003.0 BA Falcon

Brake Caliper
Disassembly
Item Description 2. Remove brake pads (10&11) from abutment

bracket.
1 Sealing Ring
2 Caliper Body
3 Guide Pin Bolt
4 Bleed Screw Sealing Ring
5 Bleed Screw
6 Guide Pin
7 Guide Pin Boot
8 Piston Boot
9 Piston
10 Inner Pad Assembly
11 Outer Pad Assembly
12 Pad Abutment Shim
13 Abutment Bracket 3. Remove abutment bracket from mounting
1. Remove Brake Caliper. For additional information, knuckle. Remove abutment shims (12) from
refer to Section 206-03. abutment bracket.
NOTE: Ensure hose is engaged to bracket prior to 4. Withdraw guide pins (6) and boots (7) from
fitment of banjo bolt. Check routing for correct anchor plate. Separate boots from pins.
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206-03-10 Front Disk Brake 206-03-10
5. Remove pistons (9) by placing a spacer between 4. Coat piston boots (8) in specified grease and
the pistons and the caliper fingers and applying place boot over end of piston. Position each
air at the inlet port of the caliper housing until piston into caliper housing, seating each boot into
each piston is forced out of the bores. groove in caliper bore. Ensure the boot is
squarely and firmly seated in groove.
CAUTION: Inject air lightly and
progressively increase the pressure until the
piston is forced out of the bore. This
procedure is advisable to avoid physical
injury, as the pistons may develop
considerable force due to sudden pressure
increases.
6. Remove rubber piston boot (8) from bore.
7. Remove piston seal (1) from bore taking care not
to damage bore or seal locating groove.
5. Push each piston squarely into each bore by hand

until fully seated.
6. Ensure boot is fully seated in piston a caliper

grooves.
8. Remove bleed screw (5). Discard bleed screw

seal ring (4).
9. Inspect all parts as described in Cleaning and
Inspection.
Assembly
1. Place caliper assembly on a clean bench area
with the open end of caliper body (2) up.
2. Lubricate cylinder bores and pistons (9) with 7. Fit new bleed screw sealing ring (4).Reinstall
specified fluid. bleed screw (5).
3. Fit new seals (1) by positioning seal at one area 8. Lubricate guide pins (6) with specified grease.
in the groove and gently work around the cylinder Install new guide pin boots (7) onto the guide
bore with a finger until properly seated. Check to pins.
be sure the seal is not twisted or rolled in its
groove.
G96757 en 01/2003 2003.0 BA Falcon

206-03-11 Front Disk Brake 206-03-11
9. Reinstall guide pins into anchor plate, pushing the

guide pin boot over its groove. Ensure there is no
air trapped inside the boot.
10. Ensure abutment bracket mounting surfaces are
clean. Reinstall abutment bracket over brake disc,
securing anchor plate to mounting knuckle.
G96757 en 01/2003 2003.0 BA Falcon

206-04-1 Rear Disc Brake 206-04-1
SECTION : 206-04 Rear Disc Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-04-2
Rear Disc Brake.....................................................................................................................206-04-3
Service Brake ......................................................................................................................206-04-3
Parking Brake .......................................................................................................................206-04-3
Brake Calipers .......................................................................................................................206-04-4
Inspection .............................................................................................................................206-04-4
Brake Caliper Body ................................................................................................................206-04-5
Brake Caliper Assembly .........................................................................................................206-04-5
Rear Brake Hose ...................................................................................................................206-04-5
Brake Pads ............................................................................................................................206-04-6
Brake Disc ..............................................................................................................................206-04-7
Beam Axle Brake Disc ...........................................................................................................206-04-7
Brake Caliper .........................................................................................................................206-04-8
01/2003 2003.0 BA Falcon

206-04-2 Rear Disc Brake 206-04-2
SPECIFICATIONS
Rear disc brake minimum 14.5mm (0.57in)
thicknessª
Lubricants
High melting point grease Dow Corning 44/Niglube
Rx2
Pad
Lining wear limit 1.0mm
Material JBUF85FF
Description Nm
Brake caliper bolts 103
Brake disc shield bolts 11
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206-04-3 Rear Disc Brake 206-04-3
Rear Disc Brake

Rear Disc Brake System Components
Parking Brake
The parking brake utilizes a cable operated rear drum
system. For additional information, refer to Section
Item Description 206-05.
1 Knukle
2 Wheel hub
3 Washer
4 Nut
5 Rotor
6 Brake Caliper
7 Bolt
The rear wheel disc brake assembly consists of a
rotor mounted on the outer face of the axle shaft
flange and a single piston floating head caliper. A
splash shield, used primarily to prevent road
contaminants from contacting the inboard rotor and
pad surface is also mounted on the anchor bracket.
The outboard rotor and pad surfaces are protected by
the road wheel.
Service Brake
When the brake pedal is applied, brake fluid is
displaced into the caliper bore moving the piston
outward. This action forces the inner pad assembly
against the rotor. The resultant reaction forces the
caliper body and outboard pad assembly inward
against the rotor. Braking torque is transferred from
the outer and inner pad assemblies to the caliper
mounting bracket. When the brake pedal is released,
the piston seal retracts the piston a small amount
allowing the pads to release the clamping force.
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206-04-4 Rear Disc Brake 206-04-4
Brake Calipers
Inspection
1. Clean all residue from disc pad guide surfaces on
anchor bracket and caliper housing assembly.
NOTE: Always replace both axle caliper pads as
a set.
2. Inspect inner and outer pads. Lining wear limit is
1.0 mm.
3. Inspect anchor bracket. Replace anchor bracket if
corroded, worn or damaged.
4. Clean piston, housing and bleed screw. Use only
clean denatured alcohol for cleaning. Dry, filtered
compressed air should be used to dry all
components and blow out all passages in the
caliper housing and bleed screw. Care should be
taken to keep alcohol and debris away from eyes.
CAUTION: All components must be kept
away from any type of mineral oil as it will
damage rubber components.
5. Inspect piston. Replace piston if scoring, nicks,
corrosion, wear or damage is evident.
6. Inspect housing. Replace housing if bore is
scored, corroded, worn or damaged.
7. Lubricate seal and housing bore with silicone
grease or brake fluid.
8. Lubricate piston with brake fluid.
G86752 en 01/2003 2003.0 BA Falcon

206-04-5 Rear Disc Brake 206-04-5
Brake Caliper Body 2. Remove caliper mounting bolts.
Removal
NOTE: Where the use of brake fluid is required, use
only new, clean fluid to the correct specification, from
a sealed container.
1. Raise the vehicle and remove the wheel.
2. Use wheel nut to hold disc in place.
3. Remove banjo bolt and hose end. Discard
washers. Plug housing inlet port and hose end to
prevent contamination ingress or fluid loss.
4. Remove guide pin bolts (items 1 and 2) and
discard.
Installation
1. Place caliper housing assembly into its operating 3. Lift caliper free of rotor.
position. If springs are sticking through caliper 4. To install reverse steps 1-3.
housing inspection hole, lift caliper housing and
make necessary corrections to ensure springs are Rear Brake Hose
fully retained by housing.
Removal
2. Install new guide pin bolts.
3. Assemble banjo bolt, washers and hose end then
screw into housing inlet port. Torque guide bolts
to 28-34 Nm. Torque banjo bolt to specification.
fitment of banjo bolt. Check routing for correct
4. Bleed brakes ensuring that fluid reservoir is not
emptied. Start engine and pump brake pedal
slowly and firmly three times to ensure piston and
disc pads resume normal operational position.
Torque bleed screw to 9-14 Nm. Check for fluid
leakage and rectify if any found. Check fluid level
in master cylinder reservoir and fill to specified
level with new brake fluid.
NOTE: All hardware must be correctly installed Item Description
and torqued to specification. 1 Rivot
5. Install wheel and torque nuts to specification. 2 Rear Tube Connection
3 Grommet
Brake Caliper Assembly 4 Banjo Bolt
Removal and Installation 1. Disconnect rear brake tube connection.
1. Repeat steps 1 & 2 of brake caliper body removal. 2. Drill out rivot.
3. Remove grommet.
4. Remove banjo bolt.
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206-04-6 Rear Disc Brake 206-04-6
Installation 4. Position a C-clamp so that one end rests on rear

1. Install high tensile rivot. of caliper housing and the other end against outer
disc pad. Tighten clamp until piston bottoms in
base of caliper housing.
2. Connect tube to hose end.

3. Install hose grommet into bracket.
5. Remove and discard upper guide pin bolt.
4. Install banjo bolt through hose and into caliper. 6. Rotate caliper housing about lower caliper
NOTE: Ensure hose is engaged to bracket prior to mounting bolt and guide pin. Be careful not to
fitment of banjo bolt. Check routing for correct strain hose.
7. Remove inner and outer pads.
NOTE: Ensure fitment of new copper washers. NOTE: Always replace both axle caliper pads as
a set.
Brake Pads
8. Clean all residue from disc pad guide surfaces on
Removal anchor bracket and caliper housing.
9. Inspect guide pins for free movement in anchor
WARNING: Although original equipment pad bracket. Replace guide pins or boots if corroded
material is asbestos free. If non genuine pads are or damaged.
used, the following applies:
Installation
Asbestos fiber dust may be present on brake
and clutch assemblies and is hazardous to 1. Install new pads on anchor bracket. Apply
health if inhaled. approximately 0.1 gram of AKB-100 grease (or
equivalent) to pad abutment surfaces on the
Brake and clutch assemblies should be anchor bracket.
cleaned using a vacuum cleaner
recommended for use with asbestos fibers
such as a brake/clutch/service vacuum. The
bag must be labeled per OSHA instructions,
sealed, and the trash hauler notified as to the
bag’s contents.
If the vacuum suitable for asbestos is not
available, cleaning should be done wet. If dust
generation is still possible, technicians should
wear goverment-approved toxic dust purifying
respirators. Failure to follow these
1. Siphon approximately two-thirds of the total fluid
capacity from the master cylinder reservoir.
Discard the fluid (different to front brake).
2. Raise the vehicle and remove wheels. 2. Rotate caliper housing into its operating position.
3. Install two wheel nuts to retain rotor. 3. If springs are sticking through caliper housing
inspection hole, lift caliper housing and make
necessary corrections to ensure springs are fully
retained by housing.
4. Install new upper guide pin bolt and torque to
28-34 Nm.
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206-04-7 Rear Disc Brake 206-04-7
5. Top up master cylinder. Beam Axle Brake Disc

6. Start engine and pump brake pedal slowly and
firmly three times to ensure piston and disc pads Removal
resume normal operating position. 1. Raise the vehicle.
7. Check for fluid leakage and rectify if any found. 2. Wipe all dirt and grease from the brake pipe union
Check fluid level in master cylinder reservoir and and disconnect the union.
fill to specified level with new brake fluid. 3. Detach the flexible hose from the splash shield
8. Remove nuts retaining rotor and install wheels. bracket and plug the pipe and hose.
9. Lower vehicle and torque wheel nuts to 4. Remove the three screws attaching the splash
specification. shield to the axle flange.
Brake Disc Installation
1. Position the splash shield and install the attaching
Removal screws.
1. Raise the vehicle and remove the rear wheels. 2. Fit the flexible hose to the splash shield bracket
2. With the park brake control released disconnect and secure it with the locknut.
the park brake cable at the equalizer. 3. Remove the dust plugs and fit the pipe to the
hose.
4. Bleed the brakes as described in Section 206-00.
3. Disconnect the cable from the levers.

4. Remove the caliper head attaching bolts and
remove the caliper assembly from the rotor and
mounting bracket.
CAUTION: Do not allow the caliper to
hang from the hydraulic line.
5. Remove the screw securing the rotor to the axle
flange and remove the rotor (for beam axle only).
Installation
1. Position the rotor on the axle flange, ensuring that
all mounting surfaces are clean and free from
contamination which could cause possible disc
run-out. Install the securing screw.
2. Position the caliper correctly over the rotor and
slide straight into location until caliper head bolt
holes align with their respective holes in the
mounting bracket.
3. Install caliper mounting bolts and torque to
specification.
4. Connect the park brake cables to the levers and
the equalizer. Adjust the park brake as described
in Section 206-05
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206-04-8 Rear Disc Brake 206-04-8
Brake Caliper
Disassembly
Item Description 4. Remove piston (item 12). Pack a clean shop towel
between piston and housing finger then apply low
1 Bleed Screw
air pressure at housing inlet port to remove piston.
2 Caliper Housing
3 Anchor Bracket CAUTION: Apply light air pressure
initially and progressively increase until piston
4 Outer Disc Pad is forced out of bore. While removing piston
5 Boot keep hands away from piston/housing region
6 Guide Pin to avoid personal injury, as the piston may
7 Inner Disc Pad develop considerable force due to air
pressure.
8 Boot
5. Remove boot and seal using a small, pointed tool
9 Piston as per Section 206-03. Be careful not to damage
10 Seal the bore or seal groove. Discard.
11 Lower Mounting Bolt 6. Remove bleed screw (item 15) and dust cover
12 Inlet Port (item 16). Discard dust cover.
13 Upper Guide Pin Bolt Assembly
1. Remove brake caliper as described in this 1. Lubricate seal (item 13) and housing bore with
section. silicone grease or brake fluid.
2. Remove housing assembly (item 9), guide pins 2. Lubricate piston with brake fluid.
(items 3 and 4) and boots (items 5 and 6). 3. Install new seal (item 13) into housing bore seal
Discard boots. Plug anchor bracket (10) colette groove and ensure that it is not twisted.
pinholes (A) to prevent contamination ingress.
3. Remove disc pads (items 7 and 8). fitment of banjo bolt. Check routing for correct
G86759 en 01/2003 2003.0 BA Falcon

206-04-9 Rear Disc Brake 206-04-9
4. Install new boot (item 14) and piston. Install boot 8. Install disc pads on anchor bracket with outer disc
over open end of piston and feed along piston pad with clip-on insulator toward caliper housing
length towards closed end. Fully extend boot finger and inner disc pad with lining wear sensor
away from piston closed end with boot still on toward caliper piston.
piston ground surface. Install boot into housing
bore boot groove and ensure full engagement.
5. Slowly enter piston into bore by hand, then apply

steady pressure by hand to piston and press until
piston is fully seated in the bore. This process will
ensure that boot and seal are correctly positioned
in conjunction with no piston/housing bore
scoring.
6. Inspect piston and boot. Check that boot is

properly engaged in piston groove correctly.
7. Assemble dust cover and bleeder screw, then

screw into housing.
G86759 en 01/2003 2003.0 BA Falcon

206-05-1 Parking Brake and Actuation 206-05-1
SECTION : 206-05 Parking Brake and Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-05-2
Parking Brake — Sedan ........................................................................................................206-05-3
Parking Brake — Ute/Wagon .................................................................................................206-05-3
GENERAL PROCEDURES
Parking Brake Cable Adjustment ...........................................................................................206-05-4
Parking Brake Shoe Adjustment ............................................................................................206-05-4
Major Parking Brake Service .................................................................................................206-05-5
Parking Brake Shoes .............................................................................................................206-05-6
Parking Brake Handle ............................................................................................................206-05-6
Parking Brake Lever (Wagon), Column Shift (Ute) ................................................................206-05-7
IRS Parking Brake Cable Routing .........................................................................................206-05-7
Beam Axle Parking Brake Cable Routing ..............................................................................206-05-8
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Adjustment Nut 2—3
Parking Brake Screw-M6 (first 1000 10.4—12.4
vehicles only)
Parking Brake Screw-M8 20—30
Torquing of hardware is significiant to the operation of
the system.
G87680 en 01/2003 2003.0 BA Falcon

Parking Brake — Sedan

The parking brake is hand operated.
The parking brake utilises a dedicated rear drum
brake system. The service brake rotor also serves as
the parking brake drum.
The operating cable is routed from the parking brake
control assembly to the equalizer. The rear cables
connect the equalizer assembly to the rear drum
brakes.
NOTE: The following shoe and cable adjustment
procedures are to ensure correct cable/shoe settings,
the five click position to check for locking wheels is
not directly related to the effort/travel to hold the
vehicle on a grade, which will vary dependent on a
number of factors and could exceed five clicks.
Parking Brake — Ute/Wagon

Floor shift vehicles have a hand operated parking
brake.
Column shift utility vehicles have a seat mounted,
hand operated park brake with a return latch which
allows the lever to return to the rest postion after
being engaged.The engagement status of the park
brake is indicated by a warning lamp which is
illuminated when the park brake is on. An audible
warning chime is activated if the vehicle is driven
away with the park brake engaged.
The parking brake utilises a dedicated rear drum
brake system. The service brake rotor also serves as
the parking brake drum.
The operating cable is routed from the parking brake
control assembly to the equalizer. The rear cables
connect the equalizer assembly to the rear drum
brakes.
NOTE: The following shoe and cable adjustment
procedures are to ensure correct cable/shoe settings,
the four click position to check for locking wheels is
not directly related to the effort/travel to hold the
vehicle on a grade, which will vary dependent on a
number of factors and could exceed 4 clicks.
G87682 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Parking Brake Cable Adjustment Parking Brake Shoe Adjustment

Hand–Operated (Floor Shift) Adjustment
1. Adjust the parking brake shoes as described in 1. Raise the vehicle and suitably support.
this section. 2. Remove rear wheel.
2. Fully release the park brake lever. Re-apply lever 3. Remove service disc brake caliper from the
one click only. mounting plate. Refer to Section 206-04.
3. Tighten cable adjuster nut (under vehicle) until 4. Remove brake rotor by slowly turning and pulling
minimum drag is first felt on the rear wheels when outwards simultaneously keeping the brake rotor
rotating wheels by hand. square with the axle. If the brake rotor jams whilst
4. Apply the lever a further 3 clicks. removing, do not force it off. Push the brake rotor
5. Check that the rear wheels cannot be rotated by back to its original position and attempt removal
hand. again.
6. Fully release the park brake lever and check rear 5. Disconnect parking brake cable from the
wheels are free to turn by hand. operating lever at the parking brake. Inspect any
parts of doubtful strength or quality due to
7. Check operating levers at park brake are in the discolouration from heat or overstress, or are
‘OFF’ position and that there is minimum worn, they should be replaced.
clearance only between levers and cable eye.
6. Using a vernier caliper, measure shoe assembly
Sedan diameter as close as practical to the centre of the
lining material.
Ute/Wagon
Item Description
1 Adjusting Screen
2 Adjusting Nut
3 Shoe
4 Hold Down Spring
5 Screw
6 Tappet
7. Adjust shoe diameter to 189.6-189.8 mm by
turning the adjuster nut clockwise to increase
diameter.
8. Inspect brake rotor for wear and damage. Discard
worn or damaged brake rotors.
8. Check torque on p/clip tube mounting hardware. 9. Install brake rotor.
9. Check P/B warning light operates by first click. 10. Install service disc brake caliper and torque
10. Check P/B returns to floor of it’s own accord mounting bolts to specification.
when in OFF position. 11. Install rear wheel.
12. Connect parking brake cable to the operating
lever.
G87683 en 01/2003 2003.0 BA Falcon

13. Repeat 2 to 12 for the opposite side parking 8. Install adjustment pawl to the backing plate with
brake. pop rivet provided.
14. Adjust the parking brake cable in accordance with 9. Adjustment pawls are left and right hand. Ensure
the procedure described in this section. correct fitment.
10. Install parking brake adjustment screw to fully
Major Parking Brake Service home position in notched adjusting nut.
1. Raise the vehicle. 11. Back off 1/4 of a turn.
2. Remove rear wheel, disc brake caliper and rotor. 12. Install screw and nut assembly into the backing
3. Remove and discard: plate on the adjustment pawl side. Keep the shoe
Adjusting Nut slot parallel with the backing plate face.
Adjusting Screw 13. Install pushrod into tappet.
Adjusting Pawl 14. Install pushrod and tappet into backing plate.
Ensure pushrod set correctly in lever socket by
Tappet holding the lever into the backing plate whilst
Pushrod inserting pushrod and tappet.
4. Remove and discard the operating lever and dust 15. Clean excess grease away using a clean rag.
cover assembly. 16. Install shoe and lining assembly. Refer to Parking
5. Clean backing plate. The cleaning fluid must be a Brake Shoe Replacement in this section.
high flash point oil-free solvent such as 17. Repeat 2 to 14 for opposite side parking brake.
tricloroethylene or acetane. These cleaning fluids
are usually highly flammable and harmful if
vapours are inhaled for prolonged periods.
Manufacturer warnings and recommendations
should be strictly adhered to. Ensure actuation
cavity in backing plate is free from grease and
any other contamination.
6. Install lever and dust cover assembly. Slide the
lever onto the dust cover notches. Insert the lever
and dust cover assembly into the backing plate
with the lever cable retainer end positioned
downward. Refit the dust cover by stretching it
over the cast retainer on the back plate.
Item Description
1 Dust Cover
2 Lever
3 Cable Retainer
4 Dust Cover Notches
7. Lubricate actuation cavity and tappet.
CAUTION: Ensure cavity internal bore is
fully covered with grease.
G87685 en 01/2003 2003.0 BA Falcon

Parking Brake Shoes 8. Install new shoe assembly.

CAUTION: Ensure hands are clean.
Position shoe assembly over the axle shaft.
The shoe will be on the outboard side of the
actuation mechanism. Slide the shoe towards
the hold-down spring engaging the shoe tips
in both the adjusting screw and the tappet
slots.
The shoe assembly must be resting against 3
pads on the backing plate with the branding
facing outboard.
9. Install new hold-down springs and their attaching
screws. Tighten screw to 2-5 Nm.
CAUTION: Ensure the spring and screw
are fully seated. Inspect shoe assembly
position. Shoe must be central on the backing
Item Description plate and both tips located in the slots
1 Boot correctly. Check the actuation mechanism.
2 Adjuster Nut Manually apply the parking brake operation
3 Adjuster Screw lever. If the mechanism does not operate, the
parking brake must be disassembled and
4 Adjuster Pawl reassembled.
5 Shoe & Lining 10. Adjust shoe diameter. Refer to parking brake
6 Self tapping Screw shoe adjustment in this section.
7 Hold Down Spring 11. Repeat procedure for the opposite side parking
8 Back Plate brake.
9 Tappet Parking Brake Handle
10 Pushrod
11 Lever Removal
1. Remove driver seat.
2. Remove 3 M8 Screws from handle.
3. Remove HEX Screw 32x14.
2. Remove rear wheel, disc brake caliper, rotor and
cable. 4. Remove P-Clip.
3. Remove or disconnect hold-down springs by Ute/Wagon
undoing its attaching screw.
4. Remove the parking brake shoe by gently lifting
the shoe over the axle flange, the shoe will pivot
from the actuation mechanism. Once clear of the
flange, disconnect from the actuation mechanism
and discard.
CAUTION: Ensure the actuation
mechanism is not disturbed. An elastic band
may be used to contain the mechanism.
5. Clean debris and dust away from the backing
plate using a clean rag.
6. Adjust parking brake adjustment screw to fully
home position in the notched adjustment nut then
back off 1/4 of a turn.
7. Align the shoe slots in both the adjusting screw
and the tappet to be parallel with the backing
plate face.
G87686 en 01/2003 2003.0 BA Falcon

Sedan 4. Rotate P-Clips.

5. Release cable from park brake.
5. Release cable from park brake.

Installation
1. Reverse removal procedure.
IRS Parking Brake Cable Routing
Removal
1. Remove parking brake handle as shown
previously in this section.
2. Route Park Brake cable to rear of Differential.
Installation
Parking Brake Lever — Column Shift
(Ute)
Removal
1. Remove 2 retaining bolts.
3. Unclip cable as shown.
2. Remove bracket outboard of RH front seat

assembly.
3. Remove 2 HEX Screws 32x14.
G87689 en 01/2003 2003.0 BA Falcon

Installation
Beam Axle Parking Brake Cable

Routing
Removal
1. Loosen and remove adjuster nut.
2. Disconnect cables from equaliser bracket, support
brackets and from Banksia lever.
Wagon
G87689 en 01/2003 2003.0 BA Falcon

Ute - Petrol
Ute - LPG
NOTE: Note on LPG Ute there are two sets of cotton

reels to support cable over the lenght of the LPG tank.
Installation
1. Route cables per diagrams above.
2. Ensure cable ferrules and white clips are seated
into equaliser.
3. Fit adjuster nut and adjust system as per sedan.
G87690 en 01/2003 2003.0 BA Falcon

206-06-1 Hydraulic Brake Actuation 206-06-1
SECTION : 206-06 Hydraulic Brake Actuation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-06-2
Hydraulic Brake Actuation ......................................................................................................206-06-3
Hydraulic Brake System .......................................................................................................206-06-3
Dual Hydraulic Brake System ..............................................................................................206-06-3
Brake Master Cylinder .........................................................................................................206-06-3
Dual Master Cylinder Brake System (where fitted) ..............................................................206-06-3
Power Brake Booster ...........................................................................................................206-06-4
Acronyms and Abbreviations ...............................................................................................206-06-5
Hydraulic Brake Actuation ......................................................................................................206-06-6
Function Test .......................................................................................................................206-06-7
Symptom Chart ....................................................................................................................206-06-7
Connector Circuit Reference ................................................................................................206-06-8
Pinpoint Tests ....................................................................................................................206-06-10
GENERAL PROCEDURES
Adjustable Brake Indexing ...................................................................................................206-06-16
System Bleeding ..................................................................................................................206-06-16
Power Brake Booster Testing ..............................................................................................206-06-16
Hydraulic Line Repair ...........................................................................................................206-06-16
Brake Hose Replacement ....................................................................................................206-06-16
Brake Tube Replacement ....................................................................................................206-06-16
Brake Box Assembly ............................................................................................................206-06-17
Brake Pedal Adjustment Motor ............................................................................................206-06-20
Brake Pedal Motor Cables ...................................................................................................206-06-20
Brake Pedal Control Switch (where fitted) ...........................................................................206-06-21
Brake and Cruise Pedal Switch Setting ...............................................................................206-06-21
Brake Pedal Pad ..................................................................................................................206-06-22
Accelerator Pedal Pad .........................................................................................................206-06-22
Power Brake Booster ...........................................................................................................206-06-22
Dual Master Cylinder ...........................................................................................................206-06-23
Electronic Throttle Control Module .......................................................................................206-06-24
Dual Master Cylinder ...........................................................................................................206-06-24
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Brake Fluid (Ford) Mobil ESZ - M6C55A
Description Nm
Adjuster Motor Retaining Bolts 5 ± 0.5
(adjustable pedal)
Pedal Box Housing 22.5 ± 3.4
Brake Booster Retaining Nuts 22.5 ± 3.4
G22112 en 01/2003 2003.0 BA Falcon

Hydraulic Brake Actuation Dual Master Cylinder Brake System

(where fitted)
Hydraulic Brake System
WARNING: Brake fluid contains polyglycol

ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If brake
fluid contacts eyes, flush eyes for 15 minutes with
cold running water. Get medical attention if
irritation persists. If taken internally, drink water
and induce vomiting. Get medical attention
immediately.
Dual Hydraulic Brake System
The hydraulic brake system is a pedal operated,
front/rear split, dual line brake system that consists of
the following;
Power brake booster The system consists of a dual master cylinder which
Brake master cylinder incorporates a proportioning valve, on some models
Brake pressure control valves (where fitted) only a pressure differential valve assembly, a ‘fast fill’
valve assembly and a switch. The switch on the
Front disc brake caliper assemblies differential valve or fluid level switch activates a brake
Front disc brake rotors fail warning light, located on the instrument panel.
Rear disc brake calipers The primary system operates the front brakes and
Brake pipes and hoses secondary the rears.
Anti-lock Brake System (ABS) components Fast Fill Valve
Brake Master Cylinder The ‘fast fill’ (fast pressure build up) valve provides
reduced pedal travel by rapidly overcoming the large
The brake master cylinder is a dual piston type. The low pressure displacements associated with roll-back
master cylinder operates as follows; disc brakes that allow for the elimination of pad to
When the brake pedal is applied, pressure is rotor drag.
transferred by mechanical linkage to the primary As well as a conventional secondary piston, the
and secondary systems. cylinder incorporates a stepped primary piston located
Brake master cylinder pistons apply hydraulic nearest the booster.
pressure to the two circuits. The fluid moved by the larger diameter stepped piston
The master cylinder consists of; is pushed over the primary seal of the smaller
Primary and secondary pistons. diameter primary piston so bringing the brakes into
Brake master cylinder reservoir with integral fluid operation earlier.
level warning indicator (on all ABS cars and The ‘fast fill’ valve incorporates a pressure seal in one
pressure differentiated switch on non ABS utes). direction, a one-way ball valve in the other and a
Fixed proportioning valve on non ABS cars. by-pass bleed groove. In operation, the ball valve
retains fluid in the master cylinder until a pre-set line
pressure is reached, after which all further increases
in pressure are exhausted back into the reservoir,
reverting the operation of the master cylinder to that of
a normal unit. Recuperation is achieved by fluid
by-passing the pressure seal. The by-pass bleed
groove allows fluid to by-pass the ball valve ensuring
that a fluid passage is maintained between the brake
pressure circuit and reservoir in the brakes-off
position.
Pressure Differential and Proportioning Valve
Proportioning Valve (where fitted on non ABS ¾
tonne Utes)
The proportioning valve regulates the rear brake
system hydraulic pressure and is located between the
G22113 en 01/2003 2003.0 BA Falcon

rear brake system inlet and outlet ports of the master Operation
cylinder.
The Booster Servo Unit is designed to assist the effort
When the brake pedal is applied, the full rear brake applied by the driver’s foot on the brake pedal. It uses
fluid pressure passes through the proportioning valve the vacuum created in the engine inlet manifold to
to the rear brake hydraulic system until the valve split boost force applied at the master cylinder push rod in
point is attained. Above the split point, the an exact and controlled manner.
proportioning valve reduces hydraulic pressure to the The assembly is mounted between the brake pedal
rear brakes for balanced braking. and the master cylinder, with the push rod from the
The proportioning valve for ¾ tonne non ABS utes rear of the unit connected to the brake pedal, and a
has a 2.5 MPa split point, on the end face of the push rod from the front of the unit abuts the master
master cylinder body. cylinder piston.
NOTE: For 1 tonne non ABS utes, the master cylinder The force which assists the pedal effort is obtained by
does not contain proportioning valve, split point is admitting atmospheric pressure to one side of the
shown as ‘C000’ stamped on outside of cylinder. diaphragm which is suspended in a vacuum. The
Proportioning in this case is handled via a load difference in pressure moves the diaphragm/s and
sensing proportioning valve located over rear axle. this movement is used in a controlled manner to
augment the driver’s pedal effort.
Pressure Differential Valve (where fitted on non In the case of a vacuum failure, the valve and rod
ABS vehicles) assembly of the servo and the master cylinder push
The brake fail warning light switch is mounted in the rod act as a single push rod. The brakes will,
valve body with the spring-loaded plunger fitting into a therefore, work in the conventional manner, but more
tapered groove in the centre of the spool. With the effort will be required on the brake pedal.
spool in a centralized position the switch contacts
remain open. Adjustable Pedal Box
Should there be a loss of pressure in either the front Description
or rear brake system, when the brake pedal is The pedal box assembly is a unit construction
applied, the spool will move off centre closing the comprising a reinforced plastic structure upon which
switch contacts and turning on the warning light on the pedals, switchgear and adjustment motors are
the instrument panel. mounted.
After repairs have been made and the brake system The complete pedal box assembly can be removed
bled, when the brakes are applied the pressure in the from the vehicle as a single unit.
front and rear systems will equalize, centralizing the
spool and opening the switch contacts thus turning off The pedal assembly incorporates the ETC or drive by
the warning light. wire accelerator sender unit. In the adjustable version
the brake and accelerator pedals are height
Fluid Level Warning Switch (All ABS cars only) adjustable via a aswitch on the side of the steering
All ABS models have a fluid level warning switch and column.
no differential switch. Where applicable pedal adjustment is achieved by a
single drive motor attached directly to the accelerator
The warning switch is dipped into the fluid reservoir pedal with a drive cable running to a gear box on the
and interacts with a float within the fluid. When the brake pedal, adjustment of brake and accelerator
fluid level drops below a predetermined level the pedals is simultaneous.
switch activates, resulting in a warning light on the
instrument panel. Acronyms and Abbreviations
Power Brake Booster APM Accelerator Pedal Module
Description PCM Power Train Module
BEM Body Electronic Module
Both 6 and 8 cylinder vehicles are equipped with a
twin diaphragm brake booster. Step Over Height Difference Between Brake and
Accelerator Pedal
The brake booster is a self-contained
vacuum-hydraulic braking unit mounted on the engine MSC Memory Seat Controller
side of the dash panel. PPS Pedal Position Sensor
The brake booster is of the vacuum suspended type
which utilizes engine intake manifold vacuum and
atmospheric pressure for its power.
The booster unit is to be replaced, not repaired, if
found to be defective.
G22113 en 01/2003 2003.0 BA Falcon

Item Description
1 Brake Pedal Transmission
2 Adjusting Cable
3 Potentiometer (Memory Only)
4 Adjusting Motor
5 APM
6 Adjusting Motor Transmission
7 Accelerator Pedal
8 Transmission Drive Cable
9 Brake Pedal
10 Brake Lamp Switch
11 Cruise Control Cut Off Switch (Brake)
12 Brake Booster Rod Pivot
G22113 en 01/2003 2003.0 BA Falcon

Hydraulic Brake Actuation should have a thorough knowledge of brake system

operation and accepted general performance
Inspection and Verification guidelines in order to make good comparisons and
detest performance problems.
Preliminary checks Select a road that is reasonably smooth and level.
NOTE: Always check the fluid level in brake master Gravel and bumpy roads, except to demonstrate ABS
cylinder before carrying out the test procedures. If the function are not suitable. The surface does not allow
fluid level is not at the correct level, fill the reservoir the tires to grip the road equally. Avoid crowned
with specified brake fluid. roads.
NOTE: Prior to carrying out any diagnosis, make A key factor in evaluating brake concerns is the
deceleration rate. This varies from vehicle to vehicle
certain that the brake warning indicator is functional.
and with changes in operating conditions. It is evident
Visually examine front and rear tires and wheel how well the brakes are working after just a few
assemblies for damage such as uneven wear applications.
patterns, tread worm out or sidewall damage. Check these items before entering Diagnostics.
Make sure the tires are of the same size, type and,
where possible, same manufacture. Install a new tire Topic Specification
or wheel if it is damaged or excessively worm. Wheels Brake Fluid Ensure that the Reservoir is Filled
and tires must be cleared of any foreign material and Reservoir to the Max Point. Use Ford
tire pressures adjusted to the correct specification. Approved Brake Fluid Mobil ESZ -
M6C55A.
If tires exhibit uneven wear or feathering, the cause
must be corrected. Check steering and suspension CAUTION: Do not allow
components for damage or wear and, if necessary brake fluid to contact vehicle
check and adjust front alignment. paint work.
A change in brake pedal feel is usually the first Vehicle Test Ensure That Your Local State
indicator of a brake concern. The change may only be Drive to Speed Limits are Not Exceeded
normal ABS function, but maybe sufficient cause for Confirm Fault
further investigation. The brake warning indicator in
the instrument cluster and the brake fluid level in the Battery Voltage Must be Greater Than 12 Volts
brake master cylinder reservoir are also indicators of Obstructions Check for Any Obstructions at the
the system concerns. Brake Pedal Area, Such as Floor
If the wheel is locked and the vehicle must be moved, Mats and Wiring Harnesses
open the bleeder screw at the locked wheel to let out
enough fluid to relieve the pressure. Close the bleeder
Visual Inspection Chart
screw. This bleeding operation may release the Mechanical Electrical
brakes but it will not correct the locked wheel
condition, repair the locked components before Brake Pedal Fuse(s)
proceeding. Pedal Pad Relay(s)
Adjustment Wiring harness
Brake Booster mechanism Electrical connector(s)
Brake pedal switches
Inspect all hoses and connections, all unused vacuum MSC
connectors should be capped. Hoses and their
connections should be correctly secured and in good
condition with no holes, soft or collapsed areas.
Road test
Perform a road test to compare actual vehicle braking
performance with the standard performances
expected by the driver. The ability of the test driver to
make valid comparisons and detect performance
deficiencies will depend on experience. The driver
G22114 en 01/2003 2003.0 BA Falcon

Function Test
Condition Possible Source Function Test Pin Point Test
Pedal Feel Pedal Slow or does not Manual Application Test of 206-06-B
return the Brake Pedal to confirm 206-06-B
Binding / Raspy pedal Manual Test
Worn Pedal Pad Visual Inspection
Brake Lamp Switch Not Functioning Visual Inspection 206-06-C
Adjustment Visual Inspection
Lack of Braking Excessive Force Manual Application Test of
Efficiency Required the Brake Pedal to confirm
Master Cylinder Visual Inspection
Leakage Manual Application Test of
Brake Booster the Brake Pedal to confirm
Tyre Wear Visual Inspection
Tyre Pressure Pressure Check
Adjustable Pedal Memory Manual Application Test of 206-06-E
Adjustment Motor Fault the Brake Pedal to confirm 310-02-C5 & 6
No Pedal Response Measurement
Adjustment Cable
Brake and Accelerator
Pedal Heights Incorrect
Symptom Chart

Pedal Feel Brake Pedal Not Returning on Release Go to Pin Point Test 206-06-B
Excessive Pedal Travel Braking System Diagnosis. Refer to

this section.
"Raspy" feel Go to Pin Point Test 206-06-B
Pedal Binding at Pivot Go to Pin Point Test 206-06-A
Pedal Pad Worn Replace Brake Pedal Pad. Refer to

procedure in this section.
Obstruction at Pedal Go to Pin Point Test 206-06-B
Poor Braking Efficiency Faulty Brake Booster Braking System Diagnosis. Refer to
this section.
Brake Disc Pads Worn Refer to Brake section 206-03, 206-04.
Booster Rod Disconnected Go to Pin Point Test E.

Vacuum Poor, Leaking or Refer to Braking System Diagnosis.
disconnection at the Brake Booster Refer to this section.
Cruise Control not turning off when Brake Master Cylinder Leaking / Faulty Refer to Braking System Diagnosis.
brake applied Refer to this section.
Cruise Control Switch Faulty / Plug Go to Pin Point Test D
Disconnected
Stop Lamp Switch Faulty / Plug Go to Pin Point Test C
Disconnected
G22114 en 01/2003 2003.0 BA Falcon


Adjustable Brake Pedal Cannot Adjust Pedals Go to Pin Point Test E
Faulty Memory Go to Pin Point Test E
Pedal "Step Over" Height Incorrect Go to section 310-02, Pin Point Test
C.
Stop Lamp Switch Stop Lamp Switch Faulty Go to Pin Point Test C
Connector Circuit Reference
CONNECTOR C - 378 PEDAL POSITION SENSOR (POTENTIOMETER)
Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

1 BLANK
2 1491A (Blue / Yellow) Resistance / Voltage
Pedal Position Sensor A
3 1491 (White) Resistance / Voltage
Pedal Position Sensor B
CONNECTOR C - 191 BRAKE LAMP SWITCH

1 10AA (Green / Red) Ohms - Continuity
Brake Switch High (only with pedal depressed)
2 10Y (Green / Red) Ohms - Continuity
Brake Switch Signal (only with pedal depressed)
G22114 en 01/2003 2003.0 BA Falcon

CONNECTOR C - 379 PEDAL ADJUSTING MOTOR

NOTE: Ignition to be "ON" for Voltage Tests.
NOTE: Battery to be disconnected for resistance checks.

1 1489 (R), 1494 (L) Voltage less than 2 Volts
2 1490 (W), 1495 (R) Voltage less than 2 Volts
CONNECTOR C - 36 CRUISE CONTROL SWITCH (BRAKE PEDAL)

1 10AC (Green/Red) Ohms - Continuity
Cruise Control - High
2 511 (Blue/Green) Ohms - Continuity
Cruise Control - Signal
CONNECTOR C - 111 CRUISE CONTROL SWITCH (CLUTCH)

1 10AC (Green/Red) Ohms - Continuity
Cruise Control - Signal (Yes - nominal state)
2 57FH ((Blue) Ohms - Continuity
Cruise Control - High (Yes - nominal state)
G22114 en 01/2003 2003.0 BA Falcon

CONNECTOR C - 395 PEDAL BOX HARNESS

NOTE: Depending on the vehicle level some of the terminals listed below will be blank. High series connector
shown. Values given are with connector C-395 connected, ignition on and back probing the terminals.

1 10AB (Green/Red) 12 - 14 Volts
Brake and Cruise switch (High)
2 1489 (Red) Using adjustment switch - Centre =0 Volts,
Pedal adjusting motor - A Upwards = 12-14 Volts. Downwards = 0.1 Volt
3 1490 (White) Using adjustment switch - Centre =0 Volts,
Pedal adjusting motor - B Upwards = 0.1 Volt. Downwards = 12-14 Volts
4 57 H (Black) Clutch switch N/A
5 511 (Blue/Green) 12-14 Volts (Brake pedal pushed - 0 Volts)
Cruise control deactivation switch -
signal
10Y (Green/Red) 0 Volts (Brake pedal pushed - 12-14 Volts)
Brake switch - signal
1491 (White) N/A
Pedal position sensor - B
1491A (Blue/Yellow) N/A
Pedal position sensor - A
BLANK
92 (Blue/Yellow) N/A
Clutch switch - signal
Pinpoint Tests
PINPOINT TEST A : EXCESSIVE BRAKE PEDAL MOVEMENT AT PIVOT
A1 PEDAL MOVEMENT CHECK

Grasp the Brake pedal pad area with your hand. Yes
Go to A2
Move the pedal from side to side to check for movement at the upper
pivot area. No
Carry out check in the applied and not applied brake pedal position. Okay
Is the pedal movement more than the maximum of ± 3.5 mm?
G22114 en 01/2003 2003.0 BA Falcon


A2 PIVOT PIN HOUSING DAMAGE
Carry out this check the same as described in test step A 1. Yes
Replace the pedal box assembly.
Using a Torch visually inspect for any cracks around the pivot pin Refer to removal and installation instructions in
housing as the pedal is moved side to side and applied towards floor. this chapter.
Were any cracks found?
No
Okay
PINPOINT TEST B : PEDAL FEEL INCORRECT
CAUTION: Step B2, Remember to tighten the Booster retaining nuts to (22.5 +/- 3.4 NM) when the
test is completed.
B1 OBSTRUCTIONS AT PEDAL
Check for obstructions at and / under the brake pedal, such as a floor Yes
mat or wiring harness fouling the upper mechanism. Remove the obstruction and recheck
Did you find an obstruction? No
Go to B2
B2 BRAKE PEDAL RETURN

Loosen the Four nuts used to retain the brake booster to the pedal Yes
box. Replace the pedal box assembly.
Refer to removal and installation instructions in
Remove the pin used to retain the booster rod to the brake pedal. this chapter.
Detach the booster rod from the brake pedal.
No
Move the brake pedal up and down slowly, looking for evidence of Go to the brake booster. Refer to removal and
binding. installation instructions in this chapter
Did the brake pedal bind when moving up and down?
PINPOINT TEST C : STOP LAMP SWITCH

C1 STOP LAMP OPERATIONAL CHECK
Ignition ON. Yes
Stop lamp circuit Okay
Apply brake pedal.
Do the rear Stop lamps illuminate? No
Go to C2
C2 STOP LAMP CIRCUIT FUSE

Check the 15 Amp Fuse # 7. Yes
Replace Fuse and recheck.
Was Fuse blown? NOTE: If Fuse blows again, this could indicate
an electrical system fault.
No
Go to C3
G22114 en 01/2003 2003.0 BA Falcon


C3 PCM CHECK
Back probe an earth at the PCM connector terminal B25 B00 (G-R Yes
wire). PCM issue. Refer to Section 303-14.
Ignition ON. No
Apply brake pedal. Go to C4
Do the rear stop lamps now illuminate?
C4 STOP LAMP SWITCH CONTINUITY

Remove the Stop lamp switch. Refer to Section 417-01. Yes
Stop lamp switch Okay
Carry out a continuity test.
With the stop lamp switch plunger Out = Continuity. No
Replace the stop lamp switch. Refer in this
Push the stop lamp switch plunger Inwards = Open circuit. Section.
Is the stop lamp switch continuity check Okay?
PINPOINT TEST D : CRUISE CONTROL BRAKE PEDAL CUT OFF SWITCH
D1 STOP LAMP CIRCUIT FUSE

Check the 15 Amp Fuse ??? Yes
No
Go to D2
D2 CRUISE CONTROL SWITCH CONTINUITY

Remove the cruise control switch, colour Green. Refer to Section Yes
303-14. Go to D3
Carry out a continuity test. No
With the switch pin Out = Open circuit. Replace the cruise control switch. Refer to
Section 303-14.
Push the switch pin Inwards = continuity.
Is the cruise control switch continuity check Okay?
D3 SWITCH EARTH CIRCUIT CONTINUITY

Disconnect the electrical connector at the cruise control switch and Yes
the PCM. PCM issue. Refer to Section 303-14.
Check the LG wire (511) from the switch connector to the PCM No
terminal B32 RBS. Check and repair wiring or terminal fault
Was there continuity?
G22114 en 01/2003 2003.0 BA Falcon

PINPOINT TEST E : ADJUSTABLE PEDAL ISSUES

NOTE: The Pedal adjustment motor is equipped with a Thermal cutout feature. If the motor is operated for an
extended period this Thermal cutout will open circuit (trip). In this case wait for 5 Minutes to allow resetting of
the Thermal cutout device.
E1 NO ADJUSTMENT RESPONSE - PART 1

Check to see if the electric wiring connector C-379 is connected, to Yes
the pedal adjustment motor. Go to E2
Is C-379 connected? No
Reconnect the connector and retest
E2 PEDAL BOX HARNESS

Check to see if the electrical wiring connector C-395 is connected. Yes
Go to E3
Is C-395 connected?
No
Reconnect the connector and retest
E3 NO PEDAL RESPONSE
Remove the electrical connector C-379 from the pedal adjustment Yes
motor. Go to E4
Ignition On. No
Using a multimeter, check the Voltage at the terminals, Red (+) and Electrical issue at the vehicle harness. Refer to
White (-) wires at the vehicle harness connector C-379. Section 418-00 & Wiring Supplement.
Is the Voltage less than 2 Volts?
E4 ADJUSTMENT SWITCH VOLTAGE CHECK

Remove the electrical connector C-379 from the pedal adjustment Yes
motor. Go to E5 (reconnect connector C-379).
Using a multimeter, check the Voltage at the terminals, Red (+) and No
White (-) wires at the vehicle harness connector C-379. Go to E6
Ignition On. Hold down the Brake pedal adjustment switch (at steering
column).
NOTE: The voltage polarity will change when the switch is held in
the opposite direction.
Is the voltage reading equal to or greater than 12 volts?
E5 BRAKE PEDAL ADJUSTMENT SWITCH

Ignition On. Yes
Go to E7
Ensure that the "thermal cutout has not "tripped" (will have to wait 5
Minutes for reset). No
Operate Pedal adjustment switch. Replace the Adjustment Motor. Refer to
Does the motor emit a "click" sound when the switch is
operated?
G22114 en 01/2003 2003.0 BA Falcon


E6 PEDAL ACTIVATION SWITCH
Remove the lower section of the steering shroud. Refer to Section Yes
211-04. Carry out vehicle wiring harness testing. Refer to
the appropriate wiring diaghram.
Disconnect the electrical connector from the activation switch
harness. No
Push the activation switch to the forward position. Using an Ohms Replace the pedal activation switch. Refer to
meter check for continuity between the Black, Blue/Black and Section 211-05.
Blue/Orange wires.
Push the activation switch to the downwards position. Using an Ohms
meter check for continuity between the Black, Yellow and
Blue/Orange wires.
Did the activation switch have continuity in the forward /
downward Ohms check?
E7 MEMORY FUNCTION NOT OPERATING (MEMORY UNIT

ONLY)
NOTE: Pedal position sensor faults should have been set by error code Yes
from the memory seat control. Replace the adjustment cable assembly. Refer
to procedure in this section.
Disconnect the Potentiometer electrical connector C-378 from the
adjustment cable. No
If the resistance reading was greater than 10 K
Using a multimeter, check the resistance at the terminals, L - Y (+) Ω. Replace the adjustment cable. Refer to
and White (-) wires at the vehicle harness connector C-378. procedure in this section.
Reconnect connector C-378. Otherwise.
Go to E8
Was the resistance less than 1.5 KΩ?
E8 POTENTIOMETER - RESISTANCE FEED BACK STAGE-1

(MEMORY ONLY)
Adjust pedals to the fully forward position. Yes
Go to E9
Using a multimeter, check the resistance at the terminals, L - Y (+)
and White (-) wires at the vehicle harness connector C-378. No
Adjust pedals to the fully rearward position. Replace the adjustment cable. Refer to
Using a multimeter, check the resistance at the terminals, L - Y (+)
and White (-) wires at the vehicle harness connector C-378.
Is the resistance value between the fully forward and rearward
positions greater than 600 Ω?
E9 POTENTIOMETER - RESISTANCE FEED BACK STAGE-

2 (MEMORY ONLY)
Using the resistance readings taken in E 7. Yes
Go to E10
Was the resistance reading for "full forward " position between
1.5 and 4.5 KΩ? No
Adjustment cable incorrectly adjusted. Refer to
E10 ADUSTMENT CABLE

Check the adjustment cable for jamming, crushed, twisted or caught Yes
condition. Remove the adjustment cable. Refer to
Did any of the above occur? Grasp the inner cable to see if it turns freely, if
not replace the cable. Refer to procedure in this
section or the cause of twisting, jamming etc.
No
Go to E11
G22114 en 01/2003 2003.0 BA Falcon


E11 BRAKE PEDAL ADJUSTMENT TRANSMISSION / CABLE
Gently disconnect the drive cable from the adjustment motor Yes
transmission (located top of brake pedal). Go to E12
Using your fingers fully rotate the inner cable 10 times clockwise and No
10 times anticlockwise. Replace pedal box assembly. Refer to
View the brake pedal for movement while turning the inner cable. procedure in this section.
Clockwise - Rearward pedal movement, anticlockwise - Forward
pedal movement.
NOTE: When turning the inner cable the pedal will only move very
slightly. Care should be taken when viewing movement.
Does the pedal move when cable turned?
E12 ACCELERATOR ADJUSTMENT TRANSMISSION. PART -

1
Disconnect the brake pedal transmission drive cable from the brake Yes
pedal transmission. Go to E14
Ignition On. No
Operate the adjustment switch. Go to E13
Does the accelerator pedal move?
E13 ACCELERATOR ADJUSTMENT TRANSMISSION. PART-

2
Remove the pedal box assembly from the vehicle. Refer to procedure Yes
in this section. Pedal adjustment transmission operating okay.
Replace the adjusting motor. Refer to procedure
Remove the adjusting motor. Refer to procedure in this section.
in this section.
Using your fingers, fully rotate the accelerator pedal transmission
"short" cable 10 times clockwise and 10 times anti-clockwise. View No
the accelerator pedal for movement while turning the cable. Replace the pedal adjustment transmission.
Refer to procedure in this section.
NOTE: When turning the cable the accelerator pedal will only move
very slightly. Care should be taken when viewing pedal movement.
Did the cable turn?
E14 STEP OVER HEIGHT CHECK PART 1

Measure the Step over height between the Brake and Accelerator Yes
pedal. Rectify the pedal Indexing. Refer to procedure in
this section.
Is the measured height distance more than 40mm?
No
Go to E15
E15 STEP OVER HEIGHT CHECK PART 2

this section.
Is the measured height distance less than 30mm?
No
Step Over height okay, no further work required.
G22114 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Adjustable Brake Indexing Brake Hose Replacement

1. Refer to Section 310-02. A flexible brake hose should be replaced if it shows
signs of softening,cracking,leaks or abrasion.
System Bleeding When installing a brake hose,position the hose to
1. Refer to Section 206-00. avoid contact with other chassis parts.
Brake hoses should be installed as shown on the
Power Brake Booster Testing installation drawings.
1. Check the hydraulic brake system for leaks or Hoses must not be twisted.
insufficient fluid. New copper gaskets must be installed in all applicable
2. With the transmission in neutral, stop the engine locations.
and apply the parking brake. Depress the brake
pedal several times to exhaust all vacuum in the Brake Tube Replacement
system.
If a section of the brake tubing becomes damaged,the
3. With the engine shut off and all vacuum in the entire section should be replaced with tubing of the
system exhausted, depress the pedal, and hold it same type,(special doublewall steel tubing conforming
in the applied position. Start the engine. If the to specification ASTM-A 254-6T),size,shape and
vacuum system is operating, the pedal will tend to length. Copper tubing should not be used in a
fall away under foot pressure and less pressure hydraulic system.
will be required to hold the pedal in the applied
Brake lines should be installed as shown on the
position. If no action is felt, the vacuum booster
installation drawings.
system is not functioning.
Use Special Tools when bending brake tubing to fit
4. Remove the vacuum hose from the brake booster
underbody or rear axle contours.Be careful not to kink
check valve connection. Manifold vacuum should
or crack the tube.
be available at the check valve end of the hose
with the engine at idle speed and the transmission All brake tubing should have the ends formed identical
in neutral. Be sure that all unused vacuum outlets to the existing ends (using Special Tools)to provide
are properly capped, hose connectors properly leak-proof connections.Clean the brake tubing by
secured, and that vacuum hoses are in good flushing with clean brake fluid before installation.
condition. When it is established that manifold
vacuum is available to the booster, test the check
valve and replace if necessary. With the engine
shut off disconnect the vacuum hose from the
check valve. Connect a piece of tubing to the
check valve and blow into the check valve. No air
should pass through the valve. Connect the
vacuum hose to the booster and repeat Step 3. If
no downward movement of the brake pedal is felt,
replace the brake booster.
5. Operate the engine a minimum of 10 seconds at
fast idle. Stop the engine and let the vehicle stand
for 10 minutes; then, depress the brake pedal with
approximately 80 N force. The pedal feel (brake
application) should be the same as that noted with
the engine operating. If the pedal feels hard (no
power assist), replace the brake booster.
NOTE: If the brake pedal movement feels spongy,
bleed the hydraulic system to remove air from the
system.
Hydraulic Line Repair

Always bleed the applicable primary or secondary
brake system after hose or line replacement.
Install the lines and retaining clips as shown on the
illustrations.
G22115 en 01/2003 2003.0 BA Falcon

Brake Box Assembly 5. Dislodge brake booster pin clip by pulling rear and
upward.
Removal
WARNING: Wait at least one minute after
disconnecting the battery ground cable before
disconnecting any electrical connector.
CAUTION: Battery must be disconnected

prior to removing brake box assembly.
NOTE: This is not a dealer serviced item Pedal box
must be replaced if brake pedal requires replacement
because this is a safety critical assembly.
NOTE: There are four variants of the pedal box, which
include three variants to the brake pedal. Removal
and replacement is similar for all Pedal Boxes.
Removal of Pedal Box Assembly is required to service 6. Remove rotator de-coupler.
components. 7. Undo four brake booster mounting bolts.
NOTE: The steering column must first be removed to
allow removal of the pedal box.
1. Remove the lower dash panel.
8. Disconnect booster rod from brake pedal by

sliding the booster rod toward the passenger side
of the vehicle.
2. Remove side kick panel (Refer to Section
501-12).
3. Remove steering column (Refer to Section
211-04).
4. If Pedal Box is adjustable then drive brake pedal
down to lowest position as shown.
Item Description
1 Pin Clip
2 Rotator De-coupler
G22120 en 01/2003 2003.0 BA Falcon

9. Lightly pull brake pedal away from floor until clear 12. Unbolt steering intermediate shaft and pull
of booster rod. forward (away from firewall).
10. If the vehicle has a manual transmission then 13. Disconnect connectors C-317 and C-379 from
undo two clutch master cylinder bolts. pedal box assembly.
11. Disconnect accelerator electrical connection. 14. Remove fuse box out of the way.
G22120 en 01/2003 2003.0 BA Falcon

15. Undo two nuts holding pedal box to body. 2. Ensure yellow plastic clip is in place and not
damaged during assembly.
WARNING: The yellow plastic clip is part
of the pedal anti-intrusion system and MUST
be refitted if the brake booster rod has been
detached from the pedal shaft.
16. Carefully remove Pedal Box Assembly by pulling

from the points shown on the diagram.
3. Check that the rotator de-coupler is correctly

positioned on the pedal pin. The decoupling
mechanism must be correctly positioned as
shown, with 1-2 mm clearance between the lower
end of the de-coupler blade and the rotator
de-coupler.
WARNING: After any service procedures
that involve removal of the pedal box. It is
important to check that the breakaway
components have not been dislodged.
WARNING: Do not apply loads on the

accelerator, brake pedal or accelerator when
removing the pedal box assembly from the
vehicle. Loading pedals during installation or
removal can misalign or damage components.
WARNING: Remove and install pedal box

carefully and ensure that fingers are not pinched
in the process.
Installation
1. Install components in reverse order.
Item Description
1 De-coupler Blade
2 Rotator De-coupler
G22120 en 01/2003 2003.0 BA Falcon

Brake Pedal Adjustment Motor 6. Remove motor, ensure inserts remain in place.
Removal
1. Remove pedal box assembly from car Refer to
Section 206-4.
2. Remove Accelerator assembly Refer to Section
310-02
3. Rotate cable connect plug anti-clockwise and pull
plug out of motor as shown.
Installation
Brake Pedal Motor Cables

Removal
1. Rotate cable connect plug anticlokwise and pull
plug at motor end as shown.
4. Remove gear box assembly from pedal box.
2. Disconnect plug at brake pedal end as shown

using pliers.
5. Remove two screws holding motor to pedal box.
Installation
G22122 en 01/2003 2003.0 BA Falcon

Brake Pedal Control Switch (where Brake and Cruise Pedal Switch Setting
fitted) Removal
Removal 1. Remove switch assembly from mount by rotating
1. Undo three screws underneath the lower shroud. to release.
Move the steering column adjustment lever about
half way through its travel. Gently spread the
lower shroud to clear the key illumination ring.
2. Pull plunger out to the full extension.
Item Description
1 Screw
2 Adjustment lever
2. Slide the shroud down and rearwards, ensuring
the adjustment lever passes through the aperture
in the lower shroud. Unclip the wire harness for
the adjustable pedal switch.
3. Refit the switch by holding brake pedal down and

reinserting switch in to housing and rotating to
lock into position.
NOTE: Hold brake pedal down while fitting switch.
3. Remove pedal adjust switch from the shroud by

deflecting the steel retaining clips and pushing the
switch outwards.
Installation
NOTE: Ensure the steering column adjustment
lever passes under the pedal switch wire harness
when installing the lower shroud.
4. Release brake pedal gently so it returns to the
relaxed position. Lightly (less than 80N) pull brake
pedal rearwards to ensure pedal fully returns
switch. This will push the plunger in and correctly
set the switch.
G22123 en 01/2003 2003.0 BA Falcon

Brake Pedal Pad Power Brake Booster

Removal Removal
1. Remove brake pad by peeling rubber from the 1. Remove nuts attaching master cylinder to booster
pedal plate. tie rods and remove master cylinder.
2. Disconnect vacuum hose from vacuum check
valve.
6 Cylinder
Installation
NOTE: Heating the pad will assist replacement.
8 Cylinder
Accelerator Pedal Pad
Removal
1. Remove accelerator pad retention clip on the
back of the pad by inserting a small screwdriver
and prising the pedal pad over the tang of the
pedal blade. Slide the pad from the blade.
NOTE: If the pad is to be discarded, the plastic
can be broken away to simplify removal.
3. Disconnect pushrod (part of valve assembly) from

brake pedal.
4. Remove nuts from booster tie rods and remove
booster.
5. Remove four nuts securing booster to firewall and
pedal box.
6. Remove assembly.
Installation
Installation 1. Attach booster to dash panel/pedal box with nuts.
1. Fit new pad by pushing onto pedal blade until the 2. Attach push rod (part of valve assembly) to brake
pad clips over the retaining tang. pedal.
3. Connect vacuum hose to vacuum check valve.
4. Attach master cylinder with nuts to booster front
shell.
G22123 en 01/2003 2003.0 BA Falcon

Dual Master Cylinder 3. Slide the master cylinder forward and upward
from the vehicle.
NOTE: Special rubber components are used in this Installation
master cylinder, therefore the cylinder must be
1. Position the master cylinder assembly over the
repaired using only genuine kits. These kits include booster push rod and onto the two studs on the
new rubber components. Ensure all sections of the
booster assembly.
cylinder are repaired. For cleaning of internal parts of
master cylinder use clean brake fluid or methylated 2. Install the attaching nuts and torque to
spirits. specification.
The split point pressure of the proportioning valve is 3. Install the front and rear brake tubes to the master
stamped on the end face of the master cylinder body, cylinder outlet fittings. Connect the warning light
and it is most important that, should a cylinder need switch.
replacing an identical cylinder be used. 4. Fill the master cylinder with the specified brake
When removing the master cylinder from the booster, fluid to the level marked on the side of the dual
care must be taken not to disturb the pushrod and not reservoirs. Use Motorcraft approved Brake Fluid.
to depress the brake pedal after the cylinder is Do not mix low temperature brake fluids with the
removed. Failure to observe this caution may result in specified fluids for the disc brake system as
the output rod becoming dislodged inside booster. specified in Section 206-00.
5. Bleed the brake system. Refer to Hydraulic
Removal
System Bleeding in this section for the proper
1. Remove the brake tubes from the outlet ports of procedure. While bleeding brake system, check
the master cylinder. Disconnect the plug from the the brake failure warning light operates and
warning light switch. resets.
2. Remove the two nuts attaching the master 6. Operate the brake several times, then check for
cylinder to the brake booster assembly. external hydraulic leaks.
G22127 en 01/2003 2003.0 BA Falcon

Electronic Throttle Control Module

1. Refer to Section 310-02.
Dual Master Cylinder

Disassembly
Main Bore

1 Reservoir cap 16 Primary piston
2 Reservoir seal 17 ’O’ Ring
3 Reservoir 18 Differential switch assembly
4 Reservoir retaining screw 19 Proportioning valve assembly
5 Reservoir seal 20 Prop housing sleeve
6 Circlip 21 ’O’ Ring
7 Fast fill valve 22 ’O’ Ring
8 ’O’ Ring 23 End plug
9 Master cylinder body 1. Clean the outside of the master cylinder and
10 Secondary spring remove reservoir cap. Pour out and discard any
brake fluid that remains in the cylinder.
11 Secondary piston assembly
2. Unscrew reservoir-to-body retaining screw located
12 Secondary piston stop pin
at base of reservoir.
13 Cup retainer
3. Separate, by hand, the plastic reservoir from the
14 Primary cup body. Remove the reservoir sealing grommets.
15 Recuperating guide
G22128 en 01/2003 2003.0 BA Falcon

4. Invert the cylinder so that the reservoir wells face 3. Remove the valve sealing ‘O’ ring from bottom of
down. Depress the primary piston with a rod of reservoir port. The by-pass bleed groove allows
wood dowel until fully bottomed in the bore. The fluid to by-pass the ball valve. This ensures that a
secondary piston stop pin should freely fall out; if fluid passage is maintained between the brake
not, remove with long nose pliers. pressure circuit and reservoir in the Brakes Off
position.
CAUTION: Slowly return pistons to avoid
primary piston from sringing out of the bore.
5. Carefully remove primary piston assembly from
main bore of master cylinder.
6. Remove secondary piston and return spring by
using compressed air or lightly tapping the open
end of the cylinder bore squarly onto a soft piece
of wood.
7. Separate the secondary return spring from the
secondary piston locating spigot.
NOTE: The caged spring on the secondary piston
has been set to a pre-determined length. DO NOT
attempt to adjust the screw or remove the caged
spring. If cups are damaged or badly worn, the
complete seconary iston assembly MUST BE
REPLACED (as supplied in repair kit). Item Description
1 Circlip
8. Remove the seal retainer from the primary piston
by using a small screwdriver to carefully pry apart 2 Fast fill valve
the seal retainer legs. 3 O-Ring
9. Remove the recuperating guide and seal from the 4 Master Cylinder Body
primary piston. Pressure Differential Switch Assembly (Non ABS
10. Remove the O ring from the other end of the only)
piston taking EXTREME CARE not to damage the
piston. 1. Remove end plug and ‘O’ ring from master
cylinder body.
Fast-Fill Valve
2. Remove electric switch from master cylinder,
1. Using suitable circlip pliers, remove circlip ensuring the electrical earthing spring remains on
retaining the fast-fill valve in the primary reservoir the switch plunger.
port of the master cylinder. 3. Remove the proportioning valve assembly by
2. Face reservoir port down to allow the valve to fall gently bumping the master cylinder body against
out. If valve is stuck in position, lightly tap cylinder a piece of wood to dislodge the proportioning
on piece of wood to assist valve removal. valve assembly. Do not damage the assembly by
attempting to pull it out with pliers.
4. Spring must remain attached to switch plunger.
G22129 en 01/2003 2003.0 BA Falcon

Proportioning Valve (Non ABS only) 1. Assemble the large ‘O’ ring onto the end of the
primary piston.
DO NOT disassemble the proportioning valve NOTE: All hardware must be correctly installed
assembly. The valve is serviced only as a complete and torqued to specification.
assembly.
2. Install primary seal onto the end of the primary
piston, with sealing face away from guide already
assembled. The primary seal can be identified by
the 6 shallow grooves around the seal’s outer
surface.
3. Assemble the cup retaining ring onto the primary
piston. Using a small screwdriver clip the retainer
legs into the groove on the piston. Care should be
taken to avoid damage to the piston or seal.
Secondary Piston
Item Description
1 End plug
2 ’O’ Ring
3 Proportioning valve assembly
4 Master cylinder body
Assembly
1. Extreme care must be taken to avoid damaging
O-Rings when inserting proportioning value.
2. Before assembly, lubricate internal ports and Item Description
master cylinder bore with recommended brake 1 Secondary spring
fluid from a sealed container. Prior to assembly, 2 Secondary piston
ensure primary piston (without seals) is free to
move full piston stroke in the large bore.
Primary Piston
Item Description
1 Master cylinder body
2 Secondary piston stop pin
Item Description
3 Secondary piston assembly
1 Cup retainer
1. Assemble the small end of the secondary piston
2 Primary cup
spring over the end of the secondary piston. This
3 Recuperating guide should be a slight interference fit.
4 Primary piston
5 Large ’O’ Ring
G22129 en 01/2003 2003.0 BA Falcon

2. To assemble the secondary piston assembly into

the body, align the slot in the secondary piston
with the reservoir wells. This must be done so that
the stop pin can be inserted into the master
cylinder body.
Master Cylinder
Item Description protrude more than 6 mm above the bottom of the

well.
1 Fast fill valve
2. Insert the primary piston into the main bore and
2 Circlip
against the secondary piston. Then carefully push
3 ’O’ Ring - Larger both pistons down the bore until the primary
4 Primary piston piston is flush with the bore opening.
5 Split line 3. Stroke pistons and check primary piston fully
6 ’O’ Ring returns to end of bore at end of each stroke.
Ensure movement is not sticky.
7 Primary cup
Differential Warning Switch Section (Non ABS
8 Secondary cup - ’L’ Type only)
9 Secondary piston
1. Before assembly, lubricate small bore master
1. Carefully insert the secondary piston, (caged cylinder and proportioning valve with clean brake
spring end last), through the large bore and into fluid from a sealed container.
the smaller bore until the spring “bottoms”. Ensure 2. Ensure spacer and ‘O’ ring are over proportioning
the secondary spring is not dislodged from the valve spool, if they were removed, and check that
piston assembly during this operation. Fully stroke spacer and ‘O’ ring are installed around the right
the secondary piston using a soft dowel and while way.
held at the bottom of the bore install the piston
stop pin. The piston pin should easily fit in through
the larger hole of the 2 holes in the secondary
reservoir well. The top of the stop pin should not
G22129 en 01/2003 2003.0 BA Falcon

3. Insert proportioning valve (capped end first) into Item Description

bore, EXTREME CARE should be taken when 4 master cylinder body
inserting valve to ensure ‘O’ rings are not
damaged. If ‘O’ rings are damaged the master 1. Carefully install the valve ‘O’ ring in the bottom
cylinder will not function correctly and will leak shoulder of the primary reservoir port.
brake fluid. The proportioning valve assembly 2. Fit the fast-fill valve, ensuring the rubber base
must be bottomed in the bore of the master with 6 dimples if faced downwards, and secure
cylinder. with circlip.
4. Assemble a new ‘O’ ring onto the end plug, and Reservoir
screw end plug into body. Tighten end plug to
25Nm-30 Nm.
Electrical Switch (Pressure Differential)
1. Lightly smear reservoir bores and grommets with

clean brake fluid.
2. Carefully assemble grommets into reservoir bores
1. Before installing the electrical switch, ensure to locate against the shoulder in each bore.
earthing spring is installed on switch plunger as 3. Assemble reservoir into grommets.
shown in diagram.
4. Push on reservoir to align the retaining screw hole
NOTE: Electrical spring must remain firmly
in the reservoir and cylinder body. Then assemble
attached to the plunger. Small end of spring may
retaining screw, and tighten to 4-5 Nm. Screw
need to be closed down to give required
should just protrude from hole in the master
attachment.
cylinder body.
2. Assemble electrical switch to the master cylinder NOTE: Both reservoir and master cylinder holes
by hand. Tighten to a torque of 2 Nm. (DO NOT must be aligned to avoid cross threading.
OVER TIGHTEN.) Assemble new reservoir seal into reservoir cap.
Fast-Fill Valve 5. Lubricate inside of reservoir lips with clean brake
fluid to accept reservoir cap seal.
6. Push cap and seal assembly onto reservoir and
secure by pressing clip at each end to locate on
reservoir lugs. Caps should be fitted so that
lettering on cap is correct way up when viewed
from side of vehicle.
Item Description
1 Circlip
2 Fast fill valve
3 ’O’ Ring
G22129 en 01/2003 2003.0 BA Falcon

206-06x-1 Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option) 206-06x-1
SECTION : 206-06x Hydraulic Brake Actuation —

Load Proportioning Valve (1 tonne option)
CONTENTS PAGE
Hydraulic Brake Actuation — Load Proportioning Valve ......................................................206-06x-2
Load Proportioning Valve .....................................................................................................206-06x-3
01/2003 2003.0 BA Falcon

Hydraulic Brake Actuation — Load

Proportioning Valve
G45290 en 01/2003 2003.0 BA Falcon

Load Proportioning Valve Installation

1. Installation is the reverse of the removal
Removal procedure. Once installed, bleed the brake
The Load Proportioning Valve is located on the system. Refer to Hydraulic System Bleeding in
chassis rail above the rear axle. Section 206-00.
NOTE: The load proportioning valve is a
non-serviceable component and must be replaced
if faulty.
1. Remove all the brake tubes from the load

proportioning valve.
2. Loosen the strap attaching the nut.
3. Support the strap and remove any force from the

bracket, remove strap attaching nut.
4. Release strap support and remove load

proportioning valve fastening nuts.
5. Remove assembly.
G45291 en 01/2003 2003.0 BA Falcon

206-09-1 Anti Lock Control 206-09-1
SECTION : 206-09 Anti Lock Control

CONTENTS PAGE
Anti Lock Control ....................................................................................................................206-09-2
Applicable Models ................................................................................................................206-09-2
General Description .............................................................................................................206-09-2
Operation .............................................................................................................................206-09-4
Operating Modes ..................................................................................................................206-09-6
Anti Lock Control ..................................................................................................................206-09-14
Principles of Operation .......................................................................................................206-09-14
Inspection and Verification .................................................................................................206-09-14
Diagnostic Trouble Code (DTC) Chart ...............................................................................206-09-18
Connector Circuit Reference ..............................................................................................206-09-19
Pinpoint Tests ....................................................................................................................206-09-21
Rear ABS sensor — IRS .....................................................................................................206-09-27
ABS Wheel Speed Sensor — Rear (Beam Axle) ................................................................206-09-28
Front ABS Wheel Sensors ...................................................................................................206-09-29
Rear Tone Wheel .................................................................................................................206-09-29
Front Tone Wheel ................................................................................................................206-09-29
ABS Modulator Assembly ....................................................................................................206-09-29
01/2003 2003.0 BA Falcon

Anti Lock Control (ABS) or with the 4 channel Anti-lock Braking System
with Traction Control (TCS).
Applicable Models Throughout this section, the presence of [square
brackets] indicates that the information contained in
The material in this section applies both to vehicles the brackets applies only to vehicles fitted with TCS
fitted with the 3 channel Anti-lock Braking System
(Traction Control).
General Description
ABS System Layout (3 Channel ABS)
G23420 en 01/2003 2003.0 BA Falcon

System Layout (4 Channel TCS)
The system is the Bosch ABS/TCS 5.3 system, and is system. The TCS system includes additional hydraulic
basically designed to be an add-on system to the lines and components to provide traction control as an
existing master cylinder and booster assembly. The additional feature.
system comprises of the following major components. The main difference is that the rear wheels are
hydraulic modulator / ECU assembly controlled as a pair with the 3 channel system whilst
wheel speed sensors the 4 channel system controls them individually. The
individual control of the rear (driven) wheels allows
hydraulic and electrical connectors
the system’s capabilities to be expanded to
[electrical communication with the EEC] incorporate Traction Control.
The 3 channel Anti-lock Braking System and 4
channel Anti-lock Braking System with Traction
Control are quite similar in concept. Essentially, the
same wheel speed sensors and a similar
ECU/Hydraulic Modulator Assembly are used in each
G23420 en 01/2003 2003.0 BA Falcon

Anti-lock Braking (ABS and TCS) are switched to pressure hold, in order to prevent a
further increase in pressure at the rear brakes, thus
Anti-lock braking systems are a significant safety electronically reproducing a pressure-proportioning
feature designed to prevent wheel “lock-up” during function at the rear brakes.
hard brake applications. This results in improved
vehicle stability, steerability and usually, shorter Operation
stopping distances.
Anti-lock Braking (ABS and TCS)
The ABS system uses wheel sensors to detect the
approaching lock-up of a wheel. When detected, the The rotational speed of each wheel is determined by
system will automatically control the fluid pressure in inductive wheel speed sensors. When the brakes are
the corresponding brake circuit. The pressure is firstly applied, the change in rotational speed is used by the
maintained (pressure hold) or if the tendency to lock is processor in the ABS - ECU to determine the
still present, reduced. As the wheel is re-accelerated deceleration, acceleration and the slip of the wheels.
the fluid pressure is increased, thus systematically The front wheels are individually controlled with the
slowing the vehicle. rear wheels being controlled together. If one side of
The increase/hold/decrease of fluid pressure will the road surface is slippery, the rear wheel braking on
continue to occur until either the road surface this surface determines the braking pressure of both
changes, the brake pedal is released or brake pedal rear wheels. While this may cause slightly reduced
force reduced, or the vehicle stops. rear braking, it substantially increases rear end
stability.
Traction Control (TCS only)
Traction Control, or Automatic Spin Reduction WARNING: Despite this improvement to the
systems are a significant safety feature designed to braking system, you should continue to exercise
prevent wheel spin during acceleration. This results in caution in all hazardous driving situations,
improved vehicle stability and steerability. If wheel especially when driving on extreme road surfaces.
spin is desired (this may be so in some sandy The ABS system will assist in improved vehicle
conditions to avoid becoming bogged) the driver can stability and steerability under severe braking,
disable the traction control by pressing the button on usually reducing the braking distance, but may
the dash. The traction control can be enabled again not prevent an accident from occurring.
by pressing the same switch again or by cycling the
ignition.
Traction Control (TCS only)
The TCS uses wheel speed sensors to detect the The addition of a priming valve and a switching valve
spinning of one, or both, of the drive wheels. When allow the brake pressure at the rear wheels to be
detected the system will automatically apply brake applied independently of each other and of the driver.
pressure to the spinning wheel(s), and will reduce The rotational speed of each wheel is determined by
engine torque. The brake pressure in the spinning inductive wheel speed sensors. Any change in
wheel(s) is built up in small steps, so as not to rotational speed is used by the processor in the TCS
over-brake the wheel(s), and will equalise the ECU to determine the deceleration, acceleration, and
available torque between the two drive wheels the slip of the wheels.
according to the surfaces the wheels are on. The If one side of the road surface is slippery and the
engine torque is reduced via the engine management wheel on that surface spins, that rear wheel is
system (EEC). The EEC will cut fuel injection and controlled by brake pressure being applied, with
ignition to one or more cylinders depending on how perhaps some engine power reduction. If both wheels
much torque reduction is required. are on a slippery surface and spin, the wheels may be
The brake and engine intervention will continue to slightly braked but most of the control is through
occur until the wheel(s) are no longer spinning. reduction of engine power.
During traction control operation the traction control Use of brake intervention is limited when the vehicle
warning lamp will flash to inform the driver that the speed is above 40km/h to prevent excessive brake
vehicle is under traction control. This continues until temperatures being generated at the rear wheels.
traction control is finished.
WARNING: Despite this improvement to the
Electronic Brake-Force Distribution (EBD) power-train system, drivers should continue to
Electronic Brake-Force Distribution (EBD) is a system exercise caution in all hazardous driving
where by the amount of master cylinder Brake-Force situations, especially when driving on extreme
pressure applied to the rear wheels is controlled road surfaces. The TCS will assist in improved
electronically as opposed to mechanically. vehicle stability and steerability during severe
EBD ensures that the rear wheels are sensitively acceleration, usually improving the vehicle
monitored for slip with respect to the front wheels. If acceleration, but may not prevent loss of vehicle
slip is detected, the inlet valves for the rear wheels control from occurring.
G23420 en 01/2003 2003.0 BA Falcon

NOTE: LPG (Liquefied Petroleum Gas) conversions ABS

are not compatible with traction control. If an LPG
conversion is performed it must conform with Ford If a system defect is detected, the ABS will switch
recommendations and must be performed by an itself OFF. The driver can still use the base brake
approved LPG installer. The traction control will not system without the anti-lock feature. This change over
operate whilst LPG is the selected fuel. If the is indicated by means of illuminating the ABS warning
conversion does not meet Ford recommendations the light on the instrument panel.
rear brakes may overheat. TCS
Electronic Brake-Force Distribution (EBD) If a system defect is detected in the traction control
only, the traction control part of the TCS will switch
The Brake-Force Distribution is controlled by omitting itself OFF. The ABS will remain functional. If some
the currently used mechanical proportional valve(s) other fault occurs in the TCS the complete system
and controlling the pressure to the rear wheels via the (ABS and traction control) will switch itself OFF. The
current Anti-Lock Brake System (ABS). driver can still use the base brake system without the
The information as to when and how much the master anti-lock feature, and can still accelerate and drive
cylinder pressure is to be proportioned, is received normally without the traction control feature. This
from the rear and front Wheel Speed Sensors (WSS). change over is indicated by means of illuminating both
This difference in slip between the front and rear the ABS and the traction control warning lights on the
wheel speeds, is calculated and then reacted upon by instrument panel.
the ABS assembly.
Modulator and ECU
The EBD operation takes effect prior to the increased
slip rate required for ABS intervention. The ECU uses the inputs from the wheel speed
The ABS unit has additional software that will, in the sensors to determine if ABS [or traction control]
case of an EBD operation, operate the rear inlet operation is necessary, and if so, energises the
valves of the ABS Hydraulic Modulator Assembly. solenoids to control hydraulic brake pressure [and
These inlet valves will open and close as required, to communicates the desired wheel torque to the EEC].
control the amount of pressure that can be applied to The ECU controls all diagnostic functions and
the rear wheels before ABS is required. monitors all external inputs and outputs.
If the restriction of the pressure, by closing the rear NOTE: The ABS modulator and ECU is serviced only
inlet valves, does not prevent the slip from continuing as a complete assembly. The ECU should not be
to increase at the rear axle, the outlet valve will open removed from the modulator body.
and allow a reduction of the pressure to be transferred
to the accumulator of the ABS unit. The pump motor
does not operate at this stage and is therefore not in
ABS mode.
If then the pressure reduction is not sufficient to
reduce the rear wheel slip, a normal ABS operation
will take place.
The EBD uses a select low logic on the rear wheels,
that is, the condition of the rear wheel with the least
amount of traction is duplicated on the opposing
wheel.
Self-Monitoring
When the vehicle is started, the system automatically
carries out a static system analysis. Wheel speed
sensors are checked for continuity, solenoid valves Sensors and Tone Wheels
and the pump motor are operated, feedback signals
from the valves and motor are monitored [and Each wheel is fitted with a sensor and tone wheel.
communication with the EEC is acknowledged]. The front sensors are attached to the steering spindle
and the tone wheels are pressed onto the hub
As the vehicle is driven the system monitors itself by
assembly. At the rear, sensors are attached to the
comparing the input and output signals of the valves
differential housing for (IRS) or the parkbrake back
with memorised limit values, in addition to monitoring
plate (for beam axle), whilst the tone wheels are
the voltage supply. It also continuously compares the
attached to the drive shafts. Each tone wheel
wheel speed signals with each other [and
incorporates teeth which generate pulses in the wheel
continuously exchanges information with the EEC].
sensor. These pulses are used by the ECU to
calculate wheel speeds and acceleration rates.
G23420 en 01/2003 2003.0 BA Falcon

Sensor and Tone Wheel — Front ABS Indicator Light

This light will illuminate each time the ignition is turned
to the ON position and will go out after approximately
2 seconds. In the event that the ABS light remains on,
or illuminates constantly while driving, this indicates
that the ABS function is disabled. and should receive
immediate attention to restore the benefits of the ABS
features. If the fault is of a temporary nature, the ABS
will reset on the next ignition cycle and the light will
then return to normal operation. However, a fault code
will be stored in the ECU - see Diagnosis and Testing
later in this section.
NOTE: Most malfunctions in the ABS system will
cause the indicator light to illuminate indicating the
system has been disabled. Normal braking is not
affected unless the brake warning light is also
Sensor and Tone Wheel — Rear (IRS) illuminated.
Traction Control (TCS) Indicator Light

This light will illuminate, along with the ABS light, each
time the ignition is turned to the ON position and will
go out after approximately 3 seconds. If the traction
control light flashes while driving this indicates that
one or both of the drive wheels are spinning and that
the TCS is applying brakes and/or reducing engine
power. In the event that the traction control light
remains on, or illuminates constantly while driving,
this indicates that the function is disabled. If it cannot
be enabled by pressing the traction control on/off
switch it should receive immediate attention to restore
the benefits of the traction control features.
Sensor and Tone Wheel — Rear (Live Axle) If the fault is of a temporary nature, the traction
Wagon and Ute control will reset on the next ignition cycle and the
light will then return to normal operation. However, a
fault code will be stored in the ECU - see Diagnosis
and Testing later in this section.
NOTE: The traction control light can be illuminated by
turning the traction control off with the switch on the
dash. If only the traction control light is on, the ABS
function is not affected.
Traction Control Switch (TCS)

The TCS is used to toggle the traction control feature
on/off depending on the driver’s preference at the
time. When the traction control is turned off, the
indicator light will illuminate and stay on until the
system is again reactivated. The system may be
reactivated by pressing the switch again.
Brake Pipes Traction control is turned on each time the ignition is
The hydraulic connections are by conventional steel cycled regardless of whether the system was on or off
brake tubing. Two master cylinder pipes are previously.
connected to the inlets of the hydraulic modulator.
The three [four] outlets of the hydraulic modulator are
Operating Modes
connected individually to the front brake calipers and The hydraulic modulator executes ABS/TCS ECU
as a pair [TCS-individually] to the rear brake calipers. commands using six [ten], two-position solenoid
valves, [including a priming valve, and a switching
valve]. The hydraulic modulator valve positions
correspond to various ABS/TCS ECU control phases:
G23420 en 01/2003 2003.0 BA Falcon

1. Non ABS/TCS condition ABS Braking - Standard braking no ABS

2. Maintaining pressure (ABS) assistance
3. Reducing pressure (ABS) During this condition, both build and decay valves are
4. Increasing pressure (ABS) not energised; that is the ABS ECU does not supply
5. Traction control in operation (brake intervention) any current to the solenoid coils, and this provides for
conventional non ABS braking.
For explanation of ABS operation, only one segment
of the system will be described. For explanation of From the brake master cylinder, hydraulic pressure is
traction control operation, only the part of the system applied to brake circuit. If the ABS ECU does not
related to the rear wheels will be described. detect any rapid wheel deceleration, the ABS will
remain passive at this time.
ABS Braking - Standard braking no ABS assistance
G23420 en 01/2003 2003.0 BA Falcon

TCS operation - No ABS or Trac control

assistance
This is a schematic of the Hydraulic Modulator under
normal driving conditions. All the valves are in their
normal rest position allowing uninterrupted flow for
normal braking conditions. This is depicting no
pressure within the system, therefore, no application
of brakes.
Status
Inlet Valve Outlet Valve Prim- Swit- Motor
ing ching
Valve Valve
Left Right Left Right Closed Open Off
Open Open Closed Closed
G23420 en 01/2003 2003.0 BA Falcon

TCS operation - No ABS or Trac control assistance
Maintaining Pressure
When the ABS ECU detects excessive wheel
deceleration (based on the wheel speed sensor
signals), it commands the build valve to maintain
brake circuit pressure. It does this by supplying a
current to the solenoid coil. This causes the armature
and the valve to move downwards isolating the brake
circuit from the master cylinder.
NOTE: With the brake circuit isolated, brake circuit
pressure between the build solenoid and the caliper
remains constant despite increased master cylinder
hydraulic pressure.
G23420 en 01/2003 2003.0 BA Falcon

Maintaining Pressure (ABS operation)
Reducing Pressure fluid from the brake circuit back to the master cylinder
against brake pedal pressure. The return pump
If isolation of a brake circuit between the modulator continues to operate during the rest of the anti-lock
and the brake caliper does not reduce the excessive cycle.
wheel deceleration, the ABS ECU commands the
decay valve to reduce hydraulic brake pressure in the
Accumulators
brake circuit. During this phase, the ABS ECU
supplies a current to the decay solenoid coil, opening During the “pressure reduction” phase of ABS
the valve. This opens a passage from the brake circuit modulation, the accumulator temporarily stores fluid
to the accumulator and return pump inlet. from the brake circuits. Some road conditions require
the relief of a large volume of fluid from the brake
NOTE: At this time, the brake circuit is isolated from
calipers. In such conditions, the accumulator
the master cylinder by the return pump valving, and
guarantees pressure reduction. As soon as the
the return pump is energised. This action sends brake
G23420 en 01/2003 2003.0 BA Falcon

solenoid valves move to the “pressure reduction”

position, brake fluid from the brake circuit flows into
the accumulator. Thus before the return pump starts,
the accumulator allows an immediate pressure
reduction in the brake circuit.
Reducing Pressure (ABS operation)
Increasing (building-up) Pressure cycle begins again. There are approximately up to 10

cycles per second, depending on the state of the road
The wheel accelerates again as a result of the surface.
reduced braking pressure. Upon reaching a specific
limit, the ECU registers the fact that the wheel is now NOTE: Circuit pressure cannot increase above master
not being braked sufficiently. The ECU then cylinder pressure.
de-energises the build and decay valves (0 amps) and
the formerly reduced pressure is then increased so
that the wheel is again decelerated. The ABS control
G23420 en 01/2003 2003.0 BA Falcon

Increasing (Building-Up) Pressure (ABS operation)
TCS in operation (brake intervention only) to 10 times a second and can function on either of the
driven wheels, or both.
In this schematic, the right hand wheel speed sensor
has detected that the wheel is about to enter into a Status
situation where slippage can occur from excess Inlet Valve Outlet Valve Prim- Swit- Motor
engine torque for the road conditions. ing ching
The priming valve is open allowing fluid to be drawn Valve Valve
from the master cylinder by the pump assembly. The Left Right Left Right Open Closed On
switching valve is closed ensuring the fluid is directed Open Open Closed Closed
to the wheels and not back to the master cylinder.
With the right wheel tending to slip, the inlet valve on
the left side closes allowing only the brakes to be
applied to the right wheel. This will transfer the engine
torque to left wheel. This operation can be applied up
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TCS in operation
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Anti Lock Control It is important that all of the steps in the Procedure
are followed to avoid the unnecessary replacement of
Principles of Operation parts that are not faulty and to ensure that the
ABS/TCS system is returned to its designed operating
The ABS/TCS system has a self-test capability and condition.
will memorise faults for 125 key starts. Fault codes
are accessed using the WDS tester. Self-test codes Procedure
are held in the EPROM and can only be cleared using 1. Complete an ABS/TCS Concern Customer
the WDS tester. Up to 3 “on demand” or “stored” Questionnaire. Determine whether or not the
codes can be logged by the ECU. It is essential that issues raised indicate a fault with the ABS/TCS
the system is retested after any fault is rectified until system or are in fact normal operating
no further on-demand codes are displayed. characteristics of ABS/TCS systems in general.
The self test connector is located behind the fuse box 2. If a fault is indicated, proceed to the ABS/TCS
panel cover (underneath the instrument panel on the Diagnostic Procedure table.
right of the steering column). Follow the operating
procedures provided with the test equipment. 3. Follow the table. If any hard or memory DTCs are
displayed, refer to the DTC Table for a definition
WDS Tester and reference to the appropriate pin point test
flow chart for each DTC.
The WDS tester is used to communicate serially with
the ABS module for diagnostics. The WDS must be 4. When the table directs you to return to the ABS
used to carry out the following functions/tests on the Diagnostic Procedure table, return to the
ABS system: “RETURN FROM PIN POINT TEST” box and
proceed to confirm the repair.
Diagnostic Test Modes
NOTE: Ensure that all memory DTCs are cleared
Trouble code clearing PRIOR to confirming the repair. If hard DTCs still
PIDs/Data monitoring exist then the related faults also still exist.
Function test — to operate ABS modulator 5. Confirm the repair by following the ABS/TCS
components Diagnostic Procedure table. If at any time the ABS
NOTE: When operating the ABS pump using the or traction control warning lamp flashes or
WDS tester, the pump should not be allowed to run illuminates (other than the normal 3-second
for more than 5 seconds. After confirming pump period after the ignition is switched on) then there
operation, switch off the pump motor by pressing the is a fault within the ABS/TCS system.
WDS button. 6. In the event that the same DTC appears, continue
to follow the flow chart back to the same pin point
Inspection and Verification test flow chart. Conduct the same checks and if
If a vehicle is presented with an ABS/TCS concern, no fault is found the flow chart will direct you to
indicated either by way of the ABS or traction control replace the ABS Modulator Assembly.
warning lamp or by the Owner/Driver reporting an NOTE: The ABS/TCS Modulator Assembly is a
unexpected operating characteristic (eg noise, critical safety item. It should only be installed by
vibration, wheel lock-up, spinning wheels, etc.) follow trained and experienced ABS Technicians. After
the Diagnosis Procedure to: replacing the ABS/TCS Modulator Assembly, it
determine whether or not there is a fault with the will still be necessary to confirm the repair by
ABS/TCS system returning to the ABS/TCS Diagnostic Procedure
table.
locate and isolate the fault
rectify the fault 7. At the conclusion of the road test if there are no
DTCs then the system can be considered to be
confirm the repair with an ABS/TCS road test. working correctly and is ready for return to the
Owner/Driver.
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ABS/TCS CONCERN CUSTOMER QUESTIONNAIRE

Customer’s Name________________________ R/O Number________________________
Registration Number______________________ Date______________________________
Odometer Reading_______________________
PROBLEM DESCRIPTION
1. Do the ABS and traction control warning lamps come on when you start the car? Yes No
2. Do the ABS or traction control Lamps turn off after 3 seconds or do they stay on or flash?
Turns Off Stays On Flashes
3. Do the ABS or traction control lamps flash or stay on whilst driving? No Stays On Flashes
4. If not the warning lamp, what caused you to suspect a fault with the ABS or TCS system?
Was it Noise? Please describe the noise, and whether it occurred during braking, during an ABS stop,
during heavy acceleration or at some other time.
_______________________________________________________________________________________
_______________________________________________________________________________________
or was it Vibration/Harshness? Please describe the vibration/harshness, and whether it occurred during
braking, during an ABS stop or at some other time.
_______________________________________________________________________________________
_______________________________________________________________________________________
or was it the feel/travel of the brake pedal? Please describe how the brake pedal behaved, and whether it
occurred during braking, during an ABS stop or at some other time.
_______________________________________________________________________________________
_______________________________________________________________________________________
Other_______________________________________________________________________
_______________________________________________________________________________________
5. How often does it happen? Frequently Infrequently Once
6. Does it usually happen only under specific circumstances? (eg. only when the vehicle is cold, only in
the wet, only on rough or slippery surface roads, etc)
_______________________________________________________________________________________
_______________________________________________________________________________________
VEHICLE HISTORY
1. Have you had any repairs made to your vehicle recently? Describe.
_______________________________________________________________________________________
2. Have you had new tyres fitted or have you had a flat tyre recently? Yes No
3. Have you had a flat battery recently? Yes No
4. Have you had the ABS system checked or repaired previously? If so, when and why?
_______________________________________________________________________________________
G23421 en 01/2003 2003.0 BA Falcon

ABS/TCS DIAGNOSTIC PROCEDURE

DIAGNOSTIC PROCEDURE - PART A
1. Refer to the completed ABS/TCS Concern Customer
Questionnaire for information relating to when, where and how
frequently the concern is noticed.
NOTE: I. The ABS and TCS lamps only indicate the presence of
hard faults. They will not illuminate if only a memory fault is
present.
II. The ECU can store no more than 3 DTC’s. The oldest DTC will
be erased if more than 3 are present.
III. If the ABS/TCS ECU wiring loom connector is not connected
properly, the ABS & TCS lamps will remain on while the ignition
is on.
IV. If a hard fault is present, the ABS and TCS lamps will remain
lit until the fault is corrected.
2. Turn the ignition OFF
3. Connect the WDS and turn the ignition ON
Does the WDS communicate with the ABS/TCS system? Yes
Refer below
No
Refer to COMMUNICATIONS
FAULT, Pinpoint Test F.
Are there any DTC’s? Yes
Record DTC and refer to DTC
table in this section for
diagnosis and repair
procedure.
No
Go to 4. Below
4. Turn the ignition OFF then disconnect the WDS
5. Confirm correct operation of the system.
6. Go to DIAGNOSTIC PROCEDURE - PART B.
DIAGNOSTIC PROCEDURE - PART B

1. Turn the ignition ON
Do the ABS & TCS come on and then go out after 3 seconds? Yes
Go to 2. Below
No
One or both lamps do not
come on or they stay on after 3
seconds
Check bulb and wiring for open
circuits and shorts to ground.
Be sure to wiggle the wiring
whilst testing. Repair as
required.
Go to DIAGNOSTIC
PROCEDURE - PART A, Item
2.
2. Ensure that the vehicle is safe to drive.
3. Drive the vehicle above 30 km/h for at least 80 seconds.
4. Select a safe, clear section of road and perform an ABS stop.
G23421 en 01/2003 2003.0 BA Falcon

Did either of the lamps come on at all whilst driving the Yes
vehicle? Go to DIAGNOSTIC
2.
No
Go to 5. Below
5. Select a safe, clear section of road where wheel slip can occur.
Perform an acceleration hard enough to cause wheel slip
NOTE: Perform this test only if the vehicle is equipped with TCS.
Did the TCS lamp flash during the acceleration? Yes
Return the vehicle to the
customer.
No
Go to DIAGNOSTIC
2.
Diagnosis of Peculiar ABS Operating magnetic fields) may interfere with the electric
Characteristics signals being provided to the ABS ECU.
Unless the ABS/TCS Technician has a thorough Noise, Vibration, Harshness
understanding of the principles behind the operation ABS/TCS systems make loud noise whilst in
of ABS and TCS systems, it is possible that operation during heavy braking and TCS systems
misdiagnosis may occur and components may be make some noise during traction control operation.
replaced unnecessarily. It is therefore recommended The level of noise experienced in one vehicle may be
that only trained and experienced ABS/TCS higher than in another, but this does not necessarily
Technicians perform the diagnosis of ABS/TCS indicate a fault with the noisier vehicle. Typical
concerns. sources of noise are
ABS/Traction Control Lamp ABS Modulator - the modulator contains an
If the ABS or traction control warning lamp comes on electric pump and electrically operated solenoids
or stays illuminated whilst driving, refer to the that control brake fluid flow. These items all create
Diagnosis Procedure for diagnosis and repair. It is noise from the front of the vehicle. If the noise is
likely that one or more DTCs will be present in the of a metallic or grinding nature, check the security
ABS ECU memory. of the brake fluid lines and their proximity to other
tubes or vehicle bodywork (insulate where
NOTE: The traction control indicator will flash when necessary). Also check the ABS Modulator rubber
the traction control system is activating traction bushings for correct installation and contamination
control. If the light flashes only under certain with small pebbles or dirt.
circumstances, ensure that the potential for wheel
spin is not the cause. Tyres - during ABS operation the tyres are (by
definition) at the limits of their adhesion. It is
It is possible for the ABS ECU to falsely determine a normal for tyre squeal and slipping noises to be
fault with the ABS/TCS as a result of completely heard.
unrelated work taking place on the vehicle. Always The nature of ABS systems also means that a certain
check the ABS/TCS Concern Customer Questionnaire level of vibration and harshness will be felt during an
for the vehicle history prior to the ABS/TCS concern. ABS stop. The severity is very much dependent on
Examples include: the traction between the road surface and tyres.
New tyres fitted recently - under some Typical instances are
circumstances this can induce a false wheel Brake Pedal Pulsation - the brake pedal will
speed sensor fault. Perform the ABS/TCS pulsate underfoot during an ABS stop. This is due
Diagnostic Procedure to confirm correct system to the action of the ABS modulator in increasing
operation. and decreasing brake fluid pressures in various
Underinflated tyres / recent puncture - can also brake circuits.
induce a false wheel speed sensor fault. Inflate all Whole Vehicle Vibration - an ABS stop involves
tyres to specification, clear DTCs and perform the the violent application of braking forces to
road test procedure (ABS/TCS Diagnostic individual wheels in order to stop a vehicle as
Procedure) to confirm correct system operation. quickly as possible whilst maintaining directional
Electrical interference - under certain control. It should therefore not be surprising that
circumstances some electrical or electronic the vehicle occupants feel a high level of pulsating
accessories (or external high strength electric or force as they are forced forward into their
G23421 en 01/2003 2003.0 BA Falcon

seatbelts. The driver may also perceive that the the driver and passengers as the TCS attempts to
vehicle is moving about on the road. However, make the best use of the traction available.
steering control is maintained to counter any
sideway movement of the vehicle. Spongy Brake Pedal
The nature of traction control systems also means This symptom should be treated in exactly the same
that a certain level of vibration and harshness will be way as it is for non-ABS vehicles. Check the brake
felt during an traction control acceleration. The fluid condition and level and bleed the brake system
severity is very much dependent on the traction (including ABS Modulator if necessary).
between the road surface and tyres. Typical instances
are Brake Bleeding
Engine Power Reduction - ignition and fuel Bleed the brake system as normal through the calliper
injection cutout will occur during TCS operation. bleed screws. Refer to section 206-00.
The driver may hear a change in engine sound as Replacement modulators are filled with brake fluid
the engine runs on a reduced number of cylinders and should normally only require a conventional bleed
Vehicle Surging - Engine torque is being procedure to be conducted. However, if a spongy
increased and decreased independently of the pedal is present and air in the modulator is suspected,
accelerator pedal during TCS operation, and is a Service bleed using the WDS tester should be
dependent upon drive wheel adhesion. Under carried out.
some circumstances this surging may be felt by
Diagnostic Trouble Code (DTC) Chart
WDS Display Fault Description Possible Cause/Action
B1342 ECU Fault. There may be an Go to Pin Point Test E.
internal fault in the ECU.
C1145 Right Front Wheel Speed Sensor The sensor circuit may be open circuit. The
Continuity Fault fault could be in the sensor, the wiring, or the
C1165 Right Rear Wheel Speed Sensor ECU. Go to Pin Point Test A.
Continuity Fault
C1155 Left Front Wheel Speed Sensor
Continuity Fault
C1175 Left Rear Wheel Speed Sensor
Continuity Fault
C1148 Right Front Wheel Speed The sensor signal is wrong for the current
SensorOutput Fault vehicle conditions. The fault could be in the
C1168 Right Rear Wheel Speed Sensor sensor, the wiring, or the ECU; the tone wheel
Output Fault may be missing, damaged or the wrong one
fitted; sensor may have fallen out. Go to Pin
C1158 Left Front Wheel Speed Sensor Point Test B.
Output Fault
C1178 Left Rear Wheel Speed Sensor
Output Fault
C1095 Pump Motor Fault The ECU recorded a possible fault in the pump
motor circuit. (Pump runs all the time or does
not start.) Go to Pin Point Test E.
C1266 Valve Relay/Valve Relay Power There may be a fault in the power supply,
Supply Fault. modulator or ECU. Go to Pin Point Test E.
B1318 Low Voltage Failure The ECU has detected a low supply voltage.
The cause could be alternator or battery, wiring
or the ECU. Go to Pin Point Test C.
C1222 Wheel Speed Sensor Frequency The signal from one of the sensors is wrong for
Fault the current vehicle conditions. Go to Pin Point
Test B.
P1571 Brake Light Switch Failure There may be a fault in the brake light switch
NOTE: Does not cause the ABS to circuit. The fault could be in the switch,
shut down. switchwiring, tail light wiring or bulb. Go to Pin
Point Test D.
G23421 en 01/2003 2003.0 BA Falcon

WDS Display Fault Description Possible Cause/Action

U2202 Option Coding Fault The TCS ECU does not recognize the drive
train as a valid drivetrain variant. Check that all
ECU’s are correct for vehicle.
B1317 Battery Pack voltage high Supply battery voltage above 17.2 V engine.
Go to Pin Point Test C.
P1796 CAN Communication Bus Fault Partial of no CAN comms (short circuit to
Bat/Gnd) or open circuit. Go to CAN Wiring
Test
U2501 Missing token from Engine No CAN message received from
Management system EngineManagement System. (Refer PCM fault
diagnostics - Section 303-14)
U2509 Torque Reduction Request cannot In response to torque reduction request (Refer
be fulfilled by PCM to PCM fault diagnostics - Section 303-14)
ABS MODULE 31 pin connector

1 Right Rear - Ignition off: 1.6 k ± 0 .0.32 k to pin 2
524
2 Right Rear + Ignition off: 1.6 k ± 0.32k to pin 1
523
3 not used —
—
4 Right Front - Ignition off: 1.6 k ± 0.3 k to pin 5
516
G23421 en 01/2003 2003.0 BA Falcon


5 Right Front + Ignition off: 1.6 k ± 0.3 k to pin 4
514
6 Left Front - Ignition off: 1.6 k ± 0.3 k to pin 7
522
7 Left Front + Ignition off: 1.6 k ± 0.3 k to pin 6
521
8 Left Rear - Ignition off: 1.6 k ± 0.32k to pin 9
519
9 Left Rear + Ignition off: 1.6 k ± 0.32k to pin 8
518
10 not used —
—
11 Serial Diagnostics Serial Signal
70
12 not used —
—
13 not used —
901
14 Brake Light Input Brake on: >9.5V.Brake off: <2.0V
10
15 Ignition Power (ECU Relay) Ignition on: >9.5V
16
16 Ground Monitoring <0.5 with reference to battery negative
57
17 Valve Relay Power Ignition on: >9.5V
537
18 Valve Relay Power Ignition on: >9.5V
537
19 Ground (ECU Solenoid) <0.5 with reference to battery negative
—
20 ABS Light Ignition on: <2.5V. Ignition off: >9.5V
600
21 EBD Light Ignition on: <2.5V. Ignition off: >9.5V
991
29 CAN -L Serial data line (ASR only)
30 CAN -H Serial Data line (ASR only)
31 ASR on/off switch Serial Signal (ASR only)
601
G23421 en 01/2003 2003.0 BA Falcon

Pinpoint Tests
PINPOINT TEST A : WHEEL SPEED SENSOR (WSS) CONTINUITY FAULT

NOTE: CODES C1145, C1155, C1165, C1175
A1 MEASURE THE RESISTANCE OF THE WSS AT THE

SENSOR CONNECTOR
Disconnect the WSS from the vehicle harness Yes
Go to A2
Measure the resistance at the WSS connector terminals
Is the resistance between 1.28 & 1.92 K Ohms? No
Replace faulty WSS and - Clear the DTC - Go to
ABS/TCS Diagnostic Procedure Table
A2 MEASURE THE RESISTANCE OF THE WSS AT THE

ABS ECU CONNECTOR
Reconnect the WSS to the vehicle harness Yes
Go to A3
Disconnect the vehicle harness from the ABS ECU
Measure the resistance at the ECU connector terminals that No
correspond to the WSS being checked Locate high resistance fault in wiring and rectify
- Clear the DTC - Go to ABS/TCS Diagnostic
Is the resistance very close to that measured in A1? Procedure Table
A3 CHECK THE VEHICLE WIRING

Check the wiring harness and all connections between the WSS and Yes
the ABS ECU for permanent or intermittent open circuits or shorts. Be Repair or replace faulty wiring or connections -
sure to wiggle the wiring whilst testing Clear the DTC - Go to ABS/TCS Diagnostic
Procedure Table
NOTE: Never perform resistance check on ECU WSS output pins.
Always disconnect ECU before testing wiring harness and/or WSS No
Clear the DTC - Go to ABS/TCS Diagnostic
Were any permanent or intermittent open circuits or shorts Procedure Table
located? or
If this is the second time that you have reached
this point (i.e. the same DTC has reappeared
after the first cycle of diagnostics/repair and the
and no faults were found) then the ECU may be
faulty. Replace the ABS/TCS modulator and
return to ABS/TCS Diagnostic Procedure Table
to confirm the repair.
PINPOINT TEST B : WHEEL SPEED SENSOR (WSS) OUTPUT FAULT

NOTE: CODES C1148, C1158, C1168, C1178, C1222

B1 CHECK THE AIR GAP BETWEEN THE WSS AND THE
TONE WHEEL
Measure the gap between the WSS and the tone wheel Yes
Go to B2
Is the gap to specification?
No
Adjust as necessary - Clear the DTC - Go to
G23421 en 01/2003 2003.0 BA Falcon


B2 CHECK THE CONDITION OF THE TONE WHEEL
Visually inspect he tone wheel Yes
Go to B3
Is the tone wheel free from damage (broken, deformed or
chipped) and does it have 50 teeth? No
Replace the tone wheel and reset the air gap to
specification - Clear the DTC - Go to ABS/TCS
Diagnostic Procedure Table
B3 CHECKING WHEEL SPEED OUTPUT USING AN

OSCILLOSCOPE.
Viewing of Oscilloscope Patterns (WSS.) Yes
Disconnect the vehicle harness from the ABS ECU. Go to A1
Set the WDS to read oscilloscope wave patters. No
Check the oscilloscope pattern at the ECU connector Investigate and rectify cause of fault - Clear the
terminals that correspond to the WSS being checked. DTC - Go to ABS/TCS Diagnostic Procedure
Table
Raise the vehicles wheels off the ground and rotate to
achieve the below patters.
Simulated normal oscilloscope pattern:
Simulated pattern showing possible increasing and

decreasing distance between WSS and pulse wheel:
Simulated pattern showing possible chipped or

damaged teeth:
NOTE: When using an oscilloscope to check the WSS output, the

wheel must be rotated at a constant speed.
Incorrect wheel bearing clearance can cause inaccurate readings.
Does the oscilloscope pattern look similar to the above normal
pattern?
G23421 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : LOW/HIGH VOLTAGE FAILURE

NOTE: CODES - B1317, B1318
C1 CHECK VOLTAGE AT THE BATTERY

Check the battery voltage Yes
Go to C2
Check battery charging voltage (Refer to Alternator test procedure)
Is the battery voltage to specification? No
Repair as required - Clear DTC - Go to
C2 CHECK VOLTAGE AT THE ABS ECU CONNECTOR –

TERMINALS 17 & 18
Disconnect the vehicle harness from the ABS ECU Yes
Go to C3
Check the voltage at terminals 17 & 18 (Check voltage across each
terminal to ground) No
Is the voltage at terminals 17 & 18 constant battery voltage Check corresponding fuses, wiring connections
regardless of ignition position? and looms for open circuits or shorts to ground.
Be sure to wiggle the wiring whilst testing and
repair as required - Clear the DTC - Go to
C3 CHECK VOLTAGE AT THE ECU CONNECTOR -

TERMINAL 15
Check the voltage at terminal 15 (Check voltage across each terminal Yes
to ground) Go to C4
Is the voltage at terminals 15 constant battery voltage with No
ignition ON? Check corresponding fuses, wiring connections
and looms for open circuits or shorts to ground.
C4 CHECK CONTINUITY AT THE ECU CONNECTOR -

TERMINAL 16 & 19
Check the resistance at terminals 16 & 19 (Check resistance between Yes
each terminal and ground) Repair as required - Clear the DTC - Go to
Is there a high resistance or open circuit between terminals 16 &
19 and ground No
Procedure Table
or
G23421 en 01/2003 2003.0 BA Falcon

PINPOINT TEST D : BRAKE LIGHT SWITCH FAILURE

NOTE: CODES - P1571
D1 CHECK THE BRAKE LIGHTS

Check the brake lights Yes
Go to D2
Do the brake lights work?
No
Check the following. Repair as required. Clear
DTC. Go to ABS/TCS Diagnostic Procedure
Table.
Check for voltage supply at the brake light
switch
Check the operation and adjustment of the
brake light switch
Check for blown bulbs, open circuits or shorts in
the wiring from the brake light switch to the
brake lights. Be sure to wiggle the wiring whilst
testing.
D2 CHECK VOLTAGE AT THE ECU CONNECTOR -

TERMINAL 14
Disconnect the vehicle harness from the ABS ECU. Yes
Check the voltage at terminal 14 (Check voltage across each terminal Procedure Table
to ground) or
Does terminal 14 have >10V when the brakes are applied? If this is the second time that you have reached
No
Check for open circuits or shorts in the wiring
from the brake light switch to the ABS/TCS
ECU. Be sure to wiggle the wiring whilst testing -
Repair as required - Clear DTC - Go to
PINPOINT TEST E : ABS/TCS MODULATOR ASSEMBLY INTERNAL FAULT

NOTE: CODES - C1342, C1266, C1095
E1 CHECK VOLTAGE AT THE ABS ECU CONNECTOR –

TERMINALS 17 & 18
Disconnect the vehicle harness from the ABS ECU Yes
Go to E2
Check the voltage at terminals 17 & 18 (Check voltage across each
terminal to ground) No
Is the voltage at terminals 17 & 18 constant battery voltage Check corresponding fuses, wiring connections
regardless of ignition position? and looms for open circuits or shorts to ground.
G23421 en 01/2003 2003.0 BA Falcon


E2 CHECK VOLTAGE AT THE ECU CONNECTOR -
TERMINAL 15
Check the voltage at terminal 15 (Check voltage across each terminal Yes
to ground) Go to E3
Is the voltage at terminals 15 constant battery voltage with No
ignition ON? Check corresponding fuses, wiring connections
E3 CHECK CONTINUITY AT THE ECU CONNECTOR -

TERMINAL 16 & 19
Check the resistance at terminals 16 & 19 (Check resistance between Yes
each terminal and ground) Repair as required - Clear the DTC - Go to
NOTE: I. The ABS/TCS Modulator Assembly contains no
serviceable items No
NOTE: II. Under no circumstances is the ABS/TCS Modulator Procedure Table
Assembly to be dismantled or a repair attempted. or
Is there a high resistance or open circuit between terminals 16 & this point (i.e. the same DTC has reappeared
19 and ground? after the first cycle of diagnostics/repair and the
PINPOINT TEST F : COMMUNICATIONS FAULT
F1 WDS CONNECTION
Is the WDS properly plugged into the diagnostic connector? - Is Yes
the WDS properly connected to the power supply? - Is the Go to ABS/TCS ECU CONNECTOR - FITMENT
correct vehicle selected? below
No
Rectify and return to DIAGNOSTIC
PROCEDURE - PART A
F2 ABS/TCS ECU CONNECTOR - FITMENT

Is the ABS/TCS connector free from damage and corrosion and Yes
is it properly connected? Go to ABS/TCS ECU CONNECTOR -
CIRCUITS below
No
PROCEDURE - PART A
F3 ABS/TCS ECU CONNECTOR - CIRCUITS

Remove the ABS/TCS connector. Are all the terminal voltages Yes
and resistances within specification? Go to WDS below
No
Check corresponding fuses, wiring connections
Be sure to wiggle the wiring whilst testing -
PROCEDURE - PART A
G23421 en 01/2003 2003.0 BA Falcon


F4 WDS
Can the WDS establish communications with the ABS/TCS on Yes
another vehicle? If no other fault is found, the fault may be within
the ABS/TCS ECU. Replace the ABS/TCS
modulator and return to ABS/TCS Diagnostic
Procedure Table to confirm the repair.
No
The WDS is faulty. Use another WDS and return
to DIAGNOSTIC PROCEDURE - PART A
G23421 en 01/2003 2003.0 BA Falcon

Rear ABS sensor — IRS 4. Remove ABS-Knuckle Screw behind the Rotor.
Removal
1. Remove lower rear seat cushion.
5. Remove ABS Sensor.
2. Disconnect the ABS wheel sensor plug and push

it and the grommet through the floor plan.
Installation
1. Locate ABS Sensor to Knuckle using
ABS-Knuckle Screw.
2. Torque ABS-Knuckle Screw to 8.9 - 12.1 Nm.
3. Unclip Firtree Clip connecting ABS Sensor with
Control Blade. Feed ABS Sensor Cable through
hole in Control Blade.
G23422 en 01/2003 2003.0 BA Falcon

3. Feed ABS Sensor Cable through hole in Control 6. Refit lower seat cushion.
Blade.
4. Affix Firtree Clip to ABS Sensor Cable and clip to ABS Wheel Speed Sensor — Rear
the Control Blade as shown. (Beam Axle)
Removal
1. Remove the rear seat cushion. Refer to section
501-10.
2. Disconnect the ABS wheel sensor. Plug and push
it and the grommet through the floor plan.
5. Reconnect wiring plug and fit grommet.
Item Description
1 ABS Wheel Sensor Plug
2 Grommet
G23422 en 01/2003 2003.0 BA Falcon

3. Unclip ABS Sensor cable clips from the leaf 3. Remove ABS Sensor retaining bolt.
spring (3 off).
4. Remove ABS Sensor.

4. Remove ABS sensor retaining bolt and withdraw Installation
the ABS Sensor.
1. Installation is the reverse order to removal.
Rear Tone Wheel

The rear tone wheel is not separately serviceable.
The tone wheel is serviced with the complete half
shaft assembly.
Front Tone Wheel

The front hub tone wheel is not separately
serviceable. The tone wheel is serviced with the
complete hub assembly.
ABS Modulator Assembly

Removal
Installation
NOTE: The ABS Modulator Assembly is a critical
1. Installation is the reverse order to removal.
safety item. It should only be installed by trained and
Front ABS Wheel Sensors experienced ABS Technicians.
1. Ensure ignition is in the off position.
Removal
2. Disconnect wiring from modulator by sliding the
1. Disconnect ABS Sensor cable. locking slide pin out and lifting the connector from
2. Unclip fir tree clip 2 places. the modulator.
G23427 en 01/2003 2003.0 BA Falcon

3. Loosen the brake lines. 3. Refit mounting nuts and torque to specifications.
4. Loosen the 2 mounting nuts and withdraw the 4. Torque brake lines to specifications.
modulator from the vehicle.
5. Re-connect wiring by placing the connector on the

Installation locating lugs of the ABS ECU and then pushing in
1. Ensure mounting dampers are in place. the locking slide to secure the connector.
2. Position modulator ensuring fully seated in bottom
pin and hand thread to brake lines.
6. Bleed braking system as described in section

206-00 Brake System-General Information.
G23427 en 01/2003 2003.0 BA Falcon

211-00-1 Steering System — General Information 211-00-1
SECTION : 211-00 Steering System — General

Information
CONTENTS PAGE
Service Kits ............................................................................................................................211-00-2
GENERAL PROCEDURES
Power Steering System Bleeding Air .....................................................................................211-00-3
Rack and Pinion Gear Rack Bearing Preload Adjustment ....................................................211-00-4
Steering Gear Lubrication ......................................................................................................211-00-4
Steering System Exploded .....................................................................................................211-00-5
01/2003 2003.0 BA Falcon

Service Kits
Service Kit Contents Outer Tie Rod Assembly
Service Kit 26092580
Outer Tie Rod Assembly
Inner Tie Rod Assembly Service Kit 26092849
Inner Tie Rod Assembly
Metric Hex Nut
Seal Retaining Clamp
Rack And Pinion Boot Service Kit 26092851
Rack And Pinion Boot
Seal Retaining Clamp
Tie Rod End Clamp
Service Kit Grease (Not Shown)
Seal Installation Instruction Sheet (Not Shown)
Seal And Bearing Service Kit 26102901
Retaining Ring
Spool Shaft Seal
Needle And Bearing Assembly
Valve Body Ring (4)
Metric Hex Nut
Dust Cover
Adjuster Plug
Lube Shaft And Seal Instruction Sheet (Not
Shown)
Service Kit Grease (Not Shown)
Cylinder Line Assembly Service Kit (Right)
26102902
Cylinder Line Assembly
O-Ring Seal
Cylinder Line Assembly Service Kit (Left)
26102903
Cylinder Line Assembly
O-Ring Seal
Sleeve And Bushing Service Kit 26103515
Steering Gear Bushing
Steering Gear Bushing Sleeve
NOTE: Kits in bold reflect service kits supplied by
Delphi Saginaw. Parts listed below service kits are
included in each kit.
G27360 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Power Steering System Bleeding Air 6. While turning wheel, check fluid constantly.
NOTE: No bubbles are allowed.
CAUTION: You should bleed after any NOTE: For any sign of bubbles, recheck
component replacement or after disconnecting connections. Repeat step 5.
fluid line in case of steering system noise.
7. Start engine. With engine idling, maintain fluid
Bleeding is important to prevent pump damage, to
level. Reinstall cap.
ensure proper system operation and to stop
steering system noise. 8. Return wheels to centre. Lower front wheels to
ground.
NOTE: Inspect steering system. Check, and correct
as needed: 9. Keep engine running for two minutes.
10. Turn steering wheel in both directions.
Hoses must not touch any other part of vehicle.
Hose touching frame, body, or engine could 11. Verify:
cause steering system noise. Smooth power assist
All hose connections must be tight. Loose Noiseless operation
connections might not leak but could allow air into Proper fluid level
system.
No system leaks
NOTE: Use only clean, new power steering fluid. Fluid
must be: Proper fluid condition (i.e. No bubbles, no
foam and no discolouration)
Conventional climate: 12. If all proper conditions apply, procedure is
GM #1052884 - 16 ounce. complete.
GM #1050017 - 32 ounce. 13. If any problem remains, check these special
Cold climate: conditions:
GM #12345866 - 16 ounce. Fluid: If there is foam or bubbles in the fluid.
The fluid must be completely free of bubbles.
GM #12345867 - 32 ounce.
In step 5, be alert to periodic bubbles that
1. Switch ignition off. could indicate a loose connection or leaky
2. Raise front wheels off ground. O-ring seal in either the return hose or
3. Turn steering wheel full left. pressure hose. Also check for discoloured
fluid. Follow the following steps top remedy
4. Fill fluid reservoir to “FULL COLD” level. Leave the situation:
cap off. Switch ignition off.
Wait two minutes.
Recheck hose connections.
Repeat steps 7-10 of procedure.
If condition still exists then check: return
hose clamps, return hose O-ring,
pressure hose O-rings and gear cylinder
line O-rings
Noise: If the pump whines or groans then with
engine running, recheck hoses for possible
contact with frame body or engine. If no
contact is found, follow either of the below
methods:
Method one: Normal cool down
Switch engine off.
5. With assistant checking fluid level and condition, Wait for system to cool.
turn steering wheel lock-to-lock at least 20 times. Install reservoir cap.
Engine remains off. Method two: Partial fluid replacement
NOTE: On systems with long return lines or fluid Switch engine off.
coolers, turn steering wheel lock-to-lock at least Use a suction device to remove fluid
40 times. from reservoir.
Refill with cool, clean fluid.
NOTE: Trapped air may cause fluid to overflow. Install reservoir cap.
Thoroughly clean any spilled fluid to allow for leak NOTE: After either method of cooling, start engine
check.
and allow engine to come up to operating
NOTE: Keep fluid level at “FULL COLD”. temperature. If noise persists, remove and replace
G27361 en 01/2003 2003.0 BA Falcon

power steering pump. Repeat bleed procedure

following pump replacement.
Rack and Pinion Gear Rack Bearing

Preload Adjustment
1. Remove the steering gear from the vehicle. Refer
to Section 211-02.
2. Remove and discard the adjuster plug.
3. Install a new adjuster plug.

4. Turn the adjuster plug clockwise onto the rack
and pinion gear assembly until the adjuster plug
bottoms in the rack and pinion gear assembly.
5. Tighten the adjuster plug to 10 Nm (90 lb. in.)
then turn back 35 degrees to 55 degrees.
6. Install the steering gear into the vehicle. Refer to
Section 211-02.
Steering Gear Lubrication

1. The rack and pinion steering gears are lubricated
by a semi-liquid grease.
2. The correct amount of grease can only be applied
during steering gear rebuild and therefore check
and top-up is not a maintenance service
operation.
G27361 en 01/2003 2003.0 BA Falcon

Steering System Exploded
G27365 en 01/2003 2003.0 BA Falcon

Disassembled View
Item Description
1 Outer Tie Rod Assembly
2 Metric Hex Nut
3 Tie Rod End Clamp
4 Rack and Pinion Boot
5 Seal Retaining Clamp
6 Inner Tie Rod Assembly
7 Cylinder Line Assembly (Right)
8 Cylinder Line Assembly (Left)
9 O-Ring
10 Rack and Pinion Housing Assembly
11 Spool Shaft Boot
12 Retaining Ring
13 Spool Shaft Seal
14 Needle Bearing Assembly
15 Valve Body Ring
16 Pinion and Valve Assembly
17 Metric Hex Nut
18 Dust Cover
19 Rack Bearing Assembly
20 O-Ring Seal
21 Adjuster Spring
22 Adjuster Plug
23 Steering Gear Bushing
24 Steering Gear Bushing Sleeve
Parts in bold reflect service checked parts on Delphi
Saginaw’s Parts List.
G27365 en 01/2003 2003.0 BA Falcon

211-02-1 Power Steering 211-02-1
SECTION : 211-02 Power Steering

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................211-02-2
Power Steering Pump — I6 ...................................................................................................211-02-3
Power Steering Pump — V8 ..................................................................................................211-02-3
Pump Identification ...............................................................................................................211-02-4
Power Steering Pump — I6 ...................................................................................................211-02-5
Symptom Chart ....................................................................................................................211-02-5
GENERAL PROCEDURES
Start of Procedure ................................................................................................................211-02-15
Remedying Pump Noise ......................................................................................................211-02-15
Purging Power Steering System of Air ................................................................................211-02-15
Flushing Power Steering Pump (I6) .....................................................................................211-02-15
Flushing Power Steering Gear (I6) ......................................................................................211-02-15
Steering Gear Cylinder Pipe and O — Ring Seals ..............................................................211-02-17
Steering Gear Spool Shaft Seals and Bearings ..................................................................211-02-17
Power Steering Pump (I6) ....................................................................................................211-02-21
Power Steering Pump (V8) ..................................................................................................211-02-22
Power Steering Pump Pulley (V8) .......................................................................................211-02-23
Steering Gear — I6 ..............................................................................................................211-02-23
Steering Gear — V8 .............................................................................................................211-02-24
Steering Gear Bushing and Sleeve .....................................................................................211-02-24
Drive Belt (I6) .......................................................................................................................211-02-25
Quick Connect Power Steering Fitting (I6) ..........................................................................211-02-25
Power Steering Lines (I6) ....................................................................................................211-02-26
Power Steering Lines (V8) ...................................................................................................211-02-27
Resorvoir Assembly (I6) .......................................................................................................211-02-29
Resorvoir Assembly (V8) .....................................................................................................211-02-29
Control Valve Assembly (I6) ................................................................................................211-02-29
Drive Shaft Seal (I6) .............................................................................................................211-02-30
Hydraulic Pump Assembly (I6) .............................................................................................211-02-31
01/2003 2003.0 BA Falcon

SPECIFICATIONS
General Specifications Description Nm

Description Specification Fitting 65
Lubrication Connector to Discharge 30
Power Steering Hydraulic ESN M2C 134 D (Mobil Power steering pump (V8) lower bolt 20-30
System 424 or equivelant) Power steering pump (V8) upper bolts 20-30
Ford R1-424
0.95 litre approximately
(total system)
Power Steering Rack and ESA M1 C 75B
Pinion (Shell Alvania L 50 grams
PRO)
Pump Capacity 0.6 litre
Multi-Purpose Grease ESB-M1C93-B and
DOAZ-19584-AA ESR-M1C159-A
MERCON® MERCON®
Multi-Purpose ATF
XT-2-QDX
Power Steering Gear
Steering Gear Constant 47.8mm/rev
Ratio
Steering Ratio (on 18.9:1
centre)
Turns of Steering Wheel 3.09
(Stop to Stop)
Preload: Maximum 5 Nm
allowable over full travel
of rack
Description Nm
Rack Pad Locknut 75
Tube Nuts (Feed Pipes) 20
Tube Nuts (Pressure and Return) 35
Tie Rod Ball Housing 85
Pressure Switch 14
Steering Gear to Sub-frame 80
Pinion Lower Retaining Nut 40
Pinion Lower Screw Plug 60
Reservoir to Pump 50
Pump to Mounting Brackets (V8) 50
Pump to Mounting Brackets (I6) 25
Mounting Brackets to Cyl. Head (I6 47
-m8)
Mounting Brackets to Cyl. Head (I6 23
-m10)
Mounting Brackets to Cyl. Head (V8 47
-7/6)
Idler Pulley Locknut 47
Idler Pulley Bracket to Block 40
Pressure Hose Tube Nut 24
Return Hose Clamp Screw 30
Discharge Fitting to Pump 5
G37358 en 01/2003 2003.0 BA Falcon

Power Steering Pump — I6

The power steering pump is a constant displacement
vane type providing hydraulic pressure for the
steering system. The housing and internal parts of the
pump are inside the reservoir so the pump parts
operate submerged in oil. The reservoir is sealed
against the pump housing, leaving the housing face
and the shaft hub exposed.
The drive shaft is fitted with a pulley and is belt driven
from the crankshaft. The rotor is loosely splined to the
drive shaft and secured with a retaining ring. Ten
vanes are mounted in radial slots in the rotor.
An identification label showing the pump model
number is located on the outboard side of the pump
reservoir.
Power Steering Pump — V8

NOTE: On early build 4.6L and 5.4L engines there are
four bolts mounting the power steering pump to the
engine block. The fourth bolt on earlier builds may be
discarded upon the replacement of the power steering
pump.
The CIII power steering pump has the following
features:
It is a belt-driven, vane-type, power steering
pump.
It is mounted directly to the engine block by three
bolts.
The power steering pump is replaced as an
assembly.
An identification tag attached to the power
steering pump indicates the model number and
bar code. Refer to the identification tag when the
pump replacement is required.
The power steering pump uses a quick connect
fitting for the power steering pressure hose.
The power steering fluid reservoir is mounted to
the front of the engine bay on top of the shroud.
G37361 en 01/2003 2003.0 BA Falcon

System View — I6
Item Description
1 Steering Gear
2 Power Steering Pump
3 Power Steering Return Hose
4 Power Steering Fluid Cooler
5 Press & Return Hose Assy
Pump Identification
CAUTION: Always use the ID code when

ordering service parts.
An identification tag is attached to the valve housing.
Item Description
1 Model Code
2 For Manufacturing Purposes Only
3 Day
4 Shift
5 Year
6 Month
G37361 en 01/2003 2003.0 BA Falcon

Power Steering Pump — I6

Symptom Chart
Power Steering Pump (I6) Symptom Chart

Steering Pump Belt
or Steering Linkage
Adjustment

Adjustment
Steering Pump Belt
Lack of Lubrication
or Steering Linkage
Internal Parts
Worn

Steering Pump Belt
Lack of Lubrication
or Steering Linkage
Worn
G37362 en 01/2003 2003.0 BA Falcon


Steering Pump Belt
Lack of Lubrication
Bushings
or Steering Linkage
Adjustment
Internal Parts

Bushings
Adjustment
Out-of-Round Wheel

Vehicle
(Wagon)
(Wagon)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Worn
G37362 en 01/2003 2003.0 BA Falcon


Vehicle
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment

Tyre Squeal on Turns Incorrect Tyre Pressure Remove/Repair as required

Bent Spindle Arm
Bent Spindle

Lack of Lubrication
or Steering Linkage
Worn

Vehicle
(Wagon)
(Wagon)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Out-of-Round Wheel
G37362 en 01/2003 2003.0 BA Falcon


Vehicle
Bushings

Vehicle
Lack of Lubrication
Bushings
or Steering Linkage
Out-of-Round Wheel
Tracking) (Wagon)
(Wagon)
Bushings
WARNING: Whenever a repair to the power

steering system is carried out, which may permit
air to enter the fluid lines or the pump, the system
must be purged of air on completion of the repair.
CAUTION: Do not hold the steering gear

against the lock stops for more than 5 seconds.
Several of these symptoms are also common to
suspension, frame, and wheel and tyre troubles. For
this reason, be sure that the cause of the trouble is in
the power steering pump before adjusting, repairing,
or replacing any of the pump parts.
General Diagnosis

Chirp noise in steering pump Loose belt Remove/Repair as required
Belt squeal (particularly noticeable at Loose belt Remove/Repair as required
full wheel travel and standstill parking).
Growl noise in steering pump Excessive back-pressure in hoses or Remove/Repair as required

steering gear caused by restriction
Growl noise in steering pump Scored pressure plate, thrust plate or Remove/Repair as required
(particularly noticeable at full wheel rotor.
travel and standstill parking). Extreme wear of pump ring and vanes.
Groan noise in steering pump Low oil level. Remove/Repair as required

Air in the oil. Poor pressure hose
connection
Rattle noise in steering pump Vanes not installed properly. Remove/Repair as required
G37362 en 01/2003 2003.0 BA Falcon


Momentary increase in effort when Low oil level in pump Remove/Repair as required
turning wheel fast to right or left. Pump belt slipping
High internal leakage. Valve or gear
cylinder
Steering wheel surges or jerks when Low oil level Remove/Repair as required
turning with engine running, especially Loose pump belt
during parking Insufficient pump pressure
Sticky flow control valve
Hard steering or lack of assist, Loose pump belt Remove/Repair as required
especially in parking Low oil level in reservoir.
Steering gear to column misalignment
Tires not properly inflated
NOTE: If checks 1 through 4 do not
reveal cause of hard steering, follow
the Power Steering Test Procedure.
Further possible causes could be:
Insufficient pump pressure output
Excessive internal pump leakage
Excessive internal system
leakage
Foaming milky power steering fluid, Air in the fluid, and loss of fluid due to Remove/Repair as required
low fluid level and possible low internal pump leakage causing
pressure overflow.
Low pressure from steering pump Flow-control valve stuck or inoperative Remove/Repair as required
Pressure plate not flat against pump
ring
Extreme wear of pump ring and vanes
Scored pressure plate, thrust plate or
rotor
Vanes not installed properly
Vanes sticking in rotor slots
Cracked or broken thrust or pressure
plate
Power Steering Pump (V8) Symptom Chart

Steering Pump Belt
or Steering Linkage
Adjustment

Adjustment
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211-02-10 Power Steering 211-02-10

Steering Pump Belt
Lack of Lubrication
or Steering Linkage
Internal Parts
Worn

Steering Pump Belt
Lack of Lubrication
or Steering Linkage
Worn
Steering Pump Belt
Lack of Lubrication
Bushings
or Steering Linkage
Adjustment
Internal Parts
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211-02-11 Power Steering 211-02-11

Bushings
Adjustment
Out-of-Round Wheel

Vehicle
(Wagon)
(Wagon)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Worn

Vehicle
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment

Tyre Squeal on Turns Incorrect Tyre Pressure Remove/Repair as required

Bent Spindle Arm
Bent Spindle
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211-02-12 Power Steering 211-02-12

Lack of Lubrication
or Steering Linkage
Worn

Vehicle
(Wagon)
(Wagon)
Bent Spindle Arm
Bent Spindle
Bushings
Adjustment
Out-of-Round Wheel

Vehicle
Bushings

Vehicle
Lack of Lubrication
Bushings
or Steering Linkage
Out-of-Round Wheel
Tracking) (Wagon)
(Wagon)
Bushings
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211-02-13 Power Steering 211-02-13
WARNING: Whenever a repair to the power

steering system is carried out, which may permit
air to enter the fluid lines or the pump, the system
must be purged of air on completion of the repair.
CAUTION: Do not hold the steering gear

against the lock stops for more than 5 seconds.
Several of these symptoms are also common to
suspension, frame, and wheel and tyre troubles. For
this reason, be sure that the cause of the trouble is in
the power steering pump before adjusting, repairing,
or replacing any of the pump parts.
General Diagnosis
Chirp noise in steering pump Loose belt Remove/Repair as required
Belt squeal (particularly noticeable at Loose belt Remove/Repair as required
full wheel travel and standstill parking).
Growl noise in steering pump Excessive back-pressure in hoses or Remove/Repair as required

steering gear caused by restriction
Growl noise in steering pump Scored pressure plate, thrust plate or Remove/Repair as required
(particularly noticeable at full wheel rotor.
travel and standstill parking). Extreme wear of pump ring and vanes.
Groan noise in steering pump Low oil level. Remove/Repair as required

Air in the oil. Poor pressure hose
connection
Rattle noise in steering pump Vanes not installed properly. Remove/Repair as required
Momentary increase in effort when Low oil level in pump Remove/Repair as required
turning wheel fast to right or left. Pump belt slipping
High internal leakage. Valve or gear
cylinder
Steering wheel surges or jerks when Low oil level Remove/Repair as required
turning with engine running, especially Loose pump belt
during parking Insufficient pump pressure
Hard steering or lack of assist, Loose pump belt Remove/Repair as required
especially in parking. Low oil level in reservoir.
Steering gear to column misalignment
Tires not properly inflated
NOTE: If checks 1 through 4 do not
reveal cause of hard steering, follow
the Power Steering Test Procedure.
Further possible causes could be:
Insufficient pump pressure output
Excessive internal pump leakage
Excessive internal system
leakage
Foaming milky power steering fluid, Air in the fluid, and loss of fluid due to Remove/Repair as required
low fluid level and possible low internal pump leakage causing
pressure overflow.
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211-02-14 Power Steering 211-02-14

Low pressure from steering pump Flow-control valve stuck or inoperative Remove/Repair as required
Pressure plate not flat against pump
ring
Extreme wear of pump ring and vanes
Scored pressure plate, thrust plate or
rotor
Vanes not installed properly
Vanes sticking in rotor slots
Cracked or broken thrust or pressure
plate
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211-02-15 Power Steering 211-02-15
GENERAL PROCEDURES
Start of Procedure 4. Fill pump reservoir to COLD FULL mark on

dipstick. Using auxiliary starter switch, crank
After Power Steering Pump or Gear Overhaul engine, while cycling steering wheel from
After engine start up, follow these steps to eliminate lock-to-lock. Check fluid level.
excessive steering system noise due to air trapped in 5. Tightly insert the rubber stopper of the air
the system during service: evacuator assembly into pump reservoir fill neck.
1. Disconnect the starter solenoid activation wire. 6. Apply 51 kPa (15 in-Hg) maximum vacuum on
2. Connect the remote starter switch wiring the pump reservoir for a minimum of three minutes
starter solenoid and the battery positive terminal. with the engine idling. As air purges from system,
the vacuum will fall off. Maintain adequate
3. Ensure the Power Steering Pump Reservoir is full. vacuum with vacuum source.
4. Crank the engine, using the remote starter switch, 7. Release vacuum and remove vacuum source. Fill
and add fluid until the level remains constant. reservoir to COLD FULL mark.
5. While cranking the engine, rotate the steering 8. With engine idling, apply 51 kPa (15 in-Hg.)
wheel from lock-to-lock. vacuum to pump reservoir. Slowly cycle the
NOTE: Front wheels must either be off the floor or steering wheel from lock-to-lock every 30 seconds
on free running turntables during lock-to-lock for approximately five minutes. Do not hold
rotation of the steering wheel. steering wheel on stops while cycling. Maintain
6. Check the fluid level and add fluid if necessary. adequate vacuum with vacuum source as the air
purges.
7. Disconnect the remote starter switch, reconnect
the starter solenoid activation wire and start 9. Release vacuum and remove vacuum equipment.
engine, allow it to run for several minutes. Add additional fluid if necessary. Install dipstick.
8. Rotate the steering wheel from lock-to-lock. 10. Start engine and cycle steering wheel. Check for
oil leaks at all connections. In severe cases of
9. Switch engine off and check the fluid level. Add aeration, it may be necessary to repeat Steps 5
fluid if required. through 9.
10. If air is still present in the steering system, purge,
as described in diagnosis section. Flushing Power Steering Pump (I6)
Remedying Pump Noise If dirt is found in power steering gear, flush pump as
follows:
The most common noise complaint is a moan or 1. Making sure all other hoses are connected,
whine noise (refer Symptom Chart) which in most disconnect pressure hose at gear.
cases is caused by air trapped in the system.
2. Place end of hose in a container.
The system must be purged of air promptly to prevent
permanent damage to the pump. 3. Fill reservoir with Power Steering Fluid Mobil 424
or equivalent that meets spec. ESN-M2C-134D.
If the air purging operation only temporarily
overcomes the noise, check for faults that could 4. Disconnect the starter solenoid activation wire.
cause entry of air into the system. 5. Connect a remote starter switch to the starter
solenoid.
Purging Power Steering System of Air 6. While adding approximately 2 litres of fluid, crank
Air trapped in the power steering system, which the engine using the remote starter switch. When
causes a whine or moan-type noise, can be removed all fluid has been added cease cranking engine.
by using a power steering pump air evacuator 7. Re-attach pressure hose at gear.
assembly (devac tool). 8. Check fluid level, add as required.
CAUTION: Under no circumstances should 9. Remove remote starter switch and reconnect
engine vacuum be utilised. starter solenoid wire.
1. Check and fill the pump reservoir with Power Flushing Power Steering Gear (I6)
Steering Fluid Mobil 424 (or equivalent that meets
spec. ESN-M2C- 134D) to the COLD FULL mark NOTE: Always flush power steering gear when
on pump dipstick. replacing pump due to fluid contamination.
2. Raise vehicle front wheels from floor. 1. Disconnect fluid return hose at pump and place
3. Install an auxiliary starter switch in starting circuit. end in a container. Plug return hose nipple on
With ignition switch in the OFF position, and using reservoir.
auxiliary starter switch, crank engine. 2. Fill reservoir with Power Steering Fluid Mobil 424
or equivalent that meets spec. ESN-M2C-134D.
3. Disconnect the starter solenoid activation wire.
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211-02-16 Power Steering 211-02-16
4. Connect a remote starter switch to the starter

solenoid.
5. Raise the vehicle front wheels off floor.
6. While adding approximately 2 litres of fluid, crank
the engine using the remote starter switch, whilst
turning steering wheel from lock-to-lock. When all
fluid has been added cease cranking engine.
7. Lower vehicle.
8. Remove remote starter switch and reconnect
starter solenoid wire.
9. Remove plug from the reservoir return hose
nipple. Attach return hose to nipple.
10. Check fluid level. Add fluid if necessary. Do not
overfill reservoir.
11. Start engine and turn steering wheel slowly from
lock-to-lock several times. Check fluid level and
adjust as required.
12. Check for air in system. If so purge system as
explained in this chapter.
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211-02-17 Power Steering 211-02-17
Steering Gear Cylinder Pipe and O — 4. Install the cylinder line assemblies to the gear
assembly.
Ring Seals
NOTE: Tighten the valve end fittings to 16.9 Nm
Removal (12.6 lb. ft.)
1. Remove the steering gear from the vehicle. Refer Tighten the cylinder end fittings to 27 Nm (20 lb.
to your dealership service manual. ft.)
2. Loosen both cylinder line fittings on the cylinder
end of the gear assembly. Steering Gear Spool Shaft Seals and
3. Loosen both cylinder line fittings on the valve end Bearings
of the gear assembly.
Special Tool(s)
4. Remove both cylinder line assemblies from the
rack and pinion gear assembly. Valve Body Seal Protector/
5. Remove the O-ring seals from the valve end of Sizer Kit
the cylinder line. J 46192
Bearing and Seal Installer

J 46193
6. Discard the O-ring seals.

Installation
1. Inspect the cylinder lines for the following items:
Cracks
Dents Spool Shaft Seal Protector
J 46221
Damage to the threads
2. Replace the parts as needed.
3. Install the new O-ring seals to the valve end of the
cylinder lines.
Removal
to your dealership service manual.
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211-02-18 Power Steering 211-02-18
2. Remove the following from the steering gear: 8. Remove and discard the metric hex nut from the
Adjuster plug lower end of the pinion and valve assembly while
holding the spool shaft.
Adjuster spring
Rack bearing assembly with o-ring
NOTE: When performing the following procedure, do

not remove the valve assembly from the rack and
pinion gear assembly. Press the pinion end of the
valve assembly only far enough to allow removal of
the spool shaft seal and the needle bearing assembly.
9. Gently tap a pointed center punch into the
threaded end of the pinion to remove only the
following items:
Spool shaft seal
Needle bearing assembly
3. Discard the adjuster plug.

NOTE: The rack assembly must be marked inside
the rack and pinion housing to show correct
alignment. Lubrication on the rack may cause the
alignment marks to smear if the rack is moved.
4. Hold the rack firmly and mark the rack assembly
inside of the rack and pinion housing.
5. Remove the spool shaft boot.
6. Remove and discard the retaining ring from the
top of the valve housing.
7. Remove and discard the dust cover from the
bottom of the rack and pinion gear assembly.
NOTE: The spool shaft must be held in place
during the following step.
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211-02-19 Power Steering 211-02-19
10. Discard the spool shaft seal and the needle 1. Install the new valve body rings onto the valve
bearing assembly. assembly using J 46192-1. Remove J 46192-1.
NOTE: Handle the valve assembly with caution.
Failure to do so may result in replacement of the
steering gear.
11. Pull the valve assembly out of the rack and pinion
housing.
12. Remove and discard the valve body rings (4) from
the valve assembly.
2. Lubricate the valve assembly with power steering

fluid.
3. Compress the valve body rings onto the valve
assembly using J 46192-2.
NOTE: The rack assembly must be aligned before

installing the valve assembly. Failure to do so will
cause the steering wheel to be out of position.
4. Align the rack assembly using the marks inside
Installation the rack and pinion housing.
NOTE: Handle the pinion and valve assembly with NOTE: The orientation of the pinch bolt notch on
caution. Failure to do so may result in replacement of the valve assembly must be aligned as shown.
the steering gear. Failure to do so will cause the steering wheel to
be out of position.
5. With J 46192-2 still on the valve assembly, install
the valve assembly into the rack and pinion
housing.
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211-02-20 Power Steering 211-02-20
6. Remove J 46192-2 from the rack and pinion 9. Remove J 46193 from the rack and pinion
housing. housing.
NOTE: The bearings in the needle bearing assembly 10. Install J 46221 onto the valve spool shaft.
must be facing down when installing into gear. 11. Lubricate the new spool shaft seal with grease.
7. Install the new needle bearing assembly onto the 12. Install the spool shaft seal onto the spool shaft of
spool shaft of the valve assembly. the valve assembly.
8. Using the smaller end of J 46193 and a rubber 13. Using the larger end of J 46193 and a rubber
mallet, gently tap the needle bearing assembly mallet, gently tap the spool shaft seal into the rack
into the rack and pinion housing. and pinion housing.
14. Remove J 46193 from the rack and pinion
housing.
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211-02-21 Power Steering 211-02-21
15. Remove J 46221 from the valve spool shaft. 20. Lubricate the rack bearing assembly with o-ring
NOTE: The spool shaft must be held in place with lithium base grease.
during the following step. 21. Install the following items into the gear assembly:
Rack bearing assembly with o-ring
Adjuster spring
New adjuster plug
16. Install the new metric hex nut onto the pinion
while holding the valve spool shaft.
NOTE: Tighten the metric hex nut to 30 Nm (22
lb. ft.).
22. Turn the adjuster plug clockwise onto the rack
17. Install the new dust cover to the rack and pinion and pinion gear assembly until the adjuster plug
gear assembly. bottoms in the rack and pinion gear assembly.
18. Install the new retaining ring into the groove in the NOTE: Tighten the adjuster plug to 10 Nm (90 lb.
top of the valve assembly of the rack and pinion in.) then turn back 35 degrees to 55 degrees.
gear assembly. 23. Flush and bleed power steering system. Refer to
19. Install the spool shaft boot. Bleeding the Power Steering System procedure.
NOTE: Flush and bleed power steering system
(hoses, reservoir and cooler lines) with power
steering fluid.
24. Install the steering gear into the vehicle. Refer to
your dealership service manual.
Power Steering Pump (I6)

Removal
1. Using a 15mm socket, rotate the drive belt
tensioner clockwise to reduce belt tension and
remove belt.
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211-02-22 Power Steering 211-02-22
2. Remove pump and pulley as a whole unit by Removal and Installation

accessing pump attaching hardware through 1. Remove the power steering pump pulley. For
holes in pulley OR additional information, refer to Power Steering
3. Remove pump pulley using special tool #E9240 Pump Pulley (V8) in this section.
B. 2. Disconnect the power steering reservoir pump
hose and pressure line from the power steering
pump.
Drain the power steering oil reservoir.
4. Remove fluid from pump reservoir using a syringe

or syphon hose.
5. Loosen the pump pressure line connector and
detach pressure line. Detach return line. 3. Remove the three bolts and the pump.
CAUTION: Take care to prevent power
steering pump fluid loss by plugging
connections.
6. Remove pump retaining hardware and withdraw
pump from mount.
Installation
1. Position pump in front cylinder cover.
2. Install return line and torque hose clamp.
3. Install pump mounting hardware and torque to
specification.
4. Install pressure hose connector.
5. Install pump pulley using special tool No.
E9239-A. 4. To install, reverse the removal procedure.
6. Install the drive belt. Refer Figure 10 for routing. NOTE: Install a new power steering seal on the
NOTE: Ensure belt is correctly engaged on pulley power steering pressure fitting by stretching the
ribs. seal over the seal replacer until it is large enough
to slip over the threads of the fitting.
7. Fill power steering pump reservoir with specified
fluid. 5. Install the power steering pump pulley. For
8. Attach a remote starter switch and carry out start additional information, refer to Power Steering
up procedure. Pump Pulley (V8) in this section.
6. Fill, purge and leak check the system as outlined
Power Steering Pump (V8) in the relevant chapter.
Special Tool(s)
Teflon® Seal Replacer Set
211-D027 (D90P-3517-A) or
equivalent
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211-02-23 Power Steering 211-02-23
Power Steering Pump Pulley (V8) 5. Loosen the tie rod end stud nuts and free the tie
rod end stud tapers in the wheel spindles.
Special Tool(s) Remove the nuts and detach the tie rod ends
from the spindles.
Steering Pump Pulley Remover
211-016 (T69L-10300-B)
Steering Pump Pulley Replacer

211-185 (T91P-3A733-A)
Removal 6. Remove the catalytic converter assembly as

outlined in the relevant section.
1. Remove the drive belt as outlined in chapter
7. Remove the two nuts securing the steering gear
Section 303-05.
to the cross-member and remove the gear from
2. Using the special tool, remove the power steering the vehicle.
pump pulley (3A733).
Installation
Installation
1. Position the steering gear assembly on the
1. Using the special tool, install the power steering cross-member, install and tighten the securing
pump pulley (3A733). nuts.
2. Install the drive belt as outlined in chapter Section 2. Connect the tie rod ends to the wheel spindles,
303-05. install and tighten the nuts.
Steering Gear — I6
Removal
1. Raise the hood and raise the vehicle supporting it
under the body side rails.
2. Place a drain pan under the steering gear.
3. Disconnect the pump to steering gear hydraulic
lines at the gear using a six point tube nut
wrench.
4. Remove the bolt from the clamp at the lower end
of the intermediate shaft. Slide the intermediate
shaft upwards until it is clear of the steering gear
valve splines.
3. Refit the catalytic convertor assembly.
4. Centralise the steering gear and align the
intermediate shaft with the steering gear valve
and slide the shaft yoke onto the valve. Install and
tighten the lower clamp bolt.
5. Connect the hydraulic lines to the steering gear
and tighten the unions with a six point tube nut
wrench.
6. Remove drain pan and lower the vehicle.
7. Top up the pump reservoir with the specified fluid
and bleed the system as per manual.
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211-02-24 Power Steering 211-02-24
Steering Gear — V8 10. Top up the pump reservoir with the specified fluid
and bleed the system as per manual.
Removal
1. Raise the hood and raise the vehicle supporting it
Steering Gear Bushing and Sleeve
under the body side rails. Removal
2. Place a drain pan under the steering gear. 1. Remove the steering gear from the vehicle. Refer
3. Disconnect the pump to steering gear hydraulic to your dealership service manual.
lines at the gear using a standard 12 point ring 2. Remove the steering gear bushing sleeve from
spanner (double hex). the steering gear bushings.
4. Remove the bolt from the clamp at the lower end 3. Remove the steering gear bushings from the rack
of the intermediate shaft. Slide the intermediate and pinion housing.
shaft upwards until it is clear of the steering gear
valve splines.
5. Loosen the tie rod end stud nuts and free the tie
rod end stud tapers in the wheel spindles.
Remove the nuts and detach the tie rod ends
from the spindles.
6. Remove both catalytic converter assemblies as
outlined in the relevant section.
7. AUTOMATIC ONLY - Remove the torque
convertor inspection cover as outlined in the
relevant section.
8. Loosen the two nuts securing the steering gear to
the cross-member .
9. Draw the steering gear back away from the
cross-member to access both the steering gears Installation
left and right transfer tubes. 1. Install the steering gear bushings into the rack
10. Remove the left and right transfer tubes from the and pinion housing.
steering gear. NOTE: Do not apply any type of lubricant or
11. Remove the two nuts securing the steering gear grease to the steering gear bushings or the
to the cross-member and remove the gear from steering gear bushing sleeve.
the vehicle. 2. Align the steering gear bushing sleeve and install
Installation into the steering gear bushings. The steering gear
1. Position the steering gear assembly on the bushings must be flush with the steering gear
cross-member. bushing sleeve.
2. Install but only tighten the securing nuts slightly NOTE: The steering gear bushing sleeve must be
allowing the steering gear to rest safely away from properly aligned.
the cross-member.
3. Install both left and right transfer tubes into the
steering gear, tighten the securing nuts.
4. AUTOMATIC ONLY - Install the torque convertor
inspection cover as outlined in the relevant
section.
5. Connect the tie rod ends to the wheel spindles,
install and tighten the nuts.
6. Refit the catalytic convertor assemblies.
7. Centralise the steering gear and align the
intermediate shaft with the steering gear valve
and slide the shaft yoke onto the valve. Install and
tighten the lower clamp bolt.
8. Connect the hydraulic lines to the steering gear 3. Install the steering gear into the vehicle. Refer to
and tighten the unions with a 12 point ring your dealership service manual.
spanner (double hex).
9. Remove drain pan and lower the vehicle.
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211-02-25 Power Steering 211-02-25
Drive Belt (I6) 3. Install new belt over pulleys. Ensure that all
V-grooves make proper contact with the pulley as
NOTE: Vehicles are equipped with a V-ribbed shown in figure.
serpentine accessory drive belt and automatic
tensioner. Replacement belts should be of the same
type as originally installed.
NOTE: Automatic belt tensioners are spring loaded
devices which set and maintain the drive belt tension.
The drive belt should not require tension adjustment
for the life of the belt. Automatic tensioners have belt
wear indicator marks. If the indicator mark is not
between the indicator lines, the belt is worn or an
incorrect belt has been installed.
Item Description
1 Power steering pump pulley
2 Idle pulley
3 Tensioner pulley
4 A/C Compressor pulley
5 Harmonic Balancer
6 Alternator pulley
7 Water pump pulley
Item Description Quick Connect Power Steering Fitting

1 Worn belt mark (I6)
2 15mm bolt Seal Replacement
3 New belt mark If a leak occurs between the tubing and tube nut,
4 Belt wear reference mark replace the hose assembly. If a leak occurs between
the tube nut and the pump outlet, replace the teflon
NOTE: Conditions requiring belt replacement are rib
chunkout, severe glazing, frayed cords, etc. Replace seal.
any belt exhibiting one of these conditions.
NOTE: Cracks on the ribbed side of the belt are
considered acceptable. If the belt has chunks missing
from the ribs it should be replaced if two or more
adjacent ribs have lost sections 13 mm (1/2inch) or
longer, or if the missing chunks are creating a noise
or vibration.
1. Rotate automatic tensioner clockwise.
2. Remove old belt.
Item Description
1 Tube nut
2 Snap ring
3 Pump outlet
4 Rubber O-Ring
5 Rubber O-Ring
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211-02-26 Power Steering 211-02-26
1. Check fitting to determine whether leak is 6. Connect quick connector and tighten to 30 Nm.
between tube and tube nut or between tube nut The quick connect fitting may disengage if not
and pump outlet. fully assembled, if the snap ring is missing, or if
2. If leak is between tube nut and pump outlet, the tube nut or the hose end is not machined
check to ensure nut is tightened to 30 Nm. properly.
If the fitting disengages, replace the hose
CAUTION: DO NOT over-tighten. assembly. The fitting is fully engaged only when
3. If leak continues or if leak is between tube and the hose will not pull out. To test for positive
connector, remove line. engagement, the system should be properly filled,
the engine started, and the steering wheel cycled
4. Unscrew connector, and inspect and replace from lock-to-lock. When replacing pressure hose
rubber O-ring seal. assembly the following parts will be required.
5. The rubber O-ring inside the connector (quick Pressure hose assy. – Qty 1.
connect fitting) cannot be serviced with this Quick Connect Fitting – Qty 1.
design. If leak is due to the O-ring, replace the
hose assembly.
Power Steering Lines (I6)
Removal 6. Loosen both clamps on return hoses at the cooler

1. Disconnect pressure & return lines from the ends & disconnect hoses.
steering gear 7 drain the fluid into a suitable 7. Loosen clamp on return hose at reservoir &
container. remove hose.
2. Remove the bolt from the securing clamp from the 8. Remove the nuts securing the cooler to the
RH side of the 2B crossmember. subframe cooler brackets.
3. Remove the bolt from the cooler line securing 9. Remove press & rtn line assy & cooler assy from
clamp from the RH side of 2A crossmember. vehicle.
4. Remove front bumper lower valance.
5. Disconnect the pressure line from pump.
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211-02-27 Power Steering 211-02-27
Installation
1. Refit press & rtn line assy & cooler assy to
vehicle.
2. Secure the cooler to the cooler mounting brackets
on the subframe (check that the clearances from
the cooler & side chassis rail are adequate) &
tighten nuts.
3. Secure the bolt from the cooler line securing
clamp to the RH side of the 2A crossmember.
4. Secure the bolt from the press & rtn line assy
clamp to the RH side of the 2B crossmember.
5. Connect pressure & return lines to steering gear
end.
6. Connect both return hoses to cooler ends &
secure both clamps.
7. Connect return hose to resorvoir inlet & secure
clamp.
8. Refit a new quick connect fitting to pump &
connect the pressure line.
9. Refit the front bumper lower valance.
10. Fill with specified Mobil 424 oil or equivalent &
conduct specified bleed procedure.
11. Start vehicle, check for leaks, rectify if necessary.
Power Steering Lines (V8)
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211-02-28 Power Steering 211-02-28
Removal
1. Disconnect pressure & return lines from the
steering gear & drain the fluid into a suitable
container.
2. Remove the bolt from the securing clamp from the
RH side of the 2B crossmember.
3. Remove the bolt from the cooler line securing
clamp from the RH & LH side of a 2A
crossmember.
4. Remove front bumper lower valance.
5. Disconnect the pressure line from pump.
6. Loosen clamp on return hose at pump &
disconnect hoses.
7. Loosen both clamps on return hoses at the cooler
ends & disconnect hoses.
8. Loosen both clamps on return hoses at resorvoir
& remove hoses.
9. Remove the nuts securing the cooler to the
subframe cooler brackets.
10. Remove press & return line assembly & cooler
assembly from vehicle.
Installation
NOTE: When connecting a fitting with a seal ring, the
ring must be replaced, using the seal replacer special
tool.
1. Refit press & return line assembly & cooler
assembly to vehicle.
2. Secure the cooler to the cooler mounting brackets
on the subframe (check that the clearances from
the cooler side chassis rail condenser are
adequate) & tighten nuts.
3. Secure the bolts from the cooler line securing
clamp to the LH & RH side of the 2A
crossmember.
4. Secure the bolt from the press & return line assy
clamp to the RH side of the 2B crossmember.
5. Connect pressure & return lines to steering gear
end.
6. Connect return hose to pump & secure clamp.
7. Connect both return hoses to cooler ends &
secure both clamps.
8. Connect return hoses to reservoir & secure
clamps.
9. Refit a new quick connect fitting to pump &
connect the pressure line.
10. Refit the front bumper lower valance.
11. Fill with specified Mobil 424 or equivelant &
conduct specified bleed preocedure.
12. Start vehicle, check for leaks, rectify if necessary
G37380 en 01/2003 2003.0 BA Falcon

211-02-29 Power Steering 211-02-29
Resorvoir Assembly (I6) 3. Remove the power steering fluid reservoir from its
support bracket.
NOTE: Take the following precautions when servicing
the power steering pump reservoir:
Use a clean work bench and tools.
Plug the inlet and outlet openings of the pump
with plugs or masking tape.
Thoroughly clean the exterior of the pump with
solvent.
Disassembly
1. Remove pump assembly from vehicle, if
necessary for access (Refer to Power Steering
Pump Removal in this section).
2. Disconnect retaining clips from reservoir assembly
and housing.
Assembly
1. To install, reverse the removal procedure.
2. Fill and leak check the system.
Control Valve Assembly (I6)

Disassembly
3. Remove reservoir from housing.

4. Remove O-ring seal from reservoir.
Assembly
1. Lubricate new O-ring with power steering fluid.
Install O-ring seal to reservoir.
2. Connect reservoir assembly to housing.
3. Install retaining clips to reservoir and housing. Item Description
4. Install pump assembly to vehicle, if removed. 1 Housing ASM, HYD Pump
2 Spring, Flow Control
Resorvoir Assembly (V8)
3 Valve ASM, Control
Disassembly 4 Seal, O-Ring
1. Drain the power steering fluid reservoir. 5 Fitting, O-Ring Union
2. Disconnect the power steering warm drive hoses. 1. Remove pump assembly from vehicle, if
1. Loseen and move the power steering hose necessary for access (Refer to Power Steering
clamps. Pump Removal in this section).
2. Disconnect the power steering return hose 2. Remove O-ring union fitting and O-ring.
and the power steering reservoir pump hose. 3. Remove control valve assembly.
4. Remove flow control spring.
Assembly
1. Install flow control spring.
2. Install control valve assembly.
3. Install O-ring on fitting.
G37383 en 01/2003 2003.0 BA Falcon

211-02-30 Power Steering 211-02-30
4. Install fitting into hydraulic pump housing

assembly and tighten to 75Nm.
5. Install pump assembly to vehicle, if removed.
Drive Shaft Seal (I6)

Special Tool(s)
Shaft Oil Seal Installer
J 7728
Disassembly
1. Remove P/S Pump pulley using tool 7185.
2. Remove pump assembly from vehicle, if
necessary for access (Refer to Power Steering
Pump Removal in this section).

1 Pin, Pump Ring Dowel 7 Vane
2 Shaft, Drive 8 Rotor, Pump
3 Housing ASM, HYD Pump 9 Ring, Shaft Retaining
4 Seal, Drive Shaft 10 Plate, Pressure
5 Plate, Thrust 11 Seal, O-Ring
6 Ring, Pump 12 Spring, Pressure Plate
G37383 en 01/2003 2003.0 BA Falcon

211-02-31 Power Steering 211-02-31
Item Description Hydraulic Pump Assembly (I6)

13 Seal, O-Ring
14 Cover, End Special Tool(s)
15 Ring, Retaining Shaft Oil Seal Installer
3. Protect drive shaft with shim stock. J7728
NOTE: The following precautions must be observed

when servicing the power steering pump:
Use a clean work bench and tools.
Thoroughly clean the exterior of the unit with
solvent. Drain as much fluid from the pump as
possible.
If only the reservoir is to be removed, clean as
outlined.
Do not use cleaning solvents on the seal.
Item Description
1 Chisel Disassembly
2 Shaft Drive 1. Disassemble retaining ring using punch in access
hole.
3 Shim Stock
4 Housing ASM, HYD Pump
5 Seal Drive Shaft
4. Remove seal and discard (Use small chisel to cut
drive shaft seal).
Assembly
1. Install new drive shaft seal (lubricated with power
steering fluid, using tool J 7728).
Item Description
1 Punch
2 Access Hole
3 Ring Retaining
2. Disassemble internal components of pump from
pump housing by gentle pushing on drive shaft.
Components should include pressure plate
subassembly consisting of:
2. Install pump assembly to vehicle, if removed. End cover
O-ring seal
Pressure plate spring
Pressure plate
Drive shaft subassembly consisting of:
Pump rotor
Thrust plate
Drive shaft
G37385 en 01/2003 2003.0 BA Falcon

211-02-32 Power Steering 211-02-32
Shaft retaining ring and pump ring and 3. Install thrust plate and pump rotor to drive shaft.
vanes.
3. Remove O-ring from pump housing.
4. Remove dowel pins.
5. Remove drive shaft seal.
6. Remove end cover (pressure plate spring) and
O-ring from pressure plate.
7. Remove pump ring (and vanes) from drive shaft
subassembly.
8. Remove shaft retaining ring (from drive shaft).
9. Remove pump rotor (and thrust plate) from drive
shaft.
Assembly
NOTE: Clean all parts in power steering fluid, then dry Item Description
parts.
1 Shaft Drive
Inspect the following parts
2 Plate, Thrust
Pressure plate 3 Rotor, Pump
Pump ring 4 Ring, Shaft Retaining
Vanes
4. Install new shaft retaining ring onto drive shaft.
Thrust plate
5. Install drive shaft subassembly into pump
Drive shaft housing.
For scoring, pitting or chatter marks. If noted replace 6. Install vanes into pump rotor.
appropriate parts.
7. Install pump ring (with holes positioned correctly
1. Lubricate new drive shaft seal with power steering onto dowel pins in pump housing.
fluid and assemble drive shaft seal (into pump
housing) with tool J 7728.
Item Description
2. Install pump ring dowel pins into pump housing. 1 Rotor, Pump
2 Ring, Pump
8. Lubricate new O-ring with power steering fluid.
Install O-ring into groove in pump housing.
9. Assemble pressure plate.
10. Assemble pressure plate spring.
11. Lubricate new O-ring (with power steering fluid).
Assemble O-ring into end cover.
12. Lubricate outer edge of end cover with power
steering fluid.
13. Press end cover into pump housing.
G37385 en 01/2003 2003.0 BA Falcon

211-02-33 Power Steering 211-02-33
14. Assemble retaining ring into groove in pump

housing (with ring opening near access hole in
pump housing.
Item Description
1 Press
2 Retaining Ring Opening
3 Bolt Hole
4 Access Hole
5 Ring Retaining
G37385 en 01/2003 2003.0 BA Falcon

211-03-1 Steering Linkage 211-03-1
SECTION : 211-03 Steering Linkage

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................211-03-2
Steering Linkage ....................................................................................................................211-03-3
Outer Tie — Rod ....................................................................................................................211-03-4
Inner Tie — Rod .....................................................................................................................211-03-5
Steering Gear Boot ................................................................................................................211-03-7
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Tighten Specifications
Description Nm
Metric Hex Nut (inner tie rod) 30 Nm (22 lb. ft.)
Metric Hex Nut (outer tie rod) 46.7–63.3 Nm
(34–47 lb. ft.) +
120 degrees (2
flats)
Inner Tie Rod 100 Nm (74 lb.
ft.)
Valve End Fittings 16.9 Nm (12.6
lb. ft.)
Cylinder End Fittings 27 Nm (20 lb. ft.)
Metric Hex Nut (rack and pinion 30 Nm (22 lb. ft.)
assembly)
Adjuster Plug 10 Nm (90 lb.
in.) then turn
back 35 degrees
to 55 degrees
G47379 en 01/2003 2003.0 BA Falcon

Steering Linkage
G47380 en 01/2003 2003.0 BA Falcon

Outer Tie — Rod 4. Loosen the metric hex nut.
Special Tool(s)
Universal Steering Linkage
Puller
J 24319-B
Removal
to your dealership service manual.
2. Remove the tie rod ball stud and metric hex nut.
5. Remove the outer tie rod from the inner tie rod.
3. Use J 24319-B in order to separate the outer tie

rod from the steering knuckle. Installation
NOTE: Do not attempt to free the ball stud by 1. Install the outer tie rod to the inner tie rod.
using a pickle fork or wedge type tool; seal or NOTE: Tighten the metric hex nut to 30 Nm (22
bushing damage could result. Use the proper tool lb. ft.).
to separate all ball joints.
G47381 en 01/2003 2003.0 BA Falcon

2. Install the outer tie rod to the steering knuckle. Inner Tie — Rod
Special Tool(s)
Inner Tie Rod Wrench
J 34028
Removal
1. Remove the rack and pinion gear boot. Refer to
Boot Replacement procedure.
2. Place the gear in a vise. Clamp gear at solid
3. If the fastener does not meet these criteria, mount only.
REPLACE the fastener. NOTE: Do not change the steering gear preload
NOTE: This is a prevailing torque type fastener. adjustment before moving the inner tie rod from
This fastener may be reused ONLY if: the steering gear. Changing the steering gear
• The fastener and its counterpart are clean preload adjustment before removing the inner tie
and free from rust. rod could result in damage to the pinion and the
steering gear.
• The fastener develops 2 Nm (18 lb. in.) of
torque (drag) against its counterpart prior to the NOTE: The pipe wrench must be placed at the
fastener seating. valve end of the steering gear and positioned up
against the inner tie rod housing. Placing the pipe
4. Install the metric hex nut. Tighten the metric hex wrench in any other location will cause damage to
nut to 46.7–63.3 Nm (34–47 lb. ft.) + 120 degrees the steering gear.
(2 flats).
3. Place a pipe wrench on the rack next to the inner

5. Inspect and adjust the toe as necessary. Refer to
tie rod housing.
Front Toe Adjustment in your dealership service
manual. 4. Place a wrench on the flats of the inner tie rod
NOTE: Ensure that 2.5–4.5 tie rod end threads housing.
are visible beyond the tie rod nut nylon. 5. Rotate the inner tie rod housing counterclockwise,
while holding the rack stationary, until the inner tie
6. Install the steering gear into the vehicle. Refer to rod separates from the rack.
your dealership service manual.
G47381 en 01/2003 2003.0 BA Falcon

6. Remove the old LOCTITE® from the threads of 2. Attach the inner tie rod onto the rack.
the inner tie rod and rack. NOTE: The pipe wrench must be placed at the
valve end of the steering gear and positioned up
against the inner tie rod housing. Placing the pipe
wrench in any other location will cause damage to
the steering gear.
NOTE: Do not change the steering gear preload

adjustment before moving the inner tie rod from the
steering gear. Changing the steering gear preload
adjustment before removing the inner tie rod could
result in damage to the pinion and the steering gear. 3. Place a pipe wrench on the rack next to the inner
NOTE: The pipe wrench must be placed at the valve tie rod housing.
end of the steering gear and positioned up against the 4. Place a torque wrench and J 34028 on the flats of
inner tie rod housing. Placing the pipe wrench in any the inner tie rod housing. Tighten the inner tie rod
other location will cause damage to the steering gear. to 100 Nm (74 lb. ft.).
7. Place a pipe wrench on the rack next to the inner NOTE: Threads must be clean prior to LOCTITE®
tie rod housing. application.
8. Place a wrench on the flats of the inner tie rod Check LOCTITE®, or equivalent, container for
housing. expiration date. Use only enough LOCTITE® to
evenly coat threads.
9. Rotate the inner tie rod housing counterclockwise,
while holding the rack stationary, until the inner tie 5. Apply LOCTITE® 262, or equivalent, to the inner
rod separates from the rack. tie rod threads.
Installation 6. Attach the inner tie rod onto the rack.
NOTE: Threads must be clean prior to LOCTITE® NOTE: The pipe wrench must be placed at the
application. valve end of the steering gear and positioned up
Check LOCTITE®, or equivalent, container for against the inner tie rod housing. Placing the pipe
expiration date. Use only enough LOCTITE® to wrench in any other location will cause damage to
evenly coat threads. the steering gear.
1. Apply LOCTITE® 262, or equivalent, to the inner

tie rod threads.
7. Place a pipe wrench on the rack next to the inner

tie rod housing.
8. Place a torque wrench and J 34028 on the flats of
the inner tie rod housing. Tighten the inner tie rod
to 100 Nm (74 lb. ft.).
G47381 en 01/2003 2003.0 BA Falcon

9. Install the rack and pinion gear boot. Refer to 4. Remove the seal retaining clamp from the boot
Boot Replacement procedure. with side cutters.
Steering Gear Boot

Special Tool(s)
Service Boot Clamp Installer
J 22610
Removal
1. Remove the outer tie rod. Refer to Outer Tie Rod
Replacement procedure. 5. Discard the seal retaining clamp.
2. Remove the metric hex nut from the inner tie rod 6. Remove the boot from the gear assembly.
assembly.
Installation
1. Install the new seal retaining clamp onto the boot.
3. Remove the tie rod end clamp from the rack and
pinion gear boot.
2. Prior to the boot installation, apply grease to the
inner tie rod assembly and the rack and pinion
gear assembly.
3. Install the boot onto the inner tie rod assembly.

NOTE: The rack and pinion boot must not be
twisted, puckered or out of shape in any way. If
the rack and pinion boot is not shaped properly,
adjust the rack and pinion boot by hand before
installing the boot clamp.
G47383 en 01/2003 2003.0 BA Falcon

4. Install the boot onto the gear assembly until the

boot is seated in the gear assembly groove.
5. Install the boot clamp on the rack and pinion boot
with J 22610.
6. Crimp the seal retaining clamp.
7. Pinch the pliers together on the boot in order to
install the tie rod end clamp.
8. Install the tie rod end clamp onto the boot.
9. Install the metric hex nut to the inner tie rod

assembly. Do not tighten the metric hex nut.
10. Install the outer tie rod assembly. Refer to Outer
Tie Rod Replacement procedure.
G47383 en 01/2003 2003.0 BA Falcon

211-04-1 Steering Column 211-04-1
SECTION : 211-04 Steering Column

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................211-04-2
Steering Column ....................................................................................................................211-04-3
Steering Column ..................................................................................................................211-04-3
Floor Plate & Intermediate Shaft ..........................................................................................211-04-4
Steering Column Air Bag .....................................................................................................211-04-4
Steering Column Lock ..........................................................................................................211-04-4
Adjustable Steering Column ................................................................................................211-04-4
Fixed Steering Column (Column Shift Automatic) ...............................................................211-04-5
Steering Column - Accident Damage and Replacement .....................................................211-04-5
Steering Column Shrouds ......................................................................................................211-04-6
Ignition Key Barrel .................................................................................................................211-04-6
Passive-Anti-Theft-System (PATS) Unit, and key illumination ..............................................211-04-7
Adjustable Steering Column ..................................................................................................211-04-7
Fixed Steering Column (Column Shift automatic) .................................................................211-04-9
Floor Plate & Intermediate Shaft ...........................................................................................211-04-9
Driver Air Bag .......................................................................................................................211-04-10
Steering Wheel ...................................................................................................................211-04-11
Setting the Steering Column Adjustment Clamp .................................................................211-04-12
Adjustable Steering Column ...............................................................................................211-04-12
Fixed Steering Column .......................................................................................................211-04-13
Gear Shift Module ................................................................................................................211-04-14
Centralizing the Clockspring ................................................................................................211-04-14
Floor Plate and Intermediate Shaft .....................................................................................211-04-15
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Steering column to Instrument panel 18
Steering shaft to connector tube 25
Adjustment lever bolt 11
Serrated nut on clamp mechanism 11
Multifunction switch to lock housing 1.3
PATS Unit to lock housing 1.3
Lower shroud 1.3
Driver Air Bag to steering wheel 5
Steering wheel to steering column 38
Floor plate to dash panel 7
Intermediate shaft to steering rack 22
input shaft
M12 nut for shift lever on fixed column 18
Shift gate on fixed column 2
A12340 en 01/2003 2003.0 BA Falcon

Steering Column Multi-function switch, incorporating the turn

indicator, headlight on/off and dip switch, and
Steering Column wash/ wipe (including rear wash/ wipe for
wagons).
There are two types of steering column assembly Shroud covers, which incorporate a switch for
used, depending on the vehicle model. These column
adjustment of the pedals (where fitted).The lower
types are Rake/Reach (adjustable) & Column Shift shroud has impact absorbing foam for knee
Automatic (fixed). protection.
Steering wheel and Driver Air Bag assembly.
The steering column is designed to work in
conjunction with the restraint system, and may
collapse upon inflation of the airbag and subsequent
impact of the driver.
Item Description
1 Key barrel illumination light
2 Switch for adjustable pedal option
3 Column adjustment lever
The columns are fixed to the vehicle in two places.
The upper mounting point is via four bolts that fix the
column to the instrument panel, and the lower
mounting point is via a connector tube on the floor
plate.
Item Description
1 Automatic Transmission Shift Lever
Both of these columns are fitted with:
Fully integrated steering lock.
Fully integrated ignition switch. The fixed steering column incorporates a column
mounted gear shift lever for automatic vehicles, which
Ignition key lock barrel. are fitted with an optional centre front seat. The gear
Passive Anti Theft System (PATS) transceiver shift lever operates a cable, which is linked to the
unit with fully integrated key barrel illumination automatic transmission.
light ring.
The fixed steering column is identical to an adjustable
Alloy mounting bracket with 4 plastic break-away column, but has the adjustment mechanism locked in
capsules, to allow the column to move forward in one position. The gear shift mechanism is a separate
a severe impact. module welded on to the left hand side of the column.
Clockspring, which contains a ribbon of wire that The column is fixed so that the correct alignment is
electrically connects the steering wheel and Driver maintained between the gear shift mechanism, the
Air Bag to the steering column. gearshift cable and its abutment bracket.
A12341 en 01/2003 2003.0 BA Falcon

Floor Plate & Intermediate Shaft used during assembly of the universal joint to the
steering rack input shaft. The sliding joint top end is
One intermediate shaft and floor plate assembly sealed with a plastic cap and ’O’ ring, and the lower
exists for all engines and transmissions. end is sealed by a bung. The universal joint is fully
NOTE: FPV will be introducing a unique shaft for sealed, and not serviceable. The pinch bolt yoke
some XR vehicles. assembles onto the steering rack pinion, and is keyed
to fit together in only one orientation.
The floor plate consists of:
a connector tube Steering Column Air Bag
roller bearing in a rubber diaphragm The steering wheel is bolted to the top of the column
rubber torsional isolator and is fitted with a supplemental restraint system
universal joint (SRS) Driver Side Air Bag module. Before carrying
out work on or around any SRS component, observe
floor closing plate which attaches to the dash all SRS conditions and warnings to avoid
panel. unnecessary air bag deployment and possible injury.
See Section 211-04-9 & Section 501-20.
Steering Column Lock
The steering column lock is integral to the key barrel
housing. When the ignition key is turned to the "0"
position and removed, a tongue inside the steering
column lock can engage with the steering column
tube, locking it into position. When the ignition key is
turned to the "I", "II", or "III" position, the steering
column lock tongue withdraws, unlocking the steering
column tube and allowing it to rotate. For information
on the key barrel. See Section 501-14.
Item Description
1 Upper universal joint and rubber isolator
2 Floor Plate & Rubber Diaphragm
3 Sliding Joint
4 Heat Shield
5 Lower universal joint and pinch bolt yoke
6 Dash Panel
The connector tube has a plastic over-moulding which
incorporates a safety clip and captive M8 nut. A slot in
the connector tube aligns with a pip on the steering
column, and can only be assembled in one
orientation. The safety clip prevents the joint
Adjustable Steering Column
disengaging should the 8mm bolt work loose. A bung Floor shift vehicles (manual & automatic) are
is inserted into the connector tube to prevent noise, equipped with an adjustable steering column. The
water and dust from engine bay entering the adjustments are for both rake (up and down) and
passenger compartment. The roller bearing allows the reach (in and out).
column to rotate, and the rubber diaphragm acts as a Adjustment of the column is achieved by loosening
pivot, allowing the column to tilt. The floor closing the adjustment lever located underneath the column
plate is attached to the outside of the dash panel by shroud.
three nuts. The torsional isolator has a pin through it,
to maintain steering control in the event of the rubber Swing the lever down and away from the column,
failing. The universal joint is fully sealed, and not adjust the steering wheel to the desired position, then
serviceable. swing the lever fully upwards to lock the column in
position.
The intermediate shaft incorporates:
The adjustable column is fitted with a counter balance
a sliding collapse joint spring, so that column does not drop down to the
a universal joint and pinch bolt yoke lowest position when the adjustment lever is
The sliding collapse joint helps to prevent intrusion of loosened.
the steering column during a heavy impact. It is also
A12341 en 01/2003 2003.0 BA Falcon
The key barrel is lit via an illuminated ring around the

barrel. This ring is illuminated whenever the interior
lights are on.
When adjustable pedals are fitted, they are operated
via a rocker switch on the right hand side of the lower
steering column shroud covers, just forward of the
ignition barrel.
Fixed Steering Column (Column Shift
Automatic)
Column Shift vehicles are equipped with a fixed
column. It is not possible to adjust the column, as this
will interfere with the alignment between the gear shift
mechanism, and the gearshift cable and its abutment
bracket.
To select a gear, the gear shift lever must be pulled
towards the driver to disengage it from the gear shift
gate. The lever can then be rotated clockwise or
anti-clock wise to select gears. The gear selected is
indicated by an illuminated number or letter in the
instrument cluster.
Steering Column - Accident Damage and
Replacement
In a severe impact the steering column is designed to

decouple from the instrument panel attachment
points, and slide forward in the vehicle.
The steering column is bolted to the instrument panel
with four bolts. These bolts pass through white plastic
break away capsules. If these capsules have moved,
then the steering column assembly needs to be
replaced.
A12341 en 01/2003 2003.0 BA Falcon

Steering Column Shrouds Lower Shroud

1. Undo the three screws underneath the lower
shroud. Move the steering column adjustment
Upper Shroud lever (adjustable columns only) about half way
1. Unclip the upper shroud by grabbing it at the through its travel. Gently spread the lower shroud
openings where the switch levers pass through to clear the key illumination ring.
the shroud. Pull the rear of the shroud directly
upwards to disengage the two rear clips. The
shroud can then be moved rearwards to
disengage the two forward clips.
Item Description
1 Screw x 3
2 Move adjustment down
2. The rubber flap on the upper shroud is attached 2. Slide the shroud down and rearwards, ensuring
to the instrument panel via 4 arrow head clips. the adjustment lever passes through the aperture
Gently pull the rubber flap rearwards to disengage in the lower shroud. Unclip the wire harness for
the 4 clips. the adjustable pedal switch (where fitted).
3. To install the upper shroud, guide the 2 forward 3. The pedal adjust switch can be removed from the
clips into the mating parts in the lower shroud. shroud by deflecting the steel retaining clips, and
Push the shroud forward, and then down, to pushing the switch outwards.
secure the 2 rear clips. Ensure the
tongue-in-groove between the upper and lower 4. NOTE: Ensure the steering column adjustment
lever passes under the pedal switch wire harness,
shrouds are aligned. Clip the rubber flap to the
instrument panel. when installing the lower shroud.
To install the lower shroud, reverse the removal
procedure.
Ignition Key Barrel
1. Remove the upper steering column shroud. See
Section 211-04-5.
A12343 en 01/2003 2003.0 BA Falcon

2. Remove the ignition key barrel by installing the 4. Remove the screw that attaches the PATS unit to
ignition key, turning it to position "I" and then the ignition lock housing. Slide the PATS unit off
depressing the pin in the side of the ignition lock the ignition lock housing.
housing. NOTE: The ignition illumination globe is not
serviceable as a separate item. Replacement of
the PATS unit is required.
Item Description
1 Depress Pin behind illumination ring to
remove key barrel 5. To install the PATS unit, reverse the removal
procedure.
2 Align key head with "I"
6. If a new PATS unit is fitted, it will be necessary to
3. To install the ignition key barrel, reverse the re-program the Body Electronics Module. For
removal procedure. For information on the key more information on the PATS unit see Section
barrel, see Section 501-14. 419-01 & Section 419-10.
Passive-Anti-Theft-System (PATS) Adjustable Steering Column
Unit, and key illumination
Removal
Removal and Installation 1. Ensure that the front wheels and steering wheel
1. Remove the upper steering column shroud. See are in the straight ahead position. This will ensure
Section 211-04-5. that the clockspring is centralized when it is
2. Remove the lower steering column shroud. See removed.
Section 211-04-5. 2. Disarm and remove the Driver Air Bag module in
3. Remove the electrical connector from the PATS accordance with the procedure given in Section
unit. 211-04-09 of this manual.
3. Remove the steering wheel in accordance with
the procedure given in Section 211-04-10
ensuring that the front wheels are still in the
straight ahead position.
4. Remove the M8 flanged head bolt that joins the
steering column shaft to the floor plate connector
tube. Carefully lift the plastic safety clip and pull
the steering shaft rearwards out of the connector
tube.
5. Remove the upper and lower steering column
shrouds. See Section 211-04-6 & Section
211-04-5
A12346 en 01/2003 2003.0 BA Falcon

6. Disconnect the 2 wire harnesses from the 9. Remove the four bolts retaining the alloy steering
clockspring. column mounting bracket onto the instrument
panel, and completely remove the column from
the vehicle.
NOTE: The four bolts are retained in the alloy
mounting bracket using special fibre retaining
washers. Make sure all these washers are in
place before re-installing the steering column. If
one or more of the washers are missing, the alloy
mounting bracket may become distorted,
adversely affecting the column adjustment
mechanism and column break-away mechanism .
Delete all the washers from the installation if one
or more of the fibre washers are missing.
Installation
1. Before re-installing the steering column, check
that the front wheels are in the straight ahead
position.
2. Check that the clockspring has been centralized
on the steering column. See Section 211-04-13.
3. Fit the lower steering column shaft into the
connector tube on the floor plate. Loosely fit the
M8 flanged head bolt.
4. To align the alloy mounting bracket to the steering
column, close the adjustment lever so that the
clamping mechanism is just nipped up. The alloy
bracket should still be able to rotate by hand so
that it can align to the instrument panel. Secure
the four M8 mounting bracket bolts to the
instrument panel and torque to 18Nm.
NOTE: The four bolts are retained in the alloy
Item Description mounting bracket using special fibre retaining
washers. Make sure all these washers are in
1 Four mounting bolts. Torque to 18 Nm. place before re-installing the steering column. If
2 Two clockspring connectors one or more of the washers are missing, the alloy
3 One release tab for lever lock connector mounting bracket may become distorted,
adversely affecting the column adjustment
4 Pull back safety clip before removing the
mechanism and column break-away mechanism .
aluminum shaft
Delete all the washers from the installation if one
5 Torque bolt to 25 Nm or more of the fibre washers are missing.
6 Two release tabs for ignition wiring lever
5. Torque the M8 flanged head bolt in the lower
lock connector
steering column shaft to 25Nm.
7. Disconnect the ignition wire harness lever-lock 6. Connect the lever lock connectors for the multi
connector. The lever has two retaining tabs that function switch, and ignition wiring.
keep the lever locked in place. These must be
7. Connect the two clockspring connectors.
disengaged before the lever can be rotated.
8. Refit the shrouds. See Section 211-04-5.
8. Disconnect the multi-function switch wire harness
lever-lock connector. The lever has a single 9. Refit the steering wheel and Driver Air Bag. See
retaining tab that keeps the lever locked in place. Section 211-04-09 & Section 211-04-10.
This must be disengaged before the lever can be 10. Adjust the steering column through its full range to
rotated. ensure the movement is smooth.
11. Re-connect the battery.
A12346 en 01/2003 2003.0 BA Falcon

Fixed Steering Column (Column Shift 2. In the driver’s foot well, remove the M8 flanged
head bolt that joins the steering column shaft to
automatic) the floor plate connector tube. Carefully lift the
Removal and Installation plastic safety clip and pull the steering shaft
rearwards out of the connector tube.
1. The removal and installation of the Column Shift
Automatic steering column is identical to the 3. In the engine bay remove the three nuts securing
adjustable steering, but requires one additional the floor plate to the dash panel.
operation.
2. Put the gear shift lever into "Park". Underneath
the instrument panel on the LHS of the steering
column, is the cable that operates the automatic
transmission. Remove the cable end (ball socket)
from the steering column by levering it off with a
screwdriver.
Item Description
1 Floor plate securing nut
2 Intermediate nut to steering rack nut
4. Remove the bolt that secures the lower end of the
intermediate shaft to the steering rack. Slide the
intermediate shaft rearwards to collapse it,
3. To assemble the cable end ball socket, pull it removing the universal joint from the steering rack
rearwards onto the ball stud, which is fitted to the input shaft.
steering column shift mechanism. 5. The intermediate shaft and floor plate assembly
Floor Plate & Intermediate Shaft can now be removed from the vehicle.
NOTE: The apperance of the intermediate shaft in CAUTION: Be carefull collapsing steering
XR6 Turbo and XR8 will vary from that shown in that shaft .
the shaft will be fitted with a reflective sheath and in Installation
that no ’bell’ will be fitted over the lower universal 1. Ensure that the front wheels and steering wheel
joint. Removal of this type of intermediate shaft is as are in the straight ahead position.
described below with the exception that the body 2. Before installation of the floor plate assembly,
mounted intermediate shaft heat shield may need to check that the rubber gasket face on the floor
be removed to obtain adequate access to the plate, and the mating sealing surface on the dash
intermediate shaft. panel are clean and dry. Ensure that the threads
Removal of the three studs on the dash panel are clean,
1. Ensure that the front wheels and steering wheel and that the nuts are free running.
are in the straight ahead position. Tape the 3. Position the floor plate over the three studs of the
steering wheel to the upper and lower shrouds so dash panel, and loosely attach the three nuts.
that the steering wheel cannot be inadvertently 4. From the driver’s foot well, extend the steering
rotated during this procedure. This protects the shaft by hand and guide it into the floor plate
clockspring from being over-wound at full left connector tube. Install the M8 flanged head bolt
hand or right hand steering wheel lock. shaft and torque to 25Nm.
A12348 en 01/2003 2003.0 BA Falcon

5. Torque the three M6 nuts on the floor plate to deformation. Install and correctly position the new
7Nm. sensor or any other damaged supplemental
restraint system (SRS) components whether or
WARNING: Over torquing could result in not the air bag is deployed.
the stud snapping off.
WARNING: To avoid accidental deployment
and possible personal injury, the backup power
supply must be depleted before repairing or
installing a new front or side supplemental
restraint system (SRS) components and before
repairing, installing new, adjusting or striking
components near the front or side air bag
sensors, such as doors, instrument panel,
console, door latches, strikers, seats and
hoodlatches.
Please refer to the appropriate workshop manual
to determine the location of the front air bag
sensors.
To deplete the backup power supply energy,
disconnect the battery ground cable and wait at
Item Description least one minute. Be sure to disconnect auxiliary
batteries and power supplies (if equipped).
1 Floor plate securing nut
2 Intermediate nut to steering rack nut WARNING: The restraint system diagnostic
6. Slide the intermediate shaft lower universal joint tool is for restraint system repair only. Remove
yoke onto the steering rack input shaft. Note that from vehicle prior to road use. Failure to remove
the spline is keyed so that it can only be could result in injury and possible violation of
assembled in one orientation. vehicle safety standards.
7. Insert the M8 bolt into the yoke and torque to 1. Disconnect the battery. Wait at least one minute
22Nm. to deplete the backup power supply energy.
2. Rotate the steering wheel 90° from straight
Driver Air Bag ahead, to access one of the Driver Air Bag
retaining screws on the front face of the steering
NOTE: Also refer to Section 501-20B. wheel.
Removal
WARNING: Always wear safety glasses when
repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag
module. This will reduce the risk of injury in the
event of an accidental deployment.
WARNING: Never probe the connectors on

the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Vehicle sensor orientation is

critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint
system (SRS) is involved in a collision, inspect 3. Rotate the steering wheel 180° to access the
the sensor mounting bracket and wiring pigtail for other screw.
A12348 en 01/2003 2003.0 BA Falcon

4. Gently pull the Driver Air Bag away from the 2. Unscrew the retaining bolt using a Torx T50
steering wheel. driver. To stop the steering wheel rotating,
remove the key from ignition barrel, and rotate the
steering wheel to the left until the steering column
lock engages.
Item Description
1 Horn/Cruise/Audio Connector
2 Inflator Connectors 3. Install the steering wheel puller, Ford service tool
No. J-1859-A (09561-11002).
5. Disconnect the wiring to the Driver Air Bag inflator
Ensure that the pusher block is used so that the
by depressing the retaining clips on either side of
thread in the end of the steering column is not
the connector.
damaged. Loosen the wheel from the column.
6. Remove the horn/audio wiring connector.
4. Carefully feed the clockspring wire harnesses
7. Remove the Driver Air Bag from the vehicle. through the hub of the steering wheel, and
Installation remove the steering wheel from the vehicle.
1. Disconnect the battery. Wait at least one minute 5. Installation of the steering wheel is a reverse of
to deplete the backup power supply energy. the above procedure. Torque the M10 steering
2. Connect the wiring to the Driver Air Bag inflators. wheel attachment bolt to 38Nm.
The connectors are mechanically keyed to fit in
only one orientation.
3. Ensure the inflator wire harness is clipped into
position.
4. Connect the horn/audio wiring. Ensure the wire
harness is clipped into position.
5. Gently push the Driver Air Bag into the steering
wheel. Ensure all wiring is clear of the Driver Air
Bag attachment screws.
6. Rotate the steering wheel 90° from straight
ahead, to access the one of the Driver Air Bag
retaining screws on the front face of the steering
wheel. Torque the screw with a Torx T30 bit, to
5Nm.
7. Rotate the steering wheel 180° to access the
other screw.
8. Reconnect the battery.
Steering Wheel
1. Remove the Driver Air Bag. See Section
211-04-09.
A12350 en 01/2003 2003.0 BA Falcon

Setting the Steering Column 1. The clockspring is clipped into the multi-function
switch, and can be removed by deflecting and
Adjustment Clamp releasing the three retaining clips. Remove the
Assembly two electrical connectors from the wire harness
bracket.
1. Remove the bolt and washer securing the black
plastic adjustment lever to the serrated clamping
nut.
2. Remove the lever from the clamp nut.
2. Remove the three screws which secure the

multi-function wash/wipe/indicator/headlight
switch. Slide the lever-lock connector off the tag
of the wire harness bracket.
Item Description
1 Serrated Clamping Nut
2 Bolt
3 Adjustment Lever
3. Slacken off and re-tighten the clamp nut to 11Nm
torque.
4. Reposition the lever on the clamp-nut ensuring
the serrations mesh correctly, and the lever is in
the fully closed position. i.e. the main arm of the
lever is parallel to the centreline of the steering
column
5. Hold the lever and replace the washer and bolt.
Tighten the bolt to 11Nm torque.
3. Remove the electrical connector from the PATS
Adjustable Steering Column unit.
4. Remove the screw that attaches the PATS unit to
Disassembly the ignition lock housing. Slide the PATS unit off
NOTE: The degree of disassembly required will the ignition lock housing.
depend on the nature of the repair or the component NOTE: The ignition illumination globe in the PATS
which is to be replaced. Disassembly instructions are unit is not serviceable as a separate item.
given below, but it may not be necessary to carry out
5. Remove the bolt and washer securing the
all steps to effect the required repairs. These
adjustment lever, and remove the lever. Undo
instructions refer to a steering column that has been
serrated clamping nut and remove the plastic
completely removed from the vehicle.
thrust washer.
NOTE: The bolt, serrated clamp nut, and clamp
bolt use a special double start thread, and cannot
be replaced with conventional metric fasteners.
6. Remove the counter balance spring, clamp bolt
and clamping spacer.
7. Remove the alloy mounting bracket.The column is
now completely disassembled.
NOTE: The upper and lower steering shafts and
bearings are not serviceable. The upper shaft and
A12351 en 01/2003 2003.0 BA Falcon

bearing is staked into position. It has to sustain the 5. Fit the lever, washer and bolt.
impact of the driver in a severe accident, and must
not be disassembled.
NOTE: The upper & lower sections of the telescoping
steering shafts are made as an assembly, and can
only be assembled in one orientation. Carefully mark
the lower bearing carrier (white plastic) and alloy shaft
before disassembly, to ensure correct alignment. The
two flats on the lower alloy shaft are aligned to the
two LONG flats on the upper steering shaft.
NOTE: The locking mechanism for the steering
column is not serviceable. It is fully secured to provide
maximum anti-theft protection.
NOTE: The ignition switch for the steering column is
fully integrated into the lock housing, and is not 6. Fit the multi-function switch, ensuring that centre
serviceable. It is integrated to provide maximum drive hub is aligned to the two flats of the steering
anti-theft protection. shaft. Fit the three screws. Torque to 1.3Nm.
NOTE: If a new steering column is fitted, the
Assembly screws used to attach the multi-function switch
1. Assemble the alloy mounting bracket over the and lower shroud will cut their own thread into the
column. Lightly smear the working surfaces with a lock housing. A torque higher than 1.3Nm may be
general purpose grease. experienced while cutting these threads.
7. Ensure the wiring is correctly routed, then secure
the lever-lock connector to the wire harness
bracket.
Fixed Steering Column

Disassembly
1. The degree of disassembly required will depend
on the nature of the repair or the component
which is to be replaced. Complete disassembly
instructions are given below, but it may not be
necessary to carry out all steps to effect the
required repairs.
2. These instructions refer to a steering column that
2. Fit the clamping spacer, bolt and counterbalance has been completely removed from the vehicle.
spring. 3. Disassembly of the fixed steering column is
3. Fit the plastic thrust washer, ensuring that the identical to the adjustable steering column, except
protruding face of the washer is fitted into the for gear shift module.
vertical slot in the alloy bracket.
4. Fit the serrated clamping nut, and tighten to finger Assembly
tight. 1. Assembly of the fixed steering column is the same
NOTE: DO NOT tighten the clamp nut at this as adjustable column, expect for the clamping
stage, this will be done after the column is fitted to mechanism.
the vehicle, and the lever will be set at the same 2. Install the column as described in Section
time. 211-04-9.
A12353 en 01/2003 2003.0 BA Falcon

3. To set the steering column correct height, slacken 2. New Clockspring

the serrated nut on the clamping bolt, and drop Remove the grenade pin.
the column 12mm from its top position. Torque
Rotate the centre hub clockwise 1/4 of a turn,
the clamp nut to 11Nm.
relative to the body of the clockspring.
Gear Shift Module Item Description

Disassembly and Assembly 1 Remove grenade pin before installing
1. Remove the M12 nut on the shift shaft. onto column
3. Existing Clockspring
Rotate the centre hub fully anticlockwise
relative to the body of the clockspring. The
green and yellow wire harnesses should be
almost aligned to the "TOP" marking on the
body.
Rotate the centre hub clockwise 3 1/2 turns
clockwise.
Item Description
1 Selectorgate screw
2 Shift lever retaining nut - M12
2. Remove the shift lever and ball stud assembly.
3. Remove the three screws which secure the gear
shift selector gate. The column is now completely
disassembled.Further disassembly is not
recommended. 4. The clockspring is now suitable for installation on
a column that is installed into a vehicle with the
4. Assembly is the reverse of the above procedure road wheels in a straight ahead position.
5. Torque the selector gate screws to 2Nm. 5. Ensure that the two flats on the lower alloy
6. Torque the shift lever retaining nut to 18Nm. steering shaft are vertical, with the pip at the
bottom.
Centralizing the Clockspring 6. Slide the clockspring over the upper steering
shaft, and clip it to the multifunction switch.
Assembly
NOTE: This clockspring is used in another vehicle
1. Before fitting the clockspring it must be application. When installed in a Falcon it is rotated
centralized. 180 degrees, and the "TOP" mark should be
located at the bottom.
A12353 en 01/2003 2003.0 BA Falcon

7. Route the wiring and attach the two connectors to

the wire harness bracket.
8. Fit the PATS unit. See Section 211-04-6.
9. Install the column. See Section 211-04-7.
10. Re-set the steering column adjustment clamp
load. See Section 211-04-11.
11. Refit the shrouds. See Section 211-04-5 &
Section 211-04-6
Floor Plate and Intermediate Shaft

Disassembly
1. It is recommended the floor plate and
intermediate shaft should not be disassembled.
2. If it is deemed necessary to separate the upper
and lower sliding halves of the intermediate shaft,
then it is vital that an alignment mark is made on
the shafts, to ensure correct orientation on
reassembly. It is recommended that this sliding
joint is NOT disassembled.
A12357 en 01/2003 2003.0 BA Falcon

211-05-1 Steering Column Switches 211-05-1
SECTION : 211-05 Steering Column Switches

CONTENTS PAGE
Steering Column Switches .....................................................................................................211-05-2
Steering Column Switches ...................................................................................................211-05-2
Steering Column Switches .....................................................................................................211-05-3
Symptom Chart ....................................................................................................................211-05-3
Pinpoint Tests ......................................................................................................................211-05-5
Steering Column Multifunction Switch ...................................................................................211-05-7
Ignition Key Barrel ..................................................................................................................211-05-7
Pedal Adjust Switch................................................................................................................211-05-7
01/2003 2003.0 BA Falcon

Steering Column Switches

Steering Column Switches
The steering column switches consist of the following:
Multifunction switch
Ignition switch
Pedal adjustment switch (if fitted)
G57380 en 01/2003 2003.0 BA Falcon

Steering Column Switches 2. Visually inspect the ignition switch and the
steering column multifunction switch for damage;
Refer to Wiring Diagram Section 700-02 for schematic refer to the following chart:
and connector information. Visual Inspection Chart
Special Tool(s) Mechanical
Ignition switch
Multimeter Turn signal switch (component of steering
WDS column multifunction switch)
Wiper/washer switch (component of steering
column multifunction switch)
Pedal Adjust switch
3. If cause of the switch concern is not visually
apparent, proceed to Symptom Chart.
1. Verify the customer concern by operating ignition
switch and the multifunction switch.
Symptom Chart

Ignition switch is inoperative (No Ignition switch Go to PinPoint Test A.
power in ACC/ON or START) Circuitry
Battery
Wiper/washer, turn signal switch or Steering column multifunction switch Go to PinPoint Test B
headlamp switch does not operate Circuitry
correctly Battery
Adjustable pedals do not operate Pedal adjustment switch Go to PinPoint Test C
correctly Pedal box
Circuitry
Battery

C167 - View of Multifunction connector - Harness side
G57381 en 01/2003 2003.0 BA Falcon

Pinout
1 175 Park
Red
2 57 Earth (H/Lamps)
Yellow
3 293 BEM (Auto H/Lamp)
Grey
5 590A Rear Wipe
Orange / Brown
6 20 Dipper (High Beam)
Green / Orange
7 942 Rear Wash
Blue
8 56 Wiper (High) S/C to GND when high wipe on
Blue / Yellow
9 58Wiper (Low) S/C to GND when low wipe on
White / Blue
10 589 Var Wiper Earth
Orange
11 993 Var Wipe (to BEM) See “Intermittent Wipe” table below
Brown / White
12 18 Dipper (Low Beam)
Red / Yellow
13 2 Turn RH S/C to pin17 when RH Ind activated
Brown / White
14 2 Turn RH S/C to pin17 when RH Ind activated
Brown / White
16 57 Wiper, Dipper, rear wiper earth
Black, violet, pink
17 8 Turn Ign
Green / Red
20 3 Turn LH S/C to pin17 when LH Ind activated
Green
22 941 Wash (to BEM) S/C to GND when activated
Grey / Black
23 28 Wiper (Park)
Blue / Pink
24 59C Wiper (Int)
Green / White
Intermittent Wipe Resistance values
Detent Resistance
1 400 - 600Ω
2 1,372 - 1,678Ω
3 2300 - 2800Ω
4 3,218 - 3,933Ω
5 4,140 - 5,060Ω
G57381 en 01/2003 2003.0 BA Falcon

Pedal Adjust Switch Connector and Pinout

1 Pedal Circuits Batery +VE-
Yellow
3 Pedal Circuits Ground
Black
6 Pedal Circuits Motor -VE- (Back)
Light Blue / Orange Stripe
8 Pedal Circuits Motor +VE-
(Forward)
Light Blue / Black Stripe
Pinpoint Tests
PINPOINT TEST A : IGNITION SWITCH IS INOPERATIVE (NO POWER IN ACC/ON OR START)
A1 CHECK CONTINUITY OF IGNITION SWITCH AND LOCK

HOUSING
Remove steering column shrouds from vehicle. Refer to Section Yes
211-04. Check wiring for ignition switch circuit. Please
refer to wiring diagrams for details of circuits.
Disconnect ignition switch connector.
With car keys inserted, use a multimeter to check the continuity of the No
ignition switch for the various positions (ACC, ON) at the ignition Go to A2.
switch connector.
Is continuity of ignition switch accurate for each position?
A2 CHECK FUNCTIONALITY OF LOCK BARREL

Remove lock barrel from steering column. Yes
Install a new ignition switch. Refer to ignition
Check functionality of lock barrel: rotate key in barrel and confirm that
switch installation and removal section. Repeat
the shaft in barrel is turned when key is turned.
test A1 to confirm operation of system.
Is lock barrel functional? NOTE: Ignition switch is integral with column.
Need to replace column assembly. See Section
211-04.
No
Install a new lock barrel. Repeat test A1 to
confirm operation of ignition switch.
G57381 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : WIPER/WASHER OR TURN SIGNAL SWITCH DOES NOT OPERATE CORRECTLY
B1 CHECK CONTINUITY OF MULTIFUNCTION SWITCH

211-04. Check wiring for multifunction switch circuit.
Please refer to wiring diagrams for details of
Disconnect multifunction switch connector. circuits.
Use a multimeter to check the continuity of the multifunction switch for
the various positions at the multifunction switch connector. No
Install a new multifunction switch. Refer to
Is continuity of multifunction switch accurate for each position? multifunction switch installation and removal
section. Repeat tests to confirm correct
operation of system.
PINPOINT TEST C : ADJUSTABLE PEDALS DO NOT OPERATE CORRECTLY
C1 CHECK CONTINUITY OF PEDAL ADJUST SWITCH

211-04 Check wiring for Adjustable pedals circuit.
Please refer to wiring diagrams for details of
Disconnect Pedal Adjust switch connector. circuits.
Use a multimeter to check the continuity of the Pedal Adjust switch
No
Is continuity of Pedal Adjust switch accurate? Install a new Pedal Adjust switch. Repeat tests
to confirm correct operation of system.
G57381 en 01/2003 2003.0 BA Falcon

Steering Column Multifunction Switch 6. Remove the three screws that secure the
multifunction switch to the steering column and
Removal and Installation then pull of multifunction switch.
1. Disconnect the battery ground cable. For
2. Remove upper and lower steering column
shrouds. For additional information refer to
Section 211-04.
3. Remove the driver air bag and steering wheel. For
additional information refer to Section 211-04 and
Section 501-20b.
4. Remove clockspring from steering column. For
additional information refer to section Section
501-20b.
7. To install, reverse the removal procedure. Refer

to Section 211-04 for instructions for centralizing
the clockspring.
Ignition Key Barrel

1. Please refer to Section 211-04 for instructions for
removing and installing the ignition key barrel.
Pedal Adjust Switch

5. Remove the electrical connector from the PATS
unit. For additional information refer to Section 1. Disconnect the battery ground cable. For
211-04. additional information refer to Section 414-01.
2. Remove upper and lower steering column
shrouds. For additional information refer to
Section 211-04.
3. Disconnect Pedal Adjust switch connector from
wiring harness. Remove Pedal Adjust switch from
Lower Shroud.
G57385 en 01/2003 2003.0 BA Falcon

303-00-1 Engine System — General Information 303-00-1
SECTION : 303-00 Engine System — General

Information
CONTENTS PAGE
Engine ....................................................................................................................................303-00-3
Engine ....................................................................................................................................303-00-4
Symptom Chart ....................................................................................................................303-00-4
Components Tests ...............................................................................................................303-00-6
GENERAL PROCEDURES
Camshaft Journal — Diameter ...............................................................................................303-00-8
Camshaft Journal — Clearance, Plastigage Method .............................................................303-00-8
Camshaft —8 End Play, OHC Engines .................................................................................303-00-8
Camshaft — Lobe Surface .....................................................................................................303-00-8
Camshaft — Runout .............................................................................................................303-00-9
Crankshaft Main Bearing Journal — Diameter ......................................................................303-00-9
Crankshaft Main Bearing Journal — Taper ...........................................................................303-00-9
Crankshaft Main Bearing Journal — Clearance ....................................................................303-00-9
Crankshaft — End Play ........................................................................................................303-00-10
Crankshaft — Runout ..........................................................................................................303-00-10
Crankshaft — Connecting Rod Journal Taper, Out of Round .............................................303-00-10
Cylinder Bore — Taper .......................................................................................................303-00-11
Cylinder Bore — Out-of-Round ............................................................................................303-00-11
Piston — Inspection ............................................................................................................303-00-11
Piston — Pin to Bore Diameter ............................................................................................303-00-11
Piston — Diameter ...............................................................................................................303-00-12
Piston — to Cylinder Bore Clearance ..................................................................................303-00-12
Piston — Ring End Gap .......................................................................................................303-00-12
Piston — Ring-to-Groove Clearance ...................................................................................303-00-12
Piston — Pin Diameter .........................................................................................................303-00-13
Connecting Rod — Cleaning ...............................................................................................303-00-13
Connecting Rod — Large End Bore ....................................................................................303-00-13
Connecting Rod — Bushing Diameter .................................................................................303-00-13
Connecting Rod — Bend .....................................................................................................303-00-13
Connecting Rod — Twist .....................................................................................................303-00-14
Connecting Rod — Bearing Journal Clearance ...................................................................303-00-14
Roller Follower — Inspection ...............................................................................................303-00-14
Valve Rocker Arm/Lash Adjuster Assembly — Inspection ..................................................303-00-14
Hydraulic Lash Adjuster Diagnosis ......................................................................................303-00-14
Valve — Stem Diameter ......................................................................................................303-00-15
Valve — Stem to Valve Guide Clearance ............................................................................303-00-15
Valve — Inspection ..............................................................................................................303-00-15
Valve — Guide Inner Diameter ............................................................................................303-00-15
Valve — Guide Reaming .....................................................................................................303-00-16
Valve — Spring Installed Length .........................................................................................303-00-16
Valve — Spring Free Length ...............................................................................................303-00-16
01/2003 2003.0 BA Falcon

(Continued)
Valve — Spring Squareness ................................................................................................303-00-16

Valve — Spring Strength ....................................................................................................303-00-17
Valve — Seat Inspection ......................................................................................................303-00-17
Valve — Seat Width ............................................................................................................303-00-17
Valve — Seat Runout .........................................................................................................303-00-18
Cylinder Bore — Cleaning ...................................................................................................303-00-18
Cylinder Block — Core Plug Replacement ..........................................................................303-00-18
Exhaust Manifold — Inspection ...........................................................................................303-00-19
Bearing -Inspection ..............................................................................................................303-00-19
01/2003 2003.0 BA Falcon

Engine
NOTE: This section contains information, steps and
procedures that may not be specific to your engine.
This section covers general procedures and diagnosis
and testing of the engine system, except for exhaust
emission control devices, which are covered in the
Chapter 303-14, Powertrain Control Module.
The engine incorporates the following features:
a closed positive crankcase ventilation (PCV)
system. For additional information, refer to
Section 303-08.
an exhaust emission control system. For
an evaporative emission control system. For
Some engines incorporate a fail-safe cooling system.
Refer to the appropriate section in Group 303 for the
procedure.
The engine, fuel system, ignition system, emissions
system and exhaust system all affect exhaust
emission levels and must be maintained according to
the maintenance schedule. Refer to the scheduled
Maintenance Guide.
For engine identification, refer to Section 100-01. For
engine number location, refer to figure.
Engine Number Locations (I6)
Engine Number Locations (V8)
G37830 en 01/2003 2003.0 BA Falcon


Engine
Mechanical
Inspection and Verification Coolant leaks
Oil leakso Leaks in the fuel system
Since diagnosis and testing actually begins when Visibly damaged or worn parts
repairs are taken on, the following procedure is
Loose or missing nuts or bolts
recommended.
1. Verify the customer concern by operating the 3. If an obvious cause for an observed or reported
system. concern is found, correct the cause (if possible)
before proceeding to the next step.
2. Visually inspect for obvious signs of mechanical
damage or electrical damage. If the concern 4. If the concern is not visually evident, verify the
cannot be reproduced, carry out a road test symptom and refer to the Symptom Chart.
and/or visual check with the aid of the following
table.
Symptom Chart

Engine will not crank Faulty Starter System Refer to Section 303-05.
Transmission lever not in P or N. Place in P.
Seized engine Replace engine
Coolant in cylinders Replace engine
Engine cranks but will not start Ignition system inoperative Refer to appropriate Section in group
303.
Fuel system inoperative Refer Section 310-00.
Engine slow/difficult to start LPG engine requires "key-off" to Key-off LPG engine if 1st starting
regain starting enrichment after initial attempt failed.
failed start.
Variable Cam Timing (VCT) unit lock Refer to appropriate Section in group
pin not engaged at start. 303.
VCT unit Oil Control Valve jammed. Clean Oil Control Valve. Refer to
appropriate Section in group 303.
Engine misfires Fail Safe Cooling in operation Repair coolant system
Ignition system faulty Refer to appropriate Section in group

303.
Fuel system faulty Refer Section 310-00.
Restricted exhaust system Inspect Exhaust system
Intake vacuum leak Carry out Intake Manifold Vacuum test

in this section
Burned valve/poor seating Perform a compression check
Broken valve spring Inspect valve springs
Head gasket leakage Inspect head gasket
Piston damage Perform cylinder compression check
Insufficient Power Broadband Intake Manifold not Check switching occurs at 3800 rpm -
operative Refer to appropriate Section in group
303.
VCT unit(s) not operative Refer to appropriate Section in group

303.
G37831 en 01/2003 2003.0 BA Falcon


Electronic Throttle Control Unit faulty Refer to appropriate Section in group
303.
Excessive Fuel Consumption Green(low mileage) engine/vehicle Establish accurate fuel consumption
City/stop-start driving using full to full method.
Faulty Fuel System Refer to appropriate Section in group

303.
Excessive Oil Consumption Green engine Recheck at 15,000 km
Valve stem seal damaged or missing. Inspect the seals. Refer to appropriate
Section in group 303.
Oil leakage Repair oil leakage
Incorrect Oil viscosity Drain and fill with correct oil
Piston/rings/cylinder worn or damaged Repair. Refer to appropriate Section in

group 303.
Diluted oil Determine cause. Correct. Drain and

refill oil.
Crankcase overfilled Adjust oil level.
Faulty PCV Valve Check and replace. Refer to

Engine leaks oil Joint fasteners loose Tighten to specification.

Out of position or damaged seal/RTV Pressurise crankcase to 35kPa. Apply
sealant omitted/inadequate. soapy water, check for leak. Inspect
and replace. Refer to appropriate
Section in group 303.
Worn/out of position crank rotary seal Inspect and replace. Refer to

Porous casting Clean suspect area, Perform

pressurized crankcase check. Run
engine, check for leak. Replace
casting.
Sealant in Crank Damper keyway Replace sealant. Refer to appropriate
omitted or inadequate Section in group 303.
Sealant between Rear Main Cap and Perform pressurized crankcase leak
block omitted or inadequate check. Repair.
Engine Noise. Excessive Crankshaft Main bearing or Inspect and repair. Refer relevant
big end clearance. Section.
Excessive Crankshaft end play
Excessive camshaft end play
Excessive piston to bore
clearance/damaged piston/bent
connecting rod.
Excessive hydraulic valve adjuster
clearance
Soft or spongy lash adjusters Check for excessively low or high oil
Worn cam lobe or roller finger follower level. Air leak in suction side of oil
Excessive valve guide clearance pump.
Broken valve spring
Loose timing chain
Loose crank damper
Worn/noisy Front End Accessory Drive
Belt
Worn/noisy FEAD tensioner/idler
pulley
Exhaust gas leakage
Carbon in combustion chamber/top Remove carbon using proprietary
land of piston carbon removal treatment
G37831 en 01/2003 2003.0 BA Falcon

Components Tests 7. Install the components in reverse order, observing

the specified tightening torques.
Engine Oil Leaks 8. Reset the PCM fault memory.
NOTE: Before installing new gaskets or oil seals,
make sure that the fault is clearly established. If the Interpretation of the Results
oil leak cannot be identified clearly by a visual The indicated compression pressures are considered
inspection, carry out a pressurized crankcase leak within specification if the lowest reading cylinder is
check: within 75% of the highest reading.
Pressurised leak check CAUTION: If engine oil is sprayed into the

1. Clean the engine with a suitable cleaning fluid to combustion chamber, after carrying out the
remove all traces of oil. measurement run the engine at 2000 rpm for
2. Block off the line to the PCV valve. about 15 minutes, in order to burn the oil and
prevent damage to the catalytic converter.
3. Apply a regulated air supply line to the fresh air
makeup point on the rocker cover. If the measurement on one or more cylinders is much
lower than the specified value, spray some engine oil
4. Pressurise the crankcase to 35 kPa. into the combustion chamber and repeat the
5. Check for air leaks by washing the suspect area compression measurement.
with a solution of soapy water and watching for If the reading greatly improves, the piston rings are
bubbles. damaged.
6. Repair all leaks as necessary. If the reading stays the same, the cause is either
Compression Test damaged valve seats or valve stem seals.
If the measurements for two cylinders next to each
General Remarks other are both too low then it is very likely that the
NOTE: Removing fuses and disconnecting electrical cylinder head gasket between them is burnt through.
components causes the powertrain control module This can also be recognized by traces of engine oil in
(PCM) to log an error message. After the the coolant and/or coolant in the engine oil.
measurements have been carried out this error Excessive Engine Oil Consumption
message should be cleared from memory by
connecting to PDU. The amount of oil an engine uses will vary with the
way the vehicle is driven in addition to normal
The compression pressure should be checked with engine-to-engine variation. This is especially true
the engine at operating temperature. during the first 15,000 km when a new engine is being
broken in or until certain internal components become
Check The Compression Pressure conditioned. Vehicles used in heavy-duty operation
may use more oil. The following are examples of
WARNING: On manual transmissions, shift heavy-duty operation:
the transmission into neutral. On automatic trailer towing applications
transmission vehicles, select ’’P’’. Failure to
follow these instructions may result in personal severe loading applications
injury. sustained high speed operation
1. Remove the fuel pump relay. Engines need oil to lubricate the following internal
2. Start the engine - the engine will start, run for a components:
few seconds then stall. cylinder block cylinder walls
3. Remove the spark plugs. pistons and piston rings
4. Install the compression tester. intake and exhaust valve stems
5. Install an auxiliary starter switch in the starting intake and exhaust valve guides
circuit. With the ignition switch OFF, using the all internal engine components
auxiliary starter switch, crank the engine a
When the pistons move downward, a thin film of oil is
minimum of five compression strokes and record
left on the cylinder walls. As the vehicle is operated,
the highest reading. some oil is also drawn into the combustion chambers
NOTE: The approximate number of compression past the intake and exhaust valve stem seals and
strokes required to obtain the highest reading. burned.
6. Repeat the test on each cylinder, cranking the The following is a partial list of conditions that can
engine approximately the same number of affect oil consumption rates:
compression strokes. engine size
operator driving habits
G37831 en 01/2003 2003.0 BA Falcon

ambient temperatures 4. Add 1 litre of oil. Start the engine and allow to
quality and viscosity of oil idle for at least two minutes. Shut off the
engine and allow the engine oil to drain back
Operation under varying conditions can frequently be
for at least five minutes. Mark the new oil
misleading. A vehicle that has been run for several level on the dipstick using the procedure
thousand kilometers on short trips or in cold ambient
above.
temperatures may have consumed a ’’normal’’
amount of oil. However, when checking the engine oil 5. Record the vehicle’s odometer reading.
level, it may measure up to the full mark on the oil 6. Instruct the customer to drive the vehicle as
level indicator due to dilution (condensation and fuel) usual and:
in the engine crankcase. The vehicle then might be Check the oil level regularly at intervals of
driven at high speeds on the highway where the 250 km.
condensation and fuel boil off. The next time the Return to the service point when the oil
engine oil is checked it may appear that a litre of oil level drops below the ADD mark on the oil
was used in a relatively short distance. dipstick.
Make sure the selected engine oil meets the Ford Add only full litres of the same oil in an
specification and the recommended API performance emergency.
category ’’SJ/CF’’ and SAE viscosity grade as shown NOTE: The mileage at which the oil is
in the vehicle Owner Literature. It is also important added.
that the engine oil is changed at the intervals
specified for the typical operating conditions. 7. Check the oil level under the same conditions
and at the same location as in steps 3-4.
Oil consumption Test. Measure the distance from the oil level to
the UPPER mark on the oil dipstick and
The following diagnostic procedure is used to record.
determine the source of excessive oil consumption. Measure the distance between the two
NOTE: Oil use is normally greater during the first scribe marks and record.
15,000 km of service. As mileage increases, oil use Divide the first measurement by the
decreases. High speed driving, towing, high ambient second.
temperature and other factors may result in greater oil Divide the distance driven during the oil
use. test by the result. This quantity is the
approximate oil consumption rate in
1. Define excessive consumption, such as the
number of kilometers driven per liter of oil used. kilometers per litre.
If the oil consumption rate is unacceptable
Also determine customer’s driving habits, such as
go to Step 6.
sustained high speed operation, towing, extended
idle and other considerations. 6. Check the positive crankcase ventilation (PCV)
system. Make sure the system is not plugged.
2. Verify that the engine has no external oil leaks as
described under Engine Oil Leaks. 7. Check for plugged oil drain-back holes in the
3. Verify that the engine has the correct oil level. cylinder head and cylinder block.
8. If the condition still exists after carrying out the
4. Verify that the engine is not being run in an
above tests go to Step 9.
overfilled condition. Check the oil level at least
five minutes after a hot shutdown with the vehicle 9. Carry out a cylinder compression test. Refer to
parked on a level surface. the procedure in this section: Compression Test.
This can help determine the source of oil
5. Carry out an oil consumption test:
consumption such as valves, piston rings or other
1. Drain the engine oil and fill with one litre less areas.
than the recommended amount.
10. Check valve guides for excessive guide
2. Run the engine for three minutes (10 minutes clearance. Install new valve stem seals after
if cold), and allow oil to drain back for at least verifying valve guide clearance.
five minutes with vehicle parked on level
11. Worn or damaged internal engine components
surface.
can cause excessive oil consumption. Small
3. Remove the oil dipstick and wipe clean. (Do deposits of oil on the tips of the spark plugs can
not wipe with anything contaminated with be a clue to internal oil consumption.
silicone compounds.) Install the oil dipstick,
making sure to seat the oil dipstick level firmly
in the oil dipstick tube. Remove the oil dipstick
and scribe a mark on the back (unmarked)
surface at the indicated oil level. (This level
should be about the same as the ADD mark
on the face of the oil dipstick.)
G37831 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Camshaft Journal — Diameter Camshaft — End Play, OHC Engines

1. Measure each camshaft journal diameter in two 1. Remove the roller followers. Refer to the
directions. appropriate section in Group 303 for the
If it is out of specification, install new procedure.
components as necessary. Refer to the 2. Use a Dial Indicator with Bracketry to measure
appropriate section in Group 303 for the camshaft end play.
procedure. 3. Position the camshaft to the rear of the cylinder
head.
4. Zero the indicator.
5. Move the camshaft to the front of the cylinder
head. Note and record the camshaft end play.
If camshaft end play exceeds specifications,
install new camshaft and recheck end play.
Refer to the appropriate section in Group 303
for the procedure.
If camshaft end play exceeds specification
after camshaft installation, install a new
cylinder head. Refer to the appropriate
section in Group 303 for the procedure.
Camshaft Journal — Clearance,

Plastigage Method
NOTE: The camshaft journals must meet
specifications before checking camshaft journal
clearance.
1. Remove the camshaft bearing cap and lay
Plastigage across the surface. Refer to the
appropriate section in Group 303 for the
procedure.
2. Position the camshaft bearing cap and install the
bolts. Refer to the appropriate section in Group
303 for the procedure.
NOTE: Do not turn the camshaft while carrying Camshaft — Lobe Surface
out this procedure. 1. Inspect camshaft lobes for pitting or damage in
the active area. Minor pitting is acceptable outside
the active area.
If excessive pitting or damage is present,
install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.
3. Use Plastigage to verify the camshaft journal

clearance.
If it is out of specification, install new
components as necessary. Refer to the
procedure.
G37832 en 01/2003 2003.0 BA Falcon

Camshaft — Runout Crankshaft Main Bearing Journal —

NOTE: Camshaft journals must be within
Taper
specifications before checking runout. 1. Measure each of the crankshaft main bearing
journal diameters in at least two directions at each
1. Use a Dial Indicator with Bracketry to measure the end of the main bearing journal.
camshaft runout.
For additional information, refer to
Rotate the camshaft and subtract the lowest
Specifications in the appropriate section in
indicator reading from the highest indicator Group 303.
reading.
If it out of specification, install new
For additional information, refer to the
specification chart in the appropriate engine appropriate section in Group 303 for the
section.
procedure.
procedure.
Crankshaft Main Bearing Journal —

Clearance
NOTE: Crankshaft main bearing journals must be
Crankshaft Main Bearing Journal — within specifications before checking journal
Diameter clearance.
1. Measure each of the crankshaft main bearing 1. Remove the crankshaft main bearing caps and
journal diameters in at least two directions. crankshaft main bearing.
For additional information, refer to 2. Lay a piece of Plastigage across the face of each
Specifications in the appropriate section in crankshaft main bearing surface.
Group 303. NOTE: Do not turn the crankshaft while carrying
If it is out of specification, install new out this procedure. Install and remove the
components as necessary. Refer to the crankshaft main bearing cap.
procedure.
G37839 en 01/2003 2003.0 BA Falcon

3. Verify the crankshaft journal clearance. Crankshaft — Runout

For additional information, refer to NOTE: Crankshaft main bearing journals must be
Specifications in the appropriate section in within specifications before checking runout.
Group 303.
If it is out of specification, install new 1. Use the Dial Indicator with Bracketry to measure
the crankshaft runout.
appropriate section in Group 303 for the For additional information, refer to
procedure. Specifications in the appropriate section in
Group 303.
Rotate the crankshaft and subtract the lowest
dial indicator reading from the highest dial
indicator reading to figure the crankshaft
runout. If it is out of specification, install new
procedure.
Crankshaft — End Play

1. Measure the crankshaft end play. Use a Dial
Indicator with Bracketry to measure crankshaft
end play.
2. Position the crankshaft to the rear of the cylinder
block.
Crankshaft — Connecting Rod Journal
4. Move the crankshaft to the front of the cylinder
block. Note and record the crankshaft end play. Taper, Out of Round
If crankshaft end play exceeds specifications, 1. Measure the crankshaft connecting rod journal
install a new crankshaft thrust washer (6334) diameters in two directions perpendicular to one
or crankshaft thrust main bearing (6337). another at each end of the connecting rod journal.
Refer to the appropriate section in Group 303 The difference in the measurements from one end
for the procedure. to the other is the taper. Verify measurement is
within the wear limit.
Group 303.
procedure.
G37839 en 01/2003 2003.0 BA Falcon

Cylinder Bore — Out-of-Round

1. Measure the cylinder bore in two directions. The
difference is the out-of-round. Verify the
out-of-round is within the wear limit and bore the
cylinder to the next oversize limit.
Group 303.
Cylinder Bore — Taper

1. Measure the cylinder bore at the top and bottom.
Verify the cylinder bore is within the wear limit.
The difference indicates the cylinder bore taper.
Bore the cylinder to the next oversize.
Group 303.
Piston — Inspection
CAUTION: Do not use a caustic cleaning
solution or a wire brush to clean the pistons or
damage can occur.
1. Clean and inspect the (2) ring lands, (4) skirts, (3)
pin bosses, and the (1) tops of the pistons. If wear
marks, scores or glazing is found on the piston
skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Cleaner to clean the

piston ring grooves.
Make sure the oil ring holes are clean.
Piston — Pin to Bore Diameter

WARNING: Cover the end of the pin bore with
a hand or shop rag when removing the retainer
ring, since it has a tendency to spring out. Wear
eye protection.
G37843 en 01/2003 2003.0 BA Falcon

NOTE: Piston and piston pins are a matched set and Piston — Ring End Gap
should not be interchanged. Measure the piston pin
bore diameter in two directions on each side. Verify 1. Use a piston without rings to push a piston ring in
the diameter is within specification. a cylinder to the bottom of ring travel.
1. If it is out of specification, install new components CAUTION: Use care when fitting piston
as necessary. Refer to the appropriate section in rings to avoid possible damage to the piston
Group 303 for the procedure. ring or the cylinder bore.
CAUTION: Piston rings should not be
transferred from one piston to another.
NOTE: Cylinder bore must be within specification
for taper and out-of-round.
Piston — Diameter
1. Measure the piston skirt diameter 90 degrees
from the piston pin at the points indicated. For
additional information, refer to Specifications in
the appropriate section in Group 303. 2. Use a feeler gauge to measure the top piston ring
If it is out of specification, install new end gap and the second piston ring end gap.
components as necessary. Refer to the For additional information, refer to
appropriate section in Group 303 for the Specifications in the appropriate section in
procedure. Group 303.
Piston — Ring-to-Groove Clearance

1. Inspect for a step in the grooves.
2. Measure the piston ring-to-groove clearance.
Group 303.
If out of specification, install new components
as necessary. Refer to the appropriate section
in Group 303 for the procedure.
Piston — to Cylinder Bore Clearance

1. Subtract the piston diameter from the cylinder
bore diameter to find the piston-to-cylinder bore
clearance. If the measurement is outside
specification, replace the piston, or machine the
cylinder block oversize and fit oversize pistons.
G37843 en 01/2003 2003.0 BA Falcon

Piston — Pin Diameter Connecting Rod — Bushing Diameter

1. Measure the piston pin diameter in two directions 1. Measure the inner diameter of the connecting rod
at the points shown. Verify the diameter is within bushing, if equipped. Verify the diameter is within
specification. specification.
For additional information, refer to For additional information, refer to
Specifications in the appropriate section in Specifications in the appropriate section in
Group 303. Group 303.
If out of specification, install new components If out of specification, install new components
as necessary. Refer to the appropriate section as necessary. Refer to the appropriate section
in Group 303 for the procedure. in Group 303 for the procedure.
Connecting Rod — Cleaning Connecting Rod — Bend

1. Measure the connecting rod bend on a suitable
CAUTION: Do not use a caustic cleaning alignment fixture. Follow the instructions of the
solution or damage to connecting rods can occur. fixture manufacturer. Verify the bend
measurement is within specification.
Connecting Rod — Large End Bore
1. Measure the bore in two directions. The difference Specifications in the appropriate section in
is the connecting rod bore out-of-round. Verify the Group 303.
out-of-round is within specification. If out of specification, install new components
For additional information, refer to as necessary. Refer to the appropriate section
Specifications in the appropriate section in in Group 303 for the procedure.
Group 303.
G37876 en 01/2003 2003.0 BA Falcon

4. Measure the Plastigage to get the connecting rod

Connecting Rod — Twist bearing journal clearance. The Plastigage should
1. Measure the connecting rod twist on a suitable be smooth and flat. A changing width indicates a
alignment fixture. Follow the instructions of the tapered or damaged connecting rod or connecting
fixture manufacturer. Verify the measurement is rod bearing.
within specification. For additional information, refer to
For additional information, refer to Specifications in the appropriate section in
Specifications in the appropriate section in Group 303.
Group 303. If out of specification, install new components
If out of specification, install new components as necessary. Refer to the appropriate section
as necessary. Refer to the appropriate section in Group 303 for the procedure.
Roller Follower — Inspection
1. Inspect the roller for flat spots or scoring. If any
damage is found, inspect the camshaft lobes and
valve tappet for damage.
Valve Rocker Arm/Lash Adjuster

Assembly — Inspection
1. Inspect the roller for flat spots or scoring, the
valve pad for wear or pitting, and the ball socket
for smooth motion.
Do not disassemble the clip unless replacing
a part of the assembly. The clip must be a
firm fit on the rocker arm, and replaced if
removed.
Connecting Rod — Bearing Journal Replace any parts that show significant wear
Clearance or damage.
NOTE: The crankshaft connecting rod journals must

be within specifications to check the connecting rod
bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing
surface.
Item Description
1 Valve rocker arm
2 Retaining clip
3 Lash adjuster
Hydraulic Lash Adjuster Diagnosis

3. Install and tighten to specifications, then remove
A suspected faulty lash adjuster can be located by
the connecting rod bearing cap.
removing the cam cover. Check all the rockers for
NOTE: Do not turn the crankshaft during this step. signs of vertical play, or sponginess in the lash
adjuster. Rotate the crankshaft so that all rockers are
checked with the valve closed.
If necessary, operate the engine at idle and try to
locate the noise by ear, or use a piece of thin dowel to
feel the motion of the valve spring retainer. An indent
G37876 en 01/2003 2003.0 BA Falcon

will be felt on the valve with the faulty adjuster. Valve — Inspection
Air bubbles in the lubricating oil, caused by
1. Inspect the following valve areas:
excessively high or low oil level may result in spongy
lash adjusters. A leak in the oil pick-up tube, or its 1. the keeper grooves for burns and wear.
joint to the oil pump may allow air to be drawn into the 2. the valve face and the edge for pits, grooves
lubricating system. or scores.
3. the valve head for signs of burning, erosion,
Valve — Stem Diameter warpage and cracking.
1. Measure the diameter of each intake and exhaust 4. the valve head thickness for wear.
valve stem at the points shown. Verify the
diameter is within specification.
Group 303.
Item Description
1 End of stem
2 Keeper grooves
3 Valve head
4 Valve head thickness
Valve — Guide Inner Diameter

Valve — Stem to Valve Guide
Clearance 1. Measure the inner diameter of the valve guides in
two directions where indicated.
Check the valve stem to valve guide clearance of For additional information, refer to
each valve. With the cylinder head gasket face Specifications in the appropriate section in
uppermost, slide a new inlet or exhaust valve as Group 303.
appropriate into the guide to be checked until the end
of the stem is flush with the top of the valve guide.
Mount a dial indicator on the cylinder head gasket
face so that the plunger can be positioned on the
edge of the valve head at 90º to the camshaft axis.
With the dial indicator in this position and the end of
the valve stem flush with the top of the guide, move
the valve head from side to side at right angles to the
camshaft axis as far as the clearance will allow and
note the indicator reading.
If the valve head deflection exceeds the specification
for inlet or exhaust valves the guide in question is
worn excessively and should be replaced.
2. If the valve guide is not within specifications,

remove the valve guide and install a new valve
guide.
G37861 en 01/2003 2003.0 BA Falcon

Valve — Guide Reaming Valve — Spring Free Length

1. Use a hand-reaming kit to ream the valve guide. 1. Measure the free length of each valve spring.
Group 303.
2. Reface the valve seat.

3. Clean the sharp edges left by reaming.
Valve — Spring Installed Length

1. Measure the installed length of each valve spring.
Specifications in the appropriate section in Valve — Spring Squareness
Group 303.
1. Measure the out-of-square on each valve spring.
If out of specification, install new components.
Refer to the appropriate section in Group 303 Turn the valve spring and observe the space
for the procedure. between the top of the valve spring and the
square. Install a new valve spring if out of
square. Refer to the appropriate section in
Group 303 for the procedure.
G37861 en 01/2003 2003.0 BA Falcon

Valve — Spring Strength 1. Check the valve head and seat.

Check valve angles.
Special Tool(s)
Check margin width.
Valve/Clutch Spring Tester For additional information, refer to
303-006 (TOOL-6513-DD) or Specifications in the appropriate section in
equivalent Group 303.
Be sure margin width is within specification.
1. Use a Valve/Clutch Spring Tester to check the

valve spring for correct strength at the specified
valve spring length.
Group 303.
2. Inspect for abnormalities on the valve face and

seat.
Valve — Seat Width

1. Measure the valve seat width. If necessary, grind
the valve seat to specification.
Measure the intake valve seat width.
Measure the exhaust valve seat width.
Recheck the valve spring installed length after
the seats have been ground.
Valve — Seat Inspection Specifications in the appropriate section in
Group 303.
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve

seats, check valve clearance.
G37870 en 01/2003 2003.0 BA Falcon

1. Use a slide hammer or tools suitable to remove

Valve — Seat Runout the cylinder block core plug.
1. Use the Valve Seat Runout Gauge to check valve
seat runout.
2. Inspect the cylinder block plug bore for any

damage that would interfere with the correct
sealing of the plug.
Cylinder Bore — Cleaning
Cup-Type
CAUTION: If these procedures are not
followed, rusting of the cylinder bores may occur. CAUTION: Use care during this procedure so
as not to disturb or distort the cup sealing
1. Clean the cylinder bores with soap or detergent surface.
and water.
2. Thoroughly rinse with clean water and wipe dry CAUTION: When installed, the flanged edge
with a clean, lint-free cloth. must be below the chamfered edge of the bore to
3. Use a clean, lint-free cloth and lubricate the effectively seal the bore.
cylinder bores. 1. Use a tool suitable to seat the cup-type cylinder
Use Super Premium SAE Motor Oil meeting block core plug.
Ford specification.
Cylinder Block — Core Plug

Replacement
Special Tool(s)
Impact Slide Hammer
100-001 (T50T-100-A)
Expansion-Type
CAUTION: Do not contact the crown when

installing an expansion-type cylinder block core
plug. This could expand the plug before seating
and result in leakage.
G37870 en 01/2003 2003.0 BA Falcon

1. Use tool suitable to seat the expansion-type

cylinder block core plug.
Exhaust Manifold — Inspection

1. Place a Straight edge across the exhaust
manifold flanges and check for warping with a
feeler gauge.
Item Description
1 cratering-fatigue failure
2 spot glazing-improper seating
3 scratching-dirty
4 base exposed-poor lubrication
Bearing -Inspection 5 both edges worn-journal damaged
1. Inspect bearings for the following defects. 6 one edge worn-journal tapered or bearing
Possible causes are shown: not seated
1. cratering-fatigue failure
2. spot glazing-improper seating
3. scratching-dirty
4. base exposed-poor lubrication
5. both edges worn-journal damaged
6. one edge worn-journal tapered or bearing not
seated
G37875 en 01/2003 2003.0 BA Falcon

303-01a-1 Engine — I6 303-01a-1
SECTION : 303-01a Engine — I6

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01a-3
Engine — I6 .........................................................................................................................303-01a-7
Engine ................................................................................................................................303-01a-12
Inspection and Verification ..............................................................................................303-01a-12
Symptom Chart ................................................................................................................303-01a-12
Component Tests .............................................................................................................303-01a-13
GENERAL PROCEDURES
Cylinder Head Inspection ...................................................................................................303-01a-16
Valve Inspection .................................................................................................................303-01a-16
Valve Measurement ..........................................................................................................303-01a-17
Valve Guide Inspection .....................................................................................................303-01a-17
Valve Guide Replacement ................................................................................................303-01a-17
Valve Seat Inspection/Repair .............................................................................................303-01a-18
Valve Spring Inspection .....................................................................................................303-01a-18
Camshaft End Play Inspection ...........................................................................................303-01a-19
Camshaft Inspection ..........................................................................................................303-01a-19
Camshaft Journal Clearance - Plastigauge Method ..........................................................303-01a-20
Roller Follower Inspection ..................................................................................................303-01a-20
Lash Adjuster Bore Inspection ...........................................................................................303-01a-20
Cylinder Block Inspection/Repair .......................................................................................303-01a-20
Cylinder Bore - Taper .........................................................................................................303-01a-21
Cylinder Bore — Out-of-Round ..........................................................................................303-01a-21
Piston Inspection ................................................................................................................303-01a-21
Piston Clearance Inspection/ Repair ..................................................................................303-01a-21
Piston Ring Clearance Inspection ......................................................................................303-01a-22
Piston Pin Clearance Inspection ........................................................................................303-01a-22
Crankshaft Inspection ........................................................................................................303-01a-23
Crankshaft Main Bearing Clearance ..................................................................................303-01a-23
Crankshaft End Play Inspection/Repair .............................................................................303-01a-24
Connecting Rod Inspection ................................................................................................303-01a-24
Connecting Rod Big End Bearing Clearance .....................................................................303-01a-24
Connecting Rod Side Clearance Inspection ......................................................................303-01a-25
Piston and Connecting Rod Inspection ..............................................................................303-01a-25
Timing Chain Elongation ....................................................................................................303-01a-25
IN-VEHICLE REPAIRS
Oil Filter ..............................................................................................................................303-01a-26
Oil Level Indicator & Tube .................................................................................................303-01a-26
Cylinder Head Temperature Sensor .................................................................................303-01a-26
Cam Position Sensor .........................................................................................................303-01a-26
Crankshaft Position Sensor ...............................................................................................303-01a-27
01/2003 2003.0 BA Falcon

303-01a-2 Engine — I6 303-01a-2
(Continued)
Oil Pressure & Oil Temperature Sensor ............................................................................303-01a-27

Combustion Knock Sensor ................................................................................................303-01a-27
Exhaust Gas Oxygen Sensor .............................................................................................303-01a-27
Temperature - Manifold Air Pressure Sensor ....................................................................303-01a-27
Crankshaft Vibration Damper .............................................................................................303-01a-28
Crankshaft Front Oil Seal ...................................................................................................303-01a-28
Crankshaft Rear Oil Seal ...................................................................................................303-01a-28
Flywheel/Drive Plate/Clutch Pilot Bearing ..........................................................................303-01a-29
Clutch Pilot Bearing ...........................................................................................................303-01a-29
Water Pump .......................................................................................................................303-01a-29
Electronic Throttle Body and Intake Manifold ....................................................................303-01a-30
Broadband Throttle Plate ...................................................................................................303-01a-32
Broadband Throttle Shaft Vacuum Motor ..........................................................................303-01a-32
Exhaust Manifold Assembly ...............................................................................................303-01a-32
Exhaust Manifold - Front and Rear ....................................................................................303-01a-33
Oil Control Valve Seal ........................................................................................................303-01a-33
Valve Cover .......................................................................................................................303-01a-34
Ignition Coils/Wiring Loom .................................................................................................303-01a-36
Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters .............................................303-01a-37
Camshaft Removal ............................................................................................................303-01a-38
Camshaft and VCT Phasers ..............................................................................................303-01a-38
Camshaft Installation .........................................................................................................303-01a-40
Timing Chain Tensioner .....................................................................................................303-01a-41
VCT Phaser ......................................................................................................................303-01a-41
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01a-42
Rocker Arm and Lash Adjuster ..........................................................................................303-01a-43
Valve spring and Valve Stem Seal ....................................................................................303-01a-43
Front Cover ........................................................................................................................303-01a-44
Camshaft Drive ..................................................................................................................303-01a-46
Timing Chain Tensioner Release .......................................................................................303-01a-46
Cylinder Head ....................................................................................................................303-01a-47
Engine ................................................................................................................................303-01a-48
Engine Mounting ................................................................................................................303-01a-50
Engine Oil Pan ...................................................................................................................303-01a-50
Oil Pump Pickup Tube .......................................................................................................303-01a-51
Oil pump .............................................................................................................................303-01a-52
Piston and Rod Assembly ..................................................................................................303-01a-52
Main bearings/Crankshaft ..................................................................................................303-01a-53
Rear Main Bearing Cap Assembly .....................................................................................303-01a-54
Piston Ring .........................................................................................................................303-01a-54
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Key Retainer — Valve Spring ............................................................................................303-01a-55
Valve Stem Seal ................................................................................................................303-01a-55
Piston and Connecting Rod Assembly ..............................................................................303-01a-56
Piston and Connecting Rod Disassembly and Assembly ..................................................303-01a-56
Connecting Rod Bolt .........................................................................................................303-01a-56
01/2003 2003.0 BA Falcon

303-01a-3 Engine — I6 303-01a-3
SPECIFICATIONS
Lubricants and Sealants Description Specification

Description Specification Intake Manifold Vacuum
Engine Oil 10W-30 WSS M2C910 2 (I6 @ Idle rpm
ILSAC - GF2 DOHC VCT) DOHC VCT 60 kPa @ Idle in Neutral
Engine Oil 15W-40 API WSE M2C905 A (I6 LPG) LPG 60 kPa @ Idle in Neutral
SG/CE Cylinder Head/Valve Train
Silicone Sealant (Loctite WSS M4G323 A7 Combustion Chamber 65.5 - 66.5cc
5900 or similar) Volume
Anti Seize compound ESE FM99C100 A Joint face flatness 0.08mm in 150mm or
(Loctite 767 or similar) 0.18mm overall
Rubber Grease ESZ M1C223 A Cylinder head joint face 2.5 RZ (Din) @2.5
Synthetic Grease ESF M1C229 A surface finish cut-off, Wt <10.0, Mr 68%
(Dupont Krytox) min @ 2.0 um
General Specifications Minimum Cylinder head Std - 0.3 mm
deck height
Valve seat width- Intake 1.0mm - 1.4mm
Displacement 3984cc
Valve seat width-Exhaust 1.25mm - 1.75mm
Number of cylinders In line 6
Valve seat angle 44.75º
Compression Ratio
Valve seat runout 0.04mm
DOHC VCT 9.7:1
Valve stem to guide 0.020mm - 0.069mm
LPG 10.7:1
clearance
Power at specified
Valve guide parent bore 9.975mm - 10.025mm
rpm(DIN) diameter
DOHC VCT 182 kW @ 5000
Valve guide outside 10.028mm - 10.039mm
LPG 156 kW @ 4750 diameter
Torque at specified rpm Valve guide inside 6.015mm - 6.044mm
(DIN) diameter
DOHC VCT 380 Nm @ 3250 Valve head diameter- 35mm
LPG 372 Nm @ 3000 intake
Bore/Stroke 92.26mm / 99.31mm Valve head diameter - 32mm
Firing Order 1-5-3-6-2-4 exhaust
Oil Pressure - Hot @ 230kPa min Gauge Diameters
2000 rpm Valve face runout 0.05mm
Spark Plug - I6 Valve face angle 45.5º
DOHC VCT K16SR14 Valve stem diameter (In 5.975mm - 5.995mm
LPG K20SR11 & Ex)
Compression Pressure at Valve seat insert recess 35.07mm - 35.12mm
Maximum cranking speed diameter (In)
DOHC VCT 1010 Kpa Valve seat insert recess 32.37mm - 32.42mm
diameter (Ex)
LPG 1110 Kpa
Valve seat insert outer 35.192mm - 35.208mm
Idle Speed diameter (In)
Manual Trans (A/C off) Valve seat insert outer 32.492mm - 32.508 mm
DOHC VCT 700 ± 50 rpm diameter (Ex)
LPG 700 ± 50 rpm Valve spring free length 50.0 mm
Auto trans in Neutral Valve spring installed 280N / 37.8 mm
DOHC VCT 660 ± 50 rpm load/length
LPG 700 ± 50 rpm Valve spring compressed 550N / 26.8mm
Auto Trans in Drive load/length
Valve spring allowable 50N @ 26.8mm
DOHC VCT 580 ± 50 rpm
load loss
LPG 700 ± 50 rpm
G99770 en 01/2003 2003.0 BA Falcon

303-01a-4 Engine — I6 303-01a-4
Description Specification Description Specification

Valve spring - out of 2º Taper service limit 0.25mm
square Crankshaft
Rocker arm ratio 2.04 Main bearing journal 67.481mm - 67.505mm
Hydraulic Lash Adjuster 13.972mm - 13.984mm diameter
diameter Connecting rod journal 53.93mm - 53.95mm
Lash adjuster bore in 13.990mm - 14.007mm diameter
cylinder head Crankshaft free end play 0.10mm - 0.20mm
Collapsed Lash adjuster 0.5mm - 1.1mm (desired) Service Limit 0.30mm
clearance at cam
Connecting rod bearings- 0.02mm - 0.04mm
Camshaft clearance to crankshaft-
Lobe lift (In & Ex) 5.39mm desired
Valve lift(In & Ex) 11.00mm Connecting rod bearings- 0.06mm
Camshaft end play 0.1mm - 0.3mm clearance to crankshaft-
service limit
Camshaft journal 34.928mm - 34.968mm -
diameter Front Main bearings- clearance 0.02mm - 0.04mm
29.928mm - 29.968mm - to crankshaft-desired
Remainder Main bearings- clearance 0.06mm
Camshaft Journal max 0.015mm to crankshaft- service
out of round limit
Cylinder head bearing 34.987mm - 35.012mm - Connecting Rod
diameter Front Small end bore diameter
29.987mm - 30.012mm - DOHC VCT & LPG 23.132mm - 23.144mm
Remainder
Big end bore diameter 56.871mm - 56.891mm
Journal to bearing 0.019mm - 0.084mm
clearance Length (centre to centre) 153.78mm - 153.92mm
Alignment ( bore to bore- 0.20mm
Service Limit 0.120mm
max difference)Twist
Valve Timing Engine Stopped, VCT
Phasers Fully Advanced Bend 0.10mm
& VCT Locking Pins Side clearance 0.09mm - 0.27mm
Engaged (assembled to crank)
Intake Opens 27.5º BTDC Standard
Side clearanceService 0.36mm
Intake Closes 43.5º ABDC
limit
Exhaust Opens 68.5º BBDC
Piston
Exhaust Closes 2.5º BTDC
Piston diameter 92.24mm - 92.31mm
Intake Cam Centre-line 97.5º ATDC
Piston to bore clearance 0.020mm interference to
(Maximum Lift)
(new) 0.030mm clearance
Exhaust Cam Centre-line 126.5º BTDC
Piston to bore clearance- 0.09mm
(Maximum Lift)
service limit
Timing Chain Maximum 0.35 %
Elongation Intake Manifold Vacuum
@ Idle rpm
Cylinder Block
DOHC VCT 60 kPa @ Idle in Neutral
Head gasket thickness 0.25mm at body, 0.3mm
at cylinder bore LPG 60 kPa @ Idle in Neutral
Pin bore diameter
Main bearing bore 71.517mm - 71.541mm
(piston)
diameter
Cylinder bore diameter 92.25mm - 92.31mm Std DOHC, VCT & LPG 23.173mm - 23.178mm
92.75mm - 92.77 0.5mm Ring groove width - Top 1.22mm - 1.24mm
O/S Compression
93.25mm - 93.27 1.0mm Ring groove width - 1.52mm - 1.54mm
O/S Lower Compression
Out of round limit 0.025mm Ring groove width - Oil 3.01mm - 3.03mm
Out of round service limit 0.125mm Ring
G99770 en 01/2003 2003.0 BA Falcon

303-01a-5 Engine — I6 303-01a-5
Description Specification Description Nm

Piston pin length 64.50mm - 65.00mm Oil Pan Rear Face Flush or
Piston pin diameter 0.25mm
forward of
DOHC VCT, LPG 23.157mm - 23.162mm rear face of
Pin to piston clearance block
DOHC VCT & LPG 0.014mm - 0.019mm Oil Pan Drain Plug 26
Ring groove clearance- 0.03mm - 0.075mm Intake manifold- Upper to Lower 16
Top Compression New (Apply
Ring groove clearance- 0.15mm thread
Top Compression locker)
Service limit Intake Manifold- Lower to Cylinder 20
Ring groove clearance- 0.03mm - 0.075mm head (Apply
2nd Ring New thread
Ring groove clearance - 0.15mm locker)
2nd Ring Service limit Intake Manifold Strut (Upper)
Oil ring groove clearance Nil To Upper Manifold 16
- new (Delete
Oil ring groove clearance 0.20mm thread lock)
- service limit To Cylinder Head 16
Installed piston ring gap - 0.21mm - 0.36mm Intake Manifold Strut (Lower)
Top Compression - New To Lower Manifold 20
Installed piston ring gap - 0.45mm (Apply
Top Compression- thread
Service limit locker)
Installed piston ring gap- 0.35mm - 0.51mm To Cylinder Block 20
2nd Ring - New To Engine Mt. Support 50
Installed piston ring 0.60mm Fuel Rail to Intake Manifold 20
gap-2nd Ring - service Intake Manifold Butterfly Shaft Actuator 20
limit
Assembly
Oil ring (rail) gap- new 0.3mm - 0.9mm
Intake Manifold Vacuum Connectors 4
Oil ring (rail) gap-service 1.0mm (Apply
limit thread
Lubrication system sealant)
Oil capacity - Initial Fill 7.0L Intake Manifold Pressure/Temperature 3
(Dry engine) Sensor
Oil Change without Filter 5.8L Electronic Throttle Body to Upper 10
Oil Change with Filter 6.8L Intake Manifold (Apply
thread
Torque Specifications locker)
Oil threads with engine oil. Do not oil threads that Exhaust Manifold to Cylinder Head 27
require thread sealant or thread locker.
Exhaust Manifold Heat Shield - Lower 20
Description Nm Exhaust Manifold Slip Joint
Main Bearing Cap bolts 85 Stud 15
Cylinder Head Bolts Step 1: 40 Nut 23
Nm
Step 2: Flywheel/Flex Plate to Crankshaft 75
Rotate 90º Clutch Pressure Plate to Flywheel 25
clockwise Manual Flywheel Housing to Block 50
Oil Pan to Cylinder block/front cover 9 Oil Pump to Cylinder Block 10
Oil Pan to main bearing cross bolts 58 Oil Pump Pickup Tube to Oil Pump 10
(Apply
Oil Pump Pickup Tube to Main Bearing 20
thread
Bolt
sealant)
Oil Filter Adaptor to Cylinder Block 17
G99770 en 01/2003 2003.0 BA Falcon

303-01a-6 Engine — I6 303-01a-6
Description Nm Description Nm
Oil Filter to Cylinder block With oiled Cam Cover to Cylinder Head - Six 10
gasket, short bolts (Apply
hand thread
tighten until locker)
gasket Oil Control Valve Seals to Cam Cover 7
contacts
block face, Cam Caps to Cylinder Head 10
tighten a VCT Oil Control Valves to Cam Caps 9
further ¾ Camshaft position sensor to cylinder 9
turn head
Oil Pressure Sensor 20 Cylinder Head Temperature sensor to 15
(Apply Cylinder Head
thread Timing Chain Fixed Chain Guide to 20
sealant) Cylinder Block and Cylinder Head
Oil Temperature Sensor 20 Timing Chain Tensioner to Cylinder 9
(Apply Head
thread
sealant) Timing Chain Guide Pivot Bolt to Oil 27
Pump
Knock Sensor to Cylinder Block 20
(Apply Timing Chain Guide Pivot Nut 9
thread Crankshaft Vibration Damper/Front 125
locker) Pulley to Crankshaft
Timing Cover to Cylinder Block 20 Connecting Rod Cap to Connecting Step 1: 25
Crankshaft Position Sensor to Timing 9 rod Nm
Cover Step 2: 90º
clockwise.
Thermostat Housing to Cylinder Head 20
(Apply
thread
locker)
Water Outlet to Thermostat Housing 20
Heater Tube to Thermostat Housing 20
Heater Tube to Block (Exhaust side) 27
Water Pump to Cylinder Block 20
Engine Mount Bracket to Cylinder 50
Block (Apply
thread
locker)
Engine Mount to Engine Mount Bracket 102
Power Steering Brackets to Cyl. Head 43
and Cylinder Block
Alternator Bracket(rear) to Cylinder 25
Block
Spark Plugs 17
Variable Cam Timing Unit to Camshaft Step 1: 20
Nm
Step 2:
Rotate 40º
clockwise
Spark Plug Cover to Rocker Cover 8
Brake Hose Clip to Spark Plug Cover 3
Cam Cover to Cylinder Head - Front 13
two long bolts
G99770 en 01/2003 2003.0 BA Falcon

303-01a-7 Engine — I6 303-01a-7
Engine — I6
The 4.0L I6 is a four valve per cylinder, dual overhead
camshaft engine with individual intake and exhaust
variable cam timing units. A distributorless ignition
system with individual coils mounted above the spark
plugs is used. The cylinder block is cast iron, and is
attached to an aluminium oil pan with cross-bolted
main bearing caps to increase rigidity. The oil pump is
mounted on the nose of the crankshaft, and a single
stage roller chain drives the hollow camshafts.
Hydraulic lash adjusters and roller finger followers
activate the valves. An electronic throttle body is
employed together with a variable length intake
manifold. Petrol, LPG and Turbocharged versions are
also available.
G99771 en 01/2003 2003.0 BA Falcon

303-01a-8 Engine — I6 303-01a-8
Upper Engine Components
G99771 en 01/2003 2003.0 BA Falcon

303-01a-9 Engine — I6 303-01a-9
Upper Engine Components

Item Description
1 Coil and Boot Assembly
2 Spark Plug
3 Cap - Camshaft intake bridge - Rear
4 Camshaft - Intake
5 Cylinder head temperature sensor
6 Engine lifting eye, LH, FRT
7 Sensor Assembly camshaft timing
8 Head gasket
9 Sensor Assembly camshaft timing
10 Cylinder head
11 Lash adjuster assembly
12 Clip
13 Engine lifting eye, RH, RR
14 Valve - Inlet
15 Valve - Exhaust
16 Insert - Cylinder Head
17 Bushing - Valve guide
18 Seal - Valve stem
19 Spring - Valve
20 Retentioner - Valve spring
21 Key - Valve spring retention
22 Rocker arm
23 Cam timing assembly - Engine variable
24 Filter - Engine oil
25 Top timing chain guide
26 Cap - Camshaft exhaust bridge, FRT
27 Housing and Valve assembly camshaft
variable timing
28 Gasket - Valve rocker arm cover
29 Plate - Gasket valve rocker arm cover
30 Gasket - Rocker arm cover
31 Gasket - Spark plug
32 Cover - Valve rocker arm
33 Gasket - Spark plug cover
34 Spark plug cover assembly
35 Oil filler cap gasket
36 Oil filler cap
G99771 en 01/2003 2003.0 BA Falcon

303-01a-10 Engine — I6 303-01a-10
Lower Engine Components
G99771 en 01/2003 2003.0 BA Falcon

303-01a-11 Engine — I6 303-01a-11
Lower Engine Components

Item Description
1 Gasket - Front Cover RH
2 Timing Chain Tensioner
3 Lever arm assembly - Timing chain
tensioner
4 Timing chain
5 Guide assembly - Timing chain
6 Oil pump
7 Oil pump pick-up/ Screen
8 Sensor Assembly Engine Spark intensity
(knock sensor)
9 Flywheel assembly
10 Cover - Flywheel housing
11 Filter assembly - Oil
12 Piston compression ring, Upper
13 Piston compression ring, Lower
14 Piston Oil control, Ring
15 Piston
16 Connecting rod
17 Bearing upper - Connecting rod (Big End)
18 Bearing lower - Connecting Rod (Big End)
19 Cap - Connecting rod
20 Pin - Piston
21 Cover - Flywheel
22 Plug - Oil pan drain
23 Pan - Oil
24 Baffle - Oil pan
25 Seal - Oil pan
26 Crank windage oil baffle
27 Brace - Main bearing cap support
28 Crankshaft main bearing caps
29 Crankshaft main bearing - Lower
30 Crankshaft
31 Crankshaft main bearings - Upper
32 Cylinder block
33 Tube - Oil lever indicator
34 Oil lever indicator
35 Damper assembly - Crankshaft
36 Crank sensor
37 Crankshaft sprocket / Tone wheel
38 Switch assembly - Oil pressure
39 Seal - Oil, Cylinder front cover
40 Cover - Cylinder front
G99771 en 01/2003 2003.0 BA Falcon

303-01a-12 Engine — I6 303-01a-12
Engine Visual Inspection Chart

Mechanical
Inspection and Verification Coolant leaks
Since diagnosis and testing actually begins when Oil leaks
repairs are taken on, the following procedure is Leaks in the fuel system
recommended. Visibly damaged or worn parts
Loose or missing nuts or bolts
1. Verify the customer concern by operating the
system. 3. If an obvious cause for an observed or reported
2. Visually inspect for obvious signs of mechanical concern is found, correct the cause (if possible)
damage or electrical damage. If the concern before proceeding to the next step.
cannot be reproduced, carry out a road test 4. If the concern is not visually evident, verify the
and/or visual check with the aid of the following symptom and refer to the Symptom Chart.
table.
Symptom Chart

Engine will not crank Faulty Starter System Refer Section 303-06 Starting System.
Transmission lever not in P or N. Place in P.
Seized engine Replace engine.
Coolant in cylinders Replace engine.
Engine cranks but will not start Ignition system inoperative Refer section 303-06 Starting System
Fuel system inoperative Refer section 303-04
Engine slow/difficult to start LPG engine requires "key-off" to Key-off LPG engine if 1st starting
regain starting enrichment after initial attempt failed.
failed start.
Variable Cam Timing (VCT) unit lock
pin not engaged at start.
VCT unit Oil Control Valve jammed. Clean Oil Control Valve. Refer to Valve
Cover Section.
Engine misfires Fail Safe Cooling in operation Repair coolant system
Ignition system faulty Refer Section 303-06
Fuel system faulty Refer Section 303-04
Restricted exhaust system Inspect Exhaust system
Intake vacuum leak Carry out Intake Manifold Vacuum test

in this section
Burned valve/poor seating Perform a compression check
Broken valve spring Inspect valve springs
Head gasket leakage Inspect head gasket
Piston damage Perform cylinder compression check
Insufficient Power Broadband Intake Manifold not Check switching occurs at 3800 rpm-
operative refer Section 303-14.
VCT unit(s) not operative Refer Section 303-14.
Electronic Throttle Control Unit faulty Refer Section 303-14.
Excessive Fuel Consumption Green(low mileage) engine/vehicle Establish accurate fuel consumption
City/stop-start driving using full-to-full method.
Faulty Fuel System Refer Section 303-04
G99772 en 01/2003 2003.0 BA Falcon

303-01a-13 Engine — I6 303-01a-13

Excessive Oil Consumption Green engine Recheck at 15,000 km
Valve stem seal damaged or missing. Inspect the seals.
Oil leakage Repair oil leakage
Incorrect Oil viscosity Drain and fill with correct oil
Piston/rings/cylinder worn or damaged Repair. Refer Section 303-00.
Diluted oil Determine cause. Correct. Drain and

refill oil.
Crankcase overfilled Adjust oil level.
Faulty PCV Valve Check and replace.
Engine leaks oil Joint fasteners loose Tighten to specification.

Out of position or damaged seal/RTV Pressurise crankcase to 35kPa. Apply
sealant omitted/inadequate. soapy water, check for leak. Inspect
and replace.
Worn/out of position crank rotary seal Inspect and replace.
Porous casting Clean suspect area, Perform

pressurized crankcase check. Run
engine, check for leak. Replace
casting.
Sealant in Crank Damper keyway Replace sealant.
omitted or inadequate
Sealant between Rear Main Cap and Perform pressurized crankcase leak
block omitted or inadequate check. Repair.
Engine Noise Excessive Crankshaft Main bearing or Inspect and repair. Refer relevant
big end clearance. Section.
Excessive Crankshaft end play
Excessive camshaft end play
Excessive piston to bore
clearance/damaged piston/bent
connecting rod.
Excessive hydraulic valve adjuster
clearance
Worn cam lobe or roller finger follower
Excessive valve guide clearance
Broken valve spring
Loose timing chain
Loose crank damper
Worn/noisy Front End Accessory Drive
Belt
Worn/noisy tensioner/idler pulley
Exhaust gas leakage
Soft or spongy lash adjusters Check for excessively low or high oil
level. Air leak in suction side of oil
pump.
Carbon in combustion chamber/top Remove carbon using proprietary
land of piston carbon removal treatment
Component Tests Pressurised leak check
Engine Oil Leaks 1. Clean the engine with a suitable cleaning fluid to
remove all traces of oil.
NOTE: Before installing new gaskets or oil seals,
make sure that the fault is clearly established. If the 2. Block off the line to the PCV valve.
oil leak cannot be identified clearly by a visual 3. Apply a regulated air supply line to the fresh air
inspection, carry out a pressurized crankcase leak makeup point on the rocker cover.
check. 4. Pressurise the crankcase to 35 kPa.
G99772 en 01/2003 2003.0 BA Falcon

303-01a-14 Engine — I6 303-01a-14
5. Check for air leaks by washing the suspect area If the reading stays the same, the cause is either
with a solution of soapy water and watching for damaged valve seats, or valve stem seals.
bubbles. If the measurements for two adjacent cylinders are
6. Repair all leaks as necessary. both too low, then it is very likely that the cylinder
head gasket between the cylinder is burnt through.
General Remarks This can also be recognized by traces of engine oil in
NOTE: Removing fuses and disconnecting electrical the coolant and/or coolant in the engine oil.
components causes the powertrain control module
Excessive Engine Oil Consumption
(PCM) to log an error message. After the
measurements have been carried out this error The amount of oil an engine uses will vary with the
message should be cleared from memory by way the vehicle is driven in addition to normal
connecting to WDS. engine-to-engine variation. This is especially true
The compression pressure should be checked with during the first 15,000 km when a new engine is being
the engine at operating temperature. broken in or until certain internal components become
conditioned. Vehicles used in heavy-duty operation
Check The Compression Pressure may use more oil. The following are examples of
heavy-duty operation:
WARNING: On manual transmissions, shift trailer towing applications
the transmission into neutral. On automatic severe loading applications
transmission vehicles, select ’’P’’. Failure to sustained high speed operation
injury. Engines need oil to lubricate the following internal
components:
1. Remove the fuel pump relay.
cylinder block cylinder walls
2. Start the engine and run for a few seconds, then
stall. pistons and piston rings
3. Remove the spark plugs. intake and exhaust valve stems
4. Install an adaptor and compression tester. intake and exhaust valve guides
5. Install an auxiliary starter switch in the starting all internal engine components
circuit. With the ignition switch OFF, use the When the pistons move downward, a thin film of oil is
auxiliary starter switch to crank the engine a left on the cylinder walls. As the vehicle is operated,
minimum of five compression strokes, and record some oil is also drawn into the combustion chambers
the highest reading. Note the approximate past the intake and exhaust valve stem seals and
number of compression strokes required to obtain burned.
the highest reading. The following is a partial list of conditions that can
6. Repeat the test on each cylinder, cranking the affect oil consumption rates:
engine approximately the same number of engine size
compression strokes. operator driving habits
7. Install the components in reverse order, observing ambient temperatures
the specified tightening torques.
quality and viscosity of oil
8. Reset the PCM fault memory.
Operation under varying conditions can frequently be
Interpretation of the Results misleading. A vehicle that has been run for several
thousand kilometers on short trips or in cold ambient
The indicated compression pressure is considered to
temperatures may have consumed a ’’normal’’
be within specification if the lowest reading cylinder is
amount of oil. However, when checking the engine oil
within 75% of the highest reading.
level, it may measure up to the full mark on the oil
level indicator due to dilution (condensation and fuel)
CAUTION: If engine oil is sprayed into the in the engine crankcase. If the vehicle is then driven
combustion chamber, run the engine at 2000rpm at high speeds on a highway where the condensation
for about 15 minutes (in order to burn the oil and and fuel boil off, the next time the engine oil is
prevent damage to the catalytic converter) after checked it may appear that a litre of oil was used in a
carrying out the measurement. relatively short distance.
If the measurement on one or more cylinders is Make sure the selected engine oil meets the Ford
significantly lower than the specified value, spray specification and the recommended API performance
some engine oil into the combustion chamber and category ’’SJ/CF’’ and SAE viscosity grade as shown
repeat the compression measurement. in the vehicle’s Owner’s Manual. It is also important
If the reading greatly improves, the piston rings are that the engine oil is changed at the intervals
damaged. specified for the typical operating conditions.
G99772 en 01/2003 2003.0 BA Falcon

303-01a-15 Engine — I6 303-01a-15
Oil consumption Test 1.0 litres used for 10mm distance below the
FULL mark for the 4.0L I6 engines. For
The following diagnostic procedure is used to engines employing the alternate method of
determine the source of excessive oil consumption. marking the dipstick with levels corresponding
NOTE: Oil use is normally greater during the first to a volume difference of 1 litre, note the
15,000 km of service. As mileage increases, oil use distance the new oil level is below the Top
decreases. High speed driving, towing, high ambient scribed mark and divide this by the distance
temperature and other factors may result in greater oil between the original two scribed marks. This
use. gives the volume of oil in litres used during
1. Define excessive consumption such as the the test.
number of kilometers driven per litre of oil used. 7. Divide the distance travelled (kilometres)
Also determine customer’s driving habits, such as during the test by the amount of oil used
sustained high speed operation, towing, extended (litres) to produce the oil consumption in
idle and other considerations. kilometres per litre.
2. Verify that the engine has no external oil leaks as 8. If the oil consumption is unacceptable go to
described in the Engine Oil Leaks section. Step 9.
3. Verify that the engine has the correct oil level. 6. Check the positive crankcase ventilation (PCV)
system. Make sure the system is not plugged.
4. Verify that the engine is not being run in an
overfilled condition. Check the oil level at least 7. Check for plugged oil drain-back holes in the
five minutes after a hot shutdown with the vehicle cylinder head and cylinder block.
parked on a level surface. 8. If the condition still exists after carrying out the
5. Carry out an Oil Consumption Test: above tests go to Step 9.
1. For a 4.0L I6 engine, drain the engine oil and 9. Carry out a cylinder compression test as outlined
refill the engine. Run for 10 minutes, and in the Compression Test section. This can help
allow the engine to stand for 5 minutes to determine the source of oil consumption such as
allow the oil to drain to the crankcase. valves, piston rings or other areas.
2. Top up the oil level exactly to the full mark. 10. Check valve guides for excessive guide
Allow to stand for 5 minutes and re-check. clearance. Install new valve stem seals if
NOTE: For engines other than the 4.0L I6, required.
refill the engine with one litre less oil than 11. Worn or damaged internal engine components
specified. can cause excessive oil consumption. Small
Run the engine for 10 minutes and allow to deposits of oil on the tips of the spark plugs can
stand for 5 minutes. Clean the dipstick and be a clue to internal oil consumption.
scribe a line on the back face of the dipstick Intake Manifold Vacuum Test
blade corresponding with this level, then
reinsert. Bring the engine to normal operating temperature.
Add exactly 1 litre of oil to the engine. Run for Connect a vacuum gauge or equivalent to the intake
5 minutes and allow to stand for 5 minutes. manifold. Run the engine at the specified idle speed.
Mark the new level on the back of the The vacuum gauge should read between 51-74 kPa
dipstick. This should correspond closely to the depending upon the engine condition and the altitude
FULL mark. at which the test is carried out. Subtract 4.0 kPa from
3. Record the vehicle’s odometer reading. the specified reading for every 300m of elevation
4. Instruct the customer to drive the vehicle as above sea level.
usual and: The reading should be steady. Adjust the gauge
Check the oil level regularly at intervals of damper control (where used) if the needle is fluttering
250 km. rapidly. Adjust damper until needle moves easily
Return to the service point when the oil without excessive flutter.
level drops below the ADD mark on the oil
dipstick.
Add only full litres of the same oil in an
emergency. Note the mileage at which the
oil is added.
5. Check the oil level under the same conditions
and at the same location as in steps 1-3.
6. Measure the distance from the full mark to the
current oil level on the oil dipstick and
calculate the oil usage based on a volume of
G99772 en 01/2003 2003.0 BA Falcon

303-01a-16 Engine — I6 303-01a-16
GENERAL PROCEDURES
Cylinder Head Inspection 6. Measure the manifold contact surface distortion

as shown.
WARNING: Continuous exposure with USED
engine oil has caused skin cancer in laboratory
mice. Protect your skin by washing with soap and
water immediately after this work.
1. Conduct a dye penetrant (or similar) crack test.
Replace the cylinder head if necessary.
2. Inspect for the following and repair if necessary.
1. Sunken valve seats
2. Excessive camshaft bearing clearance and
end play
3. Excessive lash adjuster bore size
3. Measure the cylinder head for distortion. This can
be achieved by using a straight edge and feeler
gauge along the horizontal and vertically aligned Maximum distortion 0.15mm
bolt holes on the shaded surface.
7. If the distortion exceeds the specification, grind
4. Repeat the procedure along the diagonal from the the surface.
top left bolt hole to the bottom right bolt hole and
along the diagonal from the top right bolt hole to
the bottom left bolt hole. Maximum grinding 0.20mm
Valve Inspection
Inspect the following valve areas:
1. The valve tip, for pitting and wear.
2. The keeper grooves, for burns and wear.
3. The stem, for wear, scuffing and bending.
4. The valve head, for burning, cracks and pitting of
the seat.
5. The valve head thickness.
Maximum distortion 0.18mm lengthways or

0.075mm in 150mm
transversely
5. If the cylinder head distortion exceeds the
maximum, repair by grinding the joint face or
replace the cylinder head.
Maximum joint face 0.3mm

machining
Minimum surface 64.0cc
combustion chamber Item Description
volume 1 Valve tip
2 Keeper grooves
3 Stem
4 Valve head
5 Valve head thickness
G99773 en 01/2003 2003.0 BA Falcon

303-01a-17 Engine — I6 303-01a-17
Valve Measurement
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
Standard Inner 6.015 - 6.044 mm

Diameter
Maximum diameter 6.070mm
Margin thickness (min) IN: 1.1mm Valve Guide Replacement

EX: 1.1mm
Removal
2. Measure the stem diameter of each valve in X
and Y directions at the three points (A, B, and C) 1. Remove the valve guide from the combustion
shown. Replace the valve if necessary. chamber side by using a drift.
Installation
Standard Diameter (IN 5.975 - 5.995mm
and EX) 1. Install the guide using a drift so the protrusion (A)
Minimum Diameter 5.950mm is as specified.
Valve Guide Inspection

Measure the inner diameter of each valve guide in X
and Y directions at the three points (A, B, and C)
shown.
Protrusion A 13.5 - 14.1 mm
G99777 en 01/2003 2003.0 BA Falcon

303-01a-18 Engine — I6 303-01a-18
2. Ream the guide to size. 3. Measure the protruding length (L) of the valve
stem. Replace the valve or valve seat if
necessary.
Diameter 6.015 - 6.044 mm
Valve Seat Inspection/Repair

1. Measure the seat contact width. If necessary,
resurface the valve seat using a 45º valve seat
cutter and/or resurface the valve face.
NOTE: After resurfacing valves or seats, check
collapsed lash adjuster clearance.
Standard dimension L IN: 50.00

EX: 47.92
Maximum dimension L IN: 51.0
EX: 48.9
Valve Spring Inspection

1. Check the valve spring load at set length
Intake 1.0 - 1.4 mm
Exhaust 1.25 - 1.75 mm
2. Verify that the seating position is at the centre of
the valve face.
1. If the seating position is too high, correct the
valve seat using a 65º (IN) or 75º (EX) cutter,
and a 45º cutter.
2. If the seating position is too low, correct the
valve seat using a 35º cutter, and a 45º cutter.
Minimum Load 500N at 26.8 mm
G99777 en 01/2003 2003.0 BA Falcon

303-01a-19 Engine — I6 303-01a-19
2. Measure the out-of-square of the valve spring. Camshaft Inspection

Replace the valve spring if necessary.
1. Set the No.1 and No.7 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.
Maximum valve spring 1.75mm

out-of-square
Camshaft End Play Inspection Maximum runout 0.1mm
1. Remove the roller followers. Refer to section 2. Check the cam lobe for cracks and pitting. Minor
303-00 for procedure. indentations are acceptable. Replace if
necessary.
2. Use a Dial Indicator with Bracketry to measure
camshaft end play.
3. Position the camshaft to the rear of the cylinder
head.
5. Move the camshaft to the front of the cylinder
head. Note and record the camshaft end play.
1. If camshaft end play exceeds specifications,
install new camshaft and recheck end play.
2. If camshaft end play exceeds specification
after camshaft installation, install a new
cylinder head.
Standard end play 0.1 - 0.3 mm

3. Measure the journal diameter in 2 directions.
Maximum end play 0.4 mm Replace the camshaft if necessary.
Standard diameter
Journal 1 34.928 - 34.968 mm
Journal 2 - 7 29.928 - 29.968 mm
G99780 en 01/2003 2003.0 BA Falcon

303-01a-20 Engine — I6 303-01a-20
Minimum diameter
Lash Adjuster Bore Inspection
Journal 1 34.900 mm
Journal 2 - 7 1. Measure the diameter of each lash adjuster bore
29.900 mm
Camshaft Journal Clearance -

Plastigauge Method
1. Remove the camshaft bearing cap and lay the
plastigauge across the surface.
2. Reinstall the camshaft bearing cap - DO NOT
rotate the camshaft.
3. Remove the camshaft bearing cap and measure
the width of the plastigauge with the scale
provided to determine the clearance. Replace the
components as required if necessary.
Standard diameter 13.990 - 14.007 mm

2. Measure the diameter of each lash adjuster.
Standard diameter 13.972 - 13.984 mm

3. Calculate the clearance between the lash adjuster
and the related lash adjuster bore. Replace the
lash adjuster or cylinder head if necessary.
Standard clearance 0.019 - 0.084 mm

Maximum clearance 0.100 mm
Roller Follower Inspection

1. Inspect the roller for flat spots or scoring.
2. Check the ball socket and valve pad for scuffing
and wear.

Cylinder Block Inspection/Repair

Measure the distortion of the cylinder block top
surface in the two directions as shown. Repair by
grinding or replace if necessary.
G99780 en 01/2003 2003.0 BA Falcon

303-01a-21 Engine — I6 303-01a-21
Maximum cylinder block distortion Service limit 0.125 mm

Direction A 0.15 mm
Cylinder bore - Reboring sizes
Direction B 0.05 mm
Size Diameter (mm)
Maximum grinding 0.20 mm Standard 92.25 - 92.31
Minimum Piston-Deck 0.50 mm 0.5 oversize 92.75 - 92.77
Maximum Surface 13.5 1.0 oversize 93.25 - 93.27
finish Rz
Piston Inspection
Cylinder Bore - Taper Measure the outer diameter of each piston at a right
Measure the cylinder bore at the top and bottom. angle (90º) to the piston pin, 45mm below the crown.
Verify the cylinder bore is within the wear limit. The
difference indicates the cylinder bore taper. Bore the
cylinder to the next oversize.
Piston Clearance Inspection/ Repair

1. Calculate the piston-to-cylinder clearance.
Service limit 0.25 mm Replace the piston or rebore the cylinders to fit
oversize piston if necessary.
Cylinder Bore — Out-of-Round
Measure the cylinder bore in two directions. The Standard Clearance 0.020 mm interference to
difference is the out-of-round. Verify the out-of-round 0.030 mm clearance
is within the wear limit and bore the cylinder to the Service Limit 0.09 mm clearance
next oversize limit.
2. If the piston is replaced, the piston rings must also
be replaced.
G99789 en 01/2003 2003.0 BA Falcon

303-01a-22 Engine — I6 303-01a-22
Piston Ring Clearance Inspection Oil 1.0 mm
1. Measure the piston ring-to-ring land clearance Piston Pin Clearance Inspection
around the entire circumference. Replace the
piston ring if necessary. 1. Measure each piston pin hole diameter in X and Y
directions at the four points (A, B, C, and D) as
shown.
Standard Clearance
Top 0.03 - 0.075 mm
Standard Diameter
Second 0.03 - 0.075 mm
DOHC VCT & LPG 23.173 - 23.178 mm
Oil Zero
2. Measure each connecting rod small end inner
Service Limit diameter in X and Y directions as shown.
Top 0.15 mm
Second 0.15 mm
Oil 0.20 mm
2. Insert the piston ring into the cylinder by hand and
use the piston to push it to the bottom of the ring
travel.
3. Measure each piston ring end gap using a feeler
gauge. Replace the piston ring if necessary.
Standard Diameter
DOHC VCT & LPG 23.132 - 23.144 mm
Standard End Gap

Top 0.21 - 0.36 mm
Second 0.35 - 0.51 mm
Oil 0.30 - 0.90 mm
Maximum End Gap
Top 0.45 mm
Second 0.60 mm
G99789 en 01/2003 2003.0 BA Falcon

303-01a-23 Engine — I6 303-01a-23
3. Measure each piston pin diameter in X and Y 2. Measure the journal diameter in X and Y direction
directions at the four points (A, B, C, and D) as at the two points (A and B) as shown. Replace the
shown. crankshaft or grind the journal and install the
undersize bearing if necessary.
Standard Diameter
DOHC VCT & LPG 23.157 - 23.162 mm Main Journal
Bearing Diameter 67.481 - 67.505 mm
4. Calculate the piston pin to piston -pin bore
clearance. Replace the piston and/or piston pin if Out-of-round 0.010 mm
necessary Taper 0.008 mm
Crank Pin
Standard Clearance
Bearing Diameter 53.93 - 53.95 mm
DOHC VCT & LPG 0.014 - 0.019 mm
Out-of-round 0.010 mm
5. Connecting rod bush as required. Taper 0.010 mm (max)
Standard Interference Crankshaft Main Bearing Clearance

DOHC VCT & LPG 0.013 - 0.030 mm 1. Position a plastigauge on top of the journals in the
axial direction.
Crankshaft Inspection 2. Install the main bearing cap. DO NOT rotate the
1. Measure the crankshaft runout. Replace the crankshaft.
crankshaft if necessary. 3. Remove the main bearing cap.
4. Measure the main journal clearance. If the
clearance exceeds the maximum, replace the
main bearing or grind the main journal and install
the undersize bearings so that the specified
clearance is obtained.
Standard End Gap

Maximum runout - 0.05 mm
between adjacent
journals
Maximum runout - 0.08 mm
between any journals Standard Clearance 0.02 - 0.04 mm
Maximum Clearance 0.06mm
G99793 en 01/2003 2003.0 BA Falcon

303-01a-24 Engine — I6 303-01a-24
Bearing size Bearing thickness

Standard 1.996 - 2.000 mm
0.250 mm undersize 2.118 - 2.128 mm
0.508 mm undersize 2.245 - 2.255 mm
1.016 mm undersize 2.499 - 2.509 mm
Crankshaft End Play Inspection/Repair

1. Install the thrust main bearing and cap.
2. Measure the crankshaft end play. Use a dial
indicator with bracketry to measure crankshaft
end play.
3. Position the crankshaft to the rear of the cylinder
block.
Twist 0.20 mm
5. Move the crankshaft to the front of the cylinder
block. Note and record the crankshaft end play.
1. If the crankshaft end play exceeds
specifications, install a new crankshaft thrust
washer or crunkshaft thrust main bearing.
Centre-to-centre 153.78 - 153.92 mm

distance
Connecting Rod Big End Bearing

Clearance
Standard end play 0.10 - 0.20 mm 1. Position a plastigauge on top of the journals in the
Maximum end play 0.30 mm axial direction.
2. Install the connecting rod cap.
Connecting Rod Inspection 3. Remove the connecting rod cap.
1. Measure each connecting rod for bending and
twist. Replace the connecting rod if necessary.
Bending 0.10 mm
G99793 en 01/2003 2003.0 BA Falcon

303-01a-25 Engine — I6 303-01a-25
4. Measure the crankpin clearance. If the clearance

exceeds the maximum, replace the connecting
rod bearing or grind the crankpin and use
undersize bearing so that the specified clearance
is obtained.
Timing Chain Elongation

To establish the percentage elongation of the Timing
chain:
1. Hang the chain vertically over a suitable pin &
Standard Clearance 0.02 - 0.04 mm hook a weight to the free end.
Maximum Clearance 0.06mm 2. Measure the length (from pin O.D. to pin O.D)
over the maximum number of chain pins possible
Bearing size Bearing thickness using vernier callipers. Note the number of pins
Standard 1.445 - 1.458 mm measured.
0.051 mm undersize 1.471 - 1.483 mm 3. Repeat the measurement across three separate
lengths of the chain and average the results.
0.254 mm undersize 1.572 - 1.585 mm
4. Measure the O.D of one chain pin with verniers.
0.508 mm undersize 1.699 - 1.712 mm
5. Calculate the theoretical chain length =
(measured number of pins - 1) x 8.0 mm pitch +
Connecting Rod Side Clearance measured pin O.D.
Inspection 6. Compare the actual length measured with the
1. Install the connecting rod cap. theoretical length: maximum elongation
2. Measure the connecting rod big end side permissible = 0.35 %.
clearance. Alternatively measure the actual length of a new chain
(as above) and compare with the original chain and
compare as a percentage of the new chain length.

Piston and Connecting Rod Inspection

Check the oscillation torque as shown. If the large end
does not drop by its own weight, replace the piston or
the piston pin.
G99799 en 01/2003 2003.0 BA Falcon

303-01a-26 Engine — I6 303-01a-26
IN-VEHICLE REPAIR
Oil Filter 3. With the tube reinstalled in the block, ensure the
O-ring is fully seated in the block counterbore.
Removal
1. Unscrew filter using a filter wrench.
Installation
1. Install as indicated.
2. Lubricate the seal with engine oil prior to
installation.
Cylinder Head Temperature Sensor

1. The cylinder head tapped hole is blind.
2. Do not use thread sealant/locker.
Oil Level Indicator & Tube

Removal
1. Remove the Oil Level indicator from the Oil Level
Tube.
2. Unscrew retaining bolt.
3. Remove Oil Level Tube.
Cam Position Sensor

1. Check the condition of the O-ring prior to
installation.
2. Lubricate the O-ring with engine oil prior to
installation.
Installation
1. Inspect the O-ring at the base of the tube for
damage and renew if necessary. Lubricate with
engine oil prior to reinstallation of the tube.
2. Insert the Oil Level Tube and secure with
retaining screw.
G99801 en 01/2003 2003.0 BA Falcon

303-01a-27 Engine — I6 303-01a-27
IN-VEHICLE REPAIR (Continued)
Crankshaft Position Sensor Combustion Knock Sensor

Removal and Installation Removal and Installation
1. Check the condition of the O-ring prior to 1. When re-installing the Knock sensor, coat the
installation. threads with Loctite 242 (or similar) thread locker.
2. Lubricate the O-ring with engine oil prior to
installation.
Exhaust Gas Oxygen Sensor

Oil Pressure & Oil Temperature Sensor
1. Coat the threads with a Nickel Anti- Seize
Removal and Installation compound (Loctite 767 or similar) per
1. When re-installing the original sensor, coat the ESE-FM99C100-A.
threads with Loctite 567 (or similar) thread
sealant. New replacement sensors are
pre-coated.
Temperature - Manifold Air Pressure

Sensor
1. Remove the Electronic Throttle Body (ETB) to
gain access to the attachment screw.
2. Inspect the condition of the O-ring prior to
installation.
G99806 en 01/2003 2003.0 BA Falcon

303-01a-28 Engine — I6 303-01a-28
3. When re-installing the ETB, coat the threads with

Loctite 242 (or similar) thread locker.
Crankshaft Front Oil Seal
Removal
1. Disconnect the battery.
2. Remove the radiator cooling fan assembly.
3. Remove the radiator.
4. Remove the front end accessory drive belt.
5. Remove the Crankshaft Vibration Damper.
6. Protect the crankshaft with a piece of soft metal or
plastic, and use a screwdriver to lever out the oil
seal.
Crankshaft Vibration Damper

Removal
1. Remove the Retaining Bolt.
2. Use SST 303-642 to remove the damper.
3. Remove key.
Item Description
1 Screwdriver (flathead)
2 Crankshaft Front Oil Seal
3 Soft Metal or Plastic (shim)
Installation
1. Clean the front cover recess and tap in the seal
until it is fully seated.
2. Lubricate the lip of the seal with engine oil.
Installation
1. Apply sealer in the keyway as shown.
2. Lubricate the seal rubbing area with engine oil.
3. Use SST 303-642 to install the damper.
4. Inspect key for damage. Replace if necessary.
3. Install the Crankshaft Vibration Damper.
Crankshaft Rear Oil Seal

Removal
1. Remove the transmission. Refer to section
307-01A (Auto trans) or 308-03A/B (Man trans).
G99806 en 01/2003 2003.0 BA Falcon

303-01a-29 Engine — I6 303-01a-29
2. Remove the flywheel. Refer to Section 307-01A Clutch Pilot Bearing

(Auto trans) or 308-01 (Man trans).
NOTE: Other potential sources of oil leak should Removal and Installation
be eliminated prior to replacing the seal. 1. Use a suitable tool to remove the pilot bearing
3. Insert a suitable brass strip between the seal and and adaptor from the flywheel. The back of the
the crankshaft to protect the crankshaft seal adaptor is notched to facilitate removal.
surface. 2. Install the new adaptor and bearing into the
4. Insert a screwdriver between the seal and the flywheel until the adaptor bottoms out. Do not
protection strip and lever out the seal. change the location of the bearing in the adaptor.
Installation
Water Pump
1. Clean the seal recess in the block.
2. Oil the lip of the seal and the shaft. Removal
3. Install the seal evenly using the SST E9312. 1. Remove the radiator cooling fan assembly. Refer
to Section 303-03A.
2. Remove the front end accessory drive belt. Refer
to Section 303-05.
3. Remove the water pump pulley. Refer to Section
303-05.
4. Remove the alternator and brace. Refer to
Section 303-04.
5. Remove the radiator lower hose (and coolant).
Refer to Section 303-03A.
Flywheel/Drive Plate/Clutch Pilot

Bearing
1. Remove the transmission. Refer to section
307-01A (Auto trans) or 308-03A/B (Man trans).
2. Remove the clutch pressure and friction plates.
3. Remove the flywheel/drive plate. Refer to Section
308-01. Item Description
4. Remove the clutch pilot bearing. Refer to Section 1 Water Pump
308-01. 2 Bolt (x4)
3 Alternator Brace
G99813 en 01/2003 2003.0 BA Falcon

303-01a-30 Engine — I6 303-01a-30
NOTE: Weeping and staining of coolant from the body 2. Remove the ETB.
drain hole is normal and permitted. When the water
pump is suspected of leaking, this should be
confirmed with a cooling system pressure test.
NOTE: The pump is a sealed unit, and should be
replaced complete if faulty.
Installation
To install, reverse the removal procedure.
1. Check the condition of the heater pipe recess in
the rear of the water pump.
2. Check the condition of the O-ring on the end of
the heater pipe and renew if damaged.
3. Lubricate the O-ring to assist assembly.
Item Description
1 Gasket - Throttle body
2 Throttle body
3 M6 screw (x4)
4 Support bracket
3. Disconnect the brake booster vacuum hose, fuel
pressure regulator hose from the manifold.
Electronic Throttle Body and Intake

Manifold
Removal
1. Remove the air duct assembly.
4. Remove the 2 upper manifold to cylinder head

braces.
Item Description
1 Air Duct
2 Retaining Bolt
G99813 en 01/2003 2003.0 BA Falcon

303-01a-31 Engine — I6 303-01a-31
5. Remove the upper intake manifold. 8. Disconnect the main gallery oil pressure and
temperature switch, knock sensor and crank
timing sensor.
Item Description
1 Intake Manifold - Upper 9. Remove the lower intake manifold.
2 M8 screws (x14)
3 Gasket - Intake manifold upper
6. Remove the 3 lower manifold to cylinder block
braces.
Item Description
1 Fuel rail
2 Support bracket
3 Knock sensor
7. Remove the fuel rail and injectors as an 4 M8 Bolts
assembly.
NOTE: The Electronic Throttle Body is a non
adjustable item. For fault finding see Section 303-14.
Installation
When re-installing the Upper intake manifold to Lower
intake manifold bolts, coat the threads with Loctite
242 (or similar) thread locker.
When reinstalling the Lower intake manifold bolts to
the cylinder head, coat the threads with Loctite 242
(or similar) thread locker.
The gaskets sealing the Upper to Lower Manifold and
the Lower Manifold to the head should not be re-used.
When reinstalling the ETB to the intake manifold, use
a new gasket and new bolts or apply Loctite 242 (or
similar) thread locker to the threads.
Torque the M6 bolts to 8-12Nm.
The Broadband throttle shaft Vacuum motor closed
position stop is set in the factory and should not be
touched, unless the vacuum motor or Broadband
G99816 en 01/2003 2003.0 BA Falcon

303-01a-32 Engine — I6 303-01a-32
throttle shaft are serviced, in which case the setting 3. Screw in the set screw 1-1.5 turns clockwise so
must be adjusted as described below. the screw now contacts the stop and the
Broadband Throttle Plates are cracked open.
Broadband Throttle Plate
Removal
1. Unscrew the retaining bolts.
2. Remove Broadband Throttle Plates.
Item Description
1 Screws
2 Activator - Throttle control
3 Throttle lever
Installation 4 Clip
1. Insert plates with tabs facing upwards and to the
screw head side. Exhaust Manifold Assembly
2. Loosely install the plate retaining screws.
3. Rotate the shaft so the plates are closed and Removal
snap the plates shut a few times to centralize 1. Remove the heat shield by unscrewing the
them in their bores. There must be no gap retaining bolts.
between the plates and their bores.
4. Apply Loctite 242 (or similar) thread locker to the
threads and tighten the plate retaining screws to
specification.
Broadband Throttle Shaft Vacuum

Motor
Removal
1. When disconnecting the vacuum motor from
throttle shaft level, remove retaining clip first.
2. Do not adjust the set screw on the throttle shaft
lever. If adjustment is necessary, or of a new
vacuum motor is fitted, reset screw by the
following procedure.
Installation
1. Apply a 40kPa vacuum to the motor or apply light
finger pressure to push the lever in a clockwise
direction against the stop.
2. Maintaining the pressure on the lever, unscrew
the set screw until there is a 0.05mm gap
between the screw and the stop.
G99816 en 01/2003 2003.0 BA Falcon

303-01a-33 Engine — I6 303-01a-33
2. Disassemble the items in the following order. 4. Loosely assemble and finally torque when fitted ti
engine.
Item Description
Item Description
1 Catalytic Converter Inlet Pipe
1 Exhaust Manifold - Rear
2 Lifting Eye
2 Gasket
3 Retaining Bolt
3 M8 - Nut
4 Heated Exhaust Gas Oxygen (HEGO)
Sensor 4 Exhaust Manifold - Front
5 Exhaust Manifold Assembly
Oil Control Valve Seal
Installation
1. Fit 2 M10 x 1.5 bolts with heads removed as Removal
guide pins. 1. Check metal garter band is still in place on the
2. Fit gasket and loosely assembled manifold onto seal.
guide pins. Refer to Exhaust Manifold - Front and
Rear section.
3. Install lower manifold to head bolts, and nip up
the bolts.
4. Remove guide pins, install remainder of bolts
excluding those used to attach the heat shield.
5. Tighten the bolts progressively to specification.
6. Tighten the front to rear manifold joint nuts to
specification.
7. Lubricate the HEGO sensor thread with Loctite
767 (or similar) anti-seize compound per
ESE-FM99C100-A.
Exhaust Manifold - Front and Rear

Item Description
Removal 1 Plate - Gasket valve rocker arm cover
1. Remove the three nuts from the studs. 2 Bolt
NOTE: If the studs screw out of the Rear Exhaust
Manifold, simply refit the studs using two suitable Installation
nuts locked together. 1. After tightening the Valve Cover retaining bolts,
Installation insert the Oil Control Valve seals into the Valve
Cover without displacing the metal garter band,
1. Clean all mating surfaces. and tighten the seal retaining bolts.
2. Fit a new front to rear manifold sealing ring.
3. Apply anti-seize compound to the manifold joint
nut threads.
G99821 en 01/2003 2003.0 BA Falcon

303-01a-34 Engine — I6 303-01a-34
Valve Cover 4. Remove the Spark Plug Cover.
Removal
Item Description
1 Bolt & Washer
2 Cap - Oil filler
Item Description 3 PCV valve
1 Intake duct 4 M5 screw
2 Screw 5 Clip-air line
2. Remove the Electronic Throttle Body (ETB) as per 6 Spark plug cover
procedure.
5. Remove the Ignition Coils.
Item Description
1 Gasket - Throttle body
2 Throttle body
3 Screw
4 Bracket
3. Remove the oil filler cap, PCV valve, brake and
PCV hoses.
G99821 en 01/2003 2003.0 BA Falcon

303-01a-35 Engine — I6 303-01a-35
6. Remove the Oil control valve seals retaining bolts. 8. Slide the valve cover backwards 20-30mm, then
Check metal garter band is still in place on the lift the front to clear the oil control valves, and
seal. then slide the cover forwards, raising the rear to
clear the camshafts and dash panel.
Item Description
1 Plate - Gasket valve rocker arm cover
2 Bolt
7. Remove valve cover retaining bolts (8).
Item Description
1 Bolt and washer
2 Bolt and washer
3 Valve cover
Installation
1. Clean the cover including PCV and fresh air
chambers, and seal grooves. Fit new seals.
G99821 en 01/2003 2003.0 BA Falcon

303-01a-36 Engine — I6 303-01a-36
2. Apply sealer WSS-M4G323 A7 in 2 places on the 2. Remove the Electronic Throttle Body (ETB).
Valve Cover to cylinder head/front cover joints as
shown, refit the cover, check the peripheral seal is
not displaced out of the groove using a mirror for
the rear of the engine.
3. When re-installing the six short bolts which retain
the Valve Cover to the cylinder head assembly,
coat the threads with Loctite 242 (or similar)
thread locker. 4. Check the Oil Control Valve
Seals, replace if necessary and refit after the
Valve Cover is tightened down.
Item Description
1 Gasket
2 Electronic Throttle Body
3 Bolt
4 Bracket
3. Remove the oil filler cap, PCV valve, brake and
PCV hoses.
4. Remove the Spark Plug Cover.
Ignition Coils/Wiring Loom
Removal
Item Description
1 Bolt
2 Oil filler cap
3 PCV valve
Item Description
4 Screw
1 Air intake tube assembly
5 Vacuum hose clip
2 Bolt
6 Spark plug cover
G99821 en 01/2003 2003.0 BA Falcon

303-01a-37 Engine — I6 303-01a-37
Installation 2. Refit the ignition coils and reconnect the wiring

1. Every time the Ignition Coils are removed, apply 2 loom to the coils & oil control valves.
grams of synthetic grease ESF-M1C229-A NOTE: The short lead is attached to the intake oil
(Dupont Krytox) using a suitable applicator (cotton control valve and the long lead is connected to
bud) to the inside of the tapered section of the coil the exhaust oil control valve.
boot, smearing it evenly over the surface.
3. Ensure all of the wiring is clear of the Spark Plug
Cover seal surfaces, and that the wiring does not
obstruct any hardware mounting points.
4. Ensure that the wiring is located correctly in the
grooves in the Valve Cover where it exits the
Spark Plug Cover when refitting the Spark Plug
Cover.
Camshafts, VCT Phaser, Oil Control

Valves, & OCV Filters
G99824 en 01/2003 2003.0 BA Falcon

303-01a-38 Engine — I6 303-01a-38
Item Description
1 VCT Oil Control Valve
2 Camshaft Bearing caps
3 Camshaft - Intake
4 Chain Guide
5 Variable Cam Timing ( VCT) unit
6 Camshaft - exhaust
7 Filter- VCT Oil Control Valve
Camshaft Removal
Removal
Remove valve cover. Refer to section 303-01. 3. Release the timing chain tension by compressing
the tensioner using SST 303-777. Refer to section
Camshaft and VCT Phasers 303-01.
Special Tool(s)
Timing chain tensioner special
service tool
Camshaft holding tool
4. Fit the SST 303-778 to the camshafts in the

central position between the caps and tighten to
prevent rotation.
1. Rotate the crankshaft so the VCT timing marks
(on the sprocket) are vertically upwards and the
crankshaft at Top Dead Centre.
2. Mark the two timing chain links above the timing
marks with a marker pen.
NOTE: The yellow and orange coloured links
used for original assembly, and assembly with the
front cover removed, are only synchronized with
the timing marks once every 38 crankshaft
revolutions, and should be ignored when working
with the front cover in place (unless
synchronized).
5. Loosen the bolt attaching the VCT units to the

camshafts.
G99824 en 01/2003 2003.0 BA Falcon

303-01a-39 Engine — I6 303-01a-39
6. Do not use the chain to prevent rotation when 7. Whilst holding the VCT phaser and timing chain,
loosening the central bolt as this load will be slide the VCT phaser forward off the camshafts
transmitted through the locked phaser mechanism and rest on top of the timing cover.
and could cause damage. NOTE: Do not remove the timing chain from the
VCT phasers.
8. Remove the tool.
9. Loosen the camshaft cap bolts 2 turns at a time in

the order shown below.
G99826 en 01/2003 2003.0 BA Falcon

303-01a-40 Engine — I6 303-01a-40
10. Remove camshaft caps. 3. Fit the respective Intake and Exhaust camshafts
11. Remove inlet & exhaust camshaft. with the timing pin positioned vertically upwards.
Take care not to damage the thrust surfaces on
Camshaft Installation journal #2.
Installation
1. Check the camshaft journal clearance.
2. Lubricate the head-cam bearing surfaces with
engine oil.
4. Check for burrs and damage on the cap-to-head

joints and the cam-to-VCT phaser joint. Tighten
bolts 2 turns at a time in the same order shown in
the removal section.
NOTE: The cam-cap oil passage must be
absolutely clean.
NOTE: Use the following illustration to identify the
Exhaust and Inlet camshafts. 5. Rotate the crankshaft so the VCT timing marks
(on the sprocket) are vertically upwards and the
crankshaft at Top Dead Centre.
6. Align the marked the two timing chain links with
the VCT timing marks sprocket.
NOTE: The yellow and orange coloured links
used for original assembly, and assembly with the
front cover removed, are only synchronized with
the timing marks once every 38 crankshaft
revolutions, and should be ignored when working
with the front cover in place (unless
synchronized).
Item Description
1 Exhaust
2 Inlet
NOTE: If a camshaft timing error is suspected, and it

is necessary to check the basic cam timing using the
valve lift loss method, then the cams must be fully
advanced and both VCT Phaser locking pins
engaged.
G99826 en 01/2003 2003.0 BA Falcon

303-01a-41 Engine — I6 303-01a-41
7. Check that the cams are fully advanced and the 1. Release the timing chain tension by compressing
locking pins engaged by gripping each camshaft the tensioner. Refer this section.
between the journals numbers 4 & 5 with a
suitable wrench using soft protective pads, and
attempt to rotate the camshaft backwards and
forwards relative to the VCT Phaser.
8. Establish the point of maximum lift on a No. 1
cylinder intake cam lobe by determining the
positions where the lift is reduced by 0.25 mm
either side of maximum lift. Note the crankshaft
angles while rotating the crankshaft in a clockwise
direction only.
9. Average the two crankshaft angles to give the
point of maximum lift.
10. Repeat this procedure for the No.1 cylinder
exhaust cam lobe.
11. Check the piston TDC in a similar way by fitting
an adaptor in the spark plug hole in cylinder No. 1 VCT Phaser
with an adjustable length pin protruding into the
cylinder so that it just prevents the piston from Special Tool(s)
reaching TDC. Lock the adjustment using a Camshaft holding tool
suitable locknut. 303-778
12. Rotate the engine clockwise until the piston
touches the pin and noting the crankshaft angle,
and then rotating it anti-clockwise, and again note
the angle.
13. Average the two crankshaft angles to give TDC,
and compare it to the timing mark on the
Removal
Crankshaft Vibration Damper to ensure that the
Damper outside element has not rotated. If there 1. Remove valve cover. Refer to Valve Cover in this
is a significant discrepancy, replace the Damper. section.
Refer to Crankshaft Vibration Damper in this 2. Fit the SST 303-778 to the camshafts in the
section. central position between caps and tighten to
prevent rotation.
Standard Intake Cam Maximum lift @ 97.5°
Timing ATDC
Standard Exhaust Cam Maximum lift @ 126.5°
Timing BTDC
Timing Chain Tensioner

Special Tool(s)
Timing chain tensioner special
service tool
303-777
3. Loosen the bolt attaching the VCT units to the

camshafts.
G99828 en 01/2003 2003.0 BA Falcon

303-01a-42 Engine — I6 303-01a-42
4. Do not use the chain to prevent rotation when 3. The filters and cam cap oil passages must be
loosening the central bolt as this load will be absolutely clean.
transmitted through the locked phaser mechanism
and could cause damage.
Rocker Arm, Lash Adjuster, Valve

5. Whilst holding the VCT phaser and timing chain, Spring and Valve Stem Seal
slide the VCT phaser forward off the camshafts
and rest on top of the timing cover. 1. Disassemble in the order indicated in the table.
NOTE: Do not remove the timing chain from the
VCT phasers.
6. Remove the tool.
Installation
2. The oil control valves & cam cap bores must be
absolutely clean.
Item Description
1 Cam follower
2 Lash adjuster retaining clip
3 Lash adjuster
4 Valve spring retainers
5 Valve spring retainer keys
G99828 en 01/2003 2003.0 BA Falcon

303-01a-43 Engine — I6 303-01a-43
Item Description 2. Remove the keys, retainers and valve spring

6 Valve spring using a suitable valve spring compressor.
7 Valve stem seal
Rocker Arm and Lash Adjuster

The rocker arm and lash adjuster are clipped together
to prevent rocker displacement under extraordinary
start up conditions.
Care should be taken when removing the assembly,
so as not to strain the clip.
Do not remove the clip unless either the rocker arm or
lash adjuster are to be replaced and fit a new clip.
If the clip is loose on the rocker arm it should be
replaced when the rocker and lash adjuster assembly
is removed from the cylinder head. 3. Remove the valve stem seal/spring seat assembly
Removal with pliers or multi-grips, being careful not to mark
1. Remove the camshaft. Refer to Camshaft in this the valve stem.
section. Installation
2. Disengage the rocker arm from the valve tip. 1. Pressurise the cylinder via an air line and adaptor.
3. The rocker arm & lash adjuster assembly can be Do not exceed 800 KPa.
raised and the lash adjuster removed from the 2. Use an 18mm inside diameter tube to gently seat
cylinder head. the valve stem seal.
Installation 3. Reassemble in the reverse order to the procedure
1. To install, reverse the removal procedure. above.
NOTE: The valve spring must be fitted with the
Valve spring and Valve Stem Seal smaller diameter end upwards.
Removal
1. Remove the appropriate spark plug, and
pressurise the cylinder via an air line and adaptor.
DO NOT exceed 800 KPa.
G99833 en 01/2003 2003.0 BA Falcon

303-01a-44 Engine — I6 303-01a-44
Front Cover
Item Description 9. Remove the two bolts and hollow dowels locating
cover to block.
1 Idle pulley
10. Remove the four oil pan to cover bolts.
2 Front cover
11. Remove all the cover to cylinder block bolts.
3 Gasket front cover
12. Remove the Front cover.
4 Crankshaft sensor
13. Raise cover before moving forward to avoid
5 Drive belt tensioner assembly damage to oil pan seal.
6 Crankshaft vibration damper
7 Dowel front cover location
8 Bolt - Front cover
Removal
2. Remove the radiator cooling fan assembly. Refer
to Section 303-03A.
4. Remove the valve cover.
5. Remove the front-end accessory drive
components (except A/C compressor), alternator
bracket and power steering pump.
6. Remove the water pump. Inspection
7. Remove the crankshaft vibration damper.
1. Remove any sealant from the oil pan to
8. Disconnect the crankshaft sensor wiring block/front cover joints and the front cover to
connector. cylinder head/rocker cover joints.
G99834 en 01/2003 2003.0 BA Falcon

303-01a-45 Engine — I6 303-01a-45
2. Check the condition of the oil pan, front cover to 4. Place the front cover against the cylinder block,
block and crankshaft rotary seals and replace if sitting on the uncompressed oil pan seal.
required. 5. Place two cross head type screwdrivers or similar
3. Ensure the joint surfaces are clean and free of oil. through two bolt holes in the front cover and into
Installation the cylinder block and lever the front cover down
into position.
1. Apply a small bead of sealant meeting Ford
specification WSS M4G323 A7 to the oil pan to 6. Fit the two lower dowels into the front cover and
block to front cover joint in 2 places as shown. into the cylinder block. Check the peripheral seals
are not displaced out of the grooves.
2. Apply a small bead of sealant WSS M4G323 A7

to the front face joint between the cylinder head Item Description
and cylinder block in 2 places as shown.
1 Bolt
2 Front cover
3 Dowel
4 Dowel
3. Apply a small bead of sealant WSS M4G323 A7

to the rocker cover to head to front cover joint in 2
places as shown.
G99834 en 01/2003 2003.0 BA Falcon

303-01a-46 Engine — I6 303-01a-46
Camshaft Drive
Item Description 6. Remove the fixed chain guide.

1 Front cover 7. Remove the chain guide (top run).
2 Gasket - Front cover
Timing Chain Tensioner Release
3 Tensioner assembly timing chain
4 Timing chain guide tension Special Tool(s)
5 Timing chain guide fixed Timing chain tensioner special
6 Timing chain service tool
7 Crankshaft tone wheel 303-777
8 Crankshaft sensor
9 Front seal
10 Crankshaft vibration damper
Removal Removal
1. Remove the front cover. 1. Rotate Lever A anti clockwise by engaging pin of
2. Remove the tensioner. SST 303-777 into hole in lever.
3. Remove the timing chain. 2. Push in plunger until 3-4mm is visible.
4. Remove the crank sprocket/timing wheel. 3. Release load from Lever A so ratchet teeth
5. Remove the moving chain guide. engage with 1st teeth on plunger.
G99834 en 01/2003 2003.0 BA Falcon

303-01a-47 Engine — I6 303-01a-47
4. Push in plunger slightly so hole in A aligns with 2. Align yellow link at 6 o’clock with its position
hole C and is locked with SST. indicator. Align orange link at 1 o’clock with the
timing indicator on tone wheel. The orange link
should be half visible within the tone wheel cut
away hole.
Installation
1. Set the crankshaft position to Top Dead Centre:
Cylinder #1 Firing (both VCT phaser timing marks
vertically upwards). Item Description
1 Yellow link
2 Yellow link position indicator
3 Timing indent on tone wheel
4 Orange link
3. Remove the SST 303-777 to release the
tensioner.
4. Rotate crankshaft back and forwards to check that
the slack is removed from chain.
5. Reverse removal procedure for camshaft drive
components.
Cylinder Head
Item Description Removal
1 Yellow links 1. Remove the radiator cooling fan assembly.
2 Timing dot on VCT 2. Remove the radiator.
3. Remove the valve cover. Refer to Valve Cover in
this section.
4. Remove front cover. Refer to Front Cover in this
section.
5. Remove timing chain.
6. Remove camshafts. Refer to Camshaft in this
section.
7. Remove intake manifold. Refer to Throttle Body
and Intake Manifold in this section.
8. Remove exhaust manifold. Refer to Exhaust
Manifold in this section.
G99837 en 01/2003 2003.0 BA Falcon

303-01a-48 Engine — I6 303-01a-48
9. Disconnect the Cylinder Head Temperature 8. Rotate bolts 90º ± 5º in the sequence shown.
(CHT), and two Camshaft position sensors from
rear of cylinder head.
Engine
10. Loosen the cylinder head bolts in the sequence
shown. Removal
1. Disconnect Hood struts and securely tie back
Engine Hood, or remove bonnet.
2. Disconnect battery leads and remove battery
cover and battery. Refer to section 414-01.
3. Remove engine accessory drive belt. Refer to
section 303-05.
4. Remove Power steering pump to engine
attachment bolts.
Installation
1. Ensure all joint surfaces are clean and free of oil
and grease.
NOTE: A new cylinder head gasket must be used.
2. Lightly lubricate the bolt threads and washer
surfaces with engine oil.
3. Tighten the cylinder head bolts in the sequence
shown.
4. Rundown all bolts to 30 Nm. Item Description
5. Retighten in sequence to 90º. 1 Reservoir and Pump
6. Back off all bolts by approx. 1 turn each. 2 Bolts
7. Tighten all bolts to 40Nm in sequence. 3 Bolts
NOTE: Leave hoses attached and locate pump clear
of engine.
5. Remove Air Cleaner assembly and induction
tubes. Refer to section 303-12.
6. Drain engine coolant at radiator tap.
7. Remove the radiator cooling fan assembly. Refer
to section 303-03a.
8. Remove the radiator assembly. Refer to section
303-03a.
G99837 en 01/2003 2003.0 BA Falcon

303-01a-49 Engine — I6 303-01a-49
9. Remove air conditioning compressor to engine 13. Disconnect vacuum hoses from intake manifold.
attachment bolts.
14. Disconnect Fuel lines at filter feed pipe under left

NOTE: Leave compressor hoses attached and locate hand side of firewall.
pump clear of engine.
10. Remove PCM module. Refer to section 303-14.
11. Disconnect the engine loom wiring plugs from the
underside of PCM.
Item Description
1 Fuel Tube Return
2 Fuel Vapor Hose
3 Fuel Tank to Vapor Hose
Item Description
4 Rear Brake Lines
1 PCM Module
5 Fuel Tube Return
2 Engine electrical connectors
15. Disconnect Heater hoses from rear of manifold
12. Disconnect transmission wiring plugs. Refer to
section 307-01.
G99830 en 01/2003 2003.0 BA Falcon

303-01a-50 Engine — I6 303-01a-50
16. Remove Hego sensor electrical connector. 23. Connect suitable engine lifter to the lift brackets
supplied and carefully remove engine assembly.
17. Remove the transmission front dust cover.

Installation
18. Remove the Converter to drive plate bolts (4)
(Automatic Trans Vehicles Only). Refer to section 1. For installation of the engine reverse the removal
307-01. procedure.
19. Remove starter motor. Refer to section 303-06.
Engine Mounting
20. Remove Transmission to engine bolts (4). Refer
to section 307-01. 1. Mount the engine on an engine rollover stand.
21. Disconnect Exhaust at engine pipe flange to
manifold. WARNING: Self-locking brake system of
the engine stand may not be effective when
the engine is held in an unbalanced position.
This could lead to sudden, rapid movement of
the engine and mounting stand handle and
cause serious injury. Never keep the engine in
an unbalanced position, and always hold the
rotating handle firmly when turning the
engine.
Engine Oil Pan

Removal
1. Remove the main bearing cross bolts.
NOTE: There are 5 main bearing cross bolts on
the right hand side and 4 on the left hand side of
22. Remove front engine mount Through bolts. the oil pan.
G99830 en 01/2003 2003.0 BA Falcon

303-01a-51 Engine — I6 303-01a-51
2. Remove the oil pan flange bolts. 4. Apply a bead of sealant Loctite 5900 (or similar)
NOTE: The 24 oil pan flange bolts are slightly at the front cover to block joint (2 places), and the
longer than the bearing cross bolts. Store them rear main bearing cap to block joint (2 places).
separately when removed.
NOTE: Only 12 right hand side pan flange bolts
are shown. There are a further 12 on left hand
side.
3. Remove the oil pan.

4. Remove the oil pan seal.
5. Align the rear face of the oil pan with the rear face
of the block when tightening the oil pan flange
bolts.
6. Coat the main bearing cross bolt threads with
Loctite 567 (or similar) thread sealant.
Installation
1. Clean all the joint surfaces.
2. Check the oil pan baffle plates for cracks and
loose rivets.
3. Fit a new seal.
7. Install oil pan flange bolts to specified torque.
Oil Pump Pickup Tube

Removal
1. Remove the oil pump. Refer to Oil Pump in this
section.
G99840 en 01/2003 2003.0 BA Falcon

303-01a-52 Engine — I6 303-01a-52
2. Remove the oil pump pickup tube. 1. Remove the pickup tube mounting bracket nut
3. Remove the pickup tube attachment bolts to oil (attached to main bearing bolt stud).
pump. 2. Remove the oil pump to block mounting bolts.
Installation 3. Remove the Front Cover. Refer to Front Cover in
1. Inspect the intake flanges on the oil pump and this section.
pickup tube for signs of damage. 4. Remove the engine oil pan. Refer to Engine Oil
2. Fit a new O-ring to this joint Pan in this section.
3. Tighten the pickup tube to oil pump bolts and 5. Remove the oil pump pickup tube.
check that the mounting bracket is sitting lightly 6. Remove the oil pump.
on the head of the main bearing bolt, or just clear NOTE: The oil pump is a non-repairable item and
by up to 1mm, before fitting the nut. should be replaced if damaged.
NOTE: Heavy bearing, or a large gap could cause
Installation
an air leak and should be corrected by adjusting
the bracket. 1. Engage the drive flats in the oil pump rotor bore
with the two flats on the crankshaft.
Oil pump 2. Gently push the oil pump into position against the
cylinder block.
Removal NOTE: Rotating the oil pump body and gently
rocking it fore and aft will assist assembly.
3. DO NOT use force.
Piston and Rod Assembly

Removal
Place the engine on a rollover stand and invert before
performing this procedure.
1. Remove the main bearing bolts.
2. Remove the windage baffle.
3. Remove the main bearing caps and lower main
bearings.
4. Rotate the crankshaft to Bottom Dead Centre on
the respective cylinders to improve access to the
connecting rod bolts.
5. Fit Connecting rod bolt protectors prior to
disengaging the connecting rod from the
crankshaft.
Item Description
1 Nut
2 Bolt
3 Oil pump
4 Pickup tube
5 Bolt
G99840 en 01/2003 2003.0 BA Falcon

303-01a-53 Engine — I6 303-01a-53
Installation
1. Use bolt protectors when installing the assembly.
NOTE: Ensure new connecting rod bolts have
been fitted, as the ’Torque to Yield’ bolts are not
reusable.
2. Ensure the cap and the connecting rod carry the

same cylinder number marking on the same side
of the rod.
3. Tighten each pair of bolts to 25Nm, then a further
90 degrees.
Item Description
1 Main bearing bolts
2 Windage baffle
3 Main bearing caps
4 Lower main crankshaft bearings
5 Crankshaft
6 Upper main crankshaft bearings
Main bearings/Crankshaft
Place the engine on a rollover stand and invert before
performing this procedure.
Removal
1. Remove the main bearing bolts.
2. Remove the windage baffle.
3. Remove the main bearing caps and lower main
bearings.
4. Remove the connecting rod caps, upper and
lower connecting rod bearings, and piston & rod
assemblies. Refer to Piston and Rod Assembly in
this section.
5. Remove the crankshaft. Item Description
6. Remove the upper main bearings. 1 Upper main crankshaft thrust bearing
2 Upper main crankshaft bearings
3 Crankshaft
G99841 en 01/2003 2003.0 BA Falcon

303-01a-54 Engine — I6 303-01a-54
Item Description 3. Ensure the notch on the piston is facing the front
4 Pivot bearing (Manual transmission only) of the engine, the valve cut-outs are on the
exhaust side, and the connecting rod oil squirt
Installation hole is on the exhaust side of the engine.
1. For installation reverse the removal procedure.
Rear Main Bearing Cap Assembly

1. Apply silicone sealant Loctite 5900 (or a sealant
which meets the Ford specification
WSS-M4G323-A7) to the rear main bearing cap to
block joint as shown.
2. Fit the rear main bearing cap and tighten within 5
minutes of application of the sealant.
3. Reverse the removal procedure.
Piston Ring
Installation
1. Verify the second piston ring is installed with the
dot upwards.
2. Position the end gaps of the piston rings as
shown.
G99841 en 01/2003 2003.0 BA Falcon

303-01a-55 Engine — I6 303-01a-55
2. Ensure the cylinder head joint face is free from

Key Retainer — Valve Spring scratches and nicks in the sealing areas around
Disassembly the cylinder bore and oil and waterways.
1. Remove the keys using a valve spring 3. Lubricate the valve guides with engine oil.
compressor.
2. Remove the valve spring retainer.
3. Remove the valve spring.
4. Remove the valve stem seal.
4. Fit new seals using an 18 mm inside diameter

drift.
Item Description
1 Key - Valve spring retainer
2 Valve spring retainer
3 Valve spring
4 Valve stem seal
Assembly
1. To assemble Reverse the disassemble procedure.
NOTE: The LPG intake valve is identified with an
"L" forged into the combustion chamber face.
Valve Stem Seal

Disassembly
1. Remove the seal using a pair of pliers.
Assembly
1. Ensure the cylinder head is clean.
G99849 en 01/2003 2003.0 BA Falcon

303-01a-56 Engine — I6 303-01a-56
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Piston and Connecting Rod Assembly Piston and Connecting Rod

Assembly
Assembly
1. Use SST 303-D034 to remove and install the
piston from the connecting rod assembly.
NOTE: Do not separate the piston and rod unless
the rod, pin or piston is to be replaced.
Item Description
1 Compression ring upper
2 Compression ring lower
3 Oil rings
4 Piston
5 Connecting rod
Connecting Rod Bolt
6 Connecting rod bolt The connecting rod bolts are permanently stretched
7 Connecting rod cap each time they are tightened and should only be used
once.
8 Connecting rod nut
Replace the connecting rod bolts prior to rebuilding
9 Gudgeon Pin the engine. The old bolts can be used to establish
bearing clearances. The correct level bolts are
marked WR/AB.
G99850 en 01/2003 2003.0 BA Falcon

303-01a-57 Engine — I6 303-01a-57
Item Description
1 WR/AA marking
2 Straight knurl
3 Diamond knurl
4 Pilot point
G99852 en 01/2003 2003.0 BA Falcon

303-01b-1 Engine — 5.4L (3V) 303-01b-1
SECTION : 303-01b Engine — 5.4L (3V)

CONTENTS PAGE
SPECIFICATIONS
Engine ..................................................................................................................................303-01b-6
Engine ..................................................................................................................................303-01b-8
IN-VEHICLE REPAIRS
Intake Manifold Upper ..........................................................................................................303-01b-9
Valve Cover LH and RH (shown) .......................................................................................303-01b-10
Crankshaft Pulley ..............................................................................................................303-01b-13
Crankshaft Front Oil Seal .................................................................................................303-01b-14
Engine Front Cover ...........................................................................................................303-01b-15
Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings ........303-01b-19
Camshaft (LH shown, RH opposite hand) ........................................................................303-01b-30
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01b-38
Valve Spring and Valve Stem Seal ....................................................................................303-01b-38
Exhaust Manifold (LH shown, RH opposite hand) .............................................................303-01b-39
Oil Filter Adapter ................................................................................................................303-01b-40
Oil Pressure Sender ..........................................................................................................303-01b-41
Oil Level Indicator and Tube ..............................................................................................303-01b-41
Oil Pan ...............................................................................................................................303-01b-42
Oil Pump Screen and Pickup Tube ....................................................................................303-01b-44
Flywheel .............................................................................................................................303-01b-44
Crankshaft Rear Oil Seal ..................................................................................................303-01b-45
Engine Mounts - RH ...........................................................................................................303-01b-46
Engine Mounts - LH ...........................................................................................................303-01b-47
Engine Removal .................................................................................................................303-01b-47
DISASSEMBLY
Engine ................................................................................................................................303-01b-56
01/2003 2003.0 BA Falcon
303-01b-2 Engine — 5.4L (3V) 303-01b-2
(Continued)

Cylinder Head ....................................................................................................................303-01b-67
ASSEMBLY
Engine ................................................................................................................................303-01b-71
01/2003 2003.0 BA Falcon

303-01b-3 Engine — 5.4L (3V) 303-01b-3
SPECIFICATIONS

Description Specification Valve face angle 45.5 deg
Lubricants and Sealants Valve seat width intake 1.2-1.4mm
SAE 5W-20 Premium WSS-M2C153-H Valve seat width exhaust 1.4-1.6mm
Synthetic Blend Motor Oil Valve seat runout TBD
XO-5W20-QSP or
Valve seat angle cyl head 44.5-45.0 deg
equivalent
Motorcraft Premium Gold WSS-M97B51-A1 (yellow Valve spring free length Does not apply
Engine Coolant VC-7-A color) Valve spring squareness TBD
(in Oregon VC-7-B) or Valve spring compression 350N +/- 17.5N at
equivalent¹ pressure at specified 42.04mm +13N for creep
Metal Surface Prep ZC-31 height (lbs) when stored 760N +/-
39N at 31.04mm
Silicone Gasket and WSE-M4G323-A4
Sealant F7AZ-19554-EA Valve spring installed 42.04 mm
or equivalent height
Instant Adhesive WSK-M2G402-A4 Valve spring installe 350N +/- 17.5N at
E8AZ-19554-A or pressure 42.04mm +13N for creep
equivalent when stored
Silicone Gasket Remover ZC-30 Roller follower ratio TBD
Engine Hydraulic Lash Adjuster
Displacement 5.4L (330 CID) Diameter TBD
Number of cylinders 8 Clearance-to-bore TBD
Bore 90.2 mm (3.55 in) Service limit TBD
Stroke 105.8 mm (4.17 in) Hydraulic leakdown rate TBD
Firing order 1-3-7-2-6-5-4-8 Collapsed lash adjuster TBD
Oil pressure minimum at 275.8-413.7 kPa (40-60 gap
2,000 rpm (engine at psi) Camshaft
normal operating Theoretical valve lift @ intake 11.1 mm exhaust
temperature) lash 11.0 mm
Oil capacity 7.0 liters with filter Lobe lift 0.584 mm
Compression ratio 9. 8:1 Allowable lobe lift loss 0.127 mm
Cylinder Head and Valve Train Journal diameter 28.607-28.633 mm
Combustion chamber 42.45-45.45 cc (2.59-2.77 Camshaft journal bore 28.657-28.682 mm
volume cu in) inside diameter
Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I Camshaft 0.04-0.095 mm
to rear) — LH journal-to-bearing
Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I clearance
to rear) — RH Runout 0.05 mm
Valve guide bore 6.015-6.044 End play 0.075-0.185 mm
diameter Cylinder Block
Valve stem diameter 5.975-5.995 Cylinder bore diameter 90.200-90.210 mm
intake —grade 1 (3.5512-3.5516 in)
Valve stem diameter 5.95-5.97 Cylinder bore diameter 90.210-90.220 mm
exhaust —grade 2 (3.5516-3.5520 in)
Valve stem-to-guide 0.020-0.045 Cylinder bore diameter 90.220-90.230 mm
clearance — intake —grade 3 (3.5520-3.5524 in)
Valve stem-to-guid 0.069-0.094 Cylinder bore maximum 0.006 mm (0.0002 in)
clearance — exhaust taper
Valve head diameter 33.62-33.98 Cylinder bore maximum 0.020 mm (0.0008 in)
intake out-of-round
Valve head diameter 37.32-37.68 Main bearing bore inside 72.401-72.422 mm
exhaust diameter (2.850-2.851 in)
Valve face runout 0.05
G89770 en 01/2003 2003.0 BA Falcon

303-01b-4 Engine — 5.4L (3V) 303-01b-4

Crankshaft Piston pin length 61.8 mm (2.433 in)
Main bearing journal 67.483-67.503 mm Piston pin-to-piston fit 0.005-0.0135 mm
diameter (2.6568-2.6576 in) (clearance) (0.0002-0.0005 in)
Main bearing journal 0.004 mm (0.0002 in) Connecting rod-to-pin 0.009-0.0235 mm
maximum taper clearance (0.0004-0.0093 in)
(straightness) Connecting rod pin bore 22.012-22.024 mm
Main bearing journal 0.0075 mm (0.0003 in) diameter (0.8666-0.8671 in)
maximum out-of-round between cross sections Connecting rod length 169.1 mm (6.6575 in)
Main bearing 0.048-0.024 mm (centerline bore-to-bore)
journal-to-cylinder block (0.0019-0.0009 in) Connecting rod maximum ± 0.038 mm (0.0015 in)
clearance allowed bend
Connecting rod journal 53.003-52.983 mm Connecting rod maximum ± 0.05 mm (0.0020 in)
diameter (2.0867-2.0859 in) allowed twist
Connecting rod journal 0.004 mm (0.0002 in) Connecting rod bearing 53.049-53.027 mm
maximum taper bore diameter (with (2.0885-2.0877 in)
Connecting rod journal 0.0075 mm (0.0003 in) assembled liners)
maximum out-of-round between cross sections Connecting rod 0.064-0.026 mm
Crankshaft maximum end 0.075-0.377 mm bearing-to-crankshaft (0.0025-0.0010 in)
play (0.0030-0.0148 in) clearance
Piston and Connecting Rod Connecting rod side 0.475-0.125 mm
Piston diameter — grade 90.175-90.165 mm clearance (0.0187-0.0049 in)
1 (at right angle to pin (3.5502-3.5498 in) Accessory Drive Belt
bore) Drive belt 6 ribs
Piston diameter — grade 90.185-90.175 mm ¹ The addition of Motorcraft Cooling System Stop
2 (at right angle to pin (3.5506-3.5502 in) Leak Pellets, VC-6, darkens Motorcraft Premium Gold
bore) Engine Coolant from yellow to golden tan.
Piston diameter — grade 90.195-90.185 mm Torque Specifications
3 (at right angle to pin (3.5510-3.5506 in)
Description Nm
bore)
Valve cover bolts 10
Piston-to-cylinder bore 0.025-0.045 mm
clearance (at grade size) (0.0010-0.0018 in) Camshaft bearing cap bolts¹ —
Piston ring end gap — 0.13-0.28 mm Variable camshaft timing (VCT) —
top (0.0051-0.0110 in) sprocket assembly bolts¹
Piston ring end gap 0.25-0.40 mm Cylinder head temperature sensor 26
—intermediate (0.0098-0.0158 in) (CHT)
Piston ring end gap — oil 0.15-0.65 mm Camshaft position (CMP) sensor bolt 10
control (0.0059-0.0256 in) Crankshaft position (CKP) sensor bolt 10
Piston ring groove width 1.53-1.55 mm Connecting rod bolts¹ —
— top (0.0602-0.0610 in) Crankshaft damper pulley bolt¹ —
Piston ring groove width 1.52-1.54 mm Crankshaft main bearing bolts —
— intermediate (0.0598-0.0606 in) (cross-mounted)¹
Piston ring groove width 3.030-3.050 mm Crankshaft main bearing bolts —
— oil control (0.1193-0.1201 in) (vertical)¹
Piston ring width 1.49-1.46 mm Cylinder heads bolts¹ —
(0.0587-0.0575 in)
Exhaust manifold nuts 25
Piston ring-to-groove 0.030-0.050 mm
clearance — top (0.0012-0.0020 in) Exhaust manifold studs 12
Piston ring-to-groove 0.030-0.080 mm Exhaust manifold-to-Y-pipe nuts 40
clearance — intermediate (0.0012-0.0031 in) Drive belt idler pulley bolt 25
Piston pin bore diameter 22.008-22.014 mm Flywheel bolts 80
(0.8665-0.8667 in) Engine front cover bolts¹ —
Piston pin diameter 22.0005-22.0030 mm Transmission-to-engine bolts 48
(0.8662-0.8663 in)
G89770 en 01/2003 2003.0 BA Falcon

303-01b-5 Engine — 5.4L (3V) 303-01b-5
Description Nm
Torque converter-to-flexplate nuts 35
Fuel injection supply manifold bracket 10
bolts
Generator upper mounting bracket 10
bolts
Generator lower mounting bolts 25
Ignition coil 6
Intake manifold to cylinder head bolts¹ —
Knock sensor 20
Oil filter 16
Oil filter adapter bolts 25
Oil level indicator tube bolt 10
Oil pan bolts¹ —
Oil pan drain plug 14
Oil pressure switch 14
Oil pump bolts 10
Oil pump screen and pickup tube bolts 10
Oil pump screen and pickup tube 25
spacer
Oil pump screen and pickup tube 25
spacer bolt
Power steering pump bolts 25
Rear main oil seal retainer bolts Spark 10
plugs
Spark plugs 18
Thermostat housing bolts 10
Throttle body spacer-to-intake manifold 10
bolts
Timing chain guide bolts 10
Timing chain hydraulic tensioner bolts 25
Coolant pump bolts 25
Coolant pump pulley bolts 25
Motor mount-to-cylinder block bolts 63
Motor mount through bolt 200
Motor mount nut 103
Oil pressure switch 14
Power steering reservoir bracket bolts 25
Power steering reservoir bracket nut 25
Ground strap nut 10
Fuel injection supply manifold bolts 10
Generator bracket bolts 10
Intake manifold bolts¹ —
Transmission cooler line bracket nut 10
¹ Refer to the procedure in this section.
G89770 en 01/2003 2003.0 BA Falcon

303-01b-6 Engine — 5.4L (3V) 303-01b-6
Engine Valve Train

The 5.4L (3V) is a V-8 engine with the following The valve train operates as follows:
features: Ball tip hydraulic lash adjusters provide automatic
dual overhead camshafts lash adjustment.
three valves per cylinder Roller followers ride on the camshaft lobes,
transferring the up-and-down motion of the
sequential multiport fuel injection (SFI) camshafts to the valves in the cylinder heads.
an aluminum intake manifold
aluminum cylinder heads
Positive Crankcase Ventilation System
a cast iron, 90-degree V-cylinder block All engines are equipped with a closed-type positive
crankcase ventilation system recycling the crankcase
individually chain-driven camshafts with a
hydraulic timing chain tensioner on each timing vapors to the upper intake manifold.
chain Lubrication System
the electronic ignition system with eight ignition
coils The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil
Identification pump screen cover and tube in the sump of the oil
Always refer to these labels when new parts are pan.
required or when checking engine calibrations. The Oil enters the main oil gallery where it is
engine parts often differ within a CID family. distributed to the crankshaft main journals and to
Verification of the identification codes will make sure both cylinder heads.
that the correct parts are obtained. These codes From the main journals, the oil is routed through
contain all the pertinent information relating to the cross-drilled passages in the crankshaft to
dates, optional equipment and revisions. The Ford lubricate the connecting rod bearings. Controlled
Master Parts Catalog contains a complete listing of leakage through the crankshaft main bearings and
the codes and their application. connecting rod bearings is slung radially outward
to cool and lubricate the cylinder walls as well as
Code Information the entire connecting rod, piston and piston rings
The engine code information label, located on the side assembly.
of the LH valve cover towards the rear, contains the The left cylinder head is fed from a drilling into the
following: supply passage feeding the main gallery at the
engine build date front of the cylinder block. The right cylinder head
engine plant code is fed from a drilling into the rear of the main
gallery. Main gallery pressure is reduced as it
engine code enters the cylinder head galleries through fixed
Induction System serviceable orifices located at the upper part of
the feed passages. It is this reduced pressure in
The sequential multiport fuel injection (SFI) provides the cylinder head galleries which feeds the
the fuel/air mixture needed for combustion in the camshaft journals, the hydraulic lash adjusters
cylinders. The eight solenoid-operated fuel injectors: and the primary and secondary timing chain
are mounted in the fuel injection supply manifold tensioners.
and the intake manifold above the cylinder heads. The camshaft lobe and roller followers are
meter fuel into the air intake stream in accordance lubricated by splash created through valve train
with engine demand. operation.
are positioned so that their tips direct fuel just Oil Pump
ahead of the engine intake valves.
The lubrication system of the 5.4L (3V) engine is
are connected in series with the fuel pressure
designed to provide optimum oil flow to critical
regulator. components of the engine through its entire operating
supply fuel from the fuel tank by a fuel pump range. The heart of the system is a positive
mounted in the fuel tank. displacement internal gear oil pump using top seal
A constant fuel pressure drop is maintained across rotors.
the fuel injectors by the fuel pressure regulator. The Generically this design is known as a gerotor pump,
fuel pressure regulator: which operates as follows:
is positioned upstream from the fuel injectors on The oil pump is mounted on the front face of the
the fuel injection supply manifold. cylinder block.
G89771 en 01/2003 2003.0 BA Falcon

303-01b-7 Engine — 5.4L (3V) 303-01b-7
The inner rotor is piloted on the crankshaft post

and is driven through flats on the crankshaft.
System pressure is limited by an integral,
internally-vented relief valve which directs the
bypassed oil back to the inlet side of the oil pump.
Oil pump displacement has been selected to
provide adequate volume to ensure correct oil
pressure both at hot idle and maximum speed.
The relief valve calibration protects the system
from excessive pressure during high viscosity
conditions.
The relief valve is designed to provide adequate
connecting rod bearing lubrication under
high-temperature and high-speed conditions.
G89771 en 01/2003 2003.0 BA Falcon

303-01b-8 Engine — 5.4L (3V) 303-01b-8
Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, Refer to
Powertrain Control/Module in Section 303-14.
G89772 en 01/2003 2003.0 BA Falcon

303-01b-9 Engine — 5.4L (3V) 303-01b-9
IN-VEHICLE REPAIR
Intake Manifold Upper 10. Remove the ten (10) bolts that secure the intake
manifold.
Removal
1. Relieve the fuel pressure. Refer to chapter 310-00
Fuel System.
3. Remove PCV hose from LH valve cover.
4. Remove the air cleaner outlet from throttle body.
For additional information, refer to Section
303-12.
5. Disconnect the electrical connectors from throttle
body motor.
6. Disconnect the electrical connectors from the
MAP sensor.
alternator.
8. Remove the four (4) screws securing the fuel rail
to the intake manifold.
11. Lift intake manifold and throttle body.

12. Disconnect the brake booster vacuum line from
the intake manifold.
9. Remove the fuel rail and fuel injectors as one 13. Remove the intake manifold.
assembly gently.
14. Remove the intake gasket.
CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces.
These tools cause scratches and gouges
which make leak paths. Use a plastic scraping
tool to remove all traces of old sealant.
G89773 en 01/2003 2003.0 BA Falcon

303-01b-10 Engine — 5.4L (3V) 303-01b-10
15. Clean and inspect the sealing surfaces. Materials

Metal Surface Prep ZC-31
Sealant
F7AZ-19554-EA or
equivalent
Instant Adhesive WSK-M2G402-A4
E8AZ-19554-A
Removal
1. Disconnect the battery and remove. Refer to
Chapter 414-01, Battery, Mounting and Cables
2. Remove the coolant supply tank and secure out of
the way. (RH side only) Refer to chapter 303-03
Engine Cooling.
Installation 3. Unclip the positive battery cable from the valve
Install in reverse order applying intake sealant to the cover. And secure out of the way. (RH side only)
mating surfaces of the intake manifold. Tighten the 4. Disconnect the variable cam timing connection at
intake manifold bolts in the order illustrated below. the front of each valve cover
5. Disconnect the ignition coils
Valve Cover LH and RH (shown)

Materials
SAE 5W-20 Premium WSS-M2C153-H
Synthetic Blend Motor Oil
XO-5W20-QSP or
equivalent
Silicone Gasket Remover ZC-30
G89773 en 01/2003 2003.0 BA Falcon

303-01b-11 Engine — 5.4L (3V) 303-01b-11
6. Remove the ignition coils. 7. Disconnect the valve cover ventilation hose from
the RH valve cover. (RH side only)
8. Disconnect the PCV valve and hose. Secure out
of the way. (LH side only)
9. Remove the rear RH and front LH lifting eyes.
10. Remove the valve cover bolts.
11. Remove the valve cover.
12. Remove the valve cover gasket.
RH Valve Cover shown
Item Description Installation

1 Bolt 1. Clean and inspect the sealing surfaces with
silicone gasket remover and metal surface prep.
2 Valve Cover
3 Valve Cover Gasket CAUTION: Do not use metal scrapers,
G89774 en 01/2003 2003.0 BA Falcon

303-01b-12 Engine — 5.4L (3V) 303-01b-12
2. Apply instant adhesive completely around the 4. Position the valve cover and gasket on the
gasket groove in the valve cover. Install a new cylinder head and install the bolts loosely. Tighten
valve cover gasket. the bolts in the sequence shown. (RH side shown
LH side is a mirror image)
3. Apply silicone gasket and sealant in two places

where the engine front cover meets the cylinder 5. Install the rear RH and front LH lifting eyes.
head. 6. Reconnect the PCV valve and hose. (LH side
NOTE: If not secured within four minutes, the only)
sealant must be removed and the sealing area 7. Reconnect the valve cover ventilation hose from
cleaned. To clean the sealing area, use silicone the RH valve cover. (RH side only)
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow 8. Install the ignition coils.
this procedure can cause future oil leakage. 9. Reconnect the variable cam timing connection at
the front of each valve cover
10. Install the coolant supply tank (RH side only)
11. Install the battery. (RH side only)
12. Clip the positive battery cable to the valve cover.
(RH side only)
G89774 en 01/2003 2003.0 BA Falcon

303-01b-13 Engine — 5.4L (3V) 303-01b-13
Crankshaft Pulley 4. Using the special tool, remove the crankshaft

pulley.
Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-009 (T58P-6316-D)
Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
Installation
1. Apply silicone gasket or LOCKTITE 5900 or
Materials equivalent to the Woodruff key slot on the
Silicone Gasket and WSE-M4G323-A4 crankshaft pulley.
Sealant NOTE: The crankshaft pulley must be installed
F7AZ-19554-EA or within four minutes after applying the silicone.
LOCTITE 5900 or
equivalent
Removal
1. Remove the drive belt. For additional information,
2. Raise and support the vehicle. For additional
information, refer to Section 100-02.
3. Remove the crankshaft pulley bolt.
2. Using the special tool, install the crankshaft

pulley.
G89774 en 01/2003 2003.0 BA Falcon

303-01b-14 Engine — 5.4L (3V) 303-01b-14
3. Install the bolt and washer. Tighten the bolt in four Materials
stages: SAE 5W-20 Premium WSS-M2C910-A2
Stage 1: Tighten to 90 Nm Synthetic Blend Motor Oil
Stage 2: Loosen one full turn. 10W-30GF2 Engine Oil
or equivalent
Stage 3: Tighten to 50 Nm
Stage 4: Tighten an additional 85-95 degrees. Removal
1. Remove the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this
section.
2. Using the special tool, remove the crankshaft front
oil seal.

5. Install the drive belt. For additional information,
Crankshaft Front Oil Seal

Installation
Special Tool(s) 1. Apply silicone gasket sealant to outer perimeter
Installer, Crankshaft Front Oil surface of crankshaft front seal.
Seal 2. Lubricate the engine front cover and the
303-635 crankshaft front oil seal inner lip with clean engine
oil.
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)
Item Description
1 Lubricate with engine oil
2 Seal with silicone gasket sealant
G89774 en 01/2003 2003.0 BA Falcon

303-01b-15 Engine — 5.4L (3V) 303-01b-15
3. Using the special tools, install the crankshaft front 2. Remove the water pump pulley.
oil seal into the engine front cover. Remove the four bolts
Remove the water pump pulley
4. Install the crankshaft pulley. For additional

section. Item Description
1 Bolts
Engine Front Cover
2 Water pump pulley
Materials 3. Remove the crankshaft pulley. For additional
Metal Surface Cleaner WSE-M5B392-A information, refer to Crankshaft Pulley in this
F4AZ-19A536-RA or section.
equivalent 4. Remove the Power Steering (P/S) bolts and
Silicone Gasket and WSE-M4G323-A4 position the power steering pump aside.
Sealant
F7AZ-19554-EA or
LOCTITE 5900 or
equivalent
10W-30GF2 Engine Oil WSS-M2C910-A2
or equivalent
Removal
1. Remove the left and right valve cover (6582). For
additional information, refer to Valve Cover-LH
and Valve Cover-RH in this section.
5. Remove A/C Compressor.

6. Disconnect the crankshaft position (CKP) sensor.
G89777 en 01/2003 2003.0 BA Falcon

303-01b-16 Engine — 5.4L (3V) 303-01b-16
7. Drain the engine oil. 11. Remove the bolt and the belt idler pulley (8678).
8. Remove the four front sump bolts (as shown). 12. Remove the engine front cover, bolts, studs, and
the gaskets.
9. Remove the crankshaft front oil seal. For

additional information, refer to Crankshaft Front 13. Clean and inspect the sealing surfaces with
Oil Seal in this section. silicone gasket remover and metal surface prep.
10. Disconnect the camshaft position (CMP) sensor. CAUTION: Do not use metal scrapers,
G89777 en 01/2003 2003.0 BA Falcon

303-01b-17 Engine — 5.4L (3V) 303-01b-17
Installation
1. Apply silicone gasket and sealant in the locations
shown.
NOTE: If the front cover and gasket are not
secured within four minutes, the sealant must be
removed and the sealing surface cleaned with
metal surface cleaner.
2. Position the engine front cover and install the

bolts and the studs in three stages:
Stage 1: Tighten numbers one through five to
25 Nm
Stage 2: Tighten numbers six and seven to 50
Nm
Stage 3: Tighten numbers 11 through 15 to
25 Nm
Item Description
1 Bolt, Hex Flange Head Pilot, M8 x 1.25 x
50
50
50
50
50
6 Stud, Hex-Head Pilot, M10 x 1.5 x 30
8 Bolt, Hex-Head Flange, M8 x 1.25 x 50
11 M8 x 1.25 x 53
12 M8 x 1.25 x 53
13 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65
14 Stud Hex Shoulder Pilot, M8 x 1.25 x 65 -
M8 x 1.25 x 27
G89777 en 01/2003 2003.0 BA Falcon

303-01b-18 Engine — 5.4L (3V) 303-01b-18
3. Install the belt idler and the bolt. 8. Install the drain plug.
4. Connect the CMP sensor. 9. Connect the CKP sensor.
5. Raise the vehicle. 10. Refit A/C compressor.

6. Tighten the sump bolts in three stages: 11. Position the power steering pump and install the
a. Stage 1: Tighten to 2 Nm bolts.
b. Stage 2: Tighten to 20 Nm
c. Stage 3: Tighten an additional 60 degrees.

section.
7. Install the crankshaft front oil seal. For additional
information, refer to Crankshaft Front Oil Seal in
this section.
G89777 en 01/2003 2003.0 BA Falcon

303-01b-19 Engine — 5.4L (3V) 303-01b-19
13. Install the water pump pulley and install the bolts. VCT Sprocket Assemblies and VCT
Housings
Special Tool(s)
SST303-775 3 Valve Camshaft
Holding Tool
SST303-448 Crankshaft
Position Tool
14. Install the left and right valve cover. For additional
information, refer to Valve Cover-LH and Valve
Cover-RH in this section.
15. Refill the engine crankcase with clean engine oil.
Timing Gears, Chains, Tensioners, Materials

Super Premium SAE WSS-M2C153-H
5W-20
XO-5W20-QSP or
equivalent
Hydraulic Chain 1L3Z-6P250-AA
Tensioner Retaining Clip
G89778 en 01/2003 2003.0 BA Falcon

303-01b-20 Engine — 5.4L (3V) 303-01b-20
Item Description
1 RH timing chain tensioner
2 RH timing chain tensioner arm
3 LH timing chain tensioner arm
4 LH timing chain tensioner bolts
5 LH timing chain tensioner
6 RH timing chain tensioner bolts
G89778 en 01/2003 2003.0 BA Falcon

303-01b-21 Engine — 5.4L (3V) 303-01b-21
Item Description
1 RH timing chain
2 LH timing chain
3 Crankshaft sprocket
4 Ignition pulse wheel
G89778 en 01/2003 2003.0 BA Falcon

303-01b-22 Engine — 5.4L (3V) 303-01b-22
Item Description
1 RH timing chain guide bolt
2 RH timing chain guide
3 LH timing chain guide bolt
4 RH timing chain guide bolt
5 LH timing chain guide bolt
6 LH timing chain guide
G89778 en 01/2003 2003.0 BA Falcon

303-01b-23 Engine — 5.4L (3V) 303-01b-23
Item Description
1 RH camshaft phaser sprocket assembly
bolt
3 LH camshaft phaser sprocket assembly
bolt
G89778 en 01/2003 2003.0 BA Falcon

303-01b-24 Engine — 5.4L (3V) 303-01b-24
Item Description 4. Remove the bolts, the RH timing chain tensioner

and tensioner arm.
1 RH variable camshaft timing (VCT)
housing assembly
2 RH VCT housing assembly bolts
3 LH VCT housing assembly bolts
4 LH variable camshaft timing (VCT) housing
assembly
Removal
1. Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
2. Remove the LH and RH valve covers. For
additional information, refer to Valve Cover in this
section.
3. Remove the bolts, the LH timing chain tensioner
and tensioner arm.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-25 Engine — 5.4L (3V) 303-01b-25
5. Remove the ignition pulse wheel from the

crankshaft.
6. Remove the RH and LH timing chains and the

crankshaft sprocket.
Remove the RH timing chain from the
camshaft sprocket.
Remove the LH timing chain from the
camshaft sprocket.
Remove the LH timing chain.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-26 Engine — 5.4L (3V) 303-01b-26
7. Remove the crankshaft sprocket. 12. Remove the bolts and the variable camshaft
8. Remove both timing chain guides. timing housing.
Discard the gasket.
CAUTION: Unless otherwise instructed, at
no time when the timing chains are removed
and the cylinders heads are installed is the
crankshaft or camshaft to be rotated. Severe
piston and valve damage will occur.
Remove the bolts.
Remove both timing chain guides.
13. Repeat steps 9 to 11 for removal of LH

components.
Installation
1. Install a new gasket, the variable camshaft timing
housing and the bolts.
9. Fit the SST 303-775 to camshaft in the central

position between caps and tighten to prevent
rotation.
WARNING: When tightening hex key bolts
on SST 303-775 make sure both bolts are
tightened evenly.
2. Install the RH camshaft variable timing sprocket

assembly and loosely install a new bolt and
washer.
10. Remove bolt and washer on RH camshaft.

CAUTION: Apply an even force on hand
tools to remove the camshaft phaser sprocket
assembly or damage may occur to the
camshaft or camshaft phaser unit.
11. Discard RH Phasor sprocket.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-27 Engine — 5.4L (3V) 303-01b-27
3. With SST303-775 in place holding the camshafts, 8. Pre-position the camshafts.

tighten the bolts in two stages Rotate the LH camshaft until the timing mark
Stage 1: Tighten to 40 Nm. is approximately at 12 o’clock.
Stage 2: Tighten an additional 90 degrees. Rotate the RH camshaft until the timing mark
is approximately at 11 o’clock.
CAUTION: Only use hand tools to
remove the camshaft phaser sprocket
4. Repeat steps 1 to 3 for the LH camshaft phaser
sprocket.
5. Compress the tensioner plunger, using a vice.
CAUTION: Timing chain procedures must
be followed exactly or damage to valves and
pistons will result.
9. Position the crankshaft so the number on cylinder

is at TDC using special tool 303-448
NOTE: The number one cylinder is at top dead
centre (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.
6. Install a retaining clip on the tensioner to hold the

plunger in during installation.
NOTE: If the retaining clip is not available insert a
paper clip into the tensioner spring hole.
10. Install the timing chain guides
7. Remove the tensioner from the vise.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-28 Engine — 5.4L (3V) 303-01b-28
11. Remove the crankshaft holding tool 13. If copper links are not visible on timing chains,
12. Install the crankshaft sprocket, making sure the hold chains straight mark two links on one end
flange faces forward. and one link on the other end and use as timing
marks.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-29 Engine — 5.4L (3V) 303-01b-29
14. Position the lower end of the LH (inner) timing 16. Position the LH timing chain tensioner arm on the
chain on the crankshaft sprocket, aligning the dowel pin and install the LH timing chain tensioner
timing mark on the outer flange of the crankshaft bolts.
sprocket with the single copper link (or single NOTE: The LH timing chain tensioner arm has a
marked link) on the chain. bump near the dowel hole for identification.
15. Position the timing chain on the camshaft 17. Remove The retaining clip or paperclip from the
sprocket with the camshaft sprocket timing mark LH timing chain tensioner.
positioned between the two copper (marked)
chain links.
NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.
18. Position the lower end of the RH (outer) timing

chain on the crankshaft sprocket, aligning the
timing mark on the sprocket with the single copper
(marked) chain link.
G89778 en 01/2003 2003.0 BA Falcon

303-01b-30 Engine — 5.4L (3V) 303-01b-30
19. Position the RH timing chain on the camshaft 23. Install the crankshaft sensor ring on the
sprocket. Make sure the camshaft sprocket timing crankshaft.
mark is positioned between the two copper
(marked) chain links. WARNING: Check markings on sensor
NOTE: The lower half of the timing chain must be ring to ensure correct installation.
positioned above the tensioner arm dowel.
20. Position the RH timing chain tensioner arm on the
dowel pin and install the RH timing chain
tensioner bolts.
24. Install the engine front cover. For additional

section.
25. Install the LH and RH Valve covers. For additional
information, refer to Valve Covers in this section.
21. Remove the retaining clip from the RH timing
chain tensioner.
Camshaft (LH shown, RH opposite
hand)
Special Tool(s)
Crankshaft position tool
303-448
Camshaft holding tool 303-775
22. As a post-check, verify correct alignment of all

timing marks.
Materials
5W-20
XO-5W20-QSP or
equivalent
Metal Surface Prep ZC-31
G89778 en 01/2003 2003.0 BA Falcon

303-01b-31 Engine — 5.4L (3V) 303-01b-31
Item Description
2 RH camshaft phaser sprocket assembly bolt
3 LH camshaft phaser sprocket assembly bolt
G89779 en 01/2003 2003.0 BA Falcon

303-01b-32 Engine — 5.4L (3V) 303-01b-32
Item Description 3. Position the crankshaft so the number one

cylinder is at TDC with the special tool, 303-448.
1 LH camshaft bearing cap bolt
2 Front LH camshaft bearing cap center (TDC) when the stud on the engine block
3 LH camshaft bearing cap fits into the slot in the handle of the special tool.
4 LH camshaft
5 Camshaft roller follower
6 Hydraulic lash adjuster
Removal
1. Remove the LH and RH valve covers. For
additional information, refer to Valve Cover in this
section.
section.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-33 Engine — 5.4L (3V) 303-01b-33
4. Remove the bolts, the timing chain tensioner and 8. Fit the SST 303-775 to the camshaft in the central
tensioner arm. position between the caps and tighten to prevent
rotation.
WARNING: When tightening hex key bolts
on SST 303-775 make sure both bolts are
tightened evenly.
9. Remove the bolt and the camshaft phaser
sprocket assembly.
Discard the bolt and washer.
CAUTION: Apply an even force on
hand tools to remove the camshaft phaser
sprocket assembly or damage may occur
to the camshaft or camshaft phaser unit.
CAUTION: Do not use the timing
5. Compress the tensioner plunger, using a vice. chains to prevent rotation when loosening
the central bolt as this load will be
CAUTION: Timing chain precedure must transmitted through the locked phaser
be followed exactly or damage to valves and mechanism and could cause damage.
10. Do not allow the timing chains to slip off the

6. Install a retaining clip on the tensioner to hold the crankshaft sprocket.
plunge in during installation.
11. Remove SST 303-775.
7. Remove the tensioner from the vise.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-34 Engine — 5.4L (3V) 303-01b-34
12. Remove the camshaft bearing cap bolts in the 2. Install the camshaft and the camshaft bearing
sequence shown. caps in their original locations.
NOTE: The camshaft bearing caps must be
installed in their original locations. Record
camshaft bearing cap locations.
Lubricate the camshaft bearing caps with
clean engine oil.
Position the camshaft bearing caps.
Install the bolts loosely.
3. Tighten the bolts in the sequence shown to 10
Nm.
13. Remove the camshaft bearing caps and the

camshaft.
installed in their original locations. Record
14. Clean and inspect the camshaft bearing caps.
15. Repeat steps 4 to 11 for RH camshaft.
Installation
1. Lubricate the camshaft journals with clean engine
oil. 4. Fit the SST 303-775 to the LH camshaft in the
central position between the caps and tighten to
prevent rotation.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-35 Engine — 5.4L (3V) 303-01b-35
5. Install the camshaft variable timing sprocket 9. Rotate the LH camshaft with the Camshaft
assembly and loosley install a new bolt and positioning tool until the timing mark is
washer. (RH shown) approxiamately at 12 o’clock.
6. Tighten the bolt in two stages: 10. Rotate the RH camshaft with the Camshaft
positioning tool until the timing mark is
CAUTION: Only use hand tools to remove approxiamately at 11 o’clock.
the camshaft phaser sprocket assembly or
11. Tighten the camshaft holding tools.
damage may occur to the camshaft or
camshaft phaser unit. CAUTION: Do not turn the engine over
1. Stage 1: Tighten to 40 Nm. with the camshaft positioning tool or damage
2. Stage 2: Tighten an an additional 90 degrees. to the camshaft sprocket or bolt may occur.
7. Loosen SST 303-775 camshaft holding tool but do CAUTION: Unless otherwise instructed, at
not remove. no time when the timing chains are removed
8. If copper links are not visible on timing chains, and the cylinder heads are installed is the
hold chains straight mark two links on one end crankshaft or camshaft to be rotated. Severe
and one link on the other end and use as timing piston and valve damage wil occur.
marks.
CAUTION: Rotate the crankshaft
counterclockwise only. Do not rotate past
position and/or valve damage can occur.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-36 Engine — 5.4L (3V) 303-01b-36
12. Position the crankshaft so the number one

cylinder is at TDC with the special tool.
center (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.
13. Install the timing chain guide.

NOTE: Illustration shows both LH and RH timing
guides.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-37 Engine — 5.4L (3V) 303-01b-37
14. Position the lower end of the LH (inner) timing 17. Position the LH timing chain tensioner arm on the
chain on the crankshaft sprocket, aligning the dowel pin and install the LH timing chain
timing mark on the outer flange of the crankshaft tensioner.
sprocket with the single copper (marked) link on NOTE: The LH timing chain tensioner arm has a
the chain. bump near the dowel hole for identification.
15. Position the timing chain on the camshaft 18. Remove the retaining clip or paperclip from the
sprocket with the camshaft sprocket timing mark LH timing chain tensioner.
positioned between the two copper (marked)
chain links.
NOTE: Ensure the upper half of the timing chain
is below the tensioner arm dowel.
19. Repeat steps 4 to 18 for the RH camshaft.

timing marks.
16. Remove the camshaft holding tool.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-38 Engine — 5.4L (3V) 303-01b-38
21. Install the crankshaft sensor ring on the 4. Remove the hydraulic lash adjusters.
crankshaft. NOTE: Mark each hydraulic lash adjuster to make
sure it is returned to its original position.
WARNING: Check markings on sensor
ring to ensure correct installation.
Installation
22. Install the engine front cover. For additional Install in the reverse order to the removal.
section. Valve spring and Valve Stem Seal
23. Install the LH and RH Valve covers. For additional Removal
information, refer to Valve Covers in this section.
1. Remove the appropriate spark plug, and
pressurise the cylinder via an air line and adaptor.
Rocker Arm, Lash Adjuster, Valve DO NOT exceed 800 KPa.
Spring and Valve Stem Seal 2. Remove the keys, retainers and valve spring
Materials using a suitable valve spring compressor.
5W-20
XO-5W20-QSP or
equivalent
Removal
The rocker arm and lash adjuster are clipped together
to prevent rocker displacement under extraordinary
start up conditions. Care should be taken when
removing the assembly, so as not to strain the clip.
Do not remove the clip unless either the rocker arm of
lash adjuster are to be eplafed and fit a new clip. Do
not remove the clip unless either the rocker arm of
lash adjuster are to be replaced and fit a new clip. If
the clip is loose on the rocker arm it should be
replaced when the rocker and lash adjuster assembly 3. Remove the valve stem seal/spring seat assembly
is removed from the cylinder head. with pliers or multi-grips, being careful not to mark
the valve stem.
1. Remove the valve cover. For additional
information, refer to Valve Cover removal in this Installation
section. 1. Pressurise the cylinder via an air line and adaptor.
2. Remove the camshaft. For additional information, Do not exceed 800 KPa.
refer to camshaft removal in this section. 2. Use an appropriate inside diameter tube to gently
3. Remove the camshaft roller follower(s) seat the valve stem seal.
NOTE: Mark each camshaft roller followers to
make sure it is returned to its original position.
G89779 en 01/2003 2003.0 BA Falcon

303-01b-39 Engine — 5.4L (3V) 303-01b-39
3. Reassemble in the reverse order to the procedure

above.
NOTE: The valve spring must be fitted with the
smaller diameter end upwards.
Exhaust Manifold (LH shown, RH

opposite hand)
Item Description Removal

1 Exhaust manifold gasket 1. Remove the exhaust manifold.
2 Exhaust manifold Discard the gasket.
3 Exhaust manifold nuts Clean the sealing surfaces with metal surface
prep.
wire brushes, power abrasive discs, or
other abrasive means to clean the sealing
surfaces. These may cause scratches and
gouges resulting in leak paths. Use a
G89782 en 01/2003 2003.0 BA Falcon

303-01b-40 Engine — 5.4L (3V) 303-01b-40
plastic scraper to clean the sealing 4. Disconnect the oil pressure sensor.
surfaces.
Installation
1. Install a new gasket
2. Install the exhaust manifold to the cylinder head.
Tighten the exhaust manifold nuts in the
sequence shown.
5. Remove the oil pressure sender.
Oil Filter Adapter

Removal
2. Drain the cooling system. For additional
3. Remove the oil filter.
6. Disconnect the radiator lower hose.
G89782 en 01/2003 2003.0 BA Falcon

303-01b-41 Engine — 5.4L (3V) 303-01b-41
7. Remove the four bolts and the filter adapter. 2. Disconnect the oil pressure sender electrical
connector.
Discard the gasket
Installation Installation
Install in the reverse order to the removal. Install in the reverse order to the removal.
NOTE: Install a new oil filter adapter gasket. Oil Level Indicator and Tube
Oil Pressure Sender Removal
1. Remove the oil level indicator
Materials
2. Remove the bolt.
Pipe Sealant with WSK-M2G350-A2 and
Teflon© ESR-M18P7-A
D8AZ-19554-A or
equivalent
Removal
G89785 en 01/2003 2003.0 BA Falcon

303-01b-42 Engine — 5.4L (3V) 303-01b-42
3. 3. Remove the oil level indicator tube. 2. Install the special tool.
a. Install a new O-ring seal.

Installation information, refer to Section 100-02.
Install in the reverse order to the removal. 4. Remove through bolts from the engine mount
bracket and chassis.
Oil Pan 5. Drain the engine oil.
Special Tool(s)
3-Bar Engine Support 303-F073
Materials
Metal Surface Cleaner WSE-M5B392-A
F4AZ-19A536-RA or
equivalent
Sealant
F7AZ-19554-EA or 7. Raise the engine 63.5 mm.
LOCTITE 5900 or
equivalent
10W-30 GF2 Engine Oil WSS-M2C910-A2
or equivalent
Removal
1. Remove alternator, refer to Section 414-02.
8. Raise the vehicle
G89785 en 01/2003 2003.0 BA Falcon

303-01b-43 Engine — 5.4L (3V) 303-01b-43
9. Remove the bolts, oil pan and gasket. 3. Apply silicone gasket and sealant at the front
Inspect the oil pan gasket for damage. cover-to-cylinder block sealing surface.
NOTE: Be careful when removing oil pan NOTE: If the oil pan and the oil pan gasket are
gasket. It is re-usable if not damaged. not secured within four minutes, the sealant must
be removed and the sealing area cleaned with
metal surface cleaner. Allow to dry until there is
no sign of wetness, or four minutes, whichever is
longer. Failure to follow this procedure can cause
future oil leakage.
Installation
1. Clean the mating surfaces.
abrasive means to clean the sealing surfaces. 4. Install the oil pan gasket and the oil pan and
These tools cause scratches and gouges loosely install the 16 bolts.
which make leak paths. Use a plastic scraping 5. Tighten the bolts in three stages, in the sequence
tool to remove all traces of old sealant shown.
2. Apply silicone gasket and sealant at the rear oil Stage 1: Tighten to 2 Nm.
seal retainer-to-cylinder block sealing surface. Stage 2: Tighten to 20 Nm.
NOTE: If the oil pan and the oil pan gasket are
not secured within four minutes, the sealant must
future oil leakage.
Stage 3: Tighten an additional 60 degrees

G89786 en 01/2003 2003.0 BA Falcon

303-01b-44 Engine — 5.4L (3V) 303-01b-44
7. Lower the engine. Removal

Remove the special tool. 1. Remove the oil pan. For additional information,
refer to Oil Pan in this section
2. Remove the three (A) bolts and the (B) oil pump
screen cover and tube.

9. Install through bolt to the engine mount bracket
and chassis.
Installation
1. Clean and inspect the mating surfaces.
Inspect the O-ring seal
2. Install the oil pump screen cover and tube and
install the bolts.
CAUTION: Make sure the O-ring is in
place and not damaged. A missing or
damaged O-ring can cause foam in the
lubrication system, low oil pressure and
severe engine damage.
NOTE: Clean and inspect the mating surfaces
and install a new O-ring. Lubricate with clean
engine oil.
10. Lower the vehicle. 3. Install the oil pan. For additional information, refer
11. Install the alternator. For additional information, to Oil Pan Installation in this section.
12. Install the lower intake manifold. For additional Flywheel
information, refer to Intake Manifold-Upper.
Removal
1. Remove the transmission. For additional
information, refer to Automatic Transmission
Oil Pump Screen and Pickup Tube chapter 307-01 or for Manual Transmission
Materials chapter 308-03B.
10W-30 GF2 engine oil WSS-M2C910-A2 2. Remove the clutch disc and pressure plate.
or equivalent Manual transmission only. For additional
information, refer to Clutch chapter 308-01
G89786 en 01/2003 2003.0 BA Falcon

303-01b-45 Engine — 5.4L (3V) 303-01b-45
3. Remove six of the eight bolts. Loosen the two Crankshaft Rear Oil Seal
remaining bolts but leave in place.
CAUTION: Two bolts should be loosened Special Tool(s)
but left in to prevent the flywheel (6375) from Installer, Crankshaft Rear Oil
falling Seal 303-518 (T95P-6701-DH)
Remover, Crankshaft Rear Oil

Seal 303-519 (T95P-6701-EH)
Installer, Crankshaft Rear Oil

4. Separate the flywheel from the crankshaft Seal 303-516 (T95P-6701-BH)
5. Remove the bolts remaining in the crankshaft.
6. Remove the flywheel.
Installation
1. Position the flywheel onto the crankshaft and
install the flywheel-to-crankshaft bolts (6379). Remover, Crankshaft Rear Oil
Apply the threadlock and sealer to bolt Slinger 303-514
threads. (T95P-6701-AH)

Slinger 303-517
(T95P-6701-CH)
Impact Slide Hammer 100-001

(T50T-100-A)
2. Install the disc and pressure plate. Manual
transmission only. For additional information, refer
to Clutch chapter 308-01
3. Install the transmission. Refer to Automatic
Transmission chapter 307-01 or for Manual
Transmission chapter 308-03B. Removal
1. Remove the Flywheel. For additional information,
refer to Flywheel in this section.
G89788 en 01/2003 2003.0 BA Falcon

303-01b-46 Engine — 5.4L (3V) 303-01b-46
2. Using the special tools, remove the crankshaft oil 2. Using the special tools, install the crankshaft oil
slinger. slinger
3. Using the special tools, remove the crankshaft

rear oil
3. Install the Flywheel. For additional information,

refer to Flywheel in this section.
Engine Mounts - RH
Special Tool(s)
Removal
1. Install the special tool.
Installation
1. Using the special tool, install the crankshaft rear
oil seal.Using the special tools, install the
crankshaft rear oil seal.
G89788 en 01/2003 2003.0 BA Falcon

303-01b-47 Engine — 5.4L (3V) 303-01b-47
2. Raise and support the vehicle. For additional 4. 4. Remove the through bolt.
5. 5. Lower the vehicle.

3. Remove the engine mount bracket through bolt. 6. 6. Raise the engine 63.5 mm
4. Remove crossmember
5. Remove engine mount & bracket assembly from
the engine.
6. Remove engine mount heat shield.
7. Remove the engine mount.
Installation
Install in the reverse order to the removal.
Engine Mounts - LH
Special Tool(s)
7. 7. Remove the engine mount from the vehicle.

Installation
1. Install in the reverse order to the removal.
Engine Removal
Removal
1. 1. Remove the lower intake manifold. For Special Tool(s)
additional information, refer to Intake Modular Engine Lifting Bar
Manifold-Upper in this section 303-F047 (014-00073)
2. 2. Install the special tool
Holding Wrench, Fan Pulley

303-239 (T84T-6312-C)
3. 3. Raise and support the vehicle. For additional

G89792 en 01/2003 2003.0 BA Falcon

303-01b-48 Engine — 5.4L (3V) 303-01b-48
Special Tool(s) 6. Drain coolant from engine at tap left hand lower
corner.
Wrench, Fan Clutch Hub Nut
303-240 (T84T-6312-D) 7. Disconnect the lower radiator hose from the
radiator and the engine.
Materials
10W-30 GF2 engine oil WSS-M2C910-A2
or equivalent
Removal
1. Disconnect lower pivot hood struts.
2. Tie hood back.
3. Remove the radiator upper hose from the engine.
4. Remove the fan shroud.
Remove the screws. 8. Disconnect the surge tank hose from the radiator.
Lift and remove the fan pack, out of the Release the clamp.
vehicle. Slide the hose off the radiator fitting.
9. Remove the surge tank from vehicle
Disconnect vent and supply hoses from surge
tank
Remove surge tank from vehicle.
Remove the bolts
Remove the upper radiator support brackets
Remove bolts attaching condensor to radiator
Lift the radiator off the radiator mounting
insulators.
Remove the radiator mounting insulators.
11. Remove the accessory drive belt. For additional
5. Disconnect the transmission fluid cooler fittings. information, refer to Section 303-05.
Disconnect the upper transmission fluid cooler 12. Disconnect the alternator electrical connectors.
fitting. 13. Disconnect battery and alternator cables from RH
Disconnect the lower transmission fluid cooler Relay box.
fitting. 14. Remove PCM, refer to Section 303-14.
NOTE: To avoid disturbing the transmission
oil cooler fittings, use a support spanner when 15. Disconnect the wiring harness (PCM ’A’
releasing cooling lines. connector & 24 pin connector) from vehicle.
16. Disconnect transmission wiring harness from
transmission.
17. Disconnect hego sensor wiring plugs. Refer to
chapter Section 303-14p106 for more information.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-49 Engine — 5.4L (3V) 303-01b-49
18. Remove the ground strap retaining bolt. 27. Disconnect the starter motor electrical
connections.
Remove the two nuts
Remove the battery cable.
Remove the starter solenoid wire.
19. Disconnect the lower radiator hose.

20. Disconnect the heater hoses from rear of engine.
21. Disconnect brake booster vacuum hose.
22. Disconnect purge valve connection.
23. Disconnect air intake to throttle body and remove 28. Remove the nut and the starter motor ground
entire air cleaner assembly. cable
24. Disconnect fuel lines using special tool, as
outlined in Section 310-00.
25. Disconnect the power steering pressure (PSP)
sensor.
26. Remove the bolts and position the power steering
pump out of the way
29. Remove the 2 bolts and the starter motor.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-50 Engine — 5.4L (3V) 303-01b-50
30. Disconnect the crankshaft position (CKP) sensor. 36. Remove the through bolt from the RH motor
mount
31. Disconnect the A/C compressor electrical

connector. 37. Remove the plate bolts and the inspection cover
32. Remove the bolts and the A/C compressor. 38. Remove the four bolts from the torque converter
NOTE: Do not degas, position A/C compressor and discard (Auto tran only).
out of the way. NOTE: Gain access to the nuts by turning the
crank dampener counterclockwise.
33. Remove nut holding exhaust heatshield and
discard, then remove heatshield.
34. Disconnect the pipes at the exhaust manifolds.
NOTE: If studs are removed from exhaust
manifolds during disassembly, then discard studs
and nut and replace with new parts.
35. Remove the through bolt from the LH engine
mount.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-51 Engine — 5.4L (3V) 303-01b-51
39. Remove the 6 bolts from the transmission. 5. Position the transmission level indicator tube and
install the bolt.

41. Install rear lifting hook and front lifting hook. 6. Install the five bolts to the bell housing.
42. Support the transmission with a floor jack and a
block of wood.
43. Remove the engine from the vehicle.
7. Install the oil filter.
Installation
block of wood.
2. Install the engine in the vehicle.
3. Remove the special tool.
4. Raise the vehicle. For additional information, refer

to Section 100-02.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-52 Engine — 5.4L (3V) 303-01b-52
8. Install 4 new bolts to the torque converter (Auto 11. Install the bolt to the RH engine motor mount.
trans only).
NOTE: Gain access to the nuts by turning the
12. Install the bolt to the LH engine motor mount.
9. Install the plug (Auto trans only).
13. Install the starter motor and 2 bolts.
10. Install the inspection cover and the bolts.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-53 Engine — 5.4L (3V) 303-01b-53
14. Connect the cable and install the motor nut. 20. Install the A/C compressor and bolts.
15. Connect the starter motor electrical connectors. 21. Connect the A/C compressor electrical connector.
Position the starter solenoid wire.
Position the battery cable.
Install the nuts.
22. Connect the crankshaft position sensor.
16. Install the starter motor solenoid terminal cover.

17. Install the RH exhaust manifold studs.
18. Connect the exhaust pipes to the exhaust
manifolds and torque nuts to specification.
19. Install the heatshield and fasten with a new

heatshield nut.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-54 Engine — 5.4L (3V) 303-01b-54
23. Position the power steering pump and install the 34. Connect the transmission wiring harness to
bolts. transmission.
24. Connect the power steering pressure sensor. 35. Connect wiring harness (PCM ’A’ connector and
25. Lower the vehicle. 24 pin connector) to vehicle.
26. Connect the lower radiator hose. 36. Install the alternator and alternator bracket.
27. Install the stud and reposition the A/C muffler.
28. Install battery into vehicle.
29. Connect the heater hoses to rear of engine.
37. Connect the alternator electrical connectors.
30. Install surge tank into vehicle.

31. Connect vent and supply hoses to surge tank.
32. Connect the surge tank return hose.
33. Install the two bolts retaining the transmission to
the engine.
38. Connect battery and alternator cables to RH relay

box.
39. Install the accessory drive belt. For additional
40. Install the intake manifold. For additional
information, refer to Intake Manifold-Upper in this
section.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-55 Engine — 5.4L (3V) 303-01b-55
41. Install the radiator.

Install the radiator mounting insulators.
Position the radiator on the radiator mounting
insulators.
Position the brackets.
Install the bolts.
45. Install the fan shroud.

Install the fan blade and fan shroud, as a unit,
in the vehicle.
Install the screws.
42. Install the surge tank hose to the radiator.

Release the clamp.
Slide the hose onto the radiator fitting.
46. Recharge the A/C system. For additional

47. Fill the engine with oil.
48. Fill the engine cooling system. For additional
43. Connect the lower radiator hose and the upper

radiator hose.
44. Connect the transmission fluid cooler fittings.
Connect the lower transmission fluid cooler
fitting.
Connect the upper transmission fluid cooler
fitting.
oil cooler fittings, use a support hammer when
tightening fuel lines.
G89792 en 01/2003 2003.0 BA Falcon

303-01b-56 Engine — 5.4L (3V) 303-01b-56
DISASSEMBLY
Engine Disassembly
NOTE: The crankshaft rear oil seal, the oil seal slinger
Special Tool(s) and the oil seal retainer plate must be removed before
mounting the engine on the engine stand.
Slinger 1. Remove the bolts and the flexplate or the
303-514 (T95P-6701-AH) flywheel.

Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)
rear oil slinger.
Installer, Connecting Rod

303-442 (T93P-6136-A)
Lift Bracket Set, Engine

303-DS086 (D93P-6001-A)

rear oil seal.

Damper
303-009 (T58P-6316-D)

Seal
303-107 (T74P-6700-A)
G89796 en 01/2003 2003.0 BA Falcon

303-01b-57 Engine — 5.4L (3V) 303-01b-57
DISASSEMBLY (Continued)
4. Remove the bolts, oil pan and oil pan gasket. 9. Remove the intake manifold gaskets.
Clean and inspect the sealing surfaces. Clean and inspect the sealing surfaces.
wire brushes, power abrasive discs or
surfaces. These tools cause scratches and
gouges which make leak paths. Use a
plastic scraping tool to remove all traces
of old sealant.
5. Remove the bolts and the crankshaft rear oil seal

retainer plate.
Clean and inspect the sealing surfaces.
10. Remove the bolts and the generator support

bracket.
6. Install the engine onto a suitable engine stand.

7. With the engine on the engine stand, remove the
engine control sensor wiring harness.
8. Remove the bolts and the intake manifold
assembly.
11. Remove the bolts and the generator.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-58 Engine — 5.4L (3V) 303-01b-58
12. Remove the bolt. soap and water or a suitable solvent.

of old sealant.
NOTE: The bolts are part of the valve cover
and should not be removed.
NOTE: LH is shown, RH is similar.
13. Remove the bolts and the water bypass tube

assembly.
16. Remove the nuts and the two radio interference

capacitors.
NOTE: RH is shown, LH is similar.
14. Remove the eight bolts and the eight coil packs.
15. Remove the bolts and the valve covers.

Fully loosen the bolts and remove the valve
cover.
Clean the valve cover mating surface of the
cylinder head with silicone gasket remover
and metal surface prep. Follow the directions
on the packaging.
Inspect the valve cover gasket. If the gasket
is damaged, remove and discard the gasket.
Clean the valve cover gasket groove with
G89796 en 01/2003 2003.0 BA Falcon

303-01b-59 Engine — 5.4L (3V) 303-01b-59
17. Remove the eight nuts and the RH exhaust 20. Remove the bolt and the crankshaft position
manifold. (CKP) sensor.
21. Remove the eight nuts and the LH exhaust

18. Remove the bolts and the A/C compressor. manifold.
19. Remove the bolts and the A/C compressor

bracket. 22. Remove the bolts and the power steering pump.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-60 Engine — 5.4L (3V) 303-01b-60
23. Remove the bolts and the oil filter adapter. 26. Remove the bolts.
24. Remove the bolts, the coolant pump pulley, and 27. Remove the coolant pump from the cylinder block.
the accessory drive belt idler pulley.
28. Remove and discard the crankshaft pulley bolt.

25. Remove the bolts and the accessory drive belt Using the special tool, remove the crankshaft
tensioner. pulley.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-61 Engine — 5.4L (3V) 303-01b-61
29. Using the special tool, remove the crankshaft front 32. Remove the crankshaft sensor ring from the
seal. crankshaft.
30. Remove the fasteners. 33. Compress the valve springs, and remove the
NOTE: Correct fastener location is essential for camshaft roller followers.
assembly procedure. Record fastener location. NOTE: The use of a special tool may be required
for this step.
NOTE: The camshaft roller followers must be
reinstalled in their original locations. Record the
camshaft roller follower locations.
34. Position the crankshaft with the keyway at the 9
o’clock position.
31. Remove the engine front cover from the cylinder

block.
35. Remove the bolts, the RH timing chain tensioner

and tensioner arm.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-62 Engine — 5.4L (3V) 303-01b-62
36. Remove the bolts, the LH timing chain tensioner

and tensioner arm.
37. Remove the RH and LH timing chains and the

camshaft sprocket.
Remove the LH timing chain from the
camshaft sprocket.
Remove the LH timing chain and crankshaft
sprocket.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-63 Engine — 5.4L (3V) 303-01b-63
38. Remove both timing chain guides.

Remove the bolts.
Remove both timing chain guides.
39. Remove the bolt and the oil level indicator tube.
40. Remove the bolts and discard.
RH is shown; LH is similar.
2. Remove the cylinder heads.
CAUTION: The cylinder head bolts
must be discarded and new bolts must be
installed. They are tighten-to-yield
designed and cannot be reused.
CAUTION: Place cylinder head on a
cardboard or wood surface to prevent
damage to the joint face. 41. Discard the cylinder head gaskets. Clean the
engine block sealing surfaces with silicone gasket
CAUTION: Aluminum surfaces are remover and metal surface prep. Follow the
soft and can be scratched easily. Never directions on the packaging.
place the cylinder head gasket surface,
unprotected, on a bench surface. CAUTION: Do not use metal scrapers,
NOTE: The cylinder heads are cleaned as wire brushes, power abrasive discs or other
part of the cylinder head disassembly abrasive means to clean the sealing surfaces.
process. These tools cause scratches and gouges
which make leak paths. Use a plastic scraper
to remove all traces of the head gasket.
42. Remove the bolts and the oil pump screen and
pickup tube.
43. Remove the oil pump screen and pickup tube
spacer.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-64 Engine — 5.4L (3V) 303-01b-64
44. Remove the oil pump. 46. Remove the bolts and the connecting rod cap.
Discard the bolts.
1. Remove the bolts.
2. Remove the oil pump. CAUTION: Verify that the connecting rods
and rod caps have orientation numbers cast
into them. If not, number the connecting rods
and rod caps for correct orientation.
45. Before removing the pistons, inspect the top of

the cylinder bores. If necessary, remove the ridge
or carbon deposits from each cylinder using a
cylinder ridge reamer, following the manufacturer
instructions.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-65 Engine — 5.4L (3V) 303-01b-65
47. Use the special tool to push the piston through 48. Remove the fasteners.
the top of the cylinder block.
1. Remove and discard the cross-mounted main
CAUTION: Do not scratch the cylinder cap bolts.
walls or crankshaft journals with the 2. Remove the dowels.
connecting rod. 3. Remove and discard the main bearing cap
bolts.
49. Remove the five main bearing caps, the lower

crankshaft main bearings and the lower thrust
washer.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-66 Engine — 5.4L (3V) 303-01b-66
50. Remove the crankshaft, the upper crankshaft

main bearings and the upper thrust washers from
the cylinder block.
G89796 en 01/2003 2003.0 BA Falcon

303-01b-67
DISASSEMBLY AND ASSEMBLY OFEngine — 5.4L (3V)
SUBASSEMBLIES 303-01b-67
2. Remove the bolts and the variable camshaft

Cylinder Head timing housing.
Special Tool(s)
Installer, Valve Stem Oil Seal
303-383 (T91P-6571-A)
Materials
Motorcraft Silicone —
Gasket Remover
ZC-30
Motorcraft Metal Surface — 3. Remove the bolts and the bearing caps.
Prep NOTE: The camshaft bearing caps must be
ZC-31 reinstalled in their original locations. Record the
SAE 10W-30 Premium WSS-M2C153-H camshaft bearing cap locations.
XO-10W30-QSP
Disassembly
CAUTION: Cylinder head machining or
milling is not authorized by the Ford Motor
Company. Cylinder head flatness must be within
0.0254 mm (0.001 in) across a 38.1 mm (1.5 in)
square area.
CAUTION: Place the cylinder head on a

cardboard or wood surface to prevent damage to
the joint face.
1. Install the special tool and remove the bolt and
the camshaft phaser sprocket assembly.
Discard the bolt and washer.
G89798 en 01/2003 2003.0 BA Falcon

303-01b-68 Engine — 5.4L (3V) 303-01b-68
4. Remove the camshaft.
7. Remove the valve stem seals.

5. Remove the hydraulic lash adjusters.
NOTE: The hydraulic lash adjusters must be
hydraulic lash adjuster locations.
8. Clean the cylinder head sealing surfaces.

1. Remove any large deposits of silicone or
gasket material with a plastic scraper.
2. Apply silicone gasket remover, following
6. Compress the valve springs and remove the package directions, and allow to set for
valves. several minutes.
1. Remove the valve spring retainer keys. 3. Remove the silicone gasket remover with a
plastic scraper. A second application of
2. Remove the valve spring retainers. silicone gasket remover may be required if
3. Remove the valve springs. residual traces of silicone or gasket material
4. Remove the valves. remain.
4. Apply metal surface prep, following package
CAUTION: Keep the valves and valve directions, to remove any remaining traces of
spring retainer keys in order so they can oil or coolant, and to prepare the surfaces to
be reinstalled in their original locations. bond with the new gasket. Do not attempt to
NOTE: The use of a special tool may be make the metal shiny. Some staining of the
required for this step. metal surfaces is normal.
gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the
head gasket.
CAUTION: Observe all warnings or
cautions and follow all application
directions contained on the packaging of
G89798 en 01/2003 2003.0 BA Falcon

303-01b-69 Engine — 5.4L (3V) 303-01b-69
the silicone gasket remover and the metal 5. Install the hydraulic lash adjusters in their original
surface prep. locations.
NOTE: If there is no residual gasket material NOTE: Lubricate the hydraulic lash adjusters
present, metal surface prep can be used to using clean engine oil.
clean and prepare the surfaces.
Assembly
1. Install the valves in the valve guides located in the
cylinder head.
NOTE: Lubricate the valve stems using clean
engine oil.
6. Lubricate the camshaft journals with clean engine

oil.
2. Install the valve stem seals.

NOTE: The use of a special tool may be required
for this step.
3. Install the valve springs and the valve spring
retainers onto the valves.
7. Install the camshaft.

NOTE: Lubricate the camshaft using clean engine
oil.
4. Compress the valve springs. Install the valve

spring retainer keys.
NOTE: The use of a special tool may be required
for this step.
G89798 en 01/2003 2003.0 BA Falcon

303-01b-70 Engine — 5.4L (3V) 303-01b-70
8. Install the bearing caps and the bolts and tighten 10. Install the camshaft variable timing sprocket
in the sequence shown. assembly and loosely install the bolt.
NOTE: Lubricate the bearing caps using clean
engine oil.
12. Tighten the bolt in two stages:

Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
9. Install a new gasket, the variable camshaft timing
housing and the bolts.
G89798 en 01/2003 2003.0 BA Falcon

303-01b-71 Engine — 5.4L (3V) 303-01b-71
ASSEMBLY
Engine Special Tool(s)

Special Tool(s) Seal
Installer, Connecting Rod 303-516 (T95P-6701-BH)
303-442 (T93P-6136-A)

Slinger
Installer, Crankshaft Vibration 303-517 (T95P-6701-CH)
Damper
303-102 (T74P-6316-B)
Lifting Bracket Set, Engine

303-DS086 (D93P-6001-A)
Installer, Crankshaft Front Oil
Seal
303-635
Modular Engine Lift Bracket

303-F047 (014-00073) or
Installer, Front Cover Oil Seal equivalent
303-335 (T88T-6701-A)
Materials
Motorcraft Silicone —
Compressor, Piston Ring Gasket Remover
303-D032 (D81L-6002-C) or ZC-30
equivalent Motorcraft Metal Surface —
Prep
ZC-31
Sealant
Holding Tool, Crankshaft F7AZ-19554-EA or
303-448 (T93P-6303-A) equivalent
Instant Adhesive WSK-M2G402-A4
E8AZ-19554-A
SAE 10W-30 Premium WSS-M2C153-H
Synthetic Blend Engine
Oil
Installer, Crankshaft Rear Oil XO-10W30-QSP or
Seal equivalent
303-518 (T95P-6701-DH) Motorcraft Premium ESE-M97B44-A (green in
Engine Coolant color)
VC-4-A (in Canada
CXC-10; in Oregon VC-5)
or equivalent. Do not mix
coolant types.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-72 Engine — 5.4L (3V) 303-01b-72
ASSEMBLY (Continued)
Materials the correct bearing grade for this main

Motorcraft Premium Gold WSS-M97B51-A1 (yellow bearing is a ‘‘2’’.
Engine Coolant in color) Repeat this process for the remaining four
VC-7-A (in Oregon main bearings.
VC-7-B) or equivalent.
Do not mix coolant types.
Hydraulic Chain 1L3Z-6P250-AA
Tensioner Retaining Clip
Assembly
All Engines
1. Record the main bearing code found on the front
of the engine block.
2. Record the main bearing code found on the back

of the crankshaft.
3. Using the data recorded earlier and the Bearing

Select Fit Chart, Standard Bearings, determine
the required bearing grade for each main bearing.
Read the first letter of the engine block main
bearing code and the first letter of the
crankshaft main bearing code.
Read down the column below the engine
block main bearing code letter, and across the
row next to the crankshaft main bearing code
letter, until the two intersect. This is the
required bearing grade for the number one
crankshaft main bearing.
As an example, if the engine block code letter
is ‘‘F’’ and the crankshaft code letter is ‘‘D’’,
G89799 en 01/2003 2003.0 BA Falcon

303-01b-73 Engine — 5.4L (3V) 303-01b-73
Bearing Select Fit Chart, Standard Bearings
4. If oversize bearings are being used, use the

procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine
the required bearing grade for each main bearing.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-74 Engine — 5.4L (3V) 303-01b-74
Bearing Select Fit Chart, Oversize Bearings
5. Install the crankshaft upper main bearings into the

cylinder block and lubricate them with clean
engine oil.
NOTE: Before assembling the cylinder block, all
sealing surfaces must be free of chips, dirt, paint
and foreign material. Also, make sure the coolant
and oil passages are clear.
6. Install the crankshaft onto the upper crankshaft
main bearings.
NOTE: The upper thrust washers are shown for
location purposes only. Do not install the upper
thrust washers until the crankshaft is installed.
Refer to the following two steps.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-75 Engine — 5.4L (3V) 303-01b-75
7. Push the crankshaft rearward and install the rear

crankshaft upper thrust washer at the back of the
No. 5 main boss.
NOTE: The oil groove on the thrust washer must
face toward the front of the engine (against the
crankshaft thrust surface).
10. Install the crankshaft lower main bearings into the

main bearing caps and lubricate them with clean
engine oil. Locate the main bearing cap on the
cylinder block and tap into place using a plastic or
dead-blow hammer.
8. Push the crankshaft forward and install the front

crankshaft upper thrust washer at the front of the
No. 5 main boss.
face toward the front of the engine (against the
crankshaft surface).
9. Install the lower crankshaft thrust washer to the

back side of the No. 5 main bearing cap, with oil
grooves facing the crankshaft surface.
NOTE: To aid in assembly, apply petroleum jelly
to the back of the crankshaft thrust washer.
face toward the rear of the engine (crankshaft
surface).
G89799 en 01/2003 2003.0 BA Falcon

303-01b-76 Engine — 5.4L (3V) 303-01b-76
11. Install the dowel pins so the flat sides face the 12. Install the vertical main bearing cap fasteners and
crankshaft. tighten in the sequence shown.
Tighten to 40 Nm (30 lb-ft).
Tighten an additional 90 degrees.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-77 Engine — 5.4L (3V) 303-01b-77
13. Install the side bolts and tighten them in the

sequence shown.
Tighten to 30 Nm (22 lb-ft).
Tighten an additional 90 degrees.
15. Once the connecting rod is seated on the

crankshaft journal, remove the Connecting Rod
Installer.
CAUTION: Do not scratch the cylinder
walls or crankshaft journals with the
connecting rod.
14. Use the special tools to install the piston and

connecting rod with the upper connecting rod 16. Position the lower bearing and connecting rod,
bearing in place. and install the new bolts loosely.
CAUTION: Do not scratch the cylinder CAUTION: The rod cap installation must
walls or crankshaft journals with the keep the same orientation as marked during
connecting rod. disassembly.
NOTE: The next three steps are for all eight NOTE: The connecting rod caps are of the
connecting rods, rod caps and pistons. Only one ‘‘cracked’’ design and must mate with the
connecting rod, rod cap and piston is shown. connecting rod ends. Excessive bearing clearance
will result if not mated correctly.
NOTE: Make sure the identification marks on the
piston and connecting rod face toward the front of
the engine.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-78 Engine — 5.4L (3V) 303-01b-78
17. Tighten the bolts in two stages, using the 19. Position the head gasket over the dowel pins.
sequence shown.
Stage 2: Tighten an additional 105 degrees. CAUTION: Make sure all coolant
NOTE: Main bearing caps are removed for residue and foreign material are cleaned
clarity. from the block surface and cylinder bore.
CAUTION: The use of sealing aids
(aviation cement, copper spray, and glue)
is not permitted. The gasket must be
installed dry.
20. Rotate the crankshaft until the crankshaft keyway

points toward the 9 o’clock position.
18. Position the oil pump and install the bolts loosely.
Tighten the bolts in the sequence shown.
21. Position the cylinder head over the dowels and

head gasket and install the cylinder head bolts
loosely.
CAUTION: The cylinder head bolts
must be discarded and new bolts installed.
They are tighten-to-yield designed and
cannot be reused.
NOTE: NOTE: Do not turn the crankshaft until
instructed to do so.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-79 Engine — 5.4L (3V) 303-01b-79
23. Install the oil level indicator tube.

Install a new O-ring seal on the oil level
indicator tube.
Install the oil level indicator tube.
Install the bolt and tighten to 10 Nm (89 lb-in).
24. Install the RH exhaust manifold gaskets and the
exhaust manifold. Tighten the nuts in the
sequence shown.
22. Tighten the bolts in three stages, in the sequence

shown.
25. Install the LH exhaust manifold and the exhaust

manifold gaskets. Tighten the nuts in the
sequence shown.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-80 Engine — 5.4L (3V) 303-01b-80
26. Compress the tensioner plunger, using a vise. 30. Install the RH timing chain guide.
be followed exactly or damage to valves and
31. Install the LH timing chain guide.
27. Install a retaining clip on the tensioner to hold the

plunger in during installation.
32. Pre-position the camshafts.

1. Rotate the LH camshaft until the timing mark
is approximately at 6 o’clock.
2. Rotate the RH camshaft until the timing mark
28. Remove the tensioner from the vise. is approximately at 12 o’clock.
29. If the copper links are not visible, mark two links
on one end and one link on the other end, and
use as timing marks.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-81 Engine — 5.4L (3V) 303-01b-81
33. Remove the Crankshaft Holding Tool. 36. Position the timing chain on the camshaft
34. Install the crankshaft sprocket, making sure the sprocket with the camshaft sprocket timing mark
flange faces forward. positioned between the two copper (marked)
chain links.
NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment
Set to adjust the camshaft sprocket slightly to
obtain timing mark alignment.
35. Position the lower end of the LH (inner) timing

timing mark on the outer flange of the crankshaft
sprocket with the single copper (marked) link on
the chain.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-82 Engine — 5.4L (3V) 303-01b-82
37. Position the LH timing chain tensioner arm on the 40. Position the RH timing chain on the camshaft
dowel pin and install the LH timing chain sprocket. Make sure the camshaft sprocket timing
tensioner. mark is positioned between the two copper
NOTE: The LH timing chain tensioner arm has a (marked) chain links.
bump near the dowel hole for identification. NOTE: The lower half of the timing chain must be
positioned above the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment
Set to adjust the camshaft sprocket slightly to
obtain timing mark alignment.
38. Remove the retaining clip from the LH timing

chain tensioner.
41. Position the RH timing chain tensioner arm on the

dowel pin and install the RH timing chain
tensioner.
39. Position the lower end of the RH (outer) timing

timing mark on the sprocket with the single copper
(marked) chain link.
42. Remove the retaining clip from the RH timing

chain tensioner.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-83 Engine — 5.4L (3V) 303-01b-83

timing marks.
44. Install the camshaft roller followers.

1. Compress the valve spring.
2. Install the camshaft roller followers in their
original locations. 47. Install a new engine front cover gasket on the
NOTE: Lubricate the camshaft roller followers engine front cover. Position the engine front
using clean engine oil. cover. Install the fasteners finger-tight.
NOTE: The use of a special tool may be
required.
45. Install the crankshaft sensor ring on the
crankshaft.
48. Tighten the engine front cover fasteners in

sequence in three stages.
Stage 1: Tighten fasteners 1 through 5 to 25
Nm (18 lb-ft).
46. Apply a bead of silicone gasket and sealant along Stage 2: Tighten fasteners 6 and 7 to 48 Nm
the cylinder head-to-cylinder block surface at the (35 lb-ft).
locations shown. Stage 3: Tighten fasteners 8 through 15 to 48
NOTE: If the front cover is not secured within four Nm (35 lb-ft).
minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area,
use silicone gasket remover and metal surface
prep. Follow the directions on the packaging.
Failure to follow this procedure can cause future
oil leakage.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-84 Engine — 5.4L (3V) 303-01b-84

1 N806177 Bolt, Hex Flange Head Pilot, M8 14 N808140 Stud and Washer, Hex Head
x 1.25 x 53 Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
2 N806177 Bolt, Hex Flange Head Pilot, M8 15 N808140 Stud and Washer, Hex Head
x 1.25 x 53 Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
3 N806177 Bolt, Hex Flange Head Pilot, M8 49. Install the oil pump screen and pickup tube
x 1.25 x 53 spacer.
4 N806177 Bolt, Hex Flange Head Pilot, M8
x 1.25 x 53
5 N806177 Bolt, Hex Flange Head Pilot, M8
x 1.25 x 53
6 N808529 Stud, Hex Head Pilot, M10 x 1.5
x 59 — M10 x 1.5 x 30
7 N808529 Stud, Hex Head Pilot, M10 x 1.5
x 59 — M10 x 1.5 x 30
8 N808142 Screw and Washer, Hex Pilot,
M10 x 1.5 x 57.5
M10 x 1.5 x 57.5
M10 x 1.5 x 57.5
11 N808140 Stud and Washer, Hex Head
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
G89799 en 01/2003 2003.0 BA Falcon

303-01b-85 Engine — 5.4L (3V) 303-01b-85
50. Position the oil pump screen and pickup tube and 53. Position the belt idler pulley and install the bolt.
install the bolts.
and install a new O-ring. Lubricate with the O-ring
with clean engine oil.
51. Position the oil filter adapter and install the four
bolts.
NOTE: NOTE: Clean and inspect the mating
surfaces, and install new gaskets.
54. Install the coolant pump.
1. Lubricate the new O-ring seal using engine
coolant and install the O-ring seal onto the
coolant pump.
2. Position the coolant pump into the engine
block.
3. Install the bolts.
CAUTION: Do not rotate the coolant
pump housing once the coolant pump has
been positioned in the cylinder block.
Damage to the O-ring seal will occur.
52. Position the power steering pump and install the

three bolts.
55. Lubricate the engine front cover and the front oil
seal inner lip with clean engine oil.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-86 Engine — 5.4L (3V) 303-01b-86
56. Use the special tools to install the crankshaft front 59. Tighten the new crankshaft pulley bolt in four
oil seal into the engine front cover. stages.
Stage 2: Loosen 360 degrees.
57. Apply silicone gasket and sealant to the Woodruff

key slot on the crankshaft pulley.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow 60. Position the coolant pump pulley on the coolant
the directions on the packaging. Failure to follow pump and install the bolts.
this procedure can cause future oil leakage.
58. Use the special tool to install the crankshaft

pulley.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-87 Engine — 5.4L (3V) 303-01b-87
61. Position the accessory drive belt tensioner and 64. Position the A/C compressor and install the bolts.
install the bolts.
65. Install the oil drain plug.

62. Install the crankshaft position (CKP) sensor and
the bolt.
66. If a new gasket is being installed, apply instant

adhesive completely around the gasket groove in
63. Position the A/C compressor bracket and install the RH valve cover. Install the new valve cover
the bolts. gasket.
NOTE: RH shown, LH similar.
67. Apply silicone gasket and sealant in two places
where the engine front cover meets the cylinder
head.
the directions on the packaging. Failure to follow
G89799 en 01/2003 2003.0 BA Falcon

303-01b-88 Engine — 5.4L (3V) 303-01b-88
69. Position the LH valve cover and gasket on the

cylinder head and install the bolts loosely. Tighten
the bolts in the sequence shown.
68. Position the RH valve cover and gasket on the

cylinder head and install the bolts loosely. Tighten
the bolts in the sequence shown.
70. Install the eight ignition coils and bolts.

NOTE: NOTE: RH is shown, LH is similar.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-89 Engine — 5.4L (3V) 303-01b-89
71. Position the water bypass tube assembly and 74. Position the generator support bracket and install
install the bolts. the bolts.
72. Install the bolt. 75. Install the intake manifold gaskets.
73. Position the generator and install the bolts.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-90 Engine — 5.4L (3V) 303-01b-90
76. Install the intake manifold and tighten the bolts in 80. Install the special tool.
the sequence shown.
82. Install the special tool and remove the engine

77. Install the crankcase ventilation tube on the LH from the work stand.
valve cover.
78. Install the radio frequency interference capacitors.
83. Inspect the rear seal retainer plate. Clean the

mating surface for the rear seal retainer plate with
silicone gasket remover and metal surface prep.
Follow the directions on the packaging.
79. Install the engine control sensor wiring.
abrasive means to clean the aluminum
retainer plate. These tools cause scratches
and gouges, which make leak paths. Use a
plastic scraping tool to remove all traces of
old sealant.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-91 Engine — 5.4L (3V) 303-01b-91
84. Apply a 4 mm (0.16 in) bead of silicone gasket 87. Inspect the oil pan. Clean the mating surface for
and sealant around the rear oil seal retainer the oil pan with silicone gasket remover and metal
sealing surface. surface prep. Follow the directions on the
NOTE: If not secured within four minutes, the packaging.
cleaned. To clean the sealing area, use silicone CAUTION: Do not use metal scrapers,
gasket remover and metal surface prep. Follow wire brushes, power abrasive discs or other
the directions on the packaging. Failure to follow abrasive means to clean the sealing surfaces.
this procedure can cause future oil leakage. These tools cause scratches and gouges,
88. Apply silicone gasket and sealant at the rear oil
seal retainer-to-cylinder block sealing surface.
85. Install the rear oil seal retainer plate and loosely
install the six bolts.
89. Apply silicone gasket and sealant at the engine

front cover-to-cylinder block sealing surface.
86. Tighten the bolts in the sequence shown. this procedure can cause future oil leakage.
G89799 en 01/2003 2003.0 BA Falcon

303-01b-92 Engine — 5.4L (3V) 303-01b-92
90. Install the oil pan gasket and the oil pan and 91. Tighten the bolts in three stages, in the sequence
loosely install the bolts. shown.
Stage 1: Tighten to 2 Nm (18 lb-in).
G89799 en 01/2003 2003.0 BA Falcon

303-01b-93 Engine — 5.4L (3V) 303-01b-93
92. Using the special tools, install a new crankshaft 94. Install the flexplate or the flywheel and bolts.
rear oil seal. Tighten the bolts in the sequence shown.
CAUTION: Lubricate the inner lip of the
crankshaft rear oil seal with clean engine oil.
93. Using the special tools, install the crankshaft rear

oil slinger.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-1 Engine — V8 (4V) 303-01c-1
SECTION : 303-01c Engine — V8 (4V)

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01c-3
Engine .................................................................................................................................303-01c-6
Identification ......................................................................................................................303-01c-6
Code Information ...............................................................................................................303-01c-6
Induction System ...............................................................................................................303-01c-6
Valve Train ........................................................................................................................303-01c-6
Positive Crankcase Ventilation System ............................................................................303-01c-6
Lubrication System ............................................................................................................303-01c-6
Oil Pump ...........................................................................................................................303-01c-7
Cooling System .................................................................................................................303-01c-7
Drive Belt System ..............................................................................................................303-01c-7
Engine ...............................................................................................................................303-01c-17
IN-VEHICLE REPAIRS
Intake Manifold Upper ........................................................................................................303-01c-18
Intake Manifold — Lower ...................................................................................................303-01c-18
Valve Cover — RH .............................................................................................................303-01c-20
Valve Cover — LH .............................................................................................................303-01c-22
Crankshaft Pulley ..............................................................................................................303-01c-22
Crankshaft Front Oil Seal ..................................................................................................303-01c-24
Engine Front Cover ...........................................................................................................303-01c-24
Timing Drive Components .................................................................................................303-01c-28
Valve — Springs, Retainer and Valve Stem Seal ..............................................................303-01c-33
Hydraulic Lash Adjusters ..................................................................................................303-01c-35
Roller Followers ................................................................................................................303-01c-35
Camshaft ...........................................................................................................................303-01c-36
Exhaust Manifold — LH .....................................................................................................303-01c-40
Oil Filter Adapter ...............................................................................................................303-01c-40
Oil Pressure Sender ..........................................................................................................303-01c-41
Oil Level Indicator and Tube .............................................................................................303-01c-42
Oil Pan ..............................................................................................................................303-01c-42
Oil Pump Screen and Pickup Tube ...................................................................................303-01c-44
Flexplate ............................................................................................................................303-01c-45
Crankshaft Rear Oil Seal ..................................................................................................303-01c-45
Engine Mounts — RH ........................................................................................................303-01c-47
Engine Mounts — LH .........................................................................................................303-01c-47
REMOVAL
Engine ...............................................................................................................................303-01c-48
01/2003 2003.0 BA Falcon

303-01c-2 Engine — V8 (4V) 303-01c-2
(Continued)
DISASSEMBLY
Engine ...............................................................................................................................303-01c-52
Piston ................................................................................................................................303-01c-62
Cylinder Head RH and LH .................................................................................................303-01c-63
ASSEMBLY
Engine ...............................................................................................................................303-01c-70
INSTALLATION
Engine ...............................................................................................................................303-01c-89
01/2003 2003.0 BA Falcon

303-01c-3 Engine — V8 (4V) 303-01c-3
SPECIFICATIONS

Description Specification Alignment bore-to-bore ± 0.038 mm (0.0015 in)
Magnetic clutch max. bend
Air gap between pulley 0.35 mm-0.75 mm (0.014 Side play (as assembled 0.300 ± 0.175 mm
and hub in 0.029 in) to crank)-standard play (0.0118 ± 0.0069 in)
Displacement 5.4L (4V) Side play (as assembled 0.475 mm (0.0187 in)
to crank)-max. play
No. cylinders 8
Piston
Bore/stroke 90.215/105.8 mm
(3.552/4.165 in) Cylinder bore diameter 90.200-90.210 mm
Grade 1 (3.5511-3.5515 in)
Firing order 1-3-7-2-6-5-4-8
Cylinder bore diameter 90.210-90.220 mm
Camshaft
Grade 2 (3.5516-3.5521 in)
Lobe lift exhaust LH 6.5958 mm (0.2597 in)
Cylinder bore diameter 90.220-90.230 mm
Lobe lift exhaust RH 6.5855 mm (0.2593 in) Grade 3 (3.5519-3.5524 in)
Lobe lift intake 6.58077 mm (0.250847 Piston diameter (Grade 90.180 ± 0.005 mm
in) 2) at right angle to pin (3.5504 ± 0.0002 in)
Lobe lift – allowable lift 0 bore
loss Piston to bore clearance -0.005 to +0.025 mm
Valve lift @ zero 10.00 mm (0.3937 in) (-0.0002 to 0.001 in)
lash-intake Pin bore diameter 22.008-22.014 mm
Valve lift @ zero 10.00 mm (0.3937 in) (piston) (0.8665-0.8667 in)
lash-exhaust Pin diameter 22.0005-22.0030 mm
Camshaft end play 0.027-0.190 mm (0.8662-0.8663 in)
(0.0011-0.0075 in) Pin clearance (negative 0.01395-0.005 mm
Camshaft end play 0.025-0.190 mm or positive) (0.001-0.0002 in)
service limit (0.0010-0.0075 in) Pin bore diameter (rod) 22.012-22.024 mm
Camshaft journal to 0.076-0.025 mm (0.8666-0.8671 in)
bearing clearance (0.0030-0.0010 in) Pin clearance (negative 0.009-0.0235 mm
Clearance service 26.962-26.936 mm or positive) (rod) (0.0002-0.0009 in)
limit-journal diameters (1.0615-1.0605 in) Ring groove width top 1.53-1.55 mm
Clearance service 27.012-26.987 mm (0.0602-0.061 in)
limit-journal inside (1.0635-1.0625 in) Ring groove width 1.52-1.54 mm
diameter (cap intermediate (0.0598-0.0606 in)
assembled)
Ring groove width oil 3.030-3.050 mm
Clearance service 0.09 mm (0.0035 in) (4 control (0.1193-0.1201 in)
limit-Camshaft runout: places)
Piston ring gap top 0.13-0.28 mm
Full indicator
(0.0051-0.0111 in)
measurement on all
journals when supported Piston ring gap 0.25-0.40 mm
on front and rear intermediate (0.0098-0.0157 in)
journals. Piston ring gap oil control 0.15-0.65 mm
Connecting Rod (0.0059-0.0256 in)
Big end journal inside 53.049-53.027 mm Crankshaft
diameter with assembled (2.0885-2.0877 in) Main bearing journal 67.483-67.503 mm
liners diameter (2.6568-2.6576 in)
Rod bearing to journal 0.064-0.026 mm Main bearing journal 0.0075 mm (0.0003 in)
clearance (0.0025-0.001 in) diameter: maximum between cross sections
Pin bore diameter (rod) 22.024-22.012 mm out-of-round
(0.867-0.8666 in) Main bearing journal 0.004 mm (0.0002 in)
Rod length (centerline 169.1 mm (6.6575 in) diameter: maximum taper
bore-to-bore) (straightness)
Alignment bore-to-bore ± 0.05 mm (0.0021 in) Runout: FIM of center 0.05 mm (0.0019 in) (3
max. twist journals when located on places)
front and rear journal
G89770 en 01/2003 2003.0 BA Falcon

303-01c-4 Engine — V8 (4V) 303-01c-4

Crankshaft journal to 0.048-0.024 mm Valve spring out of 2.5 degrees
main bearing clearance (0.001891-0.0009 in) square limit - intake
Connecting rod journal 53.003-52.983 mm Valve spring out of 2.5 degrees
diameter (2.0867-2.0859 in) square limit - exhaust
Connecting rod journal 0.0075 mm (0.0003 in) Valve guide inside 7.044-7.015 mm
diameter: maximum between cross sections diameter (0.2773-0.2762 in)
out-of-round Lubricants
Connecting rod journal 0.004 mm (0.0002 in) Silicone Gasket and WSE-M4G323-A4
diameter: maximum taper Sealant F7AZ-19554-EA
Crankshaft end play 0.075-0.377 mm Metal Surface Cleaner WSE-M5B392-A
(0.003-0.0148 in) F4AZ-19A536-RA
Cylinder Head/Valve Train Engine Coolant ESE-M97B44-A
Combustion chamber 53 ± 1.5cc /WSS-M97B51-A
volume (3.2342-0.0915 ci) 10W30 GF2 Engine Oil WSS-M2C910-A
Valve seat width - intake 2.1-1.9 mm Pipe Sealant with WSK-M2G350-A2 and
(0.0827-0.0748 in) Teflon® D8AZ-19554-A ESR-M18P7-A
Valve seat width - 2.1-1.9 mm or equivalent
exhaust (0.0827-0.0748 in)
Valve seat angle 45.00-44.50 degrees
Description Nm
Valve seat runout (TIR) 0.025 mm (0.001 in)
Valve cover bolts¹ —
Valve stem guide 0.069-0.020 mm
clearance - intake (0.0027-0.0008 in) Camshaft bearing cap bolts¹ —
Camshaft sprocket bolts 120
Valve stem guide 0.095-0.045 mm (0.0037
clearance - exhaust - 0.0018 in) Connecting rod bolts¹ —
Valve head diameter - 37.11-36.86 mm Crankshaft damper pulley bolt¹ —
intake (1.461-1.4512 in) Crankshaft main bearing bolts (cross —
Valve head diameter - 30.12-29.87 mm mounted)¹
exhaust (1.1858-1.176 in) Crankshaft main bearing bolts —
Valve face runout (limit) 0.05 mm (0.0019 in) (vertical)¹
Valve face angle 45.75-45.25 degrees Cylinder heads bolts¹ —
Valve stem diameter - 6.995-6.975 mm Exhaust manifold nuts 23-27
intake (0.2754-0.2746 in) Drive belt idler pulley bolt 25
Valve stem diameter - 6.970-6.949 mm Flywheel bolts 73-87
exhaust (0.2744-0.2736 in) Engine front cover bolts¹ —
Valve spring compression 711.7 N @ 26.4 Heater return tube bolt 20-30
pressure - intake
Heater supply tube screw & washer 8-12
Valve spring compression 711.7 N @ 26.4
pressure - exhaust Ignition coil cover bolts 10
Valve spring free length - 45.5 Lower intake manifold bolts¹ —
intake Upper intake manifold bolts¹ —
Valve spring free length - 50.2 mm (1.9764 in) Oil filter adapter bolt 25
exhaust Oil level indicator tube bolt 10
Valve spring installed 289.1 N @ 36.14 Oil pan bolts¹ —
pressure - intake
Oil pan drain plug 11-16
Valve spring installed 289.1 N @ 36.14 Oil pressure switch 12-16
pressure - exhaust
Oil pump bolts 10
Valve spring installed 272.6 N @ 36.15
pressure service limit - Oil pump screen cover and tube bolts 10
intake Oil pump screen cover and tube 25
Valve spring installed 272.6 N @ 36.15 spacer
pressure service limit - Power steering pump bolts 25
exhaust
G89770 en 01/2003 2003.0 BA Falcon

303-01c-5 Engine — V8 (4V) 303-01c-5
Description Nm
Radio ignition interference capacitor 10
bolts
Rear main oil seal retainer bolts 10
Spark plugs 10
Timing chain guide bolts 10
Timing chain hydraulic tensioner bolts 25
Water pump bolts 20-30
Water pump pulley bolts 25
Power steering bracket lower bolts 25
Motor mount cross bolts 80
Motor mount through bolts 80
¹ Refer to the procedure in this section.
G89770 en 01/2003 2003.0 BA Falcon

303-01c-6 Engine — V8 (4V) 303-01c-6
Engine A constant fuel pressure drop is maintained across

the fuel injectors by the fuel pressure regulator. The
The 5.4L (4V) is a V-8 engine with the following fuel pressure regulator:
features: is positioned upstream from the fuel injectors on
dual overhead camshafts the fuel injection supply manifold.
four valves per cylinder Valve Train
sequential multiport fuel injection (SFI)
The valve train operates as follows:
an aluminum intake manifold
Ball tip hydraulic lash adjusters provide automatic
aluminum cylinder heads lash adjustment.
a cast iron, 90-degree V-cylinder block Roller followers ride on the camshaft lobes,
individually chain-driven camshafts with a transferring the up-and-down motion of the
hydraulic timing chain tensioner on each timing camshafts to the valves in the cylinder heads.
chain
the electronic ignition system with eight ignition
coils All engines are equipped with a closed-type positive
crankcase ventilation system recycling the crankcase
Identification vapors to the upper intake manifold.
Always refer to these labels when new parts are
required or when checking engine calibrations. The
Lubrication System
engine parts often differ within a CID family. The engine lubrication system operates as follows:
Verification of the identification codes will make sure Oil is drawn into the oil pump through the oil
that the correct parts are obtained. These codes pump screen cover and tube in the sump of the oil
contain all the pertinent information relating to the pan.
dates, optional equipment and revisions. The Ford
Master Parts Catalog contains a complete listing of Oil enters the main oil gallery where it is
the codes and their application. distributed to the crankshaft main journals and to
both cylinder heads.
Code Information From the main journals, the oil is routed through
The engine code information label, located on the side cross-drilled passages in the crankshaft to
of the LH valve cover towards the rear, contains the lubricate the connecting rod bearings. Controlled
following: leakage through the crankshaft main bearings and
connecting rod bearings is slung radially outward
engine build date to cool and lubricate the cylinder walls as well as
engine plant code the entire connecting rod, piston and piston rings
engine code assembly.
The left cylinder head is fed from a drilling into the
Induction System supply passage feeding the main gallery at the
The sequential multiport fuel injection (SFI) provides front of the cylinder block. The right cylinder head
the fuel/air mixture needed for combustion in the is fed from a drilling into the rear of the main
cylinders. The eight solenoid-operated fuel injectors: gallery. Main gallery pressure is reduced as it
enters the cylinder head galleries through fixed
are mounted in the fuel injection supply manifold
serviceable orifices located at the upper part of
and the intake manifold above the cylinder heads.
the feed passages. It is this reduced pressure in
meter fuel into the air intake stream in accordance the cylinder head galleries which feeds the
with engine demand. camshaft journals, the hydraulic lash adjusters
are positioned so that their tips direct fuel just and the primary and secondary timing chain
ahead of the engine intake valves. tensioners.
are connected in series with the fuel pressure The camshaft lobe and roller followers are
regulator. lubricated by splash created through valve train
supply fuel from the fuel tank by a fuel pump operation.
mounted in the fuel tank.
G89771 en 01/2003 2003.0 BA Falcon

303-01c-7 Engine — V8 (4V) 303-01c-7
Oil Pump
The lubrication system of the 5.4L (4V) engine is
designed to provide optimum oil flow to critical
components of the engine through its entire operating
range. The heart of the system is a positive
displacement internal gear oil pump using top seal
rotors.
Generically this design is known as a gerotor pump,
which operates as follows:
The oil pump is mounted on the front face of the
cylinder block.
The inner rotor is piloted on the crankshaft post
and is driven through flats on the crankshaft.
System pressure is limited by an integral,
internally-vented relief valve which directs the
bypassed oil back to the inlet side of the oil pump.
Oil pump displacement has been selected to
provide adequate volume to ensure correct oil
pressure both at hot idle and maximum speed.
The relief valve calibration protects the system
from excessive pressure during high viscosity
conditions.
The relief valve is designed to provide adequate
connecting rod bearing lubrication under
high-temperature and high-speed conditions.
Cooling System
The engine cooling system includes the following:
radiator
water pump
twin electric fans
surge tank(aids in maintaining the correct volume
of engine coolant) & vent hoses
water thermostat housing
upper radiator hose
lower radiator hose
heater water hoses & tubes
water bypass tube
Drive Belt System
The 5.4L (4V) DOHC engine is equipped with a
serpentine drive belt. To make sure of maximum life,
a new drive belt should be of the same type as
originally installed.
The accessories mounted on the front of the
engine are belt-driven by the crankshaft.
The serpentine drive belt is routed over each
accessory pulley, driven by the crankshaft pulley
bolted to the crankshaft.
For service procedures, including tensioning, refer to
Section 303-05.
G89771 en 01/2003 2003.0 BA Falcon

303-01c-8 Engine — V8 (4V) 303-01c-8

1 Bolt 13 Bolt (3 req’d)
2 Washer 14 Engine front cover
3 Bolt (4 req’d) 15 Bolt (4 req’d)
4 Bolt 16 Timing chain tensioner
5 Belt idler pulley 17 Timing chain tensioner arm
6 Water pump pulley 18 Timing chain (2 req’d)
7 Crankshaft pulley 19 Timing chain guide
8 Stud (5 req’d) 20 Timing chain tensioner
9 Bolt 21 Timing chain tensioner arm
10 Camshaft position sensor 22 Timing chain (2 req’d)
11 Bolt 23 Bolt (3 req’d)
12 Crankshaft position sensor 24 Timing chain guide
G89771 en 01/2003 2003.0 BA Falcon

303-01c-9 Engine — V8 (4V) 303-01c-9
Item Description
25 Bolt
26 Crankshaft sprocket (2 req’d)
27 Ignition pulse ring
28 Power steering pump
29 Bolt (3 req’d)
30 Stud (2 req’d)
31 Bolt (8 req’d)
32 Crankshaft front seal

1 Pipe plug (4 req’d) 4 Oil level indicator tube
2 Dowel (2 req’d) 5 Bolt
3 Oil level indicator 6 Pipe plug
G89771 en 01/2003 2003.0 BA Falcon

303-01c-10 Engine — V8 (4V) 303-01c-10
Item Description
7 Retention Spring (11 mm)
8 Oil filter adapter gasket
9 Oil bypass filter
10 Oil pressure sender
11 Bolt (4 req’d)
12 Oil filter adapter (4 x 2)
13 Oil pan
14 Oil pan gasket
15 Dowel (2 req’d)
16 Plug
17 Water bypass tube
G89771 en 01/2003 2003.0 BA Falcon

303-01c-11 Engine — V8 (4V) 303-01c-11
Item Description
1 Bolt (2 req’d) (part of 6100)
2 Connecting rod (8 req’d) (part of 6100)
3 Connecting rod bearing (16 req’d)
4 Piston pin retainer (16 req’d) (part of 6100)
5 Piston pin (8 req’d) (part of 6100)
6 Piston (8 req’d) (part of 6100)
7 Piston ring (8 req’d) (part of 6100)
10 Crankcase vent tube and connector
11 Valve cover
12 Camshaft
13 Chain tensioner
14 Bolts (2 req’d)
15 Camshaft
16 Bushing
17 Washers (2 req’d)
18 Bolts (2 req’d)
19 Gear
20 Chain
21 Gear
22 Exhaust manifold gasket
23 Cylinder head gasket
24 Exhaust manifold
25 HEX Screw (8 req’d)
26 Washer (8 req’d)
27 Gasket
28 PCV Valve
G89771 en 01/2003 2003.0 BA Falcon

303-01c-12 Engine — V8 (4V) 303-01c-12
G89771 en 01/2003 2003.0 BA Falcon

303-01c-13 Engine — V8 (4V) 303-01c-13
Item Description
1 Cylinder head gasket
2 Gear
3 Bolt (2 req’d)
5 Secondary timing chain (2 req’d)
6 Screw and washer (2 req’d)
7 Timing chain vibration damper
8 Camshaft bearing cap (2 req’d)
9 Bolt (19 req’d)
10 Bolt (6 req’d)
11 Camshaft
12 Roller follower (8 req’d)
13 Bolt (10 req’d)
14 Hydraulic lash adjuster
15 Camshaft
16 Camshaft bearing cap (2 req’d)
17 Exhaust manifold gasket
18 Exhaust manifold
19 HEX Screw (8 req’d)
21 Gasket
22 Oil filler cap
23 Bolt (4 req’d)
24 Ignition coil cover
25 Spark plug (8 req’d)
26 Valve cover
28 Stud (4 req’d)
29 PCV Connector
G89771 en 01/2003 2003.0 BA Falcon

303-01c-14 Engine — V8 (4V) 303-01c-14
G89771 en 01/2003 2003.0 BA Falcon

303-01c-15 Engine — V8 (4V) 303-01c-15
Item Description
1 Heater water tube (in)
2 Heater water tube (out)
3 Engine block
4 Dowel (4 req’d)
5 Bolt (10 req’d)
6 Thrust bearing (2 req’d)
7 Crankshaft
8 Thrust bearing
9 Crankshaft bearing cap adjusting screw
(10 req’d)
10 Bolt
11 Spacer
12 Oil pump screen cover and tube
13 Bolt
14 Oil pan gasket
15 Oil pan
16 Oil pan drain plug
18 Oil pan reinforcements
19 Bolt (2 req’d)
20 Bolt (9 req’d)
21 Main bearing cap
22 Crankshaft main bearing (5 req’d)
23 Oil pump
24 Bolt (3 req’d)
25 Woodruff key
26 Crankshaft main bearing #1
27 Crankshaft main bearing upper (4 req’d)
28 Water pump
29 Bolt (4 req’d)
30 Screw & Washer
31 Water thermostat housing
G89771 en 01/2003 2003.0 BA Falcon

303-01c-16 Engine — V8 (4V) 303-01c-16
Item Description
1 Bolt (8 req’d)
2 Crankshaft oil slinger
3 Crankshaft rear oil seal
4 Crankshaft rear retainer
5 Plug
6 Plug
7 Bolt (6 req’d)
8 Flexplate
G89771 en 01/2003 2003.0 BA Falcon

303-01c-17 Engine — V8 (4V) 303-01c-17
Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, Refer to
Powertrain Control/Module in Section 303-14.
G89772 en 01/2003 2003.0 BA Falcon

303-01c-18 Engine — V8 (4V) 303-01c-18
IN-VEHICLE REPAIR
Intake Manifold Upper 4. Tighten the bolts to 8-12 Nm (89 lb-in) in the
sequence shown.
Removal
All vehicles
2. Remove PCV hose from LH valve cover.
3. Remove the air cleaner outlet from throttle body.
For additional information, refer to Section
303-12.
4. Disconnect the electrical connectors from throttle
body motor.
MAP sensor.
All vehicles
5. Fit the appearance plate to the top of the manifold
1. Remove the screws and bracket for alternator cover with four (4) screws.
support. NOTE: Allow engine to sit unstarted for min 2 hrs
2. Remove the four (4) appearance plate screws and to allow manifold to seal.
lift the appearance plate off. O-Ring is now used.
3. Remove the eight (8) upper manifold mounting
6. Fit the alternator mounting bracket with four (4)
screws.
screws.
4. Disconnect brake booster hose from brake
7. Connect the brake booster vacuum line to brake
booster.
booster.
5. Lift upper intake manifold from throttle body,
8. Fit electrical connectors to throttle body motor.
resting LHS on lower manifold. Release the quick
connectors for purge and PCV tubes and remove 9. Fit electrical connector to MAP sensor.
the tubes. 10. Fit air cleaner tube to throttle body.
6. Disconnect the brake booster vacuum line from 11. Install PCV hose to LH valve cover.
brake booster. 12. Connect the battery ground cable. For additional
7. Remove the bolts and the upper intake manifold. information, refer to Section 414-01.
8. Remove the intake gasket. 13. Refill the engine cooling system. For additional
CAUTION: Do not use metal scrapers, NOTE: If this procedure is being performed in
wire brushes, power abrasive discs or other conjunction with the engine installation procedure,
abrasive means to clean the sealing surfaces. do not fill the engine cooling system at this time.
tool to remove all traces of old sealant. Intake Manifold — Lower
Clean and inspect the sealing surfaces. Removal
Installation 1. Remove the upper intake manifold. For additional
1. Apply intake sealant. information, refer to Intake Manifold — Upper.
2. Position upper intake manifold and loosely install 2. Disconnect the fuel lines. For additional
new bolts. information, refer to Section 310-00.
3. Install purge and PCV tube connections by
pushing tubes onto quick connectors.
NOTE: Ensure quick connectors are on the upper
manifold before installing upper to lower.
G89773 en 01/2003 2003.0 BA Falcon

303-01c-19 Engine — V8 (4V) 303-01c-19
3. Disconnect the electrical connector from the water 6. Remove the bolts and the radio ignition
temperature indicator sender. interference capacitors.
4. Disconnect the eight fuel injectors. 7. Remove the gaskets, install new gaskets.
5. Remove the bolts and lower intake manifold. 8. Clean the sealing surfaces.
CAUTION: Do not use metal scrapers, wire

brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak
paths. Use a plastic scraping tool to remove all
traces of old sealant.
G89774 en 01/2003 2003.0 BA Falcon

303-01c-20 Engine — V8 (4V) 303-01c-20
Installation 4. Tighten the retaining bolts to 8-10 Nm in following

1. Install the lower intake gaskets. order.
2. Install the radio ignition interference capacitors.
3. Position the lower intake manifold. Loosely install 5. Connect the water temperature indicator sensor.
the retaining bolts. 6. Connect the eight fuel injectors.
7. Connect the fuel lines. For additional information,
8. Install the upper intake manifold. For additional
information, refer to Intake Manifold—Upper in
this section.
Valve Cover — RH
Materials
Sealant
F7AZ-19554-EA or
equivalent
1. Remove surge tank from vehicle.
2. Disconnect brake lines from brake booster.
3. Partially drain the cooling system. For additional
G89774 en 01/2003 2003.0 BA Falcon

303-01c-21 Engine — V8 (4V) 303-01c-21
5. Remove the positive crankcase ventilation (PCV) 8. Remove the four ignition coils.
nylon tube from PCV valve and position the tube
aside.
9. Separate the engine control wiring harness from

the valve cover studs.
6. Remove the bolts and the ignition coil cover.
10. Remove the eight bolts, two studs and the valve
7. Disconnect the four ignition coils. cover.
NOTE: Apply silicone gasket and sealant in the
locations shown.
G89775 en 01/2003 2003.0 BA Falcon

303-01c-22 Engine — V8 (4V) 303-01c-22
6. Separate the engine wiring harness from the

Valve Cover — LH valve cover studs.
Materials
Sealant
F7AZ-19554-EA or
equivalent
1. Remove the upper intake manifold. For additional
this section.
2. Remove the engine oil level indicator tube bracket
bolt and position the tube aside.
7. Remove the bolts, studs and the left valve cover.

NOTE: Apply silicone gasket and sealant in the
locations shown.
3. Remove the bolts and the ignition coil cover.

4. Disconnect the four ignition coils.
5. Remove the four ignition coils.
Crankshaft Pulley
Special Tool(s)
Damper
303-009 (T58P-6316-D)

Damper
303-102 (T74P-6316-B)
G89775 en 01/2003 2003.0 BA Falcon

303-01c-23 Engine — V8 (4V) 303-01c-23
Materials Installation
Silicone Gasket and WSE-M4G323-A4 1. Apply silicone gasket or LOCKTITE 5900 or
Sealant equivalent to the Woodruff key slot on the
F7AZ-19554-EA or crankshaft pulley.
LOCTITE 5900 or NOTE: The crankshaft pulley must be installed
equivalent within four minutes after applying the silicone.
Removal

pulley.
4. Using the special tool, remove the crankshaft

pulley.
3. Install the bolt and washer. Tighten the bolt in four

stages:
Stage 2: Loosen one full turn.
Stage 4: Tighten an additional 85-95 degrees.
G89777 en 01/2003 2003.0 BA Falcon

303-01c-24 Engine — V8 (4V) 303-01c-24
4. Lower the vehicle. Installation

5. Install the drive belt. For additional information, 1. Apply silicone gasket sealant to outer perimeter
refer to Section 303-05. surface of crankshaft front seal.
2. Lubricate the engine front cover and the
Crankshaft Front Oil Seal crankshaft front oil seal inner lip with clean engine
oil.
Special Tool(s)
Seal
303-635

303-335 (T88T-6701-A)
Item Description
Remover, Crankshaft Front Oil 1 Lubricate with engine oil
Seal 2 Seal with silicone gasket sealant
303-107 (T74P-6700-A)
3. Using the special tools, install the crankshaft front
oil seal into the engine front cover.
Materials
SAE 5W-20 Premium WSS-M2C910-A2
10W-30GF2 Engine Oil
orequivalent
Removal
section.
2. Using the special tool, remove the crankshaft front
oil seal. 4. Install the crankshaft pulley. For additional
section.
Engine Front Cover

Materials
F4AZ-19A536-RA or
equivalent
Sealant
F7AZ-19554-EA or
LOCTITE 5900 or
equivalent
10W-30GF2 Engine Oil WSS-M2C910-A2
or equivalent
G89777 en 01/2003 2003.0 BA Falcon

303-01c-25 Engine — V8 (4V) 303-01c-25
Removal 7. Drain the engine oil.

1. Remove the left and right valve cover (6582). For
additional information, refer to Valve Cover—LH
and Valve Cover—RH in this section.
2. Remove the water pump pulley.
1. Remove the four bolts.
2. Remove the water pump pulley.
8. Remove the four front sump bolts (as shown).

section.
4. Remove the Power Steering (P/S) bolts and
position the power steering pump aside.
9. Remove the crankshaft front oil seal. For

additional information, refer to Crankshaft Front
Oil Seal in this section.
10. Disconnect the camshaft position (CMP) sensor.
5. Remove A/C Compressor.

G89779 en 01/2003 2003.0 BA Falcon

303-01c-26 Engine — V8 (4V) 303-01c-26
11. Remove the bolt and the belt idler pulley (8678). 2. Position the engine front cover and install the
bolts and the studs in three stages:
Stage 1: Tighten numbers one through five to
25 Nm (18 lb-ft).
Stage 2: Tighten numbers six and seven to 50
Nm (37 lb-ft).
Stage 3: Tighten numbers 11 through 15 to
25 Nm (18 lb-ft).
12. Remove the engine front cover, bolts, studs, and

the gaskets.
Clean and inspect the front cover and oil pan
sealing surfaces.
Installation
NOTE: If the front cover and gasket are not secured
within four minutes, the sealant must be removed and
the sealing surface cleaned with metal surface
cleaner.
Item Description
1. Apply silicone gasket and sealant in the locations
shown. 1 Bolt, Hex Flange Head Pilot, M8 x 1.25 x
50
50
50
50
50
11 M8 x 1.25 x 53
G89779 en 01/2003 2003.0 BA Falcon

303-01c-27 Engine — V8 (4V) 303-01c-27
Item Description 7. Install the crankshaft front oil seal. For additional
12 M8 x 1.25 x 53 information, refer to Crankshaft Front Oil Seal in
this section.
8. Install the drain plug.
14 Stud Hex Shoulder Pilot, M8 x 1.25 x 65 -
M8 x 1.25 x 27
3. Install the belt idler and the bolt.
9. Connect the CKP sensor.
4. Connect the CMP sensor.
10. Refit A/C compressor.

bolts.

6. Tighten the sump bolts in three stages:
Stage 1: Tighten to 2 Nm (18 lb-in).

section.
G89779 en 01/2003 2003.0 BA Falcon

IN-VEHICLE
303-01c-28 REPAIR (Continued) Engine — V8 (4V) 303-01c-28
13. Install the water pump pulley and install the bolts. 2. Remove the crankshaft sensor ring from the
crankshaft.
14. Install the left and right valve cover. For additional
information, refer to Valve Cover—LH and Valve 3. Using the crankshaft holding special tool, position
Cover—RH in this section. the crankshaft as shown.
15. Refill the engine crankcase with clean engine oil. This will set the crankshaft. Keyway facing the top
of engine.
Timing Drive Components All pistons will now be away from top of the stroke
and will ensure piston and valves cannot clash.
Special Tool(s) CAUTION: Unless otherwise instructed, at
Alignment Plate, Camshaft no time when the timing chains are removed
303-445 (T93P-6256-A) and the cylinder heads are installed is the
crankshaft or the camshaft to be rotated.
Severe piston and valve damage will occur.
Holding Tool, Crankshaft

303-448 (T93P-6303-A)
Removal
CAUTION: Since the engine is not
free-wheeling, if the crankshaft or the camshafts 4. Install the camshaft alignment special tool.
are moved in any manner during removal and
installation, the crankshaft and the camshafts
must be re-synchronized.
section.
G89779 en 01/2003 2003.0 BA Falcon

303-01c-29 Engine — V8 (4V) 303-01c-29
5. This will ensure that all valves are set in a position 8. Remove the bolts and the timing chain guides.
to remove any concern for valve and piston clash.
6. Remove the two bolts, the timing chain tensioner CAUTION: The bolts are different lengths
and tensioner arm. and must be returned to their original location.
NOTE: LH shown; RH similar. NOTE: LH shown; RH similar.
7. Remove the LH and RH timing chains and the

crankshaft sprockets.
Remove the special holding tool from the
crankshaft.
Remove the timing chains from the camshaft
sprockets.
Remove the right and left timing chains and
the crankshaft sprocket from the crankshaft.
CAUTION: Unless otherwise
instructed, at no time when the timing
chains are removed and the cylinder
heads are installed is the crankshaft or the
camshaft to be rotated. Severe piston and
valve damage will occur.
Installation
CAUTION: Do not remove the special
tool from the camshafts. 1. Compress the tensioner plunger, using the edge
of a soft-jawed vise.
be followed exactly or damage to the pistons
or valves will result.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-30 Engine — V8 (4V) 303-01c-30
2. Install a thin rod into the hole in the tensioner 4. Install the timing chain guides.
housing to hold the ratchet assembly.
Remove the tensioner from the vise.
3. If the copper links are not visible, mark two links

on one end and one link on the other end, and
use as timing marks.
NOTE: There are 61 links in the timing chain.
5. Remove the camshaft alignment special tool.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-31 Engine — V8 (4V) 303-01c-31
6. Rotate the LH camshaft sprocket clockwise until 8. Install the LH timing chain onto the Camshaft
the timing mark is approximately at the 1 o’clock (exhaust) sprocket, with the timing dot on the
position. Rotate the RH camshaft timing sprocket sprocket located between the two marked
clokwise until the timing mark is approximately in (copper) links.
the 11 o’clock position.
WARNING: Do not rotate camshafts other
than the directions stated.
9. Install the chain on the crankshaft sprocket inner

set with the marked (copper) link aligned with the
timing sprocket dot.
7. Position the crankshaft so that the keyway is at
the 12 o’clock position (top).
CAUTION: Unless otherwise instructed, at
no time when the timing chains are removed
and the cylinder heads are installed is the
crankshaft or the camshaft to be rotated or
severe piston and valve damage can occur.
counter-clockwise only. Do not rotate past the
position shown or sever piston and valve
damage can occur.
NOTE: With the keyway at the 12 o’clock
position, all pistons will be away from the top of
stroke. 10. Position the crankshaft sprocket onto the
crankshaft. The crankshaft should not need
turning. If it does, inspect the timing and start
again.
11. Position the LH tensioner arm and tensioner and
install the bolts.
12. Remove the pull-key rod from the tensioner

housing.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-32 Engine — V8 (4V) 303-01c-32
13. Rotate the crankshaft counter-clockwise so that

the keyway is at approximately 11 o’clock. The
timing dot should line up with a circular moulding
behind the sprocket (on the oil pump, as shown).
counter-clockwise only. Do not rotate past the
position shown or sever piston and valve
damage can occur.
19. Position the crankshaft sensor ring on the

crankshaft.
14. Install the RH timing chain onto the Camshaft

(exhaust) sprocket, with the timing dot on the
sprocket located between the two marked
(copper) links.
15. Install the chain on the crankshaft sprocket outer
set with the marked (copper) link aligned with the
timing sprocket dot.
16. Position the RH tensioner arm and tensioner and 20. Install the engine front cover. For additional
install the bolts. information, refer to Engine Front Cover in this
NOTE: Torque as for LH tensioner. section.
17. Remove the pull-key rod from the tensioner
housing.
18. (Optional) Using the special tool, rotate the
crankshaft counter-clockwise and check the
alignments of the timing dots and marked links.
RH cam sprocket timing dot/links should be at
approximately 11 o’clock, LH cam sprocket timing
dot/links should be at approximately 1 o’clock and
the crankshaft sprocket timing dot/links should be
at approximately 6 o’clock (bottom).
CAUTION: The tensioner arms may need
to be moved to take any slack after the check
as the chains may be loosened.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-33 Engine — V8 (4V) 303-01c-33
Valve — Springs, Retainer and Valve 4. Use compressed air in the cylinder to hold both
valves in position.
Stem Seal
CAUTION: If air pressure has forced the
Special Tool(s) piston to the bottom of the cylinder any loss
Compressor, Valve Spring of air pressure will allow the valve to fall into
303-452 (T93P-6565-AR) the cylinder. If air pressure must be removed
support the valve prior to removal.

303-383 (T91P-6571-A)
Compressor, Valve Spring

303-567 (T97P-6565-AH)
5. Install the special tool between the valve spring
coils to protect the intake valve stem seal from
damage.
Spacer, Valve Spring

Compressor
303-382 (T91P-6565-AH)
Removal
CAUTION: Mark all valve component
positions. Reused valve components must be
installed in their original locations.
6. Using the special tool, compress the intake valve
1. Remove the roller followers. For additional spring. Remove the intake valve spring retainer
information, refer to Roller Followers in this keys.
section.
2. Remove the spark plugs. For additional
information, refer to Section 303-07B.
3. Position the piston of the cylinder being serviced
at the bottom of the stroke.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-34 Engine — V8 (4V) 303-01c-34
7. Remove the special tool, the valve spring retainer, Installation

the valve spring and the valve stem seal. 1. Using the special tools, install the new intake
NOTE: Valve stem seals should be visually valve stem seals. Repeat this step to install all
inspected if new seals are not installed. necessary intake valve stem seals.
8. Repeat above three steps to remove all
necessary intake valve spring assemblies.
coils to protect the exhaust valve stem seal from
damage.
2. Using the same special tools, install the new

exhaust valve stem seals. Repeat this step to
install all necessary exhaust valve stem seals.
coils to protect the intake valve stem seal from
10. Using the special tool, compress the exhaust damage.
valve spring. Remove the exhaust valve spring
retainer keys.
4. Position the intake valve spring and the spring

retainer over the intake valve stem and valve seal.
11. Remove the valve spring retainer keys, the valve 5. Using the special tool, compress the intake valve
spring retainer, the valve spring and the valve spring. Install the intake valve spring retainer
stem seal. keys.
NOTE: Valve stem seals should be visually
inspected if new seals are not installed.
necessary exhaust valve spring assemblies.
G89780 en 01/2003 2003.0 BA Falcon

303-01c-35 Engine — V8 (4V) 303-01c-35
6. Repeat above three steps to install all necessary 2. Remove the 16 hydraulic lash adjusters.
intake valve spring assemblies.
damage.
3. Inspect the roller followers. For additional

Installation
8. Position the exhaust valve spring and the spring
retainer over the exhaust valve stem and valve Roller Followers
seal.
9. Using the special tool, compress the exhaust Special Tool(s)
valve spring. Install the exhaust valve spring
retainer keys. Compressor, Valve Spring
303-452 (T93P-6565-AR)

303-567 (T97P-6565-AH)
Removal
10. Repeat above three steps to install all necessary
exhaust valve spring assemblies. CAUTION: Mark roller follower positions.
11. Remove the compressed air hose from the Reused roller followers must be installed in their
cylinder. original locations.
12. Install the spark plugs. For additional information, 1. Remove the left and right valve cover. For
refer to Section 303-07B. additional information, refer to Valve Cover—LH
13. Install the roller followers. For additional and Valve Cover—RH in this section.
information, refer to Roller Followers in this 2. Position the piston of the cylinder being repaired
section. at the bottom of the stroke and the camshaft lobe
at the base circle.
Hydraulic Lash Adjusters
Removal
1. Remove the roller followers. For additional
information, refer to Roller Followers in this
section.
G89783 en 01/2003 2003.0 BA Falcon

303-01c-36 Engine — V8 (4V) 303-01c-36
3. Using the special tool, compress the intake valve Removal

spring and remove the roller follower. 1. Remove the roller followers. For additional
section.
2. Remove the LH timing chain for the LH side and
both timing chains for the RH side. For additional
information, refer to Timing Drive Components in
this section.
4. Using the special tool, compress the exhaust

valve spring and remove the roller follower.
4. Remove the exhaust camshaft sprocket and the

intake camshaft bolt, washer and spacer.
5. Repeat above three steps to remove all the

necessary roller followers. Inspect the roller finger
followers and camshafts. For additional
Camshaft
Special Tool(s)
Holding Tool, Camshaft
303-446 (T93P-6256-AHR)
Materials
or equivalent
G89783 en 01/2003 2003.0 BA Falcon

303-01c-37 Engine — V8 (4V) 303-01c-37
6. Compress the tensioner and install a lock pin.
7. Remove the timing chain, the sprocket, and intake

camshaft sprocket spacer.
10. Mark cach camshaft for identification purposes.

NOTE: LH shown; RH similar.
9. Remove the bolts and the camshaft bearing cap

assemblies.
CAUTION: The outer bolts on the outer
cam bearing cap (exhaust) are longer and
must be returned to the same location or
engine damage may occur.
NOTE: Identify the camshaft to cylinder head
location. Caps are not interchangeable.
G89784 en 01/2003 2003.0 BA Falcon

303-01c-38 Engine — V8 (4V) 303-01c-38
11. Remove the camshafts. Installation

CAUTION: It is vital for camshafts to be 1. Install the camshafts.
marked before removal as each one is Lubricate the camshafts with clean engine oil.
different and must be re-installed inti its NOTE: LH shown; RH similar.
original position.
NOTE: Each camshaft has its part number
stamped on its shaft.
NOTE: All 4 camshafts are different.
G89784 en 01/2003 2003.0 BA Falcon

303-01c-39 Engine — V8 (4V) 303-01c-39
2. Install the camshaft bearing cap assemblies. 4. Install the camshaft sprockets and the chain as an
assembly.
CAUTION: Timing marks must be at 12
o’clock and indexed at 6 o’clock.
5. Remove the lockpin from the chain tensioner.
G89784 en 01/2003 2003.0 BA Falcon

303-01c-40 Engine — V8 (4V) 303-01c-40
7. Tighten the exhaust camshaft sprocket and the 2. Install engine in vehicle. For additional
intake camshaft bolt washer and spacer in two information, refer to Engine Installation in this
stages: section.
Tighten an additional 90 degrees. Oil Filter Adapter
Removal
2. Drain the cooling system. For additional
3. Remove the oil filter.

9. Install the left timing chain for the left side or both
timing chains for the right side. For additional
information, refer to Timing Drive Components in
this section.
10. Install the roller followers. For additional
section. 4. Disconnect the oil pressure sensor.
Exhaust Manifold — LH
Removal
NOTE: LH shown; RH similar.
1. Remove engine from vehicle. For additional
information, refer to removal of Engine in this
section.
2. Remove the exhaust manifold.
Remove the eight nuts.
Remove the exhaust manifold and discard
gasket.
Installation
1. To install, reverse the removal procedure. 5. Remove the oil pressure sender.
Install a new gasket.
G89784 en 01/2003 2003.0 BA Falcon

303-01c-41 Engine — V8 (4V) 303-01c-41
6. Disconnect the radiator lower hose. Oil Pressure Sender

Materials
Pipe Sealant with WSK-M2G350-A2 and
Teflon® ESR-M18P7-A
D8AZ-19554-A or
equivalent
2. Disconnect the oil pressure sender electrical
connector.
7. Remove the four bolts and the filter adapter.

Discard the gasket.

NOTE: If reusing the sender, clean the threads
and coat the oil pressure sensor threads with pipe
sealant.
NOTE: Install a new oil filter adapter gasket.
G89786 en 01/2003 2003.0 BA Falcon

303-01c-42 Engine — V8 (4V) 303-01c-42
Oil Level Indicator and Tube Materials

Removal and Installation or equivalent
1. Remove the oil level indicator.
Removal
2. Remove the bolt. 1. Remove alternator, refer to Section 414-02.
3. Remove the oil level indicator tube. 2. Install the special tool.
Install a new O-ring seal.

4. To install, reverse the removal procedure. information, refer to Section 100-02.
4. Remove through bolts from the engine mount
Oil Pan bracket and chassis.
Special Tool(s) 5. Drain the engine oil.
3-Bar Engine Support

303-F073
Materials
F4AZ-19A536-RA or
equivalent
Sealant 6. Lower the vehicle.
F7AZ-19554-EA or
LOCTITE 5900 or
equivalent
G89788 en 01/2003 2003.0 BA Falcon

303-01c-43 Engine — V8 (4V) 303-01c-43
7. Raise the engine 63.5 mm (2.5 inch).
3. Apply silicone gasket and sealant at the front

8. Raise the vehicle. cover-to-cylinder block sealing surface.
9. Remove the bolts, oil pan and gasket. NOTE: If the oil pan and the oil pan gasket are
Inspect the oil pan gasket for damage. be removed and the sealing area cleaned with
NOTE: Be careful when removing oil pan metal surface cleaner. Allow to dry until there is
gasket. It is re-usable if not damaged. no sign of wetness, or four minutes, whichever is
future oil leakage.
Installation
1. Clean the mating surfaces.
4. Install the oil pan gasket and the oil pan and
CAUTION: Do not use metal scrapers, loosely install the 16 bolts.
2. Apply silicone gasket and sealant at the rear oil
seal retainer-to-cylinder block sealing surface.
future oil leakage.
G89789 en 01/2003 2003.0 BA Falcon

303-01c-44 Engine — V8 (4V) 303-01c-44
5. Tighten the bolts in three stages, in the sequence 8. Raise the vehicle.
shown.
9. Install through bolt to the engine mount bracket
Stage 1: Tighten to 2 Nm (18 lb-in). and chassis.

11. Install the alternator. For additional information,
12. Install the lower intake manifold. For additional
information, refer to Intake Manifold—Upper.
Oil Pump Screen and Pickup Tube

Materials
10W-30 GF2 engine oil WSS-M2C910-A2
or equivalent
Removal
1. Remove the oil pan. For additional information,
refer to Oil Pan in this section.
2. Remove the three (A) bolts and the (B) oil pump
6. Lower the vehicle. screen cover and tube.
7. Lower the engine.
Remove the special tool.
G89789 en 01/2003 2003.0 BA Falcon

303-01c-45 Engine — V8 (4V) 303-01c-45
1. Clean and inspect the mating surfaces. 1. Position the flexplate and install the bolts in the
Inspect the O-ring seal. sequence shown.
2. Install the oil pump screen cover and tube and
install the bolts.
engine oil.
3. Install the oil pan. For additional information, refer
to Oil Pan Installation in this section.
Flexplate
Removal
information, refer to Section 307-01A.
2. Remove the bolts and the flexplate.
2. Install the transmission. For additional information,

Crankshaft Rear Oil Seal

Special Tool(s)
Seal
303-518 (T95P-6701-DH)

Seal
303-519 (T95P-6701-EH)
G89792 en 01/2003 2003.0 BA Falcon

303-01c-46 Engine — V8 (4V) 303-01c-46
Special Tool(s) 3. Using the special tools, remove the crankshaft

rear oil seal.
Seal
303-516 (T95P-6701-BH)

Slinger
303-514 (T95P-6701-AH)
Installer, Crankshaft Rear Oil Installation

Slinger 1. Using the special tool, install the crankshaft rear
303-517 (T95P-6701-CH) oil seal.
Impact Slide Hammer

100-001 (T50T-100-A)
Removal
1. Remove the flexplate. For additional information,
refer to Flexplate in this section. 2. Using the special tools, install the crankshaft oil
2. Using the special tools, remove the crankshaft oil slinger.
slinger.
3. Install the flexplate. For additional information,

refer to Flexplate in this section.
G89792 en 01/2003 2003.0 BA Falcon

303-01c-47 Engine — V8 (4V) 303-01c-47
Engine Mounts — RH 2. Install the special tool.
Special Tool(s)
303-F073
Removal

4. Remove the through bolt.

3. Remove the engine mount bracket through bolt.
4. Remove crossmember.
5. Remove engine mount & bracket assembly from 5. Lower the vehicle.
the engine.
6. Raise the engine 63.5 mm (2.5 inches).
6. Remove engine mount heat shield.
7. Remove the engine mount.
Installation
Engine Mounts — LH
Special Tool(s)
303-F073
7. Remove the engine mount from the vehicle.

Installation
Removal
1. Remove the lower intake manifold. For additional
this section.
G89794 en 01/2003 2003.0 BA Falcon

303-01c-48 Engine — V8 (4V) 303-01c-48
REMOVAL
Engine
Special Tool(s)
Modular Engine Lifting Bar
303-F047 (014-00073)
Holding Wrench, Fan Pulley

303-239 (T84T-6312-C)
6. Drain coolant from engine at tap left hand lower

corner.
7. Disconnect the lower radiator hose from the
radiator and the engine.
Wrench, Fan Clutch Hub Nut
303-240 (T84T-6312-D)
Removal
1. Disconnect lower pivot hood struts.
2. Tie hood back.
3. Remove the radiator upper hose from the engine.
4. Remove the fan shroud.
1. Remove the screws.
8. Disconnect the surge tank hose from the radiator.
2. Lift and remove the fan pack, out of the
vehicle. 1. Release the clamp.
2. Slide the hose off the radiator fitting.
9. Remove the surge tank from vehicle.
1. Disconnect vent and supply hoses from surge
tank.
2. Remove surge tank from vehicle.
5. Disconnect the transmission fluid cooler fittings.

1. Disconnect the upper transmission fluid cooler
fitting.
2. Disconnect the lower transmission fluid cooler
fitting.
oil cooler fittings, use a support spanner when
releasing cooling lines.
G89795 en 01/2003 2003.0 BA Falcon

303-01c-49 Engine — V8 (4V) 303-01c-49
REMOVAL (Continued)
10. Remove the radiator. 24. Disconnect fuel lines using special tool, as
1. Remove the bolts. outlined in Section 310-00.
2. Remove the upper radiator support brackets. 25. Disconnect the power steering pressure (PSP)
sensor.
3. Remove bolts attaching condensor to radiator.
26. Remove the bolts and position the power steering
4. Lift the radiator off the radiator mounting
pump out of the way.
insulators.
5. Remove the radiator mounting insulators.

12. Disconnect the alternator electrical connectors.
13. Disconnect battery and alternator cables from RH
Relay box.
14. Remove PCM, refer to Section 303-14-104.
15. Disconnect the wiring harness (PCM ‘A’ connector
& 24 pin connector) from vehicle.
16. Disconnect transmission wiring harness from
transmission.
17. Disconnect hego sensor wiring plugs. Refer to
chapter Section 303-14-106 for more information.
18. Remove the ground strap retaining bolt. 27. Disconnect the starter motor electrical
connections.
1. Remove the two nuts.
2. Remove the battery cable.
3. Remove the starter solenoid wire.
19. Disconnect the lower radiator hose.

20. Disconnect the heater hoses from rear of engine.
21. Disconnect brake booster vacuum hose.
22. Disconnect purge valve connection.
23. Disconnect air intake to throttle body and remove
entire air cleaner assembly.
G89795 en 01/2003 2003.0 BA Falcon

303-01c-50 Engine — V8 (4V) 303-01c-50
REMOVAL (Continued)
28. Remove the nut and the starter motor ground 31. Disconnect the A/C compressor electrical
cable. connector.
29. Remove the three bolts and the starter motor. 32. Remove the bolts and the A/C compressor.
NOTE: Do not degas, position A/C compressor
out of the way.
33. Remove nut holding exhaust heatshield and

discard, then remove heatshield.
34. Disconnect the pipes at the exhaust manifolds.
NOTE: If studs are removed from exhaust
manifolds during disassembly, then discard studs
and nut and replace with new parts.
35. Remove the through bolt from the LH engine
mount.
G89795 en 01/2003 2003.0 BA Falcon

303-01c-51 Engine — V8 (4V) 303-01c-51
REMOVAL (Continued)
36. Remove the through bolt from the RH motor 39. Remove the five bolts from the transmission.
mount.

37. Remove the plate bolts and the inspection cover. 41. Install rear lifting hook and front lifting hook.
block of wood.
43. Remove the engine from the vehicle.
38. Remove the four nuts from the torque converter

and discard (Auto tran only).
G89795 en 01/2003 2003.0 BA Falcon

303-01c-52 Engine — V8 (4V) 303-01c-52
DISASSEMBLY
Special Tool(s)
Engine
Special Tool(s) (Exhaust Side)
303-567 (T97P-6565-AH)
Seal
303-519 (T95P-6701-EH)

(Intake Side)
303-452 (T93P-6565-AR)
Slinger
303-514 (T95P-6701-AH)
Cylinder Ridge Reamer

303-016 (T64L-6011-EA)
Impact Slide Hammer
100-001 (T50T-100-A)
Disassembly
NOTE: The crankshaft rear oil seal slinger and the oil
Lift Bracket Set, Engine seal retainer plate must be removed before mounting
303-DS086 (D93P-6001-A) the engine on the engine stand.
1. Remove the bolts and the flywheel ring gear.

Damper
303-009 (T58P-6316-D)

303-442 (T93P-6136-A)

Seal
303-107 (T74P-6700-A)
G89796 en 01/2003 2003.0 BA Falcon

303-01c-53 Engine — V8 (4V) 303-01c-53
2. Using the special tools, remove the rear oil 7. Install the lifting bracket special tools on the LH
slinger. and RH sides of the engine.
NOTE: LH shown, RH similar.
3. Using the special tools, remove the rear main

seal. 8. Mount the engine on a work stand.
4. Lower the engine onto the wooden blocks. 9. Drain oil, remove filter.
5. Remove the LH exhaust manifold. Remove the bolts and the oil pan.
1. Remove the eight bolts. Clean and inspect the sealing surfaces.
2. Remove the manifold and discard the gasket.
6. Remove the stud and the oil level indicator and wire brushes, power abrasive discs or
tube. other abrasive means to clean the sealing
of old sealant.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-54 Engine — V8 (4V) 303-01c-54
10. Remove the bolts and the rear seal retainer plate. 13. Remove the cylinder block drain plugs, and drain
the coolant in a suitable container.
of old sealant.
14. Disconnect the oil pressure sender.
11. Remove the special tools from the LH and RH

sides of the engine.
15. Remove the bolts and the LH ignition coil cover.
12. Remove the RH and LH engine mounts.

G89796 en 01/2003 2003.0 BA Falcon

303-01c-55 Engine — V8 (4V) 303-01c-55
16. Disconnect the ignition coils. 19. Remove the bolts and the RH ignition coil cover.
17. Remove the ignition coils. 20. Disconnect the ignition coils.
18. Disconnect the camshaft position (CMP) sensor. 21. Remove the ignition coils.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-56 Engine — V8 (4V) 303-01c-56
22. Remove the heater return tube and heater supply 24. Remove the water pump pulley.
tubes.
2. Remove the pulley.
23. Remove the Heater supply tube.
25. Remove the water pump bolts.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-57 Engine — V8 (4V) 303-01c-57
26. Remove the water pump. 29. Using the special tool, remove the front crank
seal.
of old sealant.
30. Remove the bolt and the belt idler pulley.
31. Remove the eight spark plugs.

28. Using the special tool, remove the crankshaft

damper.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-58 Engine — V8 (4V) 303-01c-58
32. Remove the bolts, studs and the valve covers. 34. Remove the crankshaft sensor ring from the
crankshaft.
Remove the gaskets. Clean and inspect the
sealing surfaces. CAUTION: Since the engine is not
free-wheeling, if the crankshaft (6303) or the
camshafts (6250) are moved in any manner
during removal and installation, the crankshaft
other abrasive means to clean the sealing and the camshafts must be re-synchronized.
of old sealant.
35. Position the piston at the bottom of the stroke and

the camshaft lobes at the base circle.
36. Using the special tool, compress the intake valve
springs and remove the roller followers.
33. Remove the studs, bolts, and the engine front
cover.
Remove the gaskets, clean and inspect the
sealing surfaces.
37. Remove the two bolts, the timing chain tensioner

(6L266) and tensioner arm (6L255).
G89796 en 01/2003 2003.0 BA Falcon

303-01c-59 Engine — V8 (4V) 303-01c-59
38. Remove the LH and RH timing chains and the 40. Remove the RH and RH exhaust manifolds.
1. Remove the eight bolts.
Remove the timing chains from the camshaft
2. Remove the exhaust manifold and gasket.
sprockets.
NOTE: RH manifold same as LH manifold.
Remove the right and left timing chains and
the crankshaft sprocket from the crankshaft.
Item Description
1 Nut x 8
39. Remove the bolts and the timing chain guides.
2 RH manifold
CAUTION: The bolts are different lengths 41. Remove the bolts from the RH and LH cylinder
and must be returned to their original location. head and remove the cylinder heads.
NOTE: RH shown, LH similar. Discard the bolts.
42. Remove and discard head gaskets.

Clean and inspect the cylinder block and the
head sealing surfaces.
of old sealant.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-60 Engine — V8 (4V) 303-01c-60
45. Before removing pistons, inspect the top of the

cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using a
Cylinder Ridge Reamer, following manufacturer’s
instructions.
43. Remove the bolts and remove the oil pump

screen cover and tube and the spacer.
46. Remove the bolts and the connecting rod caps for
pistons number 1 and 6.
CAUTION: Do not stamp the top of
pistons. This may cause ring land damage.
NOTE: Connecting rods and rod caps should be
numbered to keep the correct orientation.
44. Remove the bolts and remove the oil pump.

Remove the gasket. Clean and inspect the
sealing surfaces.
of old sealant. 47. Discard the bolts.
NOTE: Carefully tap connecting rod bolts out.
Avoid damaging the rod cap.
48. Install the Connecting Rod Guides and push the
pistons number 1 and 6 through the top of the
cylinder block (6010).
connecting rod.
NOTE: Connecting rod guides shown uninstalled
for clarity.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-61 Engine — V8 (4V) 303-01c-61
50. Remove the crankshaft main bearing caps.

1. Remove and discard the side bolts.
2. Remove and discard the main bearing cap
bolts.
3. Remove the dowel pins.
NOTE: Crankshaft not shown for clarity.
49. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn

crankshaft 90 degrees and repeat the previous
steps.
51. Remove the crankshaft, the crankshaft thrust

washer, and the crankshaft upper main bearings
from the cylinder block.
G89796 en 01/2003 2003.0 BA Falcon

303-01c-62 Engine — V8 (4V) 303-01c-62
4. Clean and inspect the piston and connecting rod.

Piston For additional information, refer to Section
303-00.
Materials
SAE 5W-20 Premium WSS-M2C153-H Assembly
Synthetic Blend Motor Oil 1. Position the connecting rod in the piston.
XO-5W20-QSP or NOTE: Connecting rod must be installed into
equivalent piston with identification markings toward front.
Disassembly
1. Remove the clips.
NOTE: Connecting rods and rod caps are a
matched set and cannot be interchanged.
2. Remove the piston pin from the piston and

connecting rod assembly.
2. Lubricate the piston pin and pin bore with clean

engine oil.
3. Remove the connecting rod from the piston.
G89798 en 01/2003 2003.0 BA Falcon

303-01c-63 Engine — V8 (4V) 303-01c-63
3. Install the piston pin in the piston and connecting Special Tool(s)
rod assembly.
303-383 (T91P-6571-A)
Compressor Spacer, Valve

Spring
303-382 (T91P-6565-AH)
4. Install the piston pin retaining clips in the piston.

Disassembly
CAUTION: Before disassembly begins,
mark the valve position on the face of each
valve being removed. The valves must be
installed in their original positions.
Cylinder Head RH and LH

Special Tool(s)
303-567 (T97P-6565-AH)
2. Remove the exhaust camshaft sprocket and the
intake camshaft bolt, washer and spacer.

303-452 (T93P-6565-AR)
Holding Tool, Camshaft

303-446 (T93P-6256-AHR)
G89797 en 01/2003 2003.0 BA Falcon

303-01c-64 Engine — V8 (4V) 303-01c-64
3. Compress the tensioner and install a lock pin. 6. Remove the head tensioners.
4. Remove the special tool. 7. Using the special tool, compress the intake valve
spring and remove the roller follower. Repeat this
step for all necessary intake valve roller followers.
5. Remove the timing chain and the camshaft

sprocket.
valve spring and remove the roller follower.
Repeat this step for all necessary exhaust valve
roller followers.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-65 Engine — V8 (4V) 303-01c-65
9. Install the special tool between the valve spring 14. Using the special tool, compress the exhaust
coils to protect the intake valve stem seal from valve spring. Remove the exhaust valve spring
damage. retainer keys.
10. Using the special tool, compress the intake valve 15. Remove the special tool, the valve spring retainer,
spring. Remove the intake valve spring retainer the valve spring and the valve stem seal.
keys. NOTE: Valve stem seals should be visually
necessary exhaust valve spring assemblies.
11. Remove the special tool, the valve spring retainer,

the valve spring and the valve stem seal.
NOTE: Valve stem seals should be visually
necessary intake valve spring assemblies.
damage.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-66 Engine — V8 (4V) 303-01c-66
17. Remove the bolts and the camshaft bearing cap 18. Remove the camshafts.
assemblies.
CAUTION: It is vital for camshafts to be
CAUTION: The outer bolts on the outer marked before removal as each one is
cam bearing cap (exhaust) are longer and different and must be re-installed into its
must be returned to the same location or original position.
engine damage can occur. NOTE: Each camshaft has its part number
NOTE: Identify the camshaft-to-cylinder head stamped its shaft.
location. Caps are not interchangeable.
19. Remove the hydraulic lash adjusters.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-67 Engine — V8 (4V) 303-01c-67
Assembly 3. Install the camshaft bearing cap assemblies.

1. Install the hydraulic lash adjusters.
2. Install the head camshafts.

4. Using the special tools, install the new intake

valve stem seals. Repeat this step to install all
necessary intake valve stem seals.
5. Using the special tools, install the new exhaust

valve stem seals. Repeat this step to install all
necessary exhaust valve stem seals.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-68 Engine — V8 (4V) 303-01c-68
6. Install the special tool between the valve spring 11. Position the exhaust valve spring and the spring
coils to protect the intake valve stem seal from retainer over the exhaust valve stem and the
damage. valve seal.
valve spring. Install the exhaust valve spring
retainer keys.
7. Position the intake valve spring and the spring

retainer over the intake valve stem and the valve
seal.
8. Using the special tool, compress the intake valve 13. Repeat above three steps to install all necessary
spring. Install the intake valve spring retainer exhaust valve spring assemblies.
keys. 14. Using the special tool, compress the intake valve
spring and install the roller follower. Repeat this
step for all necessary intake valve roller followers.
9. Repeat above three steps to install all necessary

intake valve spring assemblies.
10. Install the special tool between the valve spring 15. Using the special tool, compress the exhaust
coil to protect the exhaust valve stem seal from valve spring and install the roller follower. Repeat
damage. this step for all necessary exhaust valve roller
followers.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-69 Engine — V8 (4V) 303-01c-69
16. Install the head tensioners. 19. Tighten the exhaust camshaft sprocket and the
intake camshaft bolts washers and spacer in two
stages:
17. Install the camshaft sprockets and the chain as an

assembly.
CAUTION: Timing marks must be at 12
o’clock and indexed at 6 o’clock.
G89797 en 01/2003 2003.0 BA Falcon

303-01c-70 Engine — V8 (4V) 303-01c-70
ASSEMBLY
Special Tool(s)
Engine
Special Tool(s) 303-335 (T88T-6701-A)
Seal
303-518 (T95P-6701-DH)
Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent
Seal
303-516 (T95P-6701-BH)
Modular Engine Lift Bracket

303-F047 (014-00073) or
equivalent
Seal
303-517 (T95P-6701-CH)
Alignment Plate, Camshaft

303-445 (T93P-6256-A)
Lifting Bracket Set, Engine
303-DS086 (D93P-6001-A)

(Exhaust Side)
303-567 (T97P-6565-AH)
303-442 (T93P-6136-A)

(Intake Side)
303-452 (T93P-6565-AR)
Seal
303-635
Holding Tool, Crankshaft

303-448 (T93P-6303-A)
Damper
303-102 (T74P-6316-B)
G89799 en 01/2003 2003.0 BA Falcon

303-01c-71 Engine — V8 (4V) 303-01c-71
Materials
F4AZ-19A536-RA or
equivalent
Sealant
F7AZ-19554-EA or
LOCTITE 5900 or
equivalent
10W-30 GF2 engine Oil WSS-M2C910-A2
or equivalent
Assembly
1. Read the first character code information on the
cylinder block face and record the information.
Item Description
1 Cylinder block identification
2 Cylinder bore grade
3 Cylinder block serial number
4 Cylinder block front face
2. Read the first character on the No. 7 crankshaft
counterweight and note it.
NOTE: Crank pistons, and rods come in three
grades.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-72 Engine — V8 (4V) 303-01c-72
3. Using the data recorded in the previous two steps,

cross-reference using the chart to obtain bearing
grade.
4. Lubricate the crankshaft main bearings with clean 5. Install the crankshaft onto the upper main
engine oil and install into the cylinder block. Install bearings.
the crankshaft main bearings into the main NOTE: Do not install the upper thrust bearings
bearing caps. until the crankshaft is installed.
NOTE: Before assembling the cylinder block, all
sealing surfaces must be free from chips, dirt,
paint and foreign material. Also, make sure the
coolant and oil passages are clear.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-73 Engine — V8 (4V) 303-01c-73
6. Push the crankshaft rearward and install the

upper crankshaft thrust washer at the back of the
No. 5 main boss. Ensuring locating lug fits into
block recess.
CAUTION: Make sure the side of the
thrust washer with three 5-mm wide oil
grooves faces the crankshaft thrust surface.
9. Install the crankshaft lower main bearings into the

main bearing caps. Locate the main bearing cap
on the cylinder block and tap into place using a
plastic or deadblow hammer.
7. Push the crankshaft forward and install the front

crankshaft upper thrust washer at the front of the
No. 5 main boss.
grooves faces the crankshaft thrust surface.
8. Install the lower crankshaft thrust washer to the

back side of the No. 5 main bearing cap, with the
oil grooves facing the crankshaft surface.
grooves faces the rear of the engine.
NOTE: To aid in assembly apply petroleum jelly to
the back of the crankshaft thrust washer.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-74 Engine — V8 (4V) 303-01c-74
10. Install the main bearing cap dowel pins so the flat 11. Install and tighten the new bolts in two stages:
sides face the crankshaft.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-75 Engine — V8 (4V) 303-01c-75
12. Install and tighten the new cross-mounted bolts in 14. Using the special tools, install the No. 1 and No. 6
two stages: piston and connecting rod assemblies.
Stage 1: Tighten to 30 Nm (22 lb-ft). Lubricate the piston and ring with clean
Stage 2: Tighten an additional 90 degrees. engine oil.
NOTE: Crankshaft not shown for clarity. Lubricate the rod bearings with clean engine
oil.
connecting rod.
NOTE: Make sure the piston arrow is facing
forward.
15. Seat the connecting rods on the crankshaft

journals and remove the special tools.
13. Prepare the connecting rod and caps.

Insert the bolts in the rod cap.
Insert the upper and lower rod bearings into
the rod and cap.
NOTE: Verify the connecting rods and rod
caps for correct orientation.
NOTE: Carefully tap the connecting rod bolts
in. Avoid damaging the connecting rod.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-76 Engine — V8 (4V) 303-01c-76
16. Install the rod bearing caps and tighten the bolts 19. Install and tighten the oil pump screen and cover
in three stages: spacer.
CAUTION: The rod bearing caps must
keep the same orientation as marked
during disassembly.
NOTE: The rod bearing cap bolts are
torque-to-yield. Install new bolts each time
repaired.
20. Install the oil pump screen cover and tube, and
the bolts.
engine oil.
17. Install the piston connecting rod assemblies 3 and
5, 4 and 7, 2 and 8, by turning the crankshaft 90
degrees and repeating the previous steps.
18. Position the oil pump and gasket and install the
bolts in the sequence shown.
21. Install the cylinder head gaskets.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-77 Engine — V8 (4V) 303-01c-77
22. Install the LH and the RH cylinder heads. Loosely 24. Install the LH and RH exhaust manifold gaskets
install the new bolts. and the exhaust manifold.
Tighten the nuts in the sequence shown.
25. Compress the tensioner plunger, using the edge

of a soft-jawed vise.
be followed exactly or damage to the pistons
or valves can result.
23. Tighten the LH and RH bolts in three stages, in

the sequence shown.
26. Install a paper clip into the hose in the tensioner
housing to hold the ratchet assembly.
Remove the tensioner from the vise.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-78 Engine — V8 (4V) 303-01c-78
27. If the copper links are not visible, mark two links 29. Rotate the LH camshaft sprocket until the timing
on one end and one link on the other end, and mark is approximately at the 12 o’clock position.
use as timing marks. Rotate the RH camshaft timing sprocket until the
NOTE: There are 61 links in the timing chain. timing mark is approximately in the 11 o’clock
position.
28. Install the timing chain guides.

30. Install the special tools on the LH and RH cylinder
heads.
31. Using the special tool, position the crankshaft.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-79 Engine — V8 (4V) 303-01c-79
33. Install the crankshaft sprocket with the timing 36. Remove the paper clip.
mark facing outward.
37. Verify the camshaft and crankshaft sprocket to

34. Install the LH and RH timing chains onto the copper link alignment.
crankshaft and camshaft sprockets.
Align the two copper (marked) links with the
timing mark on the camshaft sprocket.
Align the one copper-colored link with the
timing mark on the crankshaft sprocket.
38. Remove the special tools from the LH and RH

cylinder heads.
35. Position the tensioner arms and tensioners, and

install the bolts.
39. Position the piston at the bottom of the stroke and

camshaft lobes at the base circle.
40. Repeat the previous steps to install all roller
followers.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-80 Engine — V8 (4V) 303-01c-80
41. Position the crankshaft sensor ring on the

crankshaft.
42. Apply silicone gasket sealant in the locations

shown.
Item Description
50
43. Position the engine front cover and install the
bolts and the studs in three stages: 2 Bolt, Hex Flange Head Pilot, M8 x 1.25 x
Stage 1: Tighten numbers one through five to 25 50
Nm (18 lb-ft). 3 Bolt, Hex Flange Head Pilot, M8 x 1.25 x
Stage 2: Tighten numbers six and seven to 50 50
Stage 3: Tighten numbers 11 through 15 to 25 50
50
11 Stud, Hex Shoulder Pilot, M8 x 1.25 x 65 -
M8 x 1.25 x 27
M8 x 1.25 x 27
13 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65
M8 x 1.25 x 27
15 Bolt, Hex Shoulder Pilot, M8 x 1.25 x 65
G89799 en 01/2003 2003.0 BA Falcon

303-01c-81 Engine — V8 (4V) 303-01c-81
44. Apply silicone gasket sealant in the locations 46. Install the eight spark plugs.
shown. NOTE: LH shown, RH similar.
45. Install the valve covers, the bolts, and the studs. 47. Install the bolt and the belt idler pulley.
1. Install the gaskets.
2. Install the valve covers.
48. Using the special tools, install the front crank seal.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-82 Engine — V8 (4V) 303-01c-82
49. Apply silicone gasket and sealant to the Woodruff 52. Install the water pump.
key slot on the crankshaft pulley.
Inspect and lube the water pump O-ring seal
NOTE: The crankshaft pulley must be installed before installation.
within four minutes after applying the silicone.
53. Install the four bolts.

pulley.
51. Install the bolt and washer. Tighten the bolt in four
stages:
Stage 2: Loosen one full turn.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-83 Engine — V8 (4V) 303-01c-83
54. Install the water pump pulley and the bolts. 57. Connect the RH ignition coils.
58. Install the RH ignition coil cover.
55. Install the heater return tube and the heater 59. Connect the camshaft position (CMP) sensor.
supply tubes.
Inspect and lube the O-ring seals.
56. Install the RH ignition coils.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-84 Engine — V8 (4V) 303-01c-84
60. Install the LH ignition coils. 63. Connect the oil pressure sender.
61. Connect the LH ignition coils. 64. Install the cylinder block drain plugs.
62. Install the bolts and the LH ignition coil cover.

65. Install the left and right engine mounts.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-85 Engine — V8 (4V) 303-01c-85
66. Install the lifting bracket special tool. 69. Install the rear oil seal retainer and loosely install
NOTE: LH shown, RH similar. the six bolts.
70. Tighten the bolts in the sequence shown.

67. Remove the engine from the work stand.
71. Apply silicone gasket and sealant at the

crankshaft rearseal retainer-to-cylinder block
sealing surface.
future oil leakage.
68. Apply a 4 mm (0.16 in) bead of silicone gasket

and sealant around the rear oil seal retainer
sealing surface.
NOTE: If the rear crankshaft seal retaining plate is
future oil leakage.
NOTE: The silicone must be applied on the
groove along the retainer plate.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-86 Engine — V8 (4V) 303-01c-86
72. Apply silicone gasket and sealant at the engine 74. Tighten the bolts in three stages, in the sequence
front cover-to-cylinder block sealing surface. shown.
NOTE: If the oil pan and the oil pan gasket are Stage 1: Tighten to 2 Nm (18 lb-in).
not secured within four minutes, the sealant must Stage 2: Tighten to 20 Nm (15 lb-ft).
metal surface cleaner. Allow to dry until there is Stage 3: Tighten an additional 60 degrees.
future oil leakage.
73. Install the oil pan gasket and the oil pan and
loosely install the 16 bolts.
75. Lower the engine onto wooden blocks.

G89799 en 01/2003 2003.0 BA Falcon

303-01c-87 Engine — V8 (4V) 303-01c-87
77. Install the oil level indicator and tube, and the 80. Using the special tool, install the crankshaft rear
stud. oil seal.
78. Install the LH exhaust manifold and gaskets. 81. Using the special tool, install the crankshaft oil
Tighten the bolts in the sequence shown. slinger.
79. Install the special tool and raise the engine. 82. Install the spacer plate.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-88 Engine — V8 (4V) 303-01c-88
83. Install the bolts and the flywheel.
G89799 en 01/2003 2003.0 BA Falcon

303-01c-89 Engine — V8 (4V) 303-01c-89
INSTALLATION
Engine 6. Install the five bolts to the bell housing.
Materials
or equivalent
Installation
block of wood.
2. Install the engine in the vehicle.
7. Install the oil filter.
4. Raise the vehicle. For additional information, refer

to Section 100-02.
5. Position the transmission level indicator tube and
install the bolt.
8. Install four new nuts to the torque converter (Auto
trans only).
G89800 en 01/2003 2003.0 BA Falcon

303-01c-90 Engine — V8 (4V) 303-01c-90
INSTALLATION (Continued)
9. Install the plug (Auto trans only). 12. Install the bolt to the LH engine motor mount.
10. Install the inspection cover and the bolts. 13. Install the starter motor and three bolts.
11. Install the bolt to the RH engine motor mount. 14. Connect the cable and install the motor nut.
G89800 en 01/2003 2003.0 BA Falcon

303-01c-91 Engine — V8 (4V) 303-01c-91
15. Connect the starter motor electrical connectors. 19. Install heatshield with new nut on lower stud, to
specified torque.
1. Position the starter solenoid wire.
2. Position the battery cable.
3. Install the nuts.
20. Install the A/C compressor and bolts.
16. Install the starter motor solenoid terminal cover.
21. Connect the A/C compressor electrical connector.
17. Install the RH exhaust manifold studs.

18. Connect the exhaust pipes to the exhaust
manifolds and torque nuts to specification.
G89800 en 01/2003 2003.0 BA Falcon

303-01c-92 Engine — V8 (4V) 303-01c-92
22. Connect the crankshaft position sensor. 33. Install the two bolts retaining the transmission to
the engine.

bolts. 34. Connect the transmission wiring harness to
transmission.
24. Connect the power steering pressure sensor.

35. Connect wiring harness (PCM ‘A’ connector and
25. Lower the vehicle. 24 pin connector) to vehicle.
26. Connect the lower radiator hose.
36. Install the alternator and alternator bracket.
27. Install the stud and reposition the A/C muffler.
28. Install battery into vehicle.
29. Connect the heater hoses to rear of engine.
30. Install surge tank into vehicle.

31. Connect vent and supply hoses to surge tank.
32. Connect the surge tank return hose.
G89800 en 01/2003 2003.0 BA Falcon

303-01c-93 Engine — V8 (4V) 303-01c-93
37. Connect the alternator electrical connectors. 42. Install the surge tank hose to the radiator.
1. Release the clamp.
2. Slide the hose onto the radiator fitting.
38. Connect battery and alternator cables to RH relay

box.
39. Install the accessory drive belt. For additional 43. Connect the lower radiator hose and the upper
information, refer to Section 303-05. radiator hose.
40. Install the intake manifold. For additional 44. Connect the transmission fluid cooler fittings.
1. Connect the lower transmission fluid cooler
this section.
fitting.
41. Install the radiator.
2. Connect the upper transmission fluid cooler
1. Install the radiator mounting insulators. fitting.
2. Position the radiator on the radiator mounting NOTE: To avoid disturbing the transmission
insulators. oil cooler fittings, use a support hammer when
3. Position the brackets. tightening fuel lines.
G89800 en 01/2003 2003.0 BA Falcon

303-01c-94 Engine — V8 (4V) 303-01c-94
45. Install the fan shroud.

1. Install the fan blade and fan shroud, as a unit,
in the vehicle.
2. Install the screws.

47. Fill the engine with oil.
48. Fill the engine cooling system. For additional
G89800 en 01/2003 2003.0 BA Falcon

303-03-1 Engine Cooling 303-03-1
SECTION : 303-03 Engine Cooling

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-03-2
Engine Cooling ......................................................................................................................303-03-3
Radiator ................................................................................................................................303-03-3
Electric Fans ........................................................................................................................303-03-3
Water Pump .........................................................................................................................303-03-3
Cooling System ....................................................................................................................303-03-3
Cooling Maintenance ...........................................................................................................303-03-3
Engine Cooling ......................................................................................................................303-03-5
Symptom Chart ....................................................................................................................303-03-5
Tests ....................................................................................................................................303-03-6
Pressure Test .......................................................................................................................303-03-8
Supply Tank Cap Pressure Test ..........................................................................................303-03-8
Thermostat Test ...................................................................................................................303-03-8
Coolant System ....................................................................................................................303-03-8
Cooling Fan Self Test - All Models ......................................................................................303-03-8
GENERAL PROCEDURES
Coolant Level Check .............................................................................................................303-03-9
Cooling Color Inspection .......................................................................................................303-03-9
Adjusting Anti — Freeze Protection Level ..........................................................................303-03-10
Anti — Freeze Replacement ...............................................................................................303-03-10
Draining and Filling the Cooling System .............................................................................303-03-10
Radiator Cleaning ...............................................................................................................303-03-10
Thermostat ..........................................................................................................................303-03-12
Thermostat Housing — 8 Cylinder ......................................................................................303-03-12
Thermostat Housing — 6 Cylinder ......................................................................................303-03-12
Water Pump — 6 Cylinder ...................................................................................................303-03-13
Water Pump — V8 ...............................................................................................................303-03-14
Radiator ..............................................................................................................................303-03-14
Fan ......................................................................................................................................303-03-16
Radiator Hose .....................................................................................................................303-03-16
Coolant Supply Tank ...........................................................................................................303-03-16
01/2003 2003.0 BA Falcon

SPECIFICATIONS
General Specifications Specific Approximate Remains Solidfies at

Description Specification Gravity % of Fluid to (C°) (C°)
Anti-Freeze
Fan Speeds
(by volume)
Passenger Side 1400, 2300 RPM @ 1.050 30 -16 -39
12.0V
1.042 25 -13 -29
Driver Side 1400, 2300 RPM @
12.0V 1.034 20 -9 -19
Fan Motor Rating 160 W 1.026 15 -7 -14
Coolant Capacities 1.016 10 -4 -8
6 Cylinder Engine 12.5 litres Torque Specifications - 6 & 8 Cylinder
8 Cylinder Engine 15 litres Description Nm
Anti-Freeze Water outlet housing 21
All Engines Motorcraft R132/R133 Radiator support bracket 10
Radiator Cleaner Radiator hose clamps 5
All Engines Motorcraft R1-5 Transmission oil cooler tube nuts 20
Radiator Cap Pressure (Supply Tank) Fan shroud asy screw to radiator 6
All Engines 120 kPa Water pump I6 20
Thermostat Water pump V8 25
6 Cylinder Starts to open 89° - 93°C Water pump pully V8 25
Fully open 103° - 106°C
Minimum travel of
capsule from fully closed
position: 7.1 mm
8 Cylinder Starts to open 87°C-91°C
Fully Open 105°C
Coolant Additive
Level of Additive Volume Volume Service
Protection Specification of of Interval
Additive Water
Anti- MES- 33% 67% 3 Years
corrosion MN121-C (5.3 (10.7 100,000
& (Motorcraft litre) litre) km
anti- R1-52)
freeze to
minimum
temp. of
-16°C
Anti- MES- 50% (8 50% (8 4 Years
corrosion MN121-C litre) litre) 120,000
& (Motorcraft km
anti- R1-52)
freeze to
minimum
temp. of
-37°C
Anti-Freeze Concentration
Specific Approximate Remains Solidfies at
Gravity % of Fluid to (C°) (C°)
Anti-Freeze
(by volume)
1.080 50 -37 -58
1.065 40 -25 -45
G97830 en 01/2003 2003.0 BA Falcon

Engine Cooling Water Pump

A centrifugal-type water pump is mounted on the front
Radiator of the cylinder block.
The radiators are of the tube and fin-core type with A vane-type impeller supplies coolant through
the tubes arranged for horizontal coolant flow. centrifugal action to the water pump oitlet port.
Two header tanks, one at each end of the core If the pump is found to be faulty remove and discard
provide uniform distribution of the coolant to the as it is of a sealed unit type which cannot be repaired.
tubes. The radiator outlet port is connected to the
water pump inlet port. The radiator inlet port is Cooling System
connected to the coolant outlet housing of the engine, The cooling system operates as follows:
thereby permitting coolant circulation through the
radiator when the thermostat is open. Coolant flows through the radiator tubes and is
cooled by air passing over the cooling fins
Midway down the right hand side radiator header tank assisted by the radiator electric fans.
is the coolant supply tank feed port, this connects the
cooling system with the supply tank. The supply tank Coolant expands as the temperature and
provides a chamber to accommodate the expansion pressure rise in the system.
of the coolant as engine temperature increases. When the limiting system working pressure is
A small port is located at the top of the right hand side reached, the pressure relief valve in the supply
tank. It is connected to the top of the supply tank. This cap is lifted from its seat and allows coolant to
port aids the self purging of air from the cooling flow through the supply tank overflow channel.
system. The supply tank cap has a rubber seal on the
An oil cooler is located in the radiator outlet underside to prevent leakage.
header-tank to cool transmission fluid for automatic When the system temperature and pressure drop,
transmission vehicles. the coolant contracts in volume and the pressure
A draincock is located at the bottom of the left hand in the radiator is reduced.
side tank.
WARNING: Never remove the supply tank cap
The coolant supply tank cap incorporates a 120 kPa
under any conditions while the engine is
(18 psi) pressure relief valve and vacuum valve. For
operating. Failure to follow these instructions
routine coolant level inspections the tank provides a
could result in damage to the cooling system or
quick visual method for determining the coolant level
engine and/or personal injury. To avoid having
without removing the tanks cap.
scalding hot coolant or steam blow out of the
Should the coolant level exceed the capacity of the supply tank, use extreme care when removing the
header tank it is discharged out the overflow channel. supply tank cap from a hot supply tank. Wait until
The header should not be overfilled. the engine has cooled, try squeezing the upper
With the engine cold the level of coolant in the supply radiator hose to determine if the system is still
tank should between the max and min lines on the under pressure. Then wrap a thick cloth around
supply tank. the supply tank cap and turn it slowly. Step back
while the pressure is released from the cooling
Electric Fans system.
The vehicle is fitted with dual electric fans controlled When certain all the pressure has been released,
by three relays linked to the PCM module. turn the supply tank cap (still with a cloth), and
remove it.
During service operations, ensure that fan is not
rotated in a direction opposing normal operation as
WARNING: The engine radiator electric fans
this may damage the motor (refer to arrow on fan
may come on at any time without warning.
blade).
Disconnect battery ground cable before servicing
Two operating modes are used (excluding OFF) - this will clear diagnostic trouble codes and
depending on the status of the three relays adaptive learning. The vehicle must then be driven
(determined by the PCM module). The different for 30 mins and idled for 15 mins to relearn.
operating modes provide different cooling capabilities. (suggest using a 9 volt memory minder in the
Refer to Wiring Diagrams section for a schematic of cigar lighter to retain keep alive memory).
the Fan Control System.
Cooling Maintenance
CAUTION: When the ignition is in the ON Correct coolant level is essential for maximum
position the fans may start without warning. circulation and adequate cooling. In addition, for the
cooling system to perform its function it must receive
proper care. This includes maintaining corrosion
G97831 en 01/2003 2003.0 BA Falcon

protection, keeping radiator fins clean, and periodic in toxic amounts on repeated or prolonged skin
inspection of the cooling system for leakage. contact. To promote the safe handling of coolant
Use care when removing the supply tank to avoid the following precautions should be adhered to:
injury from escaping steam or hot water. Maintain adequate ventilation and do not
To prevent the build up of rust, sludge and other inhale vapours.
foreign material in the cooling system, add the Must never be taken internally. If accidentally
specified Corrosion Inhibitor at the intervals specified. swallowed seek medical advice immediately.
If it is found necessary to remove build up of foreign Avoid skin contact. In the event of accidental
material from the cylinder block or radiator owing to spillage onto the skin, wash off as soon as
neglect of adding an inhibitor, use the specified possible. If clothing is splashed it should be
radiator cleaner. Removal of such material restores removed and washed to avoid prolonged skin
cooling efficiency and avoids over-heating. contact.
In severe cases where cleaning solvents will not Avoid spillage on vehicle paint work. Wash off
properly clean the cooling system for efficient immediately with water.
operation, it will be necessary to use the pressure
flushing method.
Various types of flushing equipment are available. If
pressure flushing is used, make sure the cylinder
head bolts are properly tightened to prevent possible
water leakage into the cylinders.
NOTE: Always remove the thermostat prior to
pressure flushing the engine.
When pressure flushing the engine or radiator, flush in
the reverse direction to normal water flow.
A pulsating or reversed direction of flushing water will
loosen sediment more quickly than a steady flow in
the normal direction of coolant flow.
The pressure applied to the radiator must not exceed
the supply tank cap relief pressure.
The coolant is water plus corrosion inhibitor and
Ethylene Glycol antifreeze (Motorcraft R1-33) Refer to
specifications.
CAUTION: Motorcraft R1-33 is not compatible

with soluble oil or soluble oil based additives, or
leak-stop additives. Do not use these other
additives in the vehicle’s cooling system.
If any of these other additives have been added to the
coolant, the system must be drained and cleaned with
Motorcraft radiator cleaner R1-5 and then thoroughly
reverse flushed before refilling with clean water and
the specified quantity of Motorcraft R1-33. Refer to
“DRAINING AND FILLING THE COOLING SYSTEM”
in this part.
WARNING: Do not remove the coolant supply

cap when the engine is hot. Allow the engine to
cool before removing the cap. Even then use
extreme care when removing the cap; wrap a thick
cloth around the cap and turn it slowly. Step back
while pressure is released from the cooling
system. When sure that all pressure has been
released, using the cloth, remove the cap.
WARNING: Motorcraft R1-33

Anti-Freeze/Anti-Boil Concentrate contains
ethylene glycol and/or other constituents which
are toxic if taken internally and can be absorbed
G97831 en 01/2003 2003.0 BA Falcon

Engine Cooling
Special Tool(s) Visual Inspection Chart
Radiator Cap/Cooling System Mechanical Electrical
Pressure Tester Damaged hoses. Circuitry
Available Commercially E 9353 Loose/damaged hose open/shorted.
(Litchfield Tools) clamps. Damaged fan control
Constant Tension Clamp Tool Damaged thermostat. relays
Drive Belt Damaged head Damaged radiator
Available Commercially E 9353 gaskets. electric motor, fan
(Litchfield Tools) Damaged water blade and fan shroud
pump. assembly.
Damaged radiator. Damaged or faulty
Inspection and Verification Damaged supply tank PCM.
1. Verify the concern by operating the engine cooling Damaged heater core. Open circuit in FAN 2
system to duplicate the concern. motor.
2. Inspect to determine if one of the following 3. If the concern(s) remains after the inspection,
mechanical or electrical concerns apply: determine the symptom(s) and proceed to the
following Symptom Chart.
Symptom Chart

Loss of Engine Coolant Damaged radiator. Go to Test A.
Damaged water pump.
Loose/damaged radiator hoses.
Loose/damaged heater hoses.
Damaged heater core.
Damaged engine gaskets.
Damaged supply tank.
Demaged cap relief valve.
Demaged drain cock.
Engine Overheats Damaged thermostat. Go to Test B.

Damaged water pump.
Internal engine coolant leak.
Cooling fans inoperative.
Radiator coolant flow obstruction
(internal)
Radiator air flow obstruction (external
fins)
Heater core blocked.
Openings or grille blocked.
Damaged or faulty PCM.
Airlock in system
Engine Does Not Reach Normal Damaged thermostat. Go to Test C.
Operating Temperature Cooling fans, PCM fault.
Low engine coolant.
Water pump leaking Gasket (leak at pump/block interface) CHECK bolt torques. Perform pressure
test both statically and dynamically
and visually confirm leak. REPLACE
water pump if necessary.
O-Ring (leak at heater tube) Perform pressure test both statically

and dynamically and visually confirm
leak. REPLACE O-Ring.
Weep hole A small amount of weep through this

hole is considered normal and
acceptable. Perform pressure test both
statically and dynamically and visually
confirm leak. REPLACE water pump if
necessary.
G97832 en 01/2003 2003.0 BA Falcon

Tests
TEST A : LOSS OF COOLANT
Test Step Result/Action to Take

A1 CHECK COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes
proceeding. Go to A2
No
Check coolant level coolant supply tank. REFILL coolant.
Is coolant level OK? Go to A2
A2 CHECK FOR VISIBLE LEAKAGE
Engine coolant has an added dye colour that makes the Yes
coolant an excellent leak detector. Rectify leak.
Check entire cooling system for visible leakage. RETEST system.
Is there visible leakage? No
Go to A3
A3 CHECK SUPPLY TANK CAP
Using a Radiator/Heater Core Pressure Tester test Yes
radiator cap as outlined in this section. Go to A4
Did supply tank cap test OK? No
REPLACE damaged supply tank cap.
RETEST system.
A4 CHECK COOLANT FOR INTERNAL LEAKAGE
Visually inspect coolant in radiator and coolant supply Yes
tank for signs of transmission or engine oil. If engine oil is evident, Go to Section
Is oil evident in coolant? 308-03.
If transmission oil is evident, Go to
Section 307-01 or Section 308-03.
No
Go to A5
A5 CHECK ENGINE AND TRANSMISSION FOR COOLANT
Remove oil level indicator from engine and transmission. Yes
Carefully inspect oil level indicator for evidence of If coolant is in engine, Go to Section
coolant. 303-00.
Is coolant evident? If coolant is in transmission, Go to
Section 307-01 or Section 308-03.
No
Go to A6
A6 PRESSURE TEST COOLING SYSTEM
NOTE: Check inside vehicle for possible heater core Yes
leakage. Rectify leak.
RETEST system.
Using a Radiator/Heater Core Pressure Tester conduct a No
pressure test. Cooling system is operational at this
Check for any signs of visible leakage. time.
Is there leakage? RETEST system.
G97832 en 01/2003 2003.0 BA Falcon

TEST B : ENGINE OVERHEATS

B1 CHECK COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes
proceeding. Go to B2
No
Remove supply tank cap and check coolant level at REFILL coolant.
supply tank. Go to A
Is coolant level OK?
B2 CHECK COOLANT CONDITION
Check coolant for contaminants such as rust or corrosion. Yes
Also check for fluid discoloration. Go to B3
Is coolant condition OK? No
FRETEST system.LUSH system.
B3 CHECK FOR AIRFLOW OBSTRUCTION
Visually inspect A/C condenser core and radiator core for Yes
obstructions such as leaves or bugs. REMOVE obstruction and
Is there any obstruction? CLEAN A/C condenser core and
radiator.
RETEST system.
No
Go to B4
B4 CHECK HEATER CORE OPERATION
Install supply tank cap. Yes
As engine starts to warm up, feel the inlet and outlet Go to B5
heater water hoses. They should feel the same after three No
or four minutes. TURN engine OFF before it
Is outlet heater water hose the same temperature as overheats. SERVICE heater core.
the inlet heater water hose? RETEST system.
B5 CHECK WATER THERMOSTAT OPERATION
Allow engine to run for 10 minutes. Yes
Feel the inlet and outlet heater water hoses and the REPLACE water thermostat.
underside of the upper radiator hose. RETEST system.
Are the upper radiator hose and heater water hoses No
cold? Leave engine RUNNING.
Go to B6
B6 CHECK COOLING FAN
Refer to Cooling Fan Self Test in this section.
TEST C : ENGINE DOES NOT REACH
NORMAL OPERATING TEMPERATURE

C1 CHECK ENGINE TEMPERATURE
Start engine and allow to RUN for 15 minutes. Yes
Feel inlet and outlet heater water hoses and underside of REPLACE water thermostat.
upper radiator hose. RETEST system.
Are upper radiator hose and heater water hoses cold? No
CHECK coolant temperature gauge
for correct operation.
G97832 en 01/2003 2003.0 BA Falcon

Pressure Test foreign material between the gasket and cap

body. Refer to supply tank Cap Cleaning and
It is recommended that a cooling system pressure test Inspection. Rinse supply tank cap in clean water.
gauge be used to properly test the system for:
NOTE: The supply tank cap used on this system is
Blown or leaking cooling system sealing gaskets. unique; replace only with the proper supply tank cap.
Internal or external coolant leakage.
2. Replenish the engine coolant at the supply tank.
Pressure cap malfunction.
3. Install the supply tank cap.
Many types of pressure gauges are available for use.
Therefore, it is recommended that the gauge Cooling Fan Self Test - All Models
manufacturer’s instructions be followed when
performing the test. The cooling fan motors and circuits are tested during
a PCM KOEO TEST. Refer to Section 303-14
NOTE: Never exceed the rated pressure indicated on Powertrain Control Module.
the pressure cap when performing the pressure test.
Fan Relay 1 Relay 2 Relay 3 Fan 1 Fan 2
Supply Tank Cap Pressure Test Speed
OFF OFF OFF OFF OFF OFF
1. Remove the supply tank cap.
2. Use water to clean the cap seal and the vacuum LO ON OFF OFF LOW LOW
relief valve. HI ON ON ON HIGH HIGH
3. Install the cap on a pressure test unit following the
manufacturer’s directions.
4. Slowly depress the plunger of the test unit pump
until the highest reading is achieved on the
gauge.
5. This reading should be within the specification for
the cap being tested.
6. Repeat the test several times. If the gauge
reading is not within specification replace the cap.
Thermostat Test
Thermostat Removed
Remove the thermostat and immerse it in boiling
water. Remove when open and place a .05 mm feeler
gauge in the throat of the thermostat and allow the
thermostat to cool and clamp on the feeler gauge.
Suspend a thermometer into a container of cool water
and heat the water.
Suspend the thermostat by the feeler gauge into the
container of warming water. When the thermostat
opens and drops off the feeler gauge, note the
temperature.
Refer to Specifications in this section for the operating
temperatures and opening dimensions.
If the problem being investigated is insufficient heat,
the thermostat should be checked for leakage. This
may be done by holding the thermostat up to a lighted
background. Slight leakage of light at one or two
locations on the perimeter of the valve may be
detected. This should be considered normal.
Coolant System
In the event no engine coolant is observed in the
supply tank, or when a coolant level change does not
occur, check the system as follows:
1. With the engine cold, remove the supply tank cap,
and inspect the filler neck sealing gasket for
G97832 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Coolant Level Check ESE-M97B44-A / WSS-M97B51-A1. Ford R1-33

meets this specification and is green in colour.
The coolant level is maintained by a coolant supply
1. Inspect the coolant color:
tank located on the right hand fender apron just
ahead of the suspension tower. If there is no coolant If Engine Coolant R-33 or equivalent meeting
visible in the supply tank the procedure quoted under Ford specification ESE-M97B44-A has a
‘DRAINING AND FILLING THE COOLING SYSTEM’ clear, light green or blue color, this indicates
must be used. higher water content than required.
Do not remove coolant supply tanks pressure cap for Dark brown could indicate unauthorized
routine coolant level inspections. The coolant supply stopleak may have been used. Flush the
tank provides a quick visual method for determining system and refill with the correct mixture of
the coolant level without removing the pressure gap. water and Premium Engine Coolant.
With the engine cold, the level of the coolant supply A light or reddish brown color indicates that
tank should be between the MIN and MAX lines on its rust may be present in the cooling system.
side wall. An iridescent sheen on top of the coolant
could indicate a trace of oil is entering the
WARNING: Do not attempt to remove the system. For additional information on engine
supply tank cap under any circumstances while diagnosis, refer to Diagnosis in this section.
the engine is operating or while the engine is hot.
A milky brown color may indicate that either
To do so might lead to damage to the cooling
engine oil or transmission fluid is entering the
system and the engine and could result in serious
cooling system. If transmission fluid is
personal injury from hot coolant or steam
suspected the cause may be a leaky radiator,
blowout. Switch off the engine and wait until it has
pressure test the cooling system. For
cooled. Use extreme care when removing the cap
additional information, refer to component
and wrap a thick cloth around the cap and turn it
tests in this section. If engine oil is suspected
slowly. Step back while the pressure is released
the cause of the leak may be internal to the
from the cooling system. When you are sure all
engine. For additional information on engine
the pressure has been released – still with a cloth
diagnosis, refer to Diagnosis in this section.
– turn cap and remove it.
If transmission fluid is contaminated with
NOTE: The level of the coolant in the supply tank
engine coolant the cause may be a leaky
should only be checked when the engine is cold.
radiator, pressure test the system. For
Remove the supply tank cap. additional information, refer to the component
Fill the supply tank to the FULL/MAX mark with tests in this section.
specified coolant. 2. If engine coolant appearance is good, test the
Refit the supply tank cap correctly (fully tighten by engine coolant range with the battery and
hand). antifreeze tester:
NOTE: If the coolant tank requires topping up to Maximum range is 50/50.
maintain the correct level of coolant, the complete Minimum range is 33/67.
cooling system should be checked without delay. 3. Adjust coolant range and level if necessary:
NOTE: When topping up the cooling system a mixture If coolant is low, add specified coolant mixture
of clean drinkable water and Motorcraft R1-33 only.
inhibitor should be used. Adding water only will dilute If the engine coolant tests to weak, add
the inhibitor and reduce its effectiveness. Refer to straight engine coolant concentrate until the
specifications. readings are within acceptable levels.
If the engine coolant tests strong, remove
Cooling Color Inspection some of the engine coolant and add water
until the readings are within acceptable levels.
CAUTION: Check the coolant level, engine oil NOTE: Use only clean drinkable water In the engine
and transmission fluid, top off the coolant if cooling system. It is strongly recommended that in
needed, if there is engine coolant in the engine oil areas of heavily mineralised water (e.g. bore water),
or transmission fluid the cause must be corrected only non-mineralised water (e.g. rain water) is used.
and oil/fluid changed or major component damage Mineral deposits on cooling surfaces will reduce the
may occur. effectiveness of an engine cooling system and lead to
The initial factory coolant fill is a 33% by volume engine overheating.
mixture of glycol-based anti-freeze/ant-corrosion
inhibitors in water, meeting Ford specification
G97834 en 01/2003 2003.0 BA Falcon

303-03-10 Engine Cooling 303-03-10
Adjusting Anti — Freeze Protection 2. Place a suitable container below the radiator
draincock. The front bumper “lower air deflector”
Level has a drainage aperture adjacent to the radiator
NOTE: All vehicles are factory supplied with 33% draincock and doesn’t need removal.
concentration of R1-33 anti-freeze, which provides Open the draincock or remove lower radiator
protection to -16 C. hose and allow to drain.
The specific gravity of the coolant should be checked Close the radiator draincock when finished.
at the recommended service intervals and the To Refill
concentration adjusted by adding either, anti-freeze
alone, a mixture of anti-freeze and water or water 1. Refit the lower radiator hose or drain plug.
alone, depending on whether the specific gravity is 2. Add the specified amount of anti-freeze to the
low, correct or high. The specific gravity is checked coolant supply tank.
using an anti-freeze tests hydrometer with the coolant
3. Fill the system with clean water to the “ADD/MIN”
cold.
mark on the supply tank.
Example: Checking a 50-50 concentration of NOTE: CAPACITY: Includes heater and coolant
Motorcraft R1-33 anti-freeze (1.080 coolant specific pressure bottle.
gravity).
Most service refills are about 80 percent of
If the hydrometer reading is 1.080 or greater, no capacity listed. This is because not all coolant is
adjustment is necessary. drained the cooling system.
If the reading is less than 1.080, add R1-33 to the
cooling system at the rate of 1 litre for each 0.012 4. Install the cap one turn only or depress and turn
S.G. increase required (e.g. 1.068 to 1.080). until fully locked.
5. Set the heater control to ‘HOT’(for an Automatic
NOTE: Draw of sufficient coolant to allow for the Climate Control system set the temperature to
addition of the required quantity of R-133. 32°C).
NOTE: The heater control doesn’t require setting
Anti — Freeze Replacement to hot as the heater core is constantly flowing
NOTE: The cooling system should be drained, flushed coolant.
with clean water and refilled with water and
6. Start the engine and run it at 2000 rpm for 10
anti-freeze according to the recommendations given in
minutes to open the thermostat and purge air from
the Specifications section of this Section. the system.
Vehicles must be refilled using specified quantities of
7. Top up the supply tank to the “FULL/MAX” mark.
R1-33 in the cooling system.
8. Replace the cap.
Draining and Filling the Cooling 9. Refit the lower air deflector. This procedure must
System be followed to ensure correct system
performance.
Draining
Radiator Cleaning
WARNING: To avoid personal injury, do not Condition of driving - Town, City and Casual
unscrew the coolant pressure relief cap while Driving
engine is operating or hot. The cooling system is
under pressure; steam and hot liquid can come 1. Loosen the top two radiator mounting brackets.
out forcefully when the cap is loosened slightly. NOTE: Cleaning of the radiator exterior is
Failure to follow these instructions may result in important to obtain maximum radiator efficiency
personal injury. and cooling performance.
2. Tilt the radiator and fan assembly rearwards from
CAUTION: The coolant must be recovered in the top.
a suitable, clean container for reuse. If the coolant
is contaminated it must be recycled or disposed 3. Use air pressure line to clear the debris then
of correctly. wash by using a hose (pressure cleaning is too
aggressive) between radiator and condenser. Do
NOTE: About 80% of coolant capacity can be not point the nozzle near the radiator and
recovered with the engine in the vehicle. Dirty, rusty condenser fins as this may damage them.
or contaminated coolant requires replacement.
4. Reposition radiator. Refer to the Radiator
1. Release the pressure in the cooling system by removal/installation in this section for additional
slowly turning the pressure relief cap one half turn information.
counterclockwise. When the pressure is released, Condition of driving - Outback, Dirt and Field
remove the pressure relief cap.
G97834 en 01/2003 2003.0 BA Falcon

303-03-11 Engine Cooling 303-03-11
Driving
1. Remove the radiator as described in the Radiator
removal in this section.
2. Use air pressure line to clear the debris then
wash by using a hose (pressure cleaning is too
aggressive) between radiator and condenser. Do
not point the nozzle near the radiator and
condenser fins as this may damage them.
3. Reinstall the radiator as described in the Radiator
removal in this section.
4. Top up the coolant and transmission oil per
specifications.
G97838 en 01/2003 2003.0 BA Falcon

303-03-12 Engine Cooling 303-03-12
Thermostat 6. Refill and bleed the cooling system as previously

described in this section.
Removal and Installation NOTE: On thermostats that have a bleeder valve,
1. Partially drain the engine coolant so that the the thermostat should be positioned with bleeder
coolant level is below the thermostat. For valve at the 12 o’clock position as viewed from
additional information refer to Cooling System front of engine.
Draining Filling and Bleeding in this section.
2. Remove the two bolts and separate the water Thermostat Housing — 8 Cylinder
outlet adapter from the thermostat housing and Removal and Installation
slide (with hoses attached) to one side.
NOTE: The 5.4-3V V8 thermostat housing is located
6 Cylinder at the coolant cross over manifold between the
cylinder heads.
1. Disconnect the battery. For additional information
refer to Electrical system section.
2. Remove the drive belt as previously described in
this section.
3. Remove the alternator. For additional information
refer to Electrical system section.
4. Drain the engine coolant as previously described
in this section.
5. Remove the Thermostat as previously described
in this section.
6. Remove the two bolts securing the coolant
manifold to the LHS cylinder head.
Item Description 7. Remove the bolt securing the coolant manifold to
1 Bolt the RHS cylinder head.
2 Housing 8. Remove the inlet manifold bolt clamping the
coolant manifold and loosen the adjacent inlet
3 Thermostat manifold bolts to allow removal of coolant
4 Conn water outlet manifold.
8 Cylinder 9. Clean and inspect the gasket.
10. Fitting a new gasket/s requires inlet manifold
removal. For additional information refer to Fuel
system section.
11. Clean and inspect the sealing surfaces. To install,
reverse the removal procedure.
12. Refill and bleed the cooling system as previously
described in this section.
Thermostat Housing — 6 Cylinder

1. Remove the thermostat. For additional
Item Description information, refer to Thermostat in this section.
1 Bolt 2. Remove the bolt and clamp that holds the heater
tube to the housing. Remove the bolt holding the
2 Thermostat heater tube on the inlet manifold. Withdraw the
3 Housing heater tube from the thermostat housing.
3. Remove the thermostat and the O-ring seal.
4. Clean and inspect the sealing surfaces.
5. To install reverse the removal procedure.
G97839 en 01/2003 2003.0 BA Falcon

303-03-13 Engine Cooling 303-03-13
3. Remove the two bolts and separate the 3. Remove the water pump from the cylinder block
thermostat housing from the cylinder head. being careful not to damage the heater pipe. This
pipe is a slide fit with an ‘O’ ring seal.
Item Description
1 Bolt
2 O-ring
3 Seal
4 Bolt
5 Housing
6 Thermostat
7 Conn Water outlet
4. Clean and inspect the sealing surfaces after
removing all traces of gasket material.
5. Fit a new gasket and O-ring.
6. To install, reverse the removal instructions.
7. Refill and bleed the cooling system as previously 4. If necessary, the water pump pulley can be
described in this section. removed using 888-000.
Water Pump — 6 Cylinder Installation
NOTE: If necessary, install the water pump pulley
Special Tool(s) before installing the water pump, using 416-D001.
Installer Power Steering Pump 1. Clean the heater outlet pipe and the matching
Pulley (6 & 8 Cylinder) opening in the water pump. Lubricate a new ‘O’
416-D001 ring seal and install on the heater pipe.
(A7005) 2. Clean the pump and cylinder block mating
surfaces and install a new gasket coated with
water resistant sealer.
3. Position the water pump on the cylinder block and
Remover Power Steering Pump heater pipe. Install the bolts and lock washers.
Pulley (6 & 8 Cylinder) 888-000 4. Refit the lower radiator hose.
(A7185) 5. Install the drive belt, refer to Section 303-03a.
6. Fill the cooling system as described in Section
303-03a.
Removal
1. Drain the cooling system as described in Section
303-03a.
2. Remove the accessory drive belt.
G97847 en 01/2003 2003.0 BA Falcon

303-03-14 Engine Cooling 303-03-14
Water Pump — V8 CAUTION: Do not rotate the coolant pump

Removal housing once installed in the engine. Damage the
O-Ring seal can occur, causing the coolant pump
1. Drain the engine coolant. For additional to leak.
information, refer to General Procedures in this
section. NOTE: Install a new O-Ring seal and lubricate with
the same clean engine coolant that is present in the
2. Loosen the coolant pump pulley bolts. system. Do not mix coolant types.
Installation
Radiator
Removal
1. Drain the cooling system as described in General
Procedures Section. Disconnect the upper and
lower radiator hoses.
2. Disconnect the coolant supply hose from the side
of the radiator and the bleed hose from the top of
the radiator.
6 Cylinder
4. Remove the bolts and the coolant pump pulley.
Item Description
1 Hose assy. Upper
5. Remove the four bolts and the coolant pump. 2 Hose assy. Bleed
3 Hose to engine vent
6. If necessary wipe the coolant pump mounting

surface with a soft cloth.
G97847 en 01/2003 2003.0 BA Falcon

303-03-15 Engine Cooling 303-03-15
8 Cylinder 9. Remove the screws securing the fan shroud and

fans to the top of the radiator, lift the shroud from
the clips on the bottom of the radiator and lay it
back.
Item Description
1 Hose assy. to bleed
2 Hose assy. Upper 10. Remove the radiator upper mounting brackets
3 Hose assy. Radiator overflow and carefully lift the radiator from the vehicle.
Installation
3. On vehicles equipped with automatic transmission
disconnect the oil cooler lines at the radiator by 1. Locate the radiator in the vehicle and install the
unscrewing the AF 17mm fittings and plug to upper support brackets.
guard against contamination entry. 2. Locate the fan shroud in the brackets on the
4. Remove the air cleaner intake duct. bottom of the radiator and install the two securing
screws at the top of the shroud.
5. Remove the grille.
3. Connect the upper and lower hoses and the
6. XR6 Turbo vehicles: remove intercooler (see coolant supply hose. Connect the bleed hose to
303-04b for procedure). the radiator.
7. Remove the 4 bolts holding the A/C condenser 4. Connect the electrical connections to the fans.
and wire or cable tie the condenser to the top
crossmember. 5. Remove the support cable tie/wire from the top
condensor and install the 4 A/C condensor
mounting bolts
6. Install the air cleaner intake duct.
7. XR6 Turbo vehicles: install intercooler (see
303-04b for procedure).
8. Connect the oil cooler lines (auto only) do not
over tighten the fittings as this will demage the oil
cooler.
9. Install air cleaner intake duct.
10. Install the grille.
11. Fill the cooling system as described in General
Procedures Section.
8. Disconnect the electrical connections to the fans.
G97842 en 01/2003 2003.0 BA Falcon

303-03-16 Engine Cooling 303-03-16
Fan 3. Insert a new ‘C’ Spring Clip. Do not re-use the old
clip.
Removal 4. Rotate fan (in the direction of normal operation) to
1. Remove fan and shroud from vehicle. ensure it rotates freely.
5. Install fan and shroud assembly into vehicle.
Radiator Hose
NOTE: Radiator hoses should be replaced whenever
they become cracked, rotted or have a tendency to
collapse, See Draining and Filling the Cooling
System.
1. Drain radiator: then loosen the clamps at each
end of hose to be removed. Slide hose off radiator
connection and the cylinder head water outlet or
water pump connection.
2. Position the clamps and hoses as shown in the
Item Description applicable installation in this chapter. Tighten
clamps.
1 Condensor assy.
3. Fill coolant supply tank to the “FULL/MAX” mark.
2 Radiator assy.
4. Fill and bleed the cooling system as described in
3 Motor and Fan assy. Draining and Filling the Cooling System in this
4 Screw and washer assy. section.
2. Lay the assembly flat. NOTE: The hose clamps initial factory fit make
use of a torque limiting cap that’s drive shears off
3. Remove and discard the ‘C’ Spring Clip by gently once the torque valve is reached.
sliding sideways.
For service remove the cap body by prying off to
4. Gently prise drive plate from cavity. reveal the hand tool drive feature.
5. Remove fan. Install the hose clamps as close as possible to the
bead on the inlet and outlet pipes. Use only Ford
approved hoses and clamps when replacement is
necessary. Clamps with a “ bow spring‘‘ show
improved resistance to compression set of the
rubber hoses
Coolant Supply Tank

Removal
1. Remove supply tank cap and loosen radiator
drain tap and drain cooling system until no coolant
remains in the supply tank.
2. Remove the bleed tubes found on upper surface
of supply tank.
Item Description
1 Shroud
2 Fan
3 Drive plate
4 ‘C’ Spring clip
5 Screw
6 Motor
Installation
1. Place fan on spindle.
2. Install drive plate ensuring locating peg fits into
hole correctly.
G97842 en 01/2003 2003.0 BA Falcon

303-03-17 Engine Cooling 303-03-17
6 Cylinder 3. Remove the two bolts which retain the supply tank
to the vehicle and release the leg to the RH
suspension tower.
Item Description
1 Hose assy. Upper
Item Description
2 Hose assy. Bleed
1 Supply tank cap
3 Hose to engine vent
2 Screw
8 Cylinder 4. Remove coolant feed hose on side surface of
supply tank.
Installation
1. Remove supply tank cap.
2. Position coolant feed hose onto supply tank.
3. Position supply tank in vehicle and tighten coolant
feed hose.
4. Attach supply tank to vehicle using the locating
leg and two attaching screws.
5. Attach bleed tubes to the top of the supply tank.
6. Fill the supply tank with coolant as described in
General Procedures Section.
Item Description
1 Hose assy. to bleed
2 Hose assy. Upper
3 Hose assy. Radiator overflow
G97846 en 01/2003 2003.0 BA Falcon

303-04b-1 Fuel Charging and Controls — Turbocharger 303-04b-1
SECTION : 303-04b Fuel Charging and Controls —

Turbocharger
CONTENTS PAGE
SPECIFICATIONS
Turbocharger ........................................................................................................................303-04b-3
Boost Control .....................................................................................................................303-04b-3
Charge Air Cooler (Intercooler) ..........................................................................................303-04b-4
Heatshielding .....................................................................................................................303-04b-5
Turbocharger ........................................................................................................................303-04b-6
Inspection and Verification .................................................................................................303-04b-6
Symptom Chart ..................................................................................................................303-04b-6
Pinpoint Tests ....................................................................................................................303-04b-7
Turbocharger ......................................................................................................................303-04b-16
Boost Pressure Sensor ......................................................................................................303-04b-20
Wastegate Control Solenoid (WCS) .................................................................................303-04b-21
Charge Air Cooler (Intercooler) ..........................................................................................303-04b-21
01/2003 2003.0 BA Falcon

SPECIFICATIONS
NOTE:Oil threads with engine oil.

NOTE:Do not oil threads that require thread sealant
or thread locker.
Torque Specifications (Turbocharger)
Description Nm
Exhaust Manifold to Cylinder Head 27
Heat Shield to Exhaust Manifold (M8 20
Bolt, 2 places)
Turbocharger to Exhaust Manifold
Stud 27
Nut 55
Dump-Pipe to Turbocharger
Stud 15
Nut 25
Pencil Brace to Dump-Pipe 25
HEGO Sensor to Dump-Pipe 25
Oil Return Pipe to Turbocharger 20
Oil Return Pipe to Sump 20
Water Supply Tube to Turbocharger 45
Water Return Tube to Turbocharger 45
Oil Supply Tube to Turbocharger 20
Oil Supply Tube to Nut & Filter 20
Assembly
Oil Supply Nut & Filter Assembly to 20
Cylinder Block
Torque Specifications (Intercooler & Ducting)
Description Nm
Studs to cushion connectors 15
Cushion connector to intercooler 15 15
Nuts holding brackets to cushion 20
connectors
Mounting brackets to front cross 25
member
Screw hose clamps on air ducting 2
pipes & hoses
Under headlight duct retaining screw 8
Boost pressure sensor screw 2
Wastegate solenoid bracket retaining 8
screw
Cross-over duct nuts 9
G99920 en 01/2003 2003.0 BA Falcon

Turbocharger
Applicable to the XR6 Turbo model only
Item Description
1 Coolant Supply Line
2 Oil Supply Line
3 Oil Outlet Line
4 Coolant Outlet Line
The turbocharger consists of two elements, a turbine
and a compressor both installed on a single shaft and
contained within housings.
The turbocharger bearings are supplied oil from the
engine via the oil supply tube. This is returned to the
oil pan via the oil return pipe.
The turbocharger housing also receives coolant from
the engine cooling system, to assist with turbocharger
cooling. Item Description
The turbine element of the turbocharger is mounted 1 Exhaust manifold
on the exhaust manifold and uses the energy of the 2 Turbine side of turbo
exhaust gas to drive the compressor. The compressor 2 Compressor side of turbo
feeds air to the engine via the intercooler.
Boost Control
The turbocharger is governed by means of a
wastegate valve. The wastegate valve diverts some of
the exhaust gas past the turbine and therefore
regulates the speed of the turbine. The wastegate
valve is controlled by a pressure operated actuator.
The actuator incorporates a diaphragm, and uses
G99921 en 01/2003 2003.0 BA Falcon

regulated air pressure to control the wastegate. This The PCM uses the BPS output voltage to control
actuator is preset during manufacture and must not be boost pressure, dependent upon engine load,
tampered with. temperature and RPM. The control system increases
engine intake pressure by diverting excess pressure
away from the wastegate actuator through the
Wastegate Solenoid Valve. The solenoid valve is
controlled by the PCM’s TURBO output.
CONNECTIONS AT PCM
Pin C2 Boost Pressure Sensor
(BPS) Signal
Pin C28 BPS Signal Return
(SIGRTN)
Pin C21 TURBO
Pin B45 Vehicle Reference
Voltage (VREF)
Intake air pressure is further controlled by a blow-off
The air pressure to the actuator diaphragm is valve, which dumps excess pressure into the low
regulated by use of a Boost Pressure Sensor (BPS) pressure side of the intake system when the throttle is
and a Wastegate Control Solenoid (WCS). closed.
The Boost Pressure Sensor is located on the The blow-off valve is actuated by intake manifold
aluminium duct beneath the driver’s side headlight. pressure, via a rubber hose from the intake manifold.
The Wastegate Control Solenoid is mounted The blow-off valve is situated in the Cross-Over Duct
underneath the fuse box. on top of the engine.
Item Description Charge Air Cooler (Intercooler)

1 Wastgate Control Solenoid The Charge Air Cooler (CAC) is an air-to-air cooler.
2 Boost Pressure Sensor The compressed air from the turbocharger flows
The BPS measures the absolute pressure of the through the cooler, and is cooled by outside air
pre-throttle intake system for cruise control and flowing over the vanes of the CAC.
wastegate control strategy. The pressure sensing The lower temperature of the charge air increases its
element in the BPS employs a Piezo resistive sensor density, so giving improved engine efficiency and
that outputs a voltage proportional to absolute power.
pressure. The CAC is mounted in front of the radiator with four
BPS Specification rubber isolated mounts.
Absolute Pressure (kPa) Signal Voltage (V)
10 0.3
50 1.0
100 1.9
150 2.8
200 3.7
G99921 en 01/2003 2003.0 BA Falcon

Heatshielding
Two heatshields cover the exhaust manifold and the
turbocharger, to protect surrounding engine bay
components from heat damage.
A heatshield is also fitted over the engine mount
under the turbocharger, to protect the mount from
radiated heat.
Item Description
1 Rear exhaust manifold heatshield
2 Front exhaust manifold heatshield
3 Engine mount heatshield
G99921 en 01/2003 2003.0 BA Falcon

Turbocharger Visual Inspection Chart

Mechanical Electrical
Inspection and Verification Oil leak(s) Wiring harness
NOTE: It is normal for a small amount of combustion Air cleaner element Electrical connector(s)
gas to pass into the crankcase. These ’blow-by’ Air cleaner outlet pipe PCM
gases are scavenged into the air intake system Air cleaner intake pipe Boost Pressure
through the positive crankcase ventilation (PCV) Turbocharger oil Sensor
system. supply or oil return Wastegate Control
tube Solenoid
Some engine oil, in the form of a vapour is carried into Turbocharger coolant
the air intake system with the blow-by gases (this supply or return tube
engine oil also contributes to valve seat durability). Wastegate valve and
This means that oil will collect inside the air intake actuator
components and the turbocharger. This is not an Turbocharger
indication that the turbocharger oil seal has failed. The housings
turbocharger oil seal will not fail unless the bearings Turbocharger rotor
fail first, which will cause the turbocharger to become blades
noisy or seize. Charge Air Cooler
Do not install a new turbocharger due to oil inside the Ducting to and from
turbocharger or the air intake components. If a leak is the Charge Air Cooler
detected in the oil supply or return tubes or
3. If an obvious cause for an observed or reported
connections, locate and rectify the source. Do not
concern is found, correct the cause (if possible)
install a new turbocharger due to an oil leak. before proceeding to the next step.
1. Verify the customer concern.
4. If the cause is not visually evident, verify the
2. Visually inspect for the following obvious signs of symptom and refer to Symptom Chart.
mechanical and electrical damage:
Symptom Chart or renewed.

NOTE: The wastegate actuator diaphragm unit is a
fixed part of the turbocharger and cannot be adjusted

Blue smoke with excessive Turbocharger compressor rubbing on Go to PinPoint Test A.
turbocharger noise housing walls.
Turbocharger turbine rubbing on
housing walls.
Turbocharger bearings and oil seal(s)
damaged.
Excessive turbocharger noise without Turbocharger oil supply tube blocked Go to PinPoint Test A.
blue smoke or damaged.
Blue smoke without excessive Turbocharger oil return tube blocked or Go to PinPoint Test B.
turbocharger noise damaged.
Poor engine performance Wastegate control valve vacuum CHECK all vacuum line(s) are installed
line(s). and no signs of air leaks are present.
Unauthorized adjustment of the The turbocharger boost pressure is
wastegate control valve actuator rod. factory set and must not be adjusted.
CHECK that the wastegate actuator
valve and rod have not been tampered
with. If there is evidence of tampering,
INSTALL a new turbocharger. REFER
to Removal and Installation -
Turbocharger
Wastegate valve actuator rod. CHECK the wastegate valve actuator

rod moves freely. If the wastegate
valve actuator rod does not move
freely. CHECK for signs of damage or
signs of foreign material. REPAIR as
necessary. Go to PinPoint Test C
G99922 en 01/2003 2003.0 BA Falcon

Pinpoint Tests
PINPOINT TEST A : NOISY TURBOCHARGER WITH BLACK OR BLUE EXHAUST SMOKE

A1 INSPECT THE TURBOCHARGER COMPRESSOR VANES
FOR DAMAGE
Disconnect the fresh air supply duct from the turbocharger. Yes
Go to A2
Inspect the compressor rotor vanes for damage.
No
Go to A3
Is there visible damage to the rotor vanes?
G99922 en 01/2003 2003.0 BA Falcon


A2 CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR
SYSTEM COMPONENTS
Check the intake air system components for signs of foreign material. Yes
CLEAN the intake air system components.
INSTALL a new turbocharger.
REFER to Removal and Installation -
Turbocharger.
No
Go to A4
Are there any signs of foreign material?
G99922 en 01/2003 2003.0 BA Falcon


A3 CHECK THE TURBOCHARGER BEARINGS FOR
EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal. Yes

Go to A4
Make sure the turbocharger rotor spins freely within the housing.
While slowly turning the rotor assembly by hand, push the shaft No
radially and axially. INSTALL a new turbocharger.
Turbocharger.
Does the rotor spin freely within the housing?
A4 CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR

BLOCKAGE
NOTE: New sealing washers should be installed when refitting the oil Yes
pipe. INSTALL a new turbocharger oil supply pipe
and/or banjo bolt.
Disconnect the oil supply tube from the turbocharger. INSTALL a new turbocharger.
Attach a small piece of known good hose to the oil supply tube and Turbocharger
gently blow down the hose. TEST the system for normal operation.
INSPECT the banjo bolt and turbo oil gallery for signs of blockage or
oil clotting. No
Go to A5
Are there any signs of blockage?
G99922 en 01/2003 2003.0 BA Falcon


A5 INSPECT THE TURBOCHARGER TURBINE VANES FOR
DAMAGE
Remove the exhaust pipe and the dump-pipe from the turbocharger. Yes
INSTALL a new turbocharger. REFER to
Inspect the turbine vanes for damage. Removal and Installation - Turbocharger.
SOURCE and rectify the cause of the damage to
the turbine blades.
No
Go to A1
Are there any signs of damage?
G99922 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : BLUE EXHAUST SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE
B1 CHECK THE TURBOCHARGER OIL RETURN PIPE
NOTE: New sealing gaskets should be installed when refitting the oil Yes
return pipe. Go to Symptom Chart in this section for further
blue smoke diagnostics.
Disconnect the turbocharger oil return tube from the turbocharger and
from the engine sump No
INSTALL a new turbocharger oil return tube.
Remove the turbocharger oil return tube. INSTALL a new turbocharger.
Check the turbocharger oil return tube for a blockage or signs of REFER to Removal and Installation -
damage. Turbocharger.
Is the turbocharger oil return tube OK?
PINPOINT TEST C : POOR ENGINE PERFORMANCE

C1 CHECK THE WASTEGATE ACTUATOR CONTROL
HOSE
Remove the wastegate actuator control hose. Yes
INSTALL a new wastegate actuator control
Check that the hose has no cracks or holes, and that it is not blocked. hose.
No
Go to C2
Is the hose damaged?
G99922 en 01/2003 2003.0 BA Falcon


C2 CHECK THE WASTEGATE ACTUATOR DIAPHRAGM
FOR LEAKS
NOTE: The wastegate control actuator is factory set and must not be Yes
adjusted or modified. If the wastegate control actuator is not operating Go to C3
correctly, the complete turbocharger assembly must be replaced.
No
Connect one end of the wastegate actuator control hose to the INSTALL a new turbocharger.
wastegate actuator. REFER to Removal and Installation -
Turbocharger
Connect the other end of the wastegate control actuator hose to a TEST the system for normal operation.
hand pressure pump.
Using the hand pressure pump apply 35-45 kPa to the wastegate
actuator.
Item Description
1 Wastgate Actuator Rod
2 Wastgate Actuator Control Hose
Does the wastegate actuator rod move and hold its new position
until the pressure is released?
G99922 en 01/2003 2003.0 BA Falcon


C3 CHECK THE WASTEGATE CONTROL SOLENOID
NOTE: The wastegate control solenoid is factory set and must not be Yes
adjusted. REPLACE the wastegate control solenoid.
REFER to Removal and Installation - Wastegate
NOTE: If a fault develops in the turbo wastegate control system, a Control Solenoid.
standby function is carried out. The wastegate solenoid is forced fully open TEST the solenoid.
(0% duty cycle) allowing minimum mechanical boost to be delivered. If the
boost pressure is still higher than desired, torque-limiting by cylinder No
cut-out will occur. The appropriate trouble code will be logged in memory Go to C4
for retrieval during Self Test mode.
Connect a WDS tester to the diagnostic connector.

Check for Diagnostic Trouble Codes at:
- Key-On-Engine-Off (KOEO)
- Key-On-Engine-Running (KOER)
- Engine Running (cont)
DTC TEST CONDITION

MODE
P0243 KOEO, Wastegate Solenoid Circuit
KOER, Cont Malfunction
P1227 Cont Wastegate Control System
Failed - Wastegate Closed
(Over Pressure)
P1228 Cont Wastegate Control System
Failed - Wastegate Open
(Under Pressure)
Is the solenoid operation faulty?
G99922 en 01/2003 2003.0 BA Falcon


C4 CHECK THE BOOST PRESSURE SENSOR
NOTE: The Failure Mode Effects Management (FMEM) strategy will, in Yes
most cases, ensure reasonable operation of the vehicle in the event of a REPLACE the boost pressure sensor.
BPS failure. If the BPS signal is not within the normal operating range, the REFER to Removal and Installation - Boost
PCM will substitute a default value for pre-throttle absolute pressure and Pressure Sensor.
use MAP for boost control. The appropriate trouble code will be logged in TEST the sensor.
memory for retrieval during Self Test mode.
No
Connect a WDS tester to the diagnostic connector. Go to C5
Check the Parameter Identification (PID) value of the BPS. At

Key-On-Engine-Off (KOEO) the value should be between 1.8 - 2.2
Volts.
Is the PID value within the specified limits?
C5 CHECK THE BOOST PRESSURE
NOTE: The boost pressure is factory set and must not be adjusted. Yes
Go to C6
Start and run the engine until normal operating temperature is
achieved. No
REPLACE the boost pressure sensor.
Connect a WDS tester to the diagnostic connector. REFER to Removal and Installation - Boost
Pressure Sensor.
Run the engine at idle and observe the Parameter Identification (PID)
TEST the sensor.
value of the BPS. The value should be between 1.8 - 1.9 Volts (this
equates to 0.5 bar of boost).
Is the PID value within the specified limits?
G99922 en 01/2003 2003.0 BA Falcon


C6 CHECK THE CHARGE AIR COOLER AND DUCTING
Remove the air ducting that runs to and from the charge air cooler. Yes
REFER to Removal and Installation - Charge Air Cooler. Unblock or replace components as required.
REFER to Removal and Installation - Charge Air
Inspect the components for cracks, leaks or blockages. Cooler.
Remove the charge air cooler. REFER to Removal and Installation - TEST the system for normal operation.
Charge Air Cooler.
No
Inspect the cooler for cracks, leaks or blockages. TEST the fuel system. REFER to Section
310-00.
Are any blocked or damaged components evident?
G99922 en 01/2003 2003.0 BA Falcon

Turbocharger 5. Disconnect the water inlet tube from the

turbocharger.
Removal 1. Discard the sealing washers.
All vehicles 6. Disconnect the water outlet tube from the
1. Disconnect the battery ground cable. For turbocharger.
additional information, refer to Section 414-01. 1. Discard the sealing washers.
2. Remove the fresh air duct from the turbocharger.
1. Unscrew the hose clamps.
2. Remove the pipe.
Item Description
1 Water Inlet
2 Water Outlet
3. Detach the charge air cooler intake duct from the
turbocharger. 7. Disconnect the oil supply tube from the
1. Unscrew the hose clamp. turbocharger.
2. Remove the duct. 1. Discard the sealing washers.
8. Disconnect the oil return tube from the
turbocharger.
1. Discard the gasket.
4. Disconnect the HEGO sensor wiring connector at

the chassis rail.
Item Description
1 Oil supply line
2 Oil return line
G99923 en 01/2003 2003.0 BA Falcon

9. Remove the exhaust manifold and turbocharger 13. Remove the exhaust manifold, turbocharger and
heatshields. dump-pipe as a complete assembly.
1. Remove the 5 exhaust manifold and heat 1. Discard exhaust manifold gasket.
shield retaining bolts from the cylinder head.
2. Remove the two heat shield retaining screws.
3. Remove the two heat shields.
14. Inspect the condition of the engine mount

heatshield.
1. Replace if damaged.
10. Disconnect the exhaust catalyst pipe from the 15. Inspect the condition of the H-Brace.
dump-pipe. 1. Replace if damaged.
11. Disconnect the turbocharger from the H-Brace. 16. Remove the Dump-Pipe.
1. Remove and discard the two lower 1. Remove and discard the five retaining nuts.
turbocharger nuts to disconnect the H-Brace.
2. Discard the gasket.
3. Inspect the threads on the studs. Replace if
damaged.
12. Remove the remaining exhaust manifold retaining

bolts from the engine.
G99923 en 01/2003 2003.0 BA Falcon

17. Remove the turbocharger from the exhaust 2. Refit the dump-pipe to the turbocharger.
manifold.
1. Install a new dump-pipe gasket.
1. Remove and discard the two remaining nuts.
2. Use new stainless steel studs if necessary.
2. Inspect the threads on the studs. Replace if
damaged. 3. Use new copper coated nuts.
4. Torque nuts to specifications.
Installation
3. Install the exhaust manifold, turbocharger and
All vehicles
dump-pipe assembly.
NOTE: Install a new exhaust manifold gasket. 1. Install a new manifold gasket.
NOTE: Install a new dump-pipe gasket. 2. First, fit the bottom two turbocharger mounting
studs into the H-Brace holes, then lower the
NOTE: Install a new oil return line gasket.
manifold onto the head.
NOTE: Install new oil supply line sealing washers
(x2).
NOTE: Install new coolant supply line gaskets (x2).
NOTE: Install new coolant return line gaskets (x2).
1. Refit the turbocharger onto the exhaust manifold.
1. Use new stainless steel studs if necessary
2. Fit the upper two nuts only at this stage.
3. Use new copper coated nuts.
NOTE: There is no gasket between the
exhaust manifold and turbocharger.
3. Install the manifold mounting bolts, leaving

out the four bolts that mount the heat shields
and the one bolt that mounts the pencil brace.
G99923 en 01/2003 2003.0 BA Falcon

4. Fit the two remaining copper nuts to the 7. Connect the oil return tube to the turbocharger.
turbocharger mounting studs.
1. Install a new oil return line gasket.
5. Fit the pencil brace to the dump-pipe and
2. Use Loctite Thread Sealer or equivalent on
exhaust manifold
bolts.
6. Torque all the bolts to specification.
4. Install the heat shielding to the turbocharger.
1. Fit the remaining exhaust manifold bolts with
the heatshields.
2. Fit one of the heat shield retaining screws into
the dump-pipe.
3. Fit the other heat shield retaining screw into
the manifold.
4. Torque all the hardware to specification.
Item Description
1 Oil supply line
2 Oil return line
8. Connect the coolant outlet tube to the
turbocharger.
1. Install a new coolant outlet line sealing
washers.
5. Reconnect the HEGO sensor wiring. bolts.
6. Connect the exhaust catalyst to dump-pipe.
1. Use new studs if necessary.
2. Use new catalyst pipe nuts.
G99923 en 01/2003 2003.0 BA Falcon

9. Connect the coolant inlet lines to the 11. Install the fresh air inlet duct to the turbocharger.
turbocharger. 1. Install the pipe duct.
1. Install a new coolant inlet line sealing 2. Tighten the hose clamps to specification.
washers.
bolts.
12. Connect the battery ground cable. For additional

13. Start engine and check all connections for
10. Connect the charge air cooler intake pipe. oil/water/air leaks.
CAUTION: Make sure that the inside of Boost Pressure Sensor
the charge air cooler intake pipe is clean and
free from any residue as this will reduce the Removal
installation grip of the pipe to the charge air 1. Disconnect the wire harness from the BPS
cooler. Failure to follow this instruction may connector.
result in engine damage.
2. Undo the retaining bolt.
1. Install the pipe to the turbocharger.
3. Gently pull the sensor out vertically from the
2. Refit the two hose clamps and tighten to aluminium duct.
specification.
Installation
1. Push the new BPS into the aluminium duct.
2. Refit the retaining bolt and tighten.
G99923 en 01/2003 2003.0 BA Falcon

3. Reconnect the harness to the BPS. 5. Reconnect the harness to the WCS.
Charge Air Cooler (Intercooler)
Removal
1. Remove bumper and grill, Refer Section 501-19
of this workshop manual.
2. Remove horns, Refer Section 413-06 of this
workshop manual.
3. Remove RH headlamp, Refer Section 417-01 of
this workshop manual
4. Undo the clamps and disconnect the tube that
runs from the top of the intercooler to the under
headlamp duct.
5. Undo the clamps and disconnect the tube that
runs from the turbocharger to the intercooler.
Wastegate Control Solenoid (WCS)
6. Remove the nuts holding the intercooler to the
Removal passenger side mounting bracket
1. Disconnect the wire harness from the WCS 7. Remove the nuts holding the driver’s side
connector. mounting bracket to the crossmember and
2. Disconnect the hose that runs from the remove the bracket and the intercooler together.
turbocharger compressor to the WCS. 8. Remove the nuts holding the RH bracket to the
3. Disconnect the hose that runs from the WCS to intercooler.
the wastegate actuator on the turbocharger. 9. Remove the cushion connectors from the
4. Undo the retaining bolt. intercooler ends.
5. Withdraw the Wastegate Control Solenoid. 10. Remove the wiring harness from the under
headlamp duct.
11. Undo the bolt retaining the earth wire and under
headlamp duct to the body.
12. Remove the duct from under the battery tray by
twisting and removing at the same time.
Item Description
1 Hose WCS to turbo compressor
2 WCS electrical connection
3 Hose turbocharger actuator to WCS
4 Wastgate control solenoid (WCS) Item Description
Installation 1 Cool air to intake manifold
1. Fit the Wastegate Control Solenoid into position. 2 Cool air duct and BPS
2. Refit the retaining bolt and tighten. 3 TURBO to intercooler
3. Connect the hose that runs from the WCS to the 4 Cool air hose from intercooler
wastegate actuator on the turbocharger. 5 Intercooler
4. Connect the hose that runs from the turbocharger 6 Intercooler mounting bracket
compressor to the WCS.
G99926 en 01/2003 2003.0 BA Falcon

Installation
1. Installation is the reversal of the removal
procedure.
2. Check all connections to ensure there are no
airleaks.
G99926 en 01/2003 2003.0 BA Falcon

303-04c-1 Single Fuel LPG 303-04c-1
SECTION : 303-04c Single Fuel LPG

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-04c-3
Single Fuel LPG ...................................................................................................................303-04c-4
Introduction .........................................................................................................................303-04c-4
Licensing Requirements ....................................................................................................303-04c-5
Important Safety Notice .....................................................................................................303-04c-5
Notes, Cautions and Warnings ..........................................................................................303-04c-6
Vehicle Identification ..........................................................................................................303-04c-7
Description .........................................................................................................................303-04c-8
LPG System Major Components ......................................................................................303-04c-11
Converter ..........................................................................................................................303-04c-13
Engine Servicing Requirements .......................................................................................303-04c-16
Scheduled Maintenance ...................................................................................................303-04c-17
Single Fuel LPG .................................................................................................................303-04c-20
Inspection and Verification ...............................................................................................303-04c-20
Symptom Charts ...............................................................................................................303-04c-23
Connector Circuit Reference ............................................................................................303-04c-26
Primary Service ..................................................................................................................303-04c-29
LPG Filter ...........................................................................................................................303-04c-29
Tank Assembly ...................................................................................................................303-04c-29
Pressure Decanting ............................................................................................................303-04c-29
Tank Decanting ..................................................................................................................303-04c-30
Tank — Ute ........................................................................................................................303-04c-30
Tank — Wagon ..................................................................................................................303-04c-32
Tank — Sedan ...................................................................................................................303-04c-33
Fuel Gauge and Float Assembly ........................................................................................303-04c-34
Automatic Fill Limiter ..........................................................................................................303-04c-34
Service Valve (With Relief Valve on Ute and Wagon) .......................................................303-04c-35
Fuel Filler Valve .................................................................................................................303-04c-35
Pressure Relief Valve .........................................................................................................303-04c-36
Fuel Filler Hose ..................................................................................................................303-04c-36
LPG Fuel Delivery System Hose .......................................................................................303-04c-36
Bundy Tube Connection .....................................................................................................303-04c-37
Converter Including Filter Lockoff & Solenoid ....................................................................303-04c-38
Filter ...................................................................................................................................303-04c-39
Main/Idle/Prime Lockoff Solenoids .....................................................................................303-04c-39
Converter Assembly ...........................................................................................................303-04c-39
01/2003 2003.0 BA Falcon

(Continued)
Throttle Body ......................................................................................................................303-04c-40

Converter with integral Filter/Lock Off ″ Solenoid ..............................................................303-04c-41
Converter ............................................................................................................................303-04c-41
Idle Jet ................................................................................................................................303-04c-45
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Second stage section bolts (76) 4-5
Fuel Tank Manufactured by APA Second stage spring cap (51) 12-15
Industries First stage lever screws (24) 1.5-2.5
Capacity First stage cover screw (68) 1.5-2.5
Ute 92 Litres usable Idle section bolts (76) 4-5
Sedan 93 Litres usable Support plate screw (5) 2-2.5
Wagon 116 Litres usable M5 cover nuts (1) 4-6
Fuel sender 40 - 250 ohms. Normal Inlet lockoff assembly (stem) (15) 16-17
Working Range
Screw stepper motor (not shown) 4-5
Pressure relief valves Relief Pressure - 2.55
Filter lockoff assembly (15) 22-24
on tanks MPa
Filter bowl screws (65) 4-6
Pressure relief valve Relief Pressure - 3.10
(hydrostatic) on service MPa Idle plug (17) 3-6
line- Sludge drain plugs (79) 5-7
Service line Bundy-tube - Preformed Balance plug (19) 10-15
5/16 " and 3/8 " diameter
with Flexible pressure
hose to the fill line.
Converter assembly VIALLE - F5 Type
(Special)
Idle Jet 0.8mm diameter
Throttle body and mixer LPG Fuel (38mm I.D.)
assembly
Spark plugs - Iridium K 20 SR 11
Long Life
Gap 1.1 ± - 0.05mm
Description Nm
Flared connections - All 35-38
Converted bracket to spring tower 17-23
Filler valve plate to bracket fuel tank 8-12
neck
Primary/Lock Off to Converter 10-12
Idle solenoid to converter 10-12
Converter to mounting bracket 4-8
Tank to chassis mounting bolts 80
Service valve to tank 5
AFL to tank 5Nm LPG Gauge (AXIOM) 5
to tank
Converter outlet retainer 4-8
Electrical connector bracket on 4-8 plus
converter lock offs Loctite 262
Inlet union to converter Filter bowl 15-20
Fuel Tank Neck to Body 21-29
Converter Torque settings Refer to
Section
310-00.
Nut (73) 1.5-2.5
Bolt water pipes (not shown) 4-5
Second stage lever screws (37) 1.5-2.5
G86720 en 01/2003 2003.0 BA Falcon

Single Fuel LPG fitment on these vehicles may comprimise safe

vehicle operation, reduce the life of certain engine
Introduction components and result in non-compliance with
emission regulations. Ford does not warrant or
This Repair Manual has been prepared to provide take responsibility for any defect caused by or
service information relating to the option of a specially attributed to fitment of LPG to a petrol vehicle.
developed VIALLE LPG system for the Ford BA
The manual is intended for use by only
Falcon Sedan, Wagon and Ute. registered/licensed technicians operating in
It should be recognized that the information contained approved specialist gas workshops. All specialist
in this manual applies only to the BA Falcon LPG work shops should be in possession of, and
option supplied by Ford and does not apply to other technicians completely familiar with the
installations made to Ford Falcon vehicles. requirements of Australian and New Zealand
Standards Publications AS/NZS 1425 - 1999 (or
Aftermarket Fitment of LPG later) AND AS 2746 -1999 (or later), which cover
the SAA automotive LP Gas Code and SAA Gas
CAUTION: Only BA Series vehicles factory Vehicles Work Shop Codes respectively.
built with E-Gas are designed and tested by Ford Available from:
Motor Company to run on LPG. Petrol BA Series
vehicles are not compatible with LPG fitment. LPG
Standards Australia
Australian Sales 1300 65 46 46
Telephone International Services 1300 65 46 46
Customer Service Update Services 1300 65 46 46
Center:
Facsimile All Sales 1300 65 49 49
E-Mail Address sales@standard.com.au
24 hour internet advice www.standards.com.au
Internet Address
available at
Address: — 1 The Crescent Homebush
NSW 2140 P.O. Box 1055,
Strathfield NSW 2135
Administration and Phone: — (02) 9746 4700
Head Office:
Fax: — (02) 9746 8450
Telephone — (02) 9746 4732
Technical Advisory — (02) 9746 4123
Facsimile
Services:
E-Mail Address — tis@standards.com.au
Telephone — (02) 9746 4784
Seminar Services: Facsimile — (02) 9746 2950
E-Mail Address — seminars @standards.com.au
Information Center: Telephone — (02) 9746 4748
Address 232 St. Pauls Terrace, P.O.
Queensland:
Box 290, Spring Hill 4000
Address Suite 2, 237 Elizabeth Street,
Tasmania:
North Hobart 7000
Address 19-25 Raglan Street, South
Victoria:
Branches at: Melbourne 3205
Address 1274 Hay Street, West Perth
Western Australia: 6005 South Australia: 63
Greenhill Road, Wayville 5034
G86721 en 01/2003 2003.0 BA Falcon

Address Territory Construction

Northern Territory
Association 191 Stuart Highway
(Agency):
Parap 0820
Australian Capitol Address Shop 5, Level 4, The
Territory: Boulevard, Canberra 2601
Standards New Zealand

Address: Level 10, Radio New Zealand House, 155 The Terrace,
Wellington 6001 (Private Bag 2439, Wellington 6020)
Telephone: (04) 498 5990
Facsimile: (04) 498 5994
Customer Services: (04) 498 5991
Information Services: (04) 498 5992
E-Mail: snz@standards.synet.net.nz
Web Site: www.standards.co.nz
Licensing Requirements any purchaser thereof.
There are some variations relating to the obligations Important Safety Notice
of businesses regarding licensing of technicians and
Appropriate service methods and proper repair
registration of premises in different states/territories
and it is recommended that specific details of procedures are essential for the safe, reliable
operation of all motor vehicles as well as the personal
requirements for your location be checked with the
safety of the individual doing the work. This manual
relevant Licensing Authority.
provides general directions for accomplishing service
The various Authorities and their locations are listed and repair work with tested, effective techniques.
below. Following them will help assure reliability.
The specifications referred to in this publication were There are numerous variations in procedures,
in effect at the time this publication was approved for techniques, tools, and parts for servicing vehicles, as
printing. However, Ford Motor Company of Australia well as in the skill of the individual doing the work.
Limited reserve the right, subject to the laws of any This manual cannot possibly anticipate all such
state or territory and the regulations of any competent variations and provide advice or cautions as to each.
authority which may be applicable at the time, at its Accordingly, anyone who departs from the instructions
discretion and without notice, to change the provided in this manual must first establish that there
specifications of the products referred to herein at any is no compromise to personal safety nor the vehicle
time and without incurring any liability whatsoever to integrity by the choice of methods, tools or parts.
State Vehicle installation regulator Vehicle registration Installer licensing Work-

area
licensing
A.C.T. Manager, Technical Manager, Technical - -
Operations Dept of Urban Operations Transport
ServicesDickson ACT 2602 Regulation Dept Dept of
Urban Services
W.A. Regulatory Services Manager - Technical Vehicle
Manager Regulatory -
(Licensing Branch) Office of Engineering & Safety Branch
Services Office of
Energy 20 Southport St. Police Licensing Authority 22
Energy 20 Southport
Leederville WA 6007 Mount St. Perth WA 6000 St. Leederville WA
6007
N.S.W. Chief Inspector, Dangerous Manager, Automotive Manager, Technical -
Goods Chemical Safety Unit Engineering Operations Services Motor
Work Cover NSW Locked Vehicle Standards Section Vehicle Repair
Bag 10 Clarence Street NSW Roads & Traffic Authority 260 Industry Council 239
2000 Elizabeth St. Surry Hills NSW Great North Road
2010 Five Dock NSW 2046
N.T. Manager, Dept of Transport & Manager Motor Vehicle - -
Works Work Health Authority Registry Department of
DARWIN NT 0800 Transport DARWIN NT 0800
G86721 en 01/2003 2003.0 BA Falcon

State Vehicle installation regulator Vehicle registration Installer licensing

Work-
area
licensing
QLD. Chief Inspector, Gas & Manager, Motor Vehicle Chief Inspector Gas & -
Petroleum Dept of Mines & Registration Branch Petroleum Dept of
Energy 61 Mary St. Brisbane Queensland Department of Mines & Energy 61
QLD 4000 Transport Brisbane QLD 4000 Mary St. Brisbane
QLD 4000
S.A. Manager, Dangerous Manager, Vehicle Operations - -
Substances Branch Dept for Section Dept of Transport
Industrial Affairs 45 Pirie St. Kateena St. Regency Park
Adelaide SA 5000 SA 5010
TAS. Manager, Chemical Safety Registrar of Motor Vehicles Manager, Chemical -
Section Industry Safety & Department of Transport Safety Section
Mines 30 Gordons Hill Rd. GPO Box 936J Hobart Tas Industry Safety &
Rosney Park Tas 7018 7001 Mines 30 Gordons Hill
Rd. Rosney Park Tas
7018
VIC. Manager, Chemical Manager, Vehicle Safety Chairman, -
Technology Health & Safety Road Safety Division VIC Automotive
Division Victorian Work Cover Roads 60 Denmark Street Alternative Fuels
Authority World Trade Centre Kew Vic 3101 Registration Board
Melbourne Vic 3000 464 St. Kilda Road
Melbourne Vic 3004
Notes, Cautions and Warnings To prevent serious burns, avoid contact with hot
metal parts such as the radiator, exhaust
As you read through the procedures, you will come manifold, tail pipe, and muffler.
across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose. Where procedures can be conducted without
electrical power, disconnect the battery earth
NOTES give you added information that will help you lead.
to complete a particular procedure.
Do not smoke while working on the vehicle.
CAUTIONS are given to prevent you from making an
To avoid injury, always remove rings, watches,
error that could damage the vehicle.
loose hanging jewellery, and loose clothing before
WARNINGS remind you to be especially careful in beginning to work on a vehicle. Tie long hair
those areas where carelessness can cause personal securely behind the head.
injury.
Where the nature of the work will require an LPG
The following list contains some general WARNINGS equipped vehicle to remain in the workshop
that you should follow when you work on a vehicle. overnight or for longer periods, the service valve
Always wear safety glasses for eye protection. should be turned off.
Use safety stands whenever a procedure requires
you to be under the vehicle.
Be sure that the ignition switch is always in the
OFF position, unless otherwise required by the
procedure.
Set the parking brake when working on the
vehicle. If you have an automatic transmission,
set it in PARK unless instructed otherwise for a
specific operation. Place wood blocks (100mm x
100mm or larger) to the front and rear surfaces of
the tyres to provide further restraint from
inadvertent vehicle movement.
Operate the engine only in a well-ventilated area
to avoid the danger of carbon monoxide.
Keep yourself and your clothing away from
moving parts, when the engine is running,
especially the fan and belts.
G86721 en 01/2003 2003.0 BA Falcon

Vehicle Identification
G86721 en 01/2003 2003.0 BA Falcon

Sedan and Wagon Ute
Sedan Ute
Wagon
Description
The LPG fuel option utilises a VIALLE LPG system
specifically engineered to suit the Ford 4 Litre engine.
The LPG control system is fully integrated into the
vehicles Power Control Module (PCM).
Sedan and wagon units have two cylinders that are
joined together through a manifold to form 1 storage
tank that uses single filler hose. The tank has
Automatic Fill Limiter (AFL), a non-return valve, a
Service valve (incorporating an electric
solenoid-activated Lock Off), and a fuel gauge with a
G86721 en 01/2003 2003.0 BA Falcon

sender unit. The sender unit gives normal operation of state changes to a gas and in so doing, expands
the fuel gauge mounted in the instrument cluster . approximately 270 times its original liquid volume.
The Ute has two cylinders that form two separate This property results in a fuel that combines the
tanks and uses a single filler hose. Each tank has compactness of a liquid for storage and combustion
Automatic Fill Limiter (AFL), a non-return valve, a properties of a gas when mixed with air.
Service valve (incorporating an electric
Pressure vs. Temperature
solenoid-activated Lock Off), and a fuel gauge with a
sender unit. The sender unit gives normal operation of At 20°C LPG must be stored at approximately 750
the fuel gauge mounted in the instrument cluster. The kPa to remain as a liquid. This pressure is used to
liquid line has a hydrostatic valve on the Ute. push LPG through the fuel line to the engine bay to
Also for all variants included in the system is a second the converter - a Fuel Filter and Lock Off is installed
prior to the Converter. The pressure inside the fuel
Filter/Lock Off, Converter Unit and a Gas/Air Mixer,
tanks varies with ambient temperature, as ambient
which is in the engine throttle body with a filtered air
supply through the vehicle’s special for LPG air temperature increases to 40°C the vapour pressure
increases to approximately 1280 kPa
cleaner.
Operating Principles
Liquid Petroleum Gas (LPG) is a hydrocarbon fuel
similar to petrol and consists primarily of Propane and
Butane. The mix will vary by location and source. For
reasons of safety an additive is introduced to LPG
that produces a strong odour to aid in leak detection.
LPG is heavier than air, and will settle in low areas
such as service bay pits, etc. Any leaks will not readily
be dispersed and extreme care must be taken to
prevent ignition of the gas if a leak does occur. LPG
boils between -40°C and -9°C depending on actual
mixture of propane and butane (at atmospheric
pressure) and therefore must be pressurised to
approximately 750 kPa to maintain it in a liquid state.
When subjected to atmospheric pressure the liquid
G86721 en 01/2003 2003.0 BA Falcon


1 LPG Liquid Line 9 LPG Intake Manifold
2 Coolant Hoses 10 10.7:1 Compression Ratio Pistons
3 Cooler Temp. LPG Spark Plugs 11 Green Rocker Cover
4 LPG Vacuum Tree 12 Spark Plug Cover with LPG Clip
5 Fuse & Relay 13 Balance Hose
6 Electronic Throttle Body with LPG Venturi 14 Vapour Hose
7 Unique PCV Hose 15 LPG Oil Cap Designating 15W 40 Oil
8 Air Cleaner with Paper Element, Coil 16 LPG Converter
Spring Clips and a Balance Hose Tube 17 Converter Bracket
and Connector 18 Exhaust Manifold Heat Shield
G86721 en 01/2003 2003.0 BA Falcon

LPG System Major Components Sedan

Fuel Tank
The LPG fuel tanks are thick walled steel cylinders
built to safety standards. They are mounted to the
chassis.
NOTE: The tanks are heat treated in manufacture and
must not be welded or treated in any way during
installation or servicing.
Sedan
Item Description
1 Pressure relief valve
2 Fuel contents gauge with sender unit
3 AFL (Automatic Fill Limiter)
Supply fuel to the engine through pick up filter
and lock off.
Sedan
Item Description
1 Valve pad (see AUS00139)
2 Cylinders
3 Service valve
4 Stone shield
5 Service line
Sedan
Measure fuel level.

Relieve excess vapour pressure should it rise to a
high level.
Variant 80% of Total Capacity
(AFL)
Sedan 93 litres of LPG
Wagon 116 litres of LPG
Ute 92 litres of LPG
Each tank has four openings that are used to: Each tank has the following components:
Fill the tank with LPG and stop the fill when the Automatic Fill Limiter, which incorporates a
tank has reached 80% of total capacity (AFL). non-return valve.
Service valve incorporating an electric solenoid
actuated shut off valve.
Fuel contents gauge with sender unit.
Pressure relief valve.
G86721 en 01/2003 2003.0 BA Falcon

Automatic Fill Limiter UTE - Through each of the wheel arches (2

valves to shut off supply) .
The system incorporates an Automatic Fill Limiter
(AFL), which prevents the tank being filled with liquid WAGON - From underneath the vehicle between
beyond 80% of the tank volume. The 20% vapour the rear axle and the front cylinder.
space is necessary to allow for expansion of the liquid The excess flow valve will automatically close to a
that occurs as temperature increases. The AFL trickle and shut off the supply of liquid if an
incorporates a non-return valve. abnormally high flow rate occurs. This may occur if
the fuel supply line is ruptured or damaged. The
Variant Tank Capacity 80% of Total service valve incorporates a pipe that extends to the
(100%) Capacity (AFL) bottom of the tank to ensure that only liquid LPG is
Sedan 115 litres 93 litres of LPG withdrawn and directed to the converter.
Wagon 145 litres 116 litres of Pressure Relief Valves/Hydrostatic Valve
LPG
Ute 114 litres 92 litres of LPG A pressure relief valve is located on each tank and on
the service line Hydrostatic Valve located:
Service Valve and Solenoid Operated Shut UTE only - near the bottom of the firewall.
Off Valve Should the pressure at the relief valve(s) on the
The Service Valve consists of a solenoid operated, tank(s) reach approximately 2.55MPa, the valve will
normally closed shut off valve, a manual-isolating open and discharge excess pressure to the
valve and, an excess flow valve. atmosphere. The Hydrostatic Valve on the liquid
service line performs the same function but at
The solenoid operated shut off valve is energised only 3.10MPa. Once the pressure reduces below that
when the vehicle is starting or the vehicle’s engine is
pressure the valve will close automatically. During
running. When the valve is de-energised, it prevents
normal operating and under normal ambient
the flow of LPG from the tank. conditions there is no reason for the relief valve to
Wagon & Ute operate.
NOTE: The pressure relief valves are NOT a
serviceable item.
Fuel Contents Gauge

Each LPG tank fuel gauge/sender unit has a float
similar to a petrol gauge unit. (i.e. it will float up and
down with the liquid level in the tank.)
The fuel gauge will indicate FULL when the LPG liquid
level is at 80% of each tank capacity. The LPG tank
sender is interfaced with the vehicle dash mounted
fuel gauge and indicates total amount of fuel.
Fill Valve
The fill valve consists of a valve with a soft seat and a
Item Description soft housing. The fill valve is connected to the AFL
mounted on the tank by a flexible pressure hose.
1 Service valve
2 Service line Fuel Line and Filter Lock Off
3 Solenoid operated shut off valve The fuel line is made of Bundy tubing and transports
4 Fuel contents gauge with sender unit liquid LPG from both tanks to the Filter/Lock Off
5 AFL (Automatic Fill Limiter) Valve. This valve is integral with the converter and
incorporates a filter and a magnet to prevent foreign
The manual isolating valves enable the liquid supply particles interfering with the operation of the Lock Off
to the converter to be shut off in the event of an Valve.
accident or during servicing. These can be accessed
from various regions depending on the variant. The Filter/Lock Off is a safety device designed to
prevent the flow of liquid to the converter when the
SEDAN - From underneath the vehicle in the engine is not running or cranking. They are controlled
stone plate service cut out (between the two electronically by the PCM when the engine is running.
cylinders). If the engine stalls or the ignition is left switched ON,
G86721 en 01/2003 2003.0 BA Falcon

the PCM will switch OFF the supply of LPG coolant to prevent the converter from freezing as the
automatically. vaporising gas draws heat from the atmosphere. The
converter is located in the engine bay and is attached
Converter by a bracket to the right hand spring tower.
The converter is a two-stage pressure regulator,
which incorporates a heat exchanger, prime circuit
and idle circuit. The heat exchanger uses engine
Item Description below 35 kPa the primary valve opens. If the pressure
is above 35 kPa the valve closes. This action
1 Stepper Motor maintains primary pressure at the correct level. As the
2 Prime Solenoid liquid enters the primary chamber and the pressure
3 Prime Hose drops it boils and a change of state to gas occurs. A
4 Mount Bracket large amount of heat energy (latent heat of
vaporisation) is absorbed during this change of state
5 Coolant Outlet and it is therefore necessary to pass hot engine
6 Coolant Inlet coolant through a jacket in the converter body to
7 Inlet Gas Lock Off Solenoid prevent the converter from freezing up.
8 Liquid Gas Inlet NOTE: If the converter freezes at any time during its
life, it may be damaged internally. This will affect the
9 Filter & Magnet
vehicles driveability and continued safe operation. A
10 Drain Plugs registered LPG technician should inspect/repair the
11 Idle Solenoid converter.
12 Balance Hose Fitting Regular maintenance of the cooling system, coolant
13 Vapour Line Fitting level and anti-freeze is very important to ensure
correct operation of converter. From the primary
First Stage chamber the vapour moves through two different
Liquid enters the converter at tank pressure paths: The idle circuit and the secondary valve.
(approximately between 750-1280 kPa). It is then
reduced to a pressure of approximately 36 kPa (5.5
psi) in the primary chamber. If the pressure drops
G86721 en 01/2003 2003.0 BA Falcon

Second Stage central bore via the sensitive diaphragm. This

stabilises the pressure in the central bore and stops
Second stage LPG flow is controlled by a secondary the secondary valve from opening more. As the
valve. The force needed to overcome the secondary secondary valve is partially open, vapour also leaves
spring pressure and therefore control the flow, is the primary chamber through the secondary valve.
acquired from the flow amplifier system within the idle
circuit and from the engine vacuum signal present in As the engine speed increases, the pressure through
the secondary stage. The idle circuit, which the gas/air mixer reduces which in turn reduces the
incorporates the flow amplifier, remains open for as pressure in the secondary chamber. As the secondary
long as the engine is running. Flow through this chamber pressure reduces, the sensitive diaphragm
section is stopped by the idle solenoid when the restricts the flow of vapour to the central bore. This
engine stops turning. Note that, at idle the LPG causes the central bore pressure to drop further, and
vapour is supplied through both the idle circuit and the therefore, open the secondary valve more.
secondary valve. As the secondary valve releases more vapour, the
pressure in the secondary chamber is increased and
Prime Valve the sensitive diaphragm allows more vapour into the
A prime solenoid is incorporated to permit primary central bore. Once the pressures are balanced the
pressure LPG to go directly to the engine via the secondary valve reaches an equilibrium point and
stepper motor housing during starting. The stepper steady state flow is maintained.
motor does not directly control this initial primary Air Cleaner
pressure gas flow. The prime circuit is fed LPG from
the idle circuit. The air cleaner is unique on this LPG vehicle. It
includes a pipe to fit the balance hose to and also has
Heat Shield unique springs, which allow the pressure of backfire to
The exhaust manifold heat shield has an extension escape.
that protects the bottom of the converter and liquid Ram Air Balance Hose
service line.
The System includes a Ram air balance hose
connected between the converter and the air cleaner
base. The purpose of the Ram air balance is to
provide the converter with the correct pressure levels
inside the intake system, as the pressure levels will
vary away from atmospheric due to the positive Ram
air effect built up in front of the vehicle at highway
speeds. The varying pressure levels have an
influence on the positioning of the sensitive
diaphragm within the converter and ultimately the
Ram air balance assists in ensuring that the converter
is supplying gas to the engine in quantities suitable to
the current and varying operating requirements.
Stepper Motor
The stepper motor is bolted directly to the converter at
Operation Summary the vapour outlet and is connected to the mixer by a
Liquid LPG flows from the tank through the converter vapour hose. The stepper motor is a bipolar unit with
lock off and up to the primary valve. As the liquid LPG two independently controlled coils. The rotational
passes through the primary valve, the pressure is motion of the motor is converted to a linear pintle
reduced to 35 kPa and the liquid vaporises as it movement via a screw drive. In normal operation the
passes through the primary chamber. From the pintle extends and retracts as commanded by the
primary chamber the vapour either passes through PCM. This trims the flow of LPG vapour to the engine
the idle circuit or the secondary valve. The prime allowing closed loop EGO (Exhaust Gas Oxygen)
valve is fitted to the converter for starting. LPG at content control.
primary pressure flows from the idle circuit to the
Fuel Gauge and Instrument Cluster
prime valve lock off only while the idle solenoid is
energised. The LPG fuel level signal from the sender is sent
The idle vapour passes through the idle jet to the flow directly to the instrument cluster. The fuel gauge will
amplifier and then into the secondary chamber. As the show the total amount of fuel in the cylinders. The
vapour passes through the flow amplifier, it draws PCM transmits the fuel usage to the cluster, to be
vapour out of the central bore. The pressure in the used in the ’Range’ calculation, over the CAN line.
central bore is reduced and the secondary valve is
opened. At the same time vapour is leaking into the
G86721 en 01/2003 2003.0 BA Falcon

Pin Label Function

C26 GSCC Stepper motor coil
connection C
C27 GSCD Stepper motor coil
connection D
C7 GCO Solenoid relay trigger
(grounding signal)
C21 PRIME LPG Prime Solenoid
Solenoid Operation
Three solenoids valves on the sedan and wagon and
four solenoid valves on the Ute, as mentioned above,
are energized continuously whenever LPG operation
is required. The engine must be running before the
LPG Solenoid Valves
valves will open. The valves are de-energised when
The LPG system has number of solenoid valves ignition is turned off or the engine stops. The prime
depending on the variant: solenoid is operated independently of the other
SEDAN has four solenoid valves - one tank lock solenoids by the EEC in most starting conditions.
off, an engine-bay lock off, an idle circuit solenoid Stepper Motor Operation
and a prime solenoid.
WAGON has four solenoid valves - one tank lock The main LPG control is performed by the stepper
off, an engine-bay lock off, an idle circuit solenoid motor. The pintle moves back and forth over a range
and a prime solenoid. of 255 steps to trim the LPG flow. A step position of
255 is fully closed and 0 is fully open. Normal
UTE has five solenoid valves - two tank lock offs, operation is in the range of 100 to 200 steps. The
an engine-bay lock off, an idle circuit solenoid and New Generation Star Tester (NGS) or WDS can
a prime solenoid. monitor and log the stepper motor step position.
All of the solenoids are controlled by the PCM. All
solenoids, except the prime, are switched together by Reset Procedure
a relay and fuse mounted near the PCM. The stepper motor is reset by the EEC during starting
Wiring Loom to initialise the pintle position. The pintle ramps
towards the fully open position and continues pushing
The wiring connects circuits at the LPG tank, into the seat for a number of steps to guarantee that
converter, PCM and fuse panel. The PCM therefore the motor is in a known open position. The motor then
performs all of the control functions. The extends to a normal operating position. When coolant
solenoid-switching relay and fuse are directly mounted temperature (ECT) is below 20°C and engine off time
to the harness near the PCM. For protection, the relay is between 1 to 10 minutes, the stepper motor will
is covered by a moulded sheathe. The wiring open fully to determine its zero position and then
diagrams and connector pinouts are detailed in the close immediately. the stepper motor will then slowly
wiring schematic section (section 9). open to its normal operating position. This is to protect
against the possibility of rich starting under these
PCM conditions.
The PCM has direct control of the LPG stepper motor
and switches four LPG solenoids via a relay. The
Open Loop Operation
PCM also controls the prime solenoid. The PCM has The open loop stepper motor position is determined
also been specially calibrated to control the ignition within the PCM based on several operating
and transmission systems when running on LPG. This parameters. This is calculated from engine and inlet
ensures that the vehicle is operating at peak air temperatures and A/C status. The engine operates
performance and efficiency. in open loop in similar situations to petrol:
LPG related PCM pins Post start - 20 to 45 seconds depending on
temperature.
Pin Label Function Wide-open throttle
C24 GSCA Stepper motor coil The adaptive learn system also adds a learnt step
connection A position offset.
C25 GSCB Stepper motor coil
connection B
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Closed Loop Operation Vehicle Backfire Information

During closed loop operation the stepper motor is In the event of backfire, stop and inspect the vehicle
driven open and closed. The HEGO (Heated Exhaust for damage in the form of cracked or split intake
Gas Oxygen) sensor detects rich or lean air fuel components, dislodged components such as air
ratios. While the HEGO is reading a rich signal, the cleaner upper or manifold nipple caps, etc. Note that
motor ramps closed and the step position increases. in extreme cases, backfire can damage the PCV valve
When lean, the motor ramps open and the step or MAP sensor rendering the vehicle undriveable.
position decreases. Backfires are caused by poor ignition system
Starting condition or an over-lean air/fuel ratio.
During engine start, the prime solenoid pulses open Engine Coolant Hoses
and delivers fuel for a few hundred milliseconds only. Coolant hoses are connected to the heat exchanger in
The LPG lock-off solenoids are opened as the engine the converter to provide heat, which is required for the
starts to turn and the stepper motor is reset. The LPG evaporation process.
prime solenoid operation (on time) is dependant on
the engine temperature and the time since the ignition
was previously turned off.
Adaptive Learn Strategy
The PCM control strategy includes an adaptive learn
capability. The system automatically adjusts for
vehicle, environmental, and fuel differences as the car
ages. The adaptive learn system can be reset by
disconnecting the power to the PCM for a few
minutes. This is recommended after servicing the
LPG converter, engine or changing the air filter.
The Crankcase ventilation system is re-routed to the
inlet manifold near the throttle body to ensure even
Item Description
air/fuel ratio and therefore maintain a smooth idle.
1 Hose from LPG converter to heater
Vapour Hose 2 Quick connector on hose
This unique vapour hose carries the LPG vapour from 3 Hose from engine to LPG converter
the converter to the gas/air mixer.
Gas / Air Mixer Engine Servicing Requirements
There are no special running-in requirements for this
The function of the gas/air mixer is two-fold:
vehicle. Please refer to the standard running-in
Convert intake airflow into a vacuum signal that is requirements in the Owners Manual.
detected at the converter.
Thoroughly mix air and fuel together. Engine Oil
The 15W-40 oil specification is recommended.
The combustion products of LPG does not blacken
but tends to acidify the engine oil more than petrol
does. This problem may be exaggerated when oil
change intervals are extended because the oil
appears clean to the owner.
Spark Plugs
Vehicles operating continuously on LPG require a
colder range spark plug than vehicles operating on
petrol.
The recommended spark plugs for LPG are:
Specification: DENSO K20SR11
Gap: 1.1mm
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Coolant “Repair” means any repair to the vehicle which

involves opening the high pressure gas lines to the
The normal service schedule for the cooling system atmosphere.
should be adhered to. For optimum cooling system
performance of vehicles running on LPG, the NOTE: LPG fuel tanks must be removed from the
recommended coolant specification is: vehicle and be inspected and pressure tested by an
authorised tank test centre every 10 years. A plate
Motorcraft Rl-32/33 Anti-corrosion/Anti-freeze with the original test date and other information is
(33% MIN) and water. This specification provides attached to the tank. Removal of the tank should only
frost protection to a minimum temperature of be performed by a registered operator.
-16°C and should be replaced every 3
years/100,000 km (whichever comes first). NOTE: Running the vehicle on LPG places a greater
It is paramount to cooling system efficiency that this is demand on the ignition system (as compared to
the only coolant used. With the addition of extra petrol) -Accordingly the ignition system must be
components into the cooling system (the LPG maintained in excellent condition. e.g. Replace spark
Converter), it is imperative that the replacement plugs at intervals indicated below, without failure.
schedule be strictly adhered to. In addition to the normal vehicle maintenance
Should the cooling system be dirty, it is necessary to schedule as set out in the Vehicle Owners Manual the
flush out the converter coolant passages in addition to following minimum maintenance schedule should be
the engine cooling system. followed for an LPG equipped vehicle.
Some states require the inspection of the LPG system
Scheduled Maintenance annually coincident with the registration inspection.
All LPG installations must comply with standard Where this is not a requirement it is recommended
AS/NZS 1425-1999 and most states require that any that an annual inspection be performed by an
person engaged in the installation and/or repair of Authorised Ford Dealer or a registered LPG repairer
LPG vehicles must be registered. in accordance with the requirements of standard
AS/NZS 1425-1999.
Minimum LPG Maintenance Schedule
Maintenance Interval (kmx1000)
Items 15 30 45 60 75 90 105 120
High Pressure Leak Check:
Converter and lock offs I I I I I I I
All service line connections I I I I I I I I
Filler valves I I I I I I I I
LPG Tank connections I I I I I I I I
All mounting points for tightness I I
Filter/Lock Off - Inspect Filter F F
Auto fill limiter operation I I
Air Filter Element I R I* R I R I R
Spark Plugs R
Diagnostic Checks N N N N N N N N
Drain Second Stage Bodies D D D D D D D D
Inspect Idle Jet I I I I I I I I
I. Inspection of condition and testing of systems Replace every 3 years/100,000km.
operation. When coolant is due for replacement per standard
I*. Clean, replace as required. service schedule, flush out original coolant and
R. Replace. refill system with R1-32/33
Anti-corrosion/Anti-freeze (33% MIN) and water.
F. Filter/Lock - off - inspect filter replace as
necessary (high pressure leak check when NOTE: In severe/unusual (dusty/sandy) conditions the
replaced) air cleaner element should be checked, cleaned and
replaced more frequently to allow correct operation of
D. Remove plugs and drain converter body the vehicle.
N. Diagnostics check to be carried out
NOTE: By Australian law tanks must be inspected
NOTE: Engine Coolant must be maintained as
every 10 years by an authorised LPG tank tester.
follows:
G86721 en 01/2003 2003.0 BA Falcon

NOTE: The total LPG system must be periodically filter and O-Rings. Refit/replace ensuring the filter is
inspected in accordance with standard AS/NZS not crimped by the bowl.
1425-1999.
Converter Body
LPG Service Procedures
Drain Second Stage Converter Bodies
LPG number plate decals This must only be carried out by registered
Every time the vehicle is in for service or repair of any technicians.
kind, ensure that the red LPG decals are fixed to the Close the service valve.
front and rear registration plates on metal plates (in
the centre), in the diamond orientation. Run the engine until it stalls.
Try to re-start engine several times.
NOTE: 1 decal front and rear for sedan and wagon.
Prior to opening the high pressure system to
2 decals front and rear for ute. atmosphere, the battery negative lead must be
removed and carefully isolated.
Auto Fill Limiter (AFL)
Every 45,000 km it is necessary to test the operation
of the AFL. The tank must be empty to accurately
check the operation of the AFL and owners should be
encouraged to present the vehicle for service with the
tank nearly empty. Instructions to that effect appear in
the owners manual. The remaining LPG in the tank
will need to be decanted.
LPG Filter Service
The filter which is integral with converter requires
inspection and replacement (if necessary) after the
initial 15,000 km of travel and at 75,000 km intervals
thereafter. Always replace ‘O’ rings when replacing
filter.
Item Description
1 Inlet Filter Bowl
2 Plugs - to drain converter body
Despite the filter prior to the converter, sludge will
gradually accumulate in the converter body and must
be drained at least every 15,000 km to ensure correct
converter operation.
Ideally this should be performed at the same time as
the filter in the filter lock off is replaced and the
converter is devoid of gas.
There are two hex headed drain plugs located at the
base of the converter. Copper washers are installed
between the drain plug heads and the converter body
to ensure sealing of the chambers.
Item Description To drain the converter, remove the plugs and allow
1 Inlet Filter Bowl the sludge to escape – when replacing the plugs
2 Plugs - to drain converter body install new copper washers. Conduct a leak test after
replacing the plugs. This draining process must be
LPG Filter Service Procedure conducted while the converter/engine is at running
temperature.
This must only be carried out by registered
technicians. Idle Jet
Close the service valve. Clean idle jet every 15,000 km as indicated in the
Run the engine until it stalls. service schedule. The head of idle jet is a 4 mm
thread (Refer to Converter of Disassembly and
Try to restart engine several times.
Assembly in this section for Tool no. 303-689).
Prior to opening the high pressure system to
atmosphere, the battery negatlve lead must be
removed and carefully isolated. Remove the bowl,
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Leak Testing When a leak free condition has been confirmed,

heating, welding or flame cutting can be carried
High Pressure Leak Testing out as long as it is no closer than one metre to a
A high pressure leak check of the LPG system must fuel container. The service valve must be closed
be carried out at 15,000 kilometre intervals. The when a vehicle is to be left overnight in the
standard AS/NZS 1425-1999 requires that this be workshop or when stored for any period of time.
carried out at least annually. In most cases this would
Tank Testing
fall in line with one of the 15,000 km service intervals.
An important requirement of the AS/NZS 1425-1999 is
Leak Testing Equipment the testing and inspection of the LPG fuel tank. Every
The most common method of leak detection is to use ten years, the tank must be removed from the vehicle
a foam test solution. It should be a proprietary leak and tested by an Authorised Container Test Station.
test solution, specifically formulated for this purpose, Once testing is completed and passed, the tank is
eg. must not cause corrosion of steel lines etc. stamped with the test date and is ready for another
ten years service.
Electronic combustible gas detectors are also
regularly used by many Technicians. Exhaust Relocation
Refer to the operating instructions supplied with either To provide the extra space required for the gas tanks,
method to ensure accuracy and safety when leak the exhaust route has been changed and the muffler
testing. pattern modified. This arrangement however, uses
similar exhaust mounting locations as on the standard
Leak Testing Procedure
BA Falcon.
The fuel system must contain sufficient LPG liquid to
ensure a minimum vapour pressure to 450 kPa,
otherwise a leak check will not be valid.
Begin by testing:
all the tank and filler fittings.
service line joints.
Where possible run or crank the engine to ensure
all components are supplied with liquid LPG.
Test all Filter/Lock Off and Converter connections
and joints.
A large leak can actually blow away the foam solution
and not produce any bubbles, this must be carefully
monitored. Remember since LPG is heavier than air,
test thoroughly below all fittings and components.
Where a leak is indicated, remake the joint, using a
suitable sealing compound. The sealing compound
used must be specifically suitable for LPG
applications.
CAUTION: Leaking joints with parallel

threads and seats are uncommon. If this type of
joint leaks, check for correct torque. If the leak
persists after re-torquing, the joint must be
replaced. Thread sealing compounds should not
be used to seal these types of joints.
Welding and Heating
The Australian Standard has two requirements
regarding welding and heating on or near an LPG
vehicle.
Until an LPG vehicle has been tested and
confirmed leak free, a Zone 1 hazardous area
exists up to 3 metres from the perimeter of the
vehicle. No welding, heating or flame cutting may
be carried out in this area.
G86721 en 01/2003 2003.0 BA Falcon

Single Fuel LPG solution, specifically formulated for this purpose, eg.
not cause corrosion of steel lines, etc. Electronic
Inspection and Verification combustible gas detectors are also regularly used by
many Technicians. Refer to the operating instructions
supplied with either method to ensure accuracy and
WARNING: Where testing procedures require safety when leak testing.
the handling of LPG of which may result in the
release of LPG the following precautions must be Leak testing procedure
taken:
The fuel system must contain sufficient LPG liquid to
Disconnect and safely stow the vehicles ensure a minimum vapour pressure of 450 kPa,
battery earth lead. (The lead may require otherwise a leak check will not be valid.
reconnection for certain tests involving
electrically operated components.) NOTE: The pressure in the cylinder (tank) is related to
the temperature of the LPG rather than the liquid
The working area and working procedures
level.
must comply with Australian Standards (AS)
2746. Where possible run the engine to ensure all
When the tank is being filled, the normal components are supplied with liquid LPG.
precautions applicable to petrol or LPG Begin by testing:
service station areas must be observed. i.e. all the tank and filler fittings
No smoking and no ignition sources within the
working zone - ignition off and parking brake service line joints
engaged. all filter/lock-off and converter connections and
If for any reason the tank is filled beyond the joints.
80% level, the vehicle can be driven without A large leak can actually blow away the foam solution
stopping the engine for a sufficient distance and not produce any bubbles. This must be carefully
(approx. 150 km) to consume the excess fuel. monitored.
If this is not possible the excess fuel must be Remember since LPG is heavier than air, test
removed by de-canting (refer Removal and thoroughly below all fittings and components.
Installation) or by one of the methods for fuel Where a leak is indicated, remake the joint, using a
unloading as described in Australian suitable sealing compound. The seal compound used
Standards (AS) 2746. must be specifically suitable for LPG applications.
NOTE: All workshops performing repairs/
maintenance on LPG equipped vehicles should be CAUTION: Leaking joints with parallel
registered and in possession of, and technicians threads and seats are uncommon. If this type of
familiar with, the contents of standards AS/NZS 1425- joint leaks, check for correct torque. If the leak
1999 and AS 2746. persists after re-torquing, the joint must be
replaced. Thread sealing compounds should not
Leak Detection Methods be used to seal these types of joints.
There are several acceptable methods such as: NOTE: When using a liquid leak detection method,
Combustible gas detectors the liquid must be mopped from the cylinder at the
completion of the test to prevent corrosion.
Trace gas detectors
Foam LPG Tank Assembly
Total immersion Each tank assembly comprises:
Visual inspection The tank shell and valve PAD.
Refer to standards AS/NZS 1425-1999 for a complete Automatic fill limiter.
description including advantages or disadvantages of
each of the above mentioned leak detection methods. Tank gauge.
Safety valve.
High pressure leak testing Service valve with integral excess flow valve.
A high pressure leak check of the LPG system must
be carried out at each service. The standard AS/NZS Test
1425-1999 requires that this be carried out at least Pressure test with an inert gas (eg. Nitrogen) in
annually. In most cases this would fall in line with one accordance with the following procedure.
of the 15,000 kilometre intervals.
Leak testing equipment WARNING: Oxygen must NOT be used for

pressurising, furthermore compressed air can be
The most common method of leak detection is to use dangerous in association with LPG and a tank
a foam test solution. It should be a proprietary leak
G86745 en 01/2003 2003.0 BA Falcon

which has previously contained LPG must be Automatic Fill Limiter

thoroughly purged with Nitrogen if it is intended
to use compressed air for pressurising. The accuracy of the shut-off function of the automatic
fill limiter should be checked with the vehicle standing
Close the service valve. on level ground and the tyres correctly inflated in
Pressurise the container to an internal pressure of accordance with standard AS/NZS 1425-1999.
2.3 ± 0.05 MPa. The container must be emptied of liquid LPG and then
Remove the pressurising attachment. filled by a pump meter unit. The pump meter reading
Check all joints between the container and the at which the AFL cuts off shall be within ± 2% of the
components for leaks (refer Leak Detection maximum permitted filling volume i.e. 80% of the
Methods). capacity of the container.
Check the filler valve and the service valve for The capacity must be less than 92 litres for Ute, 93
leakage through the valve seats. litres for Sedan and 116 litres for Wagon .
With the valve outlet plugged or capped and the NOTE: The accuracy of the contents gauge may be
valve opened, check for leaks at the valve stem checked at the same time.
seal of any valve that is normally open in service.
Excess Flow Valve
Where a leak is indicated, rectify the fault by
replacement or resealing, and retest the area. To test the function of the excess flow valve in
accordance with AS/NZS 1425-1999 follow the steps
Testing the Installation as listed below:
The following procedure should be applied after the Using compressed air or a gas inert to LPG,
tank sub assembly has passed the required test and pressurise the LPG cylinder to an internal
has been installed in the vehicle. pressure 2.3 MPa as per clause 4.2.2 of AS/NZS
1425-1999.
WARNING: It is essential that all air be Fully disconnect the service line from the AXIOM
purged from the container before LPG pressure solenoid service valve.
tests commence, and it is more convenient if this Fully close the manual hand tap on the AXIOM
purging is carried out before the container is solenoid service valve.
installed.
Remove the solenoid coil, solenoid piston sleeve
Leak testing of gas system and solenoid piston.
After all connections have been made, the LPG Quickly open the manual hand tap on the valve
system should be tested for leaks as follows: and check that the excess flow valve functions.
WARNING: It is important that high propane WARNING: If the service line is to be

LPG, (not high butane LPG) be used for this test disconnected, first remove the battery and take
because it has a relatively high vapour pressure at steps to ensure that discharging gas does not
the lowest temperatures likely to occur in a become a hazard.
workshop. The pressure gauge on the LPG supply Manual valve
tank can be taken to represent the container
pressure reasonably accurately, and if below 450 Open and close the manual valve and test around
kPa, testing should be postponed. Under no glands and connections for leaks.
circumstances should the container be heated to Lock Off Solenoids (At Cylinders and
raise the pressure. Converter)
Place high propane LPG in the container and
ensure that the liquid lines are full of liquid phase Start the engine.
LPG. Disconnect the solenoid connector plug at the
Test all pipe and component connections, converter or both solenoid connector plugs on the
including those on remote filling lines, and test the cylinders (one on each) depending on which
filler valve. solenoid(s) you are testing.
Where a leak is indicated, rectify the fault by When the LPG in the converter and supply lines
remaking or replacing the joint, and retest the has been used up the engine should stop.
area. If the engine continues to run it indicates that
either the lock off piston is not sealing or the
solenoid(s) are inoperative.
To test the solenoid electrically a resistance
measurement needs to be taken. The correct
resistance is: 12.6 Ohms ± 4% at 20°C.
G86745 en 01/2003 2003.0 BA Falcon

Fuel Filler 1. No air should come out of the prime solenoid.

Check for damage to the coupling and for the 2. Idle solenoid still energised.
presence of foreign matter, and check that the cap is 6. Energise the prime solenoid.
attached correctly. Check that the sealing washer is in 1. High pressure air should come out of it.
place and in good order. Check that the housing 7. De-Energise prime solenoid high pressure air
containing the filler valve is soundly attached to the
should stop coming out (returns to idle flow).
vehicle, and that the remote fill line is not deformed or
damaged by twisting resulting from a loose housing or 8. De-Energise prime and idle solenoids first then
mounting. de-energise lock off solenoid.
9. Disconnect air supply. Do not shake the
Water system tests converter.
The water circulation system which supplies radiator 1. Converter should hold pressure for at least 10
water to the converter should be pressure tested for minutes.
leaks, using a conventional radiator pressure testing
2. Test pressure retention by gently inserting a
method. blunt object into the central hole of the rear
Converter cover. Air will be heard to escape from the
vapour outlet.
Converter freeze-up 3. Soap test complete converter for leaks
Converter freezing will occur if insufficient heat is including water inlet and outlet, atmospheric
available to support the change of state from liquid vent fitting and backcover openings when
LPG to a gas. This can occur if the radiator coolant converter does not hold pressure.
level is low or there is a restriction of some kind in the 10. If converter passes above test, remove hose.
converter coolant hoses, or air inlet to radiator.
11. Converter is now ready for installation.
A heat exchanger is included in the converter which is
supplied with engine coolant. In the event of freeze up Worldwide Diagnostic System (WDS) Tester
occuring, back flush the hoses and heat exchanger The WDS tester can display the stepper motor
and check coolant flow to converter. position and LPG fuel level as well as all the usual
Should the engine stall or lose power, particularly functions.
under hard acceleration, promptly inspect converter
for signs of freezing. Freezing can cause internal
Stepper Motor
leaking and damage within the converter. Stepper Motor Position
Bench Testing Converter The stepper motor moves in discrete steps from 0
(fully open) to 255 (fully closed). The step rate will
1. Place converter with diaphragms in vertical vary from 250 steps per second to 2 steps per
position making sure that the atmospheric vent
second. During a reset procedure, the motor is
fitting in the front cover is free of obstructions and
commanded to step 0 to drive the pintle wide open. It
that the converter lock off is energised. should then retract to approximately step 150. In
1. Do not energize idle solenoid. normal operation, the motor should sit in the range of
2. There should be no air coming out the vapour 120-200 steps. During steady state open loop
outlet or water chamber openings. operation, the step position will stay near constant. In
2. Apply air pressure of 6-20 BAR (80-280 psi) to closed loop, the position will oscillate 10 to 20 steps to
fuel inlet. maintain a constant air-fuel ratio.
3. Energize idle solenoid and inlet gas lock off Condition Step Position HEGO output
solenoid.
Stepper motor 0-150 N/A
1. Air should be coming out at vapour outlet. reset (APPROX.)
2. Converter may slightly pulse air at vapour Closed loop ~100-200 oscillates
outlet. This is normal. between rich
4. Install a hose to front cover atmospheric vent and lean
fitting. High throttle ~60-130 rich
1. Blow on hose with mouth. openings
2. Air flow should increase each time you blow Other open loop ~100-160 rich or lean
on hose.
5. Disconnect prime hose. LPG Self Test — KOER
The LPG self test checks that the HEGO output
responds to movements in the stepper motor. This is
performed during the KOER test. The engine must be
G86745 en 01/2003 2003.0 BA Falcon

warm before the test is started. The PCM increases Disconnect LPG solenoids in the engine bay.
the engine speed to approximately 1300 rpm. The Start engine.
stepper motor is ramped towards 180 steps or until
Engine will start and stop running shortly
the HEGO reads a lean signal. The motor is then
ramped towards 50 steps or until the HEGO reads a afterwards as the residual fuel is used up.
rich signal. Engine speed may drop slightly and run a Remove Stepper Motor Housing:
little rough during this phase. The engine speed Undo the two M6 cap screws that secure the
should then drop once. Failure to maintain engine stepper motor body to the converter.
speed or switch to rich and then lean within a Leave the stepper motor connected to the
specified time will result in a test fault (P1159 - Fuel housing.
Stepper Motor Fault). The stepper motor fault can be
due to many factors and not just the stepper motor Stepper Motor Pintle Movement:
itself. Inspect stepper motor pintle and housing for
foreign matter or water.
Stepper Motor Movement Check - Manual
Observe pintle through the LPG vapour outlet.
This test will establish whether the stepper motor is Start the engine.
being correctly driven through its reset procedure. A
The pintle should smoothly extend to fully open
failure in this test could be due to a problem in the
PCM, wiring or the motor itself. the outlet and then go to approximately half of its
full travel.
LPG Runout
The engine should stop running immediately
Stop engine afterwards due to lack of fuel.
Symptom Charts
WARNING: Before removal of any valves or fuel gauge, the LPG tank must be emptied. Refer to
“Decanting of Tank”, in the Removal and Installation chapter.
Service Valve

Will not shut off. Foreign matter between valve seat Remove foreign material.
hand tap.
Damaged shaft. Replace hand tap assembly.

Leaking valve stem. Excess flow valve Damaged or worn seal. Replace seal.
not operating/responding too early.
Defective valve. Replace valve.
Damaged flare connection. Mishandling. Replace nipple.

Excess flow valve locked closed on Defective automatic fill flow valve. Turn off manual hand tap and wait for
cylinder containing LPG preventing valve to unseat. Then replace valve.
decanting tank.
Automatic Fill Limiter (AFL) .

Fills slowly/will not fill. Damaged automatic fill limiter (AFL). Confirm with second fill at different
bowser on a different day to ensure
the issue isn’t related to fuel,
temperature or bowser pressure.
Replace automatic fill limiter (AFL)
Over/under filling. Incorrect positioning of float. Confirm with second fill.
Float defective. If faulty, replace AFL.
G86745 en 01/2003 2003.0 BA Falcon

Relief Valve

Leaking (Note:This is normal if tank Foreign matter caught between seat. Replace relief valve.
pressure is above 2.5 MPa)
Defective seat. Replace relief valve.
Inadequate spring tension. Replace relief valve.
LPG Gauge & Sender Unit

Inaccurate tank reading. Defective sender. Replace sender.
Misaligned gearing. Replace float arm.
Remains at empty. Defective sender. Replace sender.
Defective float arm. Replace float arm.
Wiring fault. Check and rectify wiring.
Leaking gas. Defective gasket. Replace gasket.
Dash-mounted fuel gauge

No indication. Empty fuel tank. Refill tank.
Broken/disconnected wire. Check wiring.
Grounded wire from sender. Check wiring.
Sender not earthed. Check earthing connection & PCM
Sender defective. Replace sender.
Erratic reading. Loose connection. Tighten connection.
Defective sender. Replace sender.
Reads full at all times. Short in wiring. Check wiring.
Defective sender. Replace sender.
Inaccurate reading. Defective sender or gauge. Replace defective part.
Receiver incompatible with sender. Check resistance in ohms.
Functional Diagnosis
Condition Probable Cause & Rectification Hints / Cautions
Driveability issues such Replace Ram-Air Balance Tube if A small crack or hole in the Balance
as stalling, roughness damaged. Refit if simply dislodged. Tube, often difficult to see, will cause a
of operation, flat spots, driveability issue.
hesitations, surges, etc.
Remove & clear Ram-Air Balance Tube Ensure care is taken not to damage
of water, grass, etc. Refit. Balance Tube during this process (see
above).
Replace Air Filter if dirty. Ensure Air A dirty Air Filter will cause driveability
Cleaner & Springs are installed correctly. issues. Always reset KAM after it is
replaced.
Clear contaminant/blockage from idle jet. The idle jet plays an important role
Refit. throughout the driving range – not just
at idle.
G86745 en 01/2003 2003.0 BA Falcon


Inspect & clean the mesh within the This requires high pressure liquid LPG
Filter/Lock-off at Converter. Refit. work and must, therefore, be conducted
by a registered technician.
Check for leaks in the Intake System A small vacuum leak from the intake
between the Air Filter Element and the Manifold or any vacuum assisted
Gas-Air Mixer, Intake Manifold or PCV component will lean out the air/fuel
System. Rectify all leaks. mixture causing driveability issues.
Check condition of PCV Valve. Replace if If the PCV Valve is broken, check the
damaged or faulty. Valve Cover for fragments. They will be
held within a baffle.
If insufficient supply of LPG is making it Prior to working on components
to the converter, ensure both Manual associated with high pressure liquid
Isolating Valves on each LPG Tank LPG, always run the vehicle with the
Service Valve are fully open and the Manual Isolating Valve closed until the
condition and security of steel Bundy engine stalls to ensure no LPG remains
tubes is satisfactory. Rectify any damage after the Service Valve.
or leaks. If there is no fault found
externally, the Service Valve and its
Strainer or a blockage within the Bundy
tubes could be the problem. Replace the
Service Valve or clear the blockage as
required.
Drain contaminant from converter whilst Draining a hot converter will allow those
still hot from recent LPG operation. Refit contaminants that solidify when cool to
both drain plugs. be drained as well. However,
precautions must be taken against
burns.
Check Secondary Chamber within the Gently pushing on the metal plate in the
Converter retains pressure for at least 10 centre of the Secondary Diaphragm
minutes after recent LPG operation. If through the hole in the Converter
not, recondition or replace converter. outboard shell should result in an
Note: Converter-related warranty claims audible release of pressure. The metal
require a Ford Prior Approval No. to be plate should move in without
issued. notchiness, indicating that the pin
behind it isn’t sticking.
Contamination, damage or Do not Key On with the Stepper Motor
electrical/mechanical fault within Stepper removed from its mounting body. It will
Motor leading to Stepper Motor seizure. reset which involves full extension and
Replace Stepper Motor. subsequent loss of the Pintle.
Wiring or connector damage or fault The NGS has a built in Self Test to
between Stepper Motor and PCM leading check fuel control. Stepper Motor
to Stepper Motor seizure, reversal of position can also be monitored - most
direction or stutter. Rectify wiring or usefully with HEGO voltage.
connector problem.
PCM not providing correct signals to Swapping PCMs to check for
Stepper Motor. Replace PCM. functionality where PATS/BETS is
active cannot be done.
Check Ignition System components for A slight ignition breakdown under load is
function and security. significant with LPG.
Backfiring Rectify problem with Ignition System. A lean mixture increases the likelihood
Check spark plug specification, gap and of a backfire with a poor Ignition
condition. Ensure COILS are in good System, but is not the true cause of the
condition. problem.
G86745 en 01/2003 2003.0 BA Falcon


Water comes out of Repair or replace Converter. Note: Cooling System maintenance is
vapour hose or Converter - related warranty claims extremely important in all
converter drain plugs require a Ford Prior Approval No. to be Converter-based LPG systems. Check
issued. Rectify Cooling System fault or engine doesn’t overheat or run cool.
blockage. Check Coolant quality and
level.
Poor fuel economy Monitor HEGO Sensor and Stepper Engine Earth Straps and the HEGO
Motor position during idle, Acceleration, Sensor are critical to efficient operation
Cruise and Deceleration. Ensure both are on LPG. Complete intake system
operating within normal ranges. sealing and Air Filter Element condition
are also important for efficient operation
on LPG.
Poor starting Check for deposits / contamination in the Refer above.
converter.
Verify Prime Valve operation on Note that the Prime Valve operates
Cranking. between 300-700 ms on Cranking but
there are certain situations where there
will be no prime operation.
All Check sensitive diaphragm (under front) The diaphragm must be free to move
cover for sludge or deposits without sticking to the converter or being
weighed down.
NOTE: Leak test the LPG system after any maintenance on LPG high pressure areas. Reset
KAM after any maintenance of the LPG system.

LPG Converter C-913

1 Circuit 16H / (R-G) 0 voltage when ignition OFF, Greater than 10
Primary Lockoff power circuit volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground.
2 Circuit 57Y / (B) 0 voltage, less than 5 Ohms to chassis ground.
Secondary Lockoff ground circuit
3 Circuit 16X / (R-G) 0 voltage when ignition OFF, Greater than 10
Secondary Lockoff power circuit volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground.
4 Circuit 1500 / (B) 0 voltage, less than 5 ohms between solenoid
Primary Solenoid ground circuit and EEC-C Pin C21 PRIM.
5 Circuit 57X / (B) 0 voltage, less than 5 Ohms to chassis ground
Primary Lockoff ground circuit
6 Circuit 592 / (W) S 12 volt square wave when measured across pin
tepper Motor Driver circuit 591 and 592. Greater than 10,000 ohms
between stepper motor and ground
G86745 en 01/2003 2003.0 BA Falcon


7 Circuit 594 / (BR-B) 12 volt square wave when measured across pin
Stepper Motor driver circuit 593 and 594. Greater than 10,000 ohms
8 Circuit 361D / (R) 0 voltage when ignition OFF, Greater than 10
Primary Solenoid power circuit volts when ignition ON and engine cranking and
running. Greater than 10,000 ohms between
solenoid and ground
9 Circuit 591 / (BR) 12 volt square wave when measured across pin
10 Circuit 593 / (BR-Y) 12 volt square wave when measured across pin
Stepper Motor C-910

1 Circuit 594 (BR-B) 12 volt square wave when measured across pin
593 and 594. Greater than 10,000 ohms
between stepper motor and ground.
2 Circuit 592 (W) 12 volt square wave when measured across pin
3 Circuit 591 (BR) 12 volt square wave when measured across pin
4 Circuit 593 (BR-Y) 12 volt square wave when measured across pin
Primary Solenoid C-905
G86745 en 01/2003 2003.0 BA Falcon


1 Circuit 1500 / (B) 0 voltage, less than 5 ohms between solenoid
Primary Solenoid ground circuit and EEC-C Pin C21 PRIM
2 Not Used
solenoid and ground
solenoid and ground
Primary Lockoff C-907

1 Circuit 57X / (B) 0 voltage, less than 5 Ohms to chassis ground
Primary Lockoff ground circuit
2 Circuit 16H / (R-G) 0 voltage when ignition OFF, Greater than 10
Primary Lockoff power circuit volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground
Secondary Lockoff C-906

1 Circuit 57Y / (B) 0 voltage, less than 5 Ohms to chassis ground
Secondary Lockoff ground circuit
2 Circuit 16X / (R-G) 0 voltage when ignition OFF, Greater than 10
Secondary Lockoff power circuit volts when engine cranking and running. Greater
than 10,000 ohms between lockoff and ground
G86745 en 01/2003 2003.0 BA Falcon

Primary Service 3. Before any tank is placed into storage the liquid
level must be checked to ensure that the contents
is not above the maximum permitted fill level
WARNING: Where removal and installation (80%). 110 litres for Ute, 92 litres for Sedan, 116
procedures require the handling of LPG which litres for Wagon.
may result in the release of LPG the following 4. The tanks must be stored in the normal attitude
precautions must be taken. i.e. as if installed in the vehicle with the supply
NOTE: Do not use a memory minder to retain line fitting capped with pressure proof fitting.
preprogrammed data in computer controlled vehicles NOTE: If the tank is to be removed for repair,
systems and the radio security code when the earth returned to a test station for inspection, or the
lead is removed. Use of memory minder may lead to tank is to be scrapped then the tank is to be
air bag deployment even though the battery is emptied and depressurised and the interior
disconnected. purged with inert gas.
1. Disconnect and safely stow the vehicle’s earth
Pressure Decanting
lead. Removal and Installation
2. The working area must be registered and working 1. With the engine running, turn off the manual
procedures must comply with Australian service valve and allow the vehicle to stall. One
Standards AS 2746. minute after stalling, try to re-start the engine to
3. Normal precautions applicable to LPG Service ensure complete exhaustion of fuel in the fuel
stations must be observed ie. No smoking and no lines.
ignition sources within the working zone - ignition 2. Disconnect the vehicle battery earth lead.
off and parking brake engaged.
3. With the service valve off - disconnect the supply
LPG Filter line. Connect the service valve of the vehicle tank
via a transfer line to the fill point of a seperate
Removal receiving cylinder.
1. Disconnect supply connector from filter bowl. 4. Open the ullage valve on the receiving cylinder
2. Remove bowl retaining screws and lower bowl and the service valve on the vehicle tank. When
and filter from filter housing. the liquid LPG has been transferred into the
receiving cylinder, shut off ullage valve and the
3. Remove and discard both ‘O’ rings and filter. service valve. Disconnect transfer line and
4. Clean out filter bowl including magnet thoroughly. connect service valve (on the vehicle tank) to a
It is recommended that ‘O’ rings and filter be burn off system, to burn off the remaining vapour
replaced. They are serviced as a kit. in the vehicle tank.
Installation
1. Install the ‘O’ rings into grooves - apply Shell R-10 WARNING: Before working on tank valves,
oil lightly with a brush. remove any valve apart from the pressure release
valve to be certain there is no residual pressure
2. Position filter with the support gauze facing up left in the vehicle tank. To remove the valve gently
(direction of flow is from fine to coarse gauze). loosen all screws to relieve residual pressure.
3. Carefully locate bowl and filter and install screws Rock the valve to be sure there is no pressure.
-tighten to 4-6 Nm. Then completely remove the valve.
Tank Assembly WARNING: To ensure that there is no
NOTE: If the tank is to be removed to enable body residual LPG in the tank when the valves are
work or similar to be performed on the vehicle, it is not removed, blow out the tank using nitrogen.
necessary for the tank to be emptied. However care
must be exercised in handling and storage of the non WARNING: Remove pistons from solenoid
emptied tank assembly. The following precautions coils on service valves. Open the hand taps to
must be observed: remove some of the residual pressure left in the
tanks.
1. Store the tanks in a well ventilated area away CAUTION: Remove pistons from solenoid
from sources of ignition and drains or pits. coils on service valves. Open the hand taps to
2. If two unemptied tanks are to be stored, as is the remove some of the residual pressure left in the
case of the ute, the conditions of AS1596 apply. tanks.
Before working on tank valves, remove any valve
apart from the pressure release valve to be certain
G86726 en 01/2003 2003.0 BA Falcon

there is no residual pressure left in the vehicle Tank Decanting

tank. To remove the valve gently loosen all screws
to relieve residual pressure. Rock the valve to be
sure there is no pressure. Then completely WARNING: LPG is heavier than air and any
remove the valve. depression, for example, a vehicle service pit, can
To ensure that there is no residual LPG in the tank be a potential reservoir for the LPG to collect.
when the valves are removed, blow out the tank Removal and Installation
using nitrogen. 1. Work must be carried out in a well ventilated area,
NOTE: The receiving cylinder requires an ullage away from any ignition source with the vehicle
valve. battery earth disconnected. (In accordance with
NOTE: You can tell that liquid has finished Australian Standards)
transferring to the cylinder either by the contents 2. There are three decanting methods as follows:
gauge in vehicle tank or by feeling the transfer hose. 1. Transfer pump - use in accordance with pump
NOTE: The dip tube in the vehicle tank will not allow instructions. (Refer note 2 below).
all liquid to transfer. There may be 2-3 litres remaining 2. Pressure decanting, refer to instruction below.
in the bottom of the vehicle tank. Hence, the need to 3. Burn off method, refer to instructions below.
burn off the remainder.
Tank — Ute
G86726 en 01/2003 2003.0 BA Falcon

Item Description 8. Replace filler neck and tighten 3 retaining bolts to

10 Nm as specified.
1 Cyl Assy Fuel Tank
NOTE: If the tank had been emptied or a new
2 Screw M12x30 tank was installed, fill the tank with LPG and
Removal check the performance of the AFL - i.e. Cuts off at
80% of tank capacity (116 litres).
1. Start the engine.
2. Turn the service valve "OFF". 9. Conduct a leak test on all connections.
3. Allow the engine to run until it stalls to use up any 10. Open the service valve and conduct a leak test on
LPG in the system. all down stream connections and components.
4. Turn the ignition off. 11. Reconnect the battery earth lead.
5. Disconnect the vehicle’s battery earth lead.
6. Raise vehicle on a hoist so it can be worked
under.
7. Remove 3 bolts retaining filler assembly - slide
upwards to release tabs.
8. Disconnect sender wiring located above right
hand tank. Remove wiring from centre upper body
mount.
9. Drop driveshaft.
10. Remove exhaust intermediate.
11. Disconnect fuel lines on left hand side under
chassis rail.
12. Disconnect left hand side ABS wiring connection
and remove clip from chassis rail.
13. Remove 5 x 12mm bolts retaining tank.
14. Carefully lower tanks to the ground using an
appropriate lifting stand.
NOTE: It is not necessary to remove the stone
shield so long as it is protected from scratching.
15. With a helper supporting the cylinder on the frame
proceed to slowly lower the cylinder ensuring the
wiring loom and LPG hoses do not get caught at
the front.
16. Once the cylinder is lower than the vehicle, move
it from beneath the vehicle.
NOTE: Empty tank mass is 60kg (approx.) so be
very careful handling it and move it to a firm base
as soon as possible.
Installation
1. Raise vehicle on a hoist so it can be worked
under.
2. Raise the tanks using an appropriate lifting stand,
aligning the 5 bolt mounting holes with the
corresponding bolt holes in the chassis.
3. Replace the 5 x 12mm bolts (2 on the chassis rail,
2 on the cross car tube) and tighten to 80 Nm as
specified.
4. Replace all wiring connectors.
5. Replace exhaust intermediate.
6. Connect and tighten fuel lines.
7. Replace drive shaft.
G86727 en 01/2003 2003.0 BA Falcon

Tank — Wagon
Item Description 12. Remove bolts, nuts and washer assemblies

retaining tank. LPG wagons have two bolts that
1 Cyl Assy Fuel Tank are accessed through holes in the rear floor.
2 Nut and Washer Asy M12
13. Carefully lower tanks to the ground using an
3 Screw M10x27 appropriate lifting stand.
Removal NOTE: It is not necessary to remove the stone
shield so long as it is protected from scratching.
2. Turn the service valve "OFF". 14. With a helper supporting the cylinder on the frame
proceed to slowly lower the cylinder ensuring the
3. Allow the engine to run until it stalls to use up any
wiring loom and LPG hoses do not get caught at
LPG in the system.
the front.
4. Turn the ignition off.
15. Once the cylinder is lower than the vehicle, move
5. Disconnect the vehicle’s battery earth lead. it from beneath the vehicle.
6. Raise vehicle on a hoist so it can be worked NOTE: Empty tank mass is 45kg (approx.) so be
under. very careful handling it and move it to a firm base
7. Remove bolt retaining filler assembly. as soon as possible.
8. Disconnect sender wiring located above front Installation
tank. 1. Raise vehicle on a hoist so it can be worked
9. Remove wiring from centre upper body mount. under.
10. Remove exhaust rear. 2. Raise the tanks using an appropriate lifting stand,
11. Disconnect fuel lines on left hand side under aligning the 3 bolt mounting holes with the
chassis rail. corresponding studs in the chassis.
3. Replace the nuts and tighten to 80 Nm as
specified. Replace the M10x27 screws and
tighten to 55Nm.
G86727 en 01/2003 2003.0 BA Falcon

4. Replace all wiring connectors.

5. Replace exhaust rear.
6. Connect and tighten fuel lines.
7. Replace filler neck and tighten retaining bolt to 10
Nm as specified.
NOTE: If the tank had been emptied or a new
tank was installed, fill the tank with LPG and
check the performance of the AFL - i.e. Cuts off at
80% of tank capacity or 116 litres for Wagon.
8. Conduct a leak test on all connections.
9. Open the service valve and conduct a leak test on
all down stream connections and components.
10. Reconnect the battery earth lead.
Tank — Sedan
Item Description 5. Disconnect the vehicle’s battery earth lead.

1 Cyl Assy Fuel Tank 6. Raise vehicle on a hoist so it can be worked
under.
2 Nut and Washer Asy M12
7. Remove bolt retaining filler assembly.
Removal 8. Disconnect sender wiring located above front
1. Start the engine. tank.
2. Turn the service valve "OFF". 9. Remove wiring from centre upper body mount.
3. Allow the engine to run until it stalls to use up any 10. Remove exhaust rear.
LPG in the system.
11. Disconnect fuel lines on left hand side under
4. Turn the ignition off. chassis rail.
G86744 en 01/2003 2003.0 BA Falcon

12. Remove 4 nuts and washer assemblies retaining 10. Remove the gauge and float retaining screws and
tank. lift out the gauge and float assembly.
13. Carefully lower tanks to the ground using an Installation
appropriate lifting stand. 1. Install a new gasket under the fuel gauge and
NOTE: It is not necessary to remove the stone carefully insert the float into the tank and locate
shield so long as it is protected from scratching. the gauge on the tank.
14. With a helper supporting the cylinder on the frame 2. Install the gauge retaining screws and torque to 5
proceed to slowly lower the cylinder ensuring the Nm.
wiring loom and LPG hoses do not get caught at 3. High pressure test the cylinder assemble to 2.3
the front. MPa in accordance with clause 4.2.2 of standard
15. Once the cylinder is lower than the vehicle, move AS/NZS 1425- 1999.
it from beneath the vehicle. 4. Refill the tank and check the performance of the
NOTE: Empty tank mass is 45kg (approx.) so be AFL, and gauge for correct registration.
very careful handling it and move it to a firm base 5. Connect the gauge sender wires.
as soon as possible.
6. Refit tank to vehicle as per procedure.
Installation 7. Turn the service valve on.
1. Raise vehicle on a hoist so it can be worked 8. Close and clamp the sealed sub compartment
under. cover.
2. Raise the tanks using an appropriate lifting stand, 9. Reconnect the battery earth lead.
aligning the 4 bolt mounting holes with the
corresponding studs in the chassis. Automatic Fill Limiter
3. Replace the nuts and tighten to 80 Nm as
specified. Removal
4. Replace all wiring connectors. 1. Start engine.
5. Replace exhaust rear. 2. Turn service valves off.
6. Connect and tighten fuel lines. 3. Run the engine until it stalls.
7. Replace filler neck and tighten retaining bolt to 10 4. Turn ignition OFF and remove battery earth lead.
Nm as specified. 5. Remove tank from vehicle as per procedure.
NOTE: If the tank had been emptied or a new 6. Remove the LPG in the tank in accordance with
tank was installed, fill the tank with LPG and the decanting procedure.
check the performance of the AFL - i.e. Cuts off at 7. Slightly loosen all AFL retaining screws to relieve
80% of tank capacity or 93 litres for Sedan. any residual pressure.
8. Conduct a leak test on all connections. 8. Disconnect the filler hose from the AFL elbow.
9. Open the service valve and conduct a leak test on 9. Remove the elbow from the AFL.
all down stream connections and components. 10. Remove the AFL from the tank by removing the
10. Reconnect the battery earth lead. AFL retaining screws.
Installation
Fuel Gauge and Float Assembly
1. Install a new gasket under the AFL and carefully
Removal insert the float into the tank and locate the AFL on
1. Start the engine. the tank.
2. Turn the service valve off. 2. Install the AFL retaining screws and torque to 5
Nm.
3. Run the engine until it stalls.
3. Apply Permabond A129 sealer, Locktite 577, or
4. Turn off the ignition and remove the battery earth equivalent to the adapter elbow and install into
lead. the AFL.
5. Remove tank from vehicle as per procedure. 4. High pressure leak test the cylinder assembly to
6. Remove the LPG in the tank in accordance with 2.3 MPa in accordance with clause 4.2.2 of
the decanting procedure. standard AS 1425-1999.
7. Disconnect the gauge sender wires. 5. Connect the filler hose to the AFL adapter elbow.
8. Slightly loosen all gauge and float retaining 6. Refit tank to vehicle as per procedure.
screws to relieve any residual pressure in the 7. Refill the tank and check the performance of the
tank. AFL against gauge registration.
9. Rock the gauge and float to ensure that no 8. Check for leaks.
residual pressure remains.
G86744 en 01/2003 2003.0 BA Falcon

9. Turn service valve on. 2. Remove 3 bolts Ute + Wagon, (1 bolt Sedan)
10. Reconnect the battery earth lead. fastening fuel filler bracket.
3. Remove valve assembly from body.
Service Valve (With Relief Valve on Installation
Ute and Wagon) 1. Installation is the reverse of the removal process,
Removal tightening 3 fastening bolts(for Ute + Wagon), 1
bolt for Sedan to 10Nm as specified.
NOTE: Ensure that pipe is sealing on the Filler
2. Turn the service valve off. Valve assembly and after installation ensure that
3. Run the engine until it stalls. LPG filler gun can be applied.
4. Turn the ignition off and remove the battery earth
lead.
5. Remove all LPG from the cylinder in accordance
with the decanting procedure.
6. Slightly loosen the four retaining screws which
secure the service valve to the cylinder. This will
relieve any residual pressure in the cylinder.
7. Rock the service valve to ensure that no residual
pressure remains.
8. Disconnect the supply hose from the service
valve.
9. Remove the solenoid coil from the service valve
by removing the M5 bolt and sliding the coil off
the service valve.
10. Remove the service valve retaining screws and lift Tray
out the service valve and pick-up tube assembly.
Note that the pick-up tube has a fuel screen on its
lower end. Be careful not to damage this when
removing the pick-up tube assembly from the
cylinder.
Installation
1. Install a new gasket under the service valve and
carefully insert the pick-up tube and fuel screen
assembly into the cylinder. Locate the service
valve on the cylinder.
2. Install the four service valve retaining screws and
progressively torque in a cross diagonal pattern to
5 Nm.
3. Reconnect the supply hose to the service valve.
4. Refit the solenoid coil onto the service valve. Cab Chassis
5. High pressure leak test the cylinder assembly to
2.3 MPa as per clause 4.2.2 of standard AS/NZS
1999.
6. Refill the cylinder and check the AFL performance
against the dispensing pump.
7. Turn the service valve on.
8. Reconnect battery earth lead.
Fuel Filler Valve

Removal
1. Disconnect pipe assembly connector at filler
valve. Plug pipe assembly to prevent entry of
any foreign matter.
G86732 en 01/2003 2003.0 BA Falcon

Sedan NOTE: SEDAN & WAGON — There is a connector to

hose on the tank assembly.
NOTE: The bundy tubing is attached to the floor pan
by pop rivets through insulated brackets and is
unlikely to ever require replacement. There is a joint,
near the base of the A pillar,which has a hydrostatic
valve attached ute only. From here, the bundy tubing
continues up and across the cowl directly to the
connector adaptor in the lower section of the filter lock
off in the engine compartment.
Fuel Delivery System - Ute
Pressure Relief Valve

This is part of the service valve on Ute and Wagon –
see service. On the Sedan it is seperate and is on the
upper valve pad.
Fuel Filler Hose
Removal
1. Disconnect the filler hose connector at AFL.
2. Disconnect the filler hose from the fuel fill valve.
Installation Item Description
1. Attach filler hose connector to fuel valve. 1 Screw
2. Check that filler hose is not squeezed between 2 Shield
the tank and body rail. Fuel Delivery System - Ute
3. Connect filler hose to AFL and torque to 28-33
Nm.
LPG Fuel Delivery System Hose
WARNING: Before commencing work on the

LPG Fuel Delivery System ensure that all gas in
the lines is used up.
Start engine.
Turn off the service valve and run the engine
until it stalls.
Endeavour to re-start the engine several
times.
Disconnect the battery negative cable
connection. Item Description
NOTE: UTE — The delivery of LPG from the tank to 1 Bundy tube
the Filter/Lock Off is via a preformed bundy tube 2 Hydrostatic valve
which is connected to each tank and joined with a ’T’ 3 Service line connectors
piece.
G86732 en 01/2003 2003.0 BA Falcon

SFLPG Fuel Filler - Wagon SFLPG Fuel Lines - Sedan

1 Tank Assy Fuel Fill 1 Screw
2 Reinf RR Floor Pan Side 2 Tube Fuel Supply
3 Screw & Washer 3 Rivet
4 Screw & Washer Removal
SFLPG Fuel Filler - Wagon Service Valve to Rear Bundy Connection
1. Disconnect the flexible hose at the service valve.
2. From under the vehicle disconnect the flexible
hose at the bundy connection.
3. Carefully pull the flexible hose through.
Installation
1. Install protective caps to both ends of the flexible
hose to prevent entry of foreign matter.
2. Carefully feed the flexible hose and connect to
service valve - tighten 28-33 Nm.
3. Connect the other end to the bundy tub connector
and tighten to 28-33 Nm.
NOTE: Ensure that the flexible hose is not twisted
during the tightening process.
Item Description
1 Tube Fuel Supply Bundy Tube Connection
2 Rivet Removal
Filter Lock Off to Front Bundy Connection
1. Using two spanners, support the connector
adapter attached to the filter lock off lower
section.
G86735 en 01/2003 2003.0 BA Falcon

2. Unscrew the service line connector at converter. Installation

1. Reverse the above procedure ensuring that the
bundy tubing is not twisted during the tightening
process.
NOTE: When the connections at either the
service line to the filter lock off or flexible hose to
bundy tube have been completed, conduct an
LPG leak test at the connections.
Converter Including Filter Lockoff &

Solenoid
WARNING: LPG under pressure is supplied

to the converter at the filter/lock off and before
removal of the converter or filter lock off is
Item Description attempted the engine should be run with the
1 Connector Adapter service valve turned off until it stalls. A restart
should be attempted to ensure that all LPG has
2 Service Line Connector
been used up. The battery earth lead should be
3 Bundy Tube disconnected and safely stowed.
4 Filter/Lockoff Removal and Installation

1 Stepper Motor 6 Coolant Inlet
2 Prime Solenoid 7 Inlet Gas Lock Off Solenoid
3 Prime Hose 8 Liquid Gas Inlet
4 Mount Bracket 9 Filter & Magnet
5 Coolant Outlet 10 Drain Plugs
11 Idle Solenoid
G86735 en 01/2003 2003.0 BA Falcon

Item Description 6. Disconnect converter wiring loom.

12 Balance Hose Fitting 7. Disconnect solenoid and stepper motor electrical
13 Vapour Line Fitting connectors.
8. Remove screws retaining converter assembly
1. The converter and filter lock off assemblies are mounting bracket to R.H. front spring tower and
bolted to mounting brackets which are in turn
lift converter from engine bay complete with
bolted to the R.H. front spring tower.
mounting bracket.
Filter
Removal
1. Disconnect supply connector from filter bowl.
2. Remove bowl retaining screws and lower bowl
and filter from filter housing.
Installation
1. Install new ’O’ rings into housing and bowl
grooves.
2. Apply Shell R10 oil to ’O’ rings with a brush.
3. Position filter into bowl with the support gauze
facing up (direction of flow is from fine to coarse
gauze).
4. Carefully locate bowl and filter and install screws Item Description
-tighten.
1 Converter & Bracket Assy
5. Reconnect supply connector - Tighten.
2 Bolt
Main/Idle/Prime Lockoff Solenoids
Removal
1. Disconnect electrical connector.
2. Test resistance of induction coil (12.6 Ohms at
20°C. 12.2 Ohms at 12°C. 13.4 Ohms at 36°C ±
4%) replace if necessary.
3. Loosen coil bracket end screw.
4. Unscrew Lockoff solenoid from converter body.
Installation
NOTE: Lockoff solenoid and lockoff spindle are
serviced as an assembly.
1. Locate solenoid and lockoff spindle in position in
converter body. Item Description
2. Tighten. (Refer to Disassembly and Assembly 1 Nut Flanged
Section.)
2 Mounting Bracket
3. Index coil to enable easy connection of electrical
connector. 3 Retainer Clip (Fir Tree)
4. Tighten coil bracket end screw to 5 Nm. Installation
1. Reverse removal instructions.
Converter Assembly
2. Refill cooling system of vehicle using drained
Removal coolant if coolant is in good condition.
1. Turn off service valve (run engine to purge system 3. Turn on LPG service valve.
of LPG). 4. Check for any LPG leaks at service line
2. Drain vehicle cooling system into a clean connection to filter/lock off and connections to
container for re-use. converter.
3. Disconnect LPG supply line. 5. After start up reset KAM.
4. Disconnect air balance tube from the converter.
5. Disconnect vapour hose from stepper motor.
G86739 en 01/2003 2003.0 BA Falcon

Throttle Body
NOTE: LPG vehicles have a Gas/Air mixer built into
the throttle body.
Removal
1. Disconnect LPG vapour hose.
2. Remove as per petrol throttle body.
Installation
1. Reverse removal instructions.
G86739 en 01/2003 2003.0 BA Falcon

Converter with integral Filter/Lock Off

&Prime Solenoid
NOTE: Ensure that all LPG in the supply system has
been used. (Refer instructions for Filter/Lock Off.)
1. After removal of the Converter from the mounting
bracket, (Refer Removal and Installation).
Dismantle, inspect, adjust and reassemble in
accordance with the procedure on the following
pages.
Converter
NOTE: Before commencing to disassemble the
converter ensure that a converter overhaul kit for
Vialle Model F5 special converter is available.
Follow steps as listed to disassemble and
reassemble converter. Reference number
identifies the part on the exploded view.
Do not remove or adjust second stage nozzle
during overhaul.
Do not drive a tool in between the sections to
separate.
NOTE: Tool No. 303-689 is necessary to remove the
idle jet from the converter.
G86742 en 01/2003 2003.0 BA Falcon

G86742 en 01/2003 2003.0 BA Falcon


1 Nut x 8 48 Secondary Lever Shield
2 Front cover 49 Second stage lever
3 Cardboard gasket (thick) 50 Second stage valve
4 Sensitive diaphragm 51 Spring cap
5 Bolt 52 Spring support cap
6 Sensitive diaphragm support plate 53 Spring second stage
7 Support plate seal 54 Coolant Gasket Support plate plastic
8 Idle Jet Venturi 55 Brass Washer
9 Brass seat 56 Primary seat
10 Idle Jet O-Ring 57 Primary Valve lever
11 Idle Jet 58 Primary Valve
12 Spring 59 Plastic Washer
13 Solenoid O-Ring 60 O-Ring x 2
14 Idle Seat and O-Ring 61 Clevis
15 Solenoid Plunger 62 Primary Diaphragm support plate
16 Stepper Motor Bolt x 2 63 Filter
17 Solenoid Stem 64 Filter Bowl
18 Solenoid Assembly 65 Bolt x 4
19 Balance plug 68 Support Plate Bolt
20 Aluminium Washer 69 Primary Stage diaphrgm
21 Slotted Prime Solenoid (where fitted) 70 Primary Valve Retaining Clip
22 Idle transfer tube 71 Primary Spring Support plate
23 O-Ring Idle transfer tube 72 Belville spring washer x 2
24 Bolt x 2 73 Nut
25 Primary Valve Shaft 74 Primary stage spring
26 Plastic Washer (where fitted) 75 Bolt x2
27 Brass Union 76 Idle slice
28 Brass Tee 77 Copper Washer
29 Bracket 78 Drain Plug x 2
30 Nut
Disassembly
31 Bolt
1. Prime hose from stepper motor to prime valve.
32 Secondary stage valve shield
2. Stepper motor retaining bolts and stepper motor.
33 Bolt x 2
3. Prime valve retaining bracket.
34 First stage body section
4. Solenoid coil and plunger from prime valve
35 Plastic Washer discard ’O’ ring and plunger.
36 Secondary stage valve shaft 5. Idle and main solenoid coils.
37 Secondary valve E-Clip 6. Idle and main lock off and idle seat assembly.
38 Secondary Pin Guide Bush NOTE: Beware idle seat spring pressure.
39 Secondary Slice NOTE: Discard idle and main lock off plunger and
40 Label 0-rings and the idle seat assembly.
41 Secondary Diaphragm 7. Spring and idle jet. Use tool 303-689.
42 Cardboard gasket (Thin) NOTE: Screw tool onto idle jet and pull unit out.
43 Rear Cover 8. Use a wire (paper clip) with small hook on the end
44 Main Bolt x 8 to remove jet O-Ring. Discard O-Ring.
45 Secondary stage pin 9. All nuts and studs.
46 Bolt x 2 NOTE: Remove all nuts from studs. Take notice
47 Coolant Chamber gasket of position of longer mounting studs in converter.
G86742 en 01/2003 2003.0 BA Falcon

10. Back cover, back cover gasket and second stage 1. Second stage lever pin. Lubricate pin with
diaphragm. Discard diaphragm and gasket. molybdenum grease only .
NOTE: Re-Assembly will be easier if the 2. Reinstall second stage shield.
converter studs remain on the main bracket and 3. Second stage lever spring, button and cap.
the converter body (minus the rear cover) is Ensure spring is correctly is seated.
gently pulled from the studs.
4. Coolant chamber gasket. Install second stage pin
11. Second stage pin. Discard pin. guide bush to second stage body section.
12. Front cover, front cover gasket and sensitive 5. Coolant chamber gasket support and second
diaphragm. Discard gasket and sensitive stage body section onto first stage body section.
diaphragm. Use eight studs to hold diaphragm in place while
13. Sensitive diaphragm support plate and gasket. assembling.
Discard gasket. NOTE: Position longer mounting studs in original
14. Two idle body section bolts. location, ensure gasket is not binding.
NOTE: Beware of primary spring pressure. 6. Second stage body section bolts.
15. Separate idle body section from first stage body 7. Second stage lever pin. Lubricate pin with
section. molybdenum grease only .
16. First stage diaphragm assembly primary lever 8. Second stage diaphragm gasket cover and gasket
assembly at the same time by lifting diaphragm paper.
and removing screws. Separate assembly and NOTE: Install large disc of second stage
discard first stage diaphragm, washers and first diaphragm towards body section.
stage lever assembly. Remove and discard
9. Idle jet, O-Ring, and seat in body section use tool
O-Ring and idle transfer tube.
303-689.
17. First stage cover and screw. NOTE: Use same type of idle jet as removed.
NOTE: Do not remove the first stage nozzle from Bevelled edge of seat should be towards ejector.
the housing. Push in until firmly seated.
18. Second stage body section bolts. NOTE: 0.8mm idle jet has a machined groove in
19. Separate second stage body section from first it.
stage body section. Retain water chamber gasket 10. Spring idle seat with O-Ring and idle lock off
support. Discard water chamber gasket. assembly.
20. Cap, spring button and second stage spring. 11. First stage lever assembly and screws.
21. Second stage lever assembly and screws. 12. O-Ring and idle transfer tube. Take care when
Discard second stage lever seat. assembling body’s that transfer tube does not
22. Bolt and water pipe bracket (not shown on dislodge.
exploded view). 13. First stage cover with screw.
23. Inlet and outlet coolant connectors (not shown on 14. First stage diaphragm assembly and spring.
explored view). Discard coolant connecters Install spring with small end towards diaphragm.
O-Rings.
NOTE: Slide retainer over end of first stage lever.
NOTE: Clean coolant connector openings in first LUBRICATE RETAINER WITH MOLYBDENUM
stage body section with 22mm or 7/8" round wire GREASE ONLY.
brush. Clean coolant connectors and especially
the grooves for the O-Rings. 15. Idle body section to first stage body section and
two idle body section bolts.
24. Remove and discard filter and O-Rings.
16. Sensitive diaphragm support plate gasket into
25. Remove and discard second stage pin guide sensitive diaphragm support plate.
bush.
17. Sensitive diaphragm support plate and screw.
NOTE: Use a punch that is smaller than the guide
bush. 18. Sensitive diaphragm, gasket, front cover, and
nuts.
NOTE: Clean all parts with solvent or mineral
NOTE: Prime valve retaining bracket.
spirits. Do not use carburator cleaner or lacquer
thinner. 19. Main solenoid.
20. 0-rings on coolant fittings (not shown).
Assembly
21. Lower and upper coolant fitting into first stage
NOTE: It is advised to use oil (Shell R-10) or acid free body section. The coolant in connector has two
vaseline on all O-Rings prior to assembly. alignment K.
G86742 en 01/2003 2003.0 BA Falcon

22. Bracket and screw to retain water pipes in place

(not shown).
1. Prime hose from stepper motor to prime
valve.
2. Stepper motor retaining bolts and stepper
motor with new O-Ring.
3. Solenoid coil and plunger from prime valve
with new O-Ring and plunger.
4. Prime valve retaining bracket.
Idle Jet
Disassembly
1. Remove idle solenoid (8mm headed bolt).
2. Remove idle solenoid stem (17mm). Take care
that the idle seat does not eject due to spring
pressure.
3. Remove idle seat carefully as seat can be easily
damaged.
4. Remove idle jet using removing tool (No.
303-689).
5. Clean idle jet with high pressure air in both
directions. Usual precautions should be taken
when using high pressure air.
NOTE: Never blow the idle jet while it is still
installed in the converter.
Assembly
1. Reassemble in the reverse order.
G86743 en 01/2003 2003.0 BA Falcon

303-05-1 Accessory Drive 303-05-1
SECTION : 303-05 Accessory Drive

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-05-2
Accessory Drive ....................................................................................................................303-05-3
Belt Tensioner - I6 & V8 .........................................................................................................303-05-3
Water Pump ..........................................................................................................................303-05-4
Accessory Drive ....................................................................................................................303-05-5
Symptom Chart ....................................................................................................................303-05-5
Belt Tensioner ......................................................................................................................303-05-5
Accessory Drive Belt .............................................................................................................303-05-6
Accessory Drive Belt Tensioner ............................................................................................303-05-6
Accessory Drive Belt Idler Pulley ..........................................................................................303-05-6
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Sealer ESZ - M4G281 - A
Description Nm
Accessory drive belt tensioner bolt - 25
4.0L I6
Accessory drive belt idler pulley bolt 25
- 4.0L I6
Water pump bolts - 4.0L I6 20
G97110 en 01/2003 2003.0 BA Falcon

Accessory Drive 8 Cylinder
6 cylinder with air conditioning
Item Description
1 Alternator pulley
Item Description 2 Pulley
1 Power steering pump pulley 3 Power steering pump pulley
2 Belt idler pulley 4 Crankshaft damper
3 Belt tensioner 5 A/C Compressor pulley
4 A/C compressor pulley 6 Belt tensioner
5 Crankshaft damper 7 Belt idler pulley
6 Alternator pulley
7 Water pump pulley Belt Tensioner - I6 & V8
6 cylinder without air conditioning
Item Description
Item Description 1 Worn belt mark
1 Power steering pump pulley 2 3/8" Square drive. Use to rotate Auto
2 Belt idler pulley Tensioner Body
3 Belt tensioner 3 New belt mark
4 A/C idler pulley 4 Belt wear reference mark
5 Crankshaft Automatic belt tensioners are spring loaded devices
6 Alternator pulley which set and maintain the drive belt tension. The
7 Water pump pulley drive belt does not require tension adjustment for the
life of the belt. Automatic tensioners have belt wear
indicator marks. If the indicator mark is not between
the indicator lines, the belt is worn or an incorrect belt
has been installed. Replace belt as outlined.
G97112 en 01/2003 2003.0 BA Falcon

Water Pump
A centrifugal-type water pump is mounted on the front
of the cylinder block.
A vane-type impeller supplies coolant through
centrifugal action to the water pump outlet port.
If the pump is found to be faulty remove and discard
as it is of a sealed unit type which cannot be repaired.
Refer to Engine Cooling in Section 303-03.
G97112 en 01/2003 2003.0 BA Falcon

Accessory Drive 3. Install a new drive belt if any of the following

conditions exist: rib chunk-out, sever glazing,
Inspection and Verification frayed cords, belt back delamination or other
concerns.
1. Verify the customer’s concern by operating the NOTE: Minor cracks in the V-grooved portion of
engine to duplicate the condition. the drive belt are considered normal and
2. Inspect to determine if any of the following acceptable. If the drive belt has chunks missing
mechanical concerns apply: from the ribs, a new drive belt should be installed.
Visual Inspection Chart 4. If the concern is not visually evident, verify the
Mechanical symptom and refer to the Symptom Chart.
Drive belt cracking/chunking
Drive belt contamination
Drive belt length incorrect
Drive belt noise or squeal
Pulley misalignment or excessive pulley run-out
Symptom Chart

Drive belt cracking Drive belt System OK
Drive belt chunking Drive belt INSTALL a new drive belt. REFER to
’Accessory Drive Belt’ in this section
Drive belt noise or squeal Pulleys DETERMINE where the noise is

coming from. CHECK pulley alignment,
freedom of rotation or damage.
REPAIR or INSTALL as necessary.
Lubrication or other contamination CHECK belt for contamination. If belt

is damaged, INSTALL a new belt.
Drive belt CHECK correct belt is fitted
Drive belt does not hold tension Drive belt cracked or damaged INSPECT belt for parallel cracking
through to backing. INSTALL new
drive belt as necessary.
Tensioner worn or damaged CHECK belt tensioner for damage and

correct operation. INSTALL a new belt
tensioner if required.
Belt Tensioner
NOTE: The only mechanical check that needs to be
made is a check for tensioner stick, grab or bind.
1. Remove the belt in the area of the tensioner.
2. Rotate the tensioner from its relaxed position
through its full stroke and back to the relaxed
position to make sure there is no stick, grab or
bind and to make sure there is tension on the belt
tensioner spring.
3. If the tensioner does not meet the above criteria,
install a new tensioner. See ’Accessory Drive Belt
Tensioner’ in this section.
G97114 en 01/2003 2003.0 BA Falcon

Accessory Drive Belt

1. Rotate the tensioner arm clockwise using a 3/8"
square drive and remove the drive belt.
Accessory Drive Belt Tensioner

1. Remove the accessory drive belt. Refer above.
2. Remove tensioner bolt and the drive belt
tensioner.
3. To install, reverse the removal procedure,

ensuring the pin locates correctly.
Accessory Drive Belt Idler Pulley
1. Remove the accessory drive belt. Refer above.
2. Remove idler bolt and the idler pulley assembly.
G97116 en 01/2003 2003.0 BA Falcon

303-06-1 Starting System 303-06-1
SECTION : 303-06 Starting System

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-06-2
Starting System — 6 Cylinder (Bosch) .................................................................................303-06-3
General Service ....................................................................................................................303-06-3
Description ...........................................................................................................................303-06-3
Operation .............................................................................................................................303-06-3
Roadside Service ..................................................................................................................303-06-3
Jump Starting .......................................................................................................................303-06-3
Connecting and Starting Procedure .....................................................................................303-06-4
Engine Starting .....................................................................................................................303-06-4
Starting System .....................................................................................................................303-06-5
Symptom Chart ...................................................................................................................303-06-5
Pinpoint Tests ......................................................................................................................303-06-5
Component Tests .................................................................................................................303-06-9
GENERAL PROCEDURES
Starting System ...................................................................................................................303-06-12
Starter Motor .......................................................................................................................303-06-14
Starter Motor .......................................................................................................................303-06-15
Starter Drive Assembly .......................................................................................................303-06-16
Solenoid Switch ..................................................................................................................303-06-16
Drive End Housing ..............................................................................................................303-06-16
Armature .............................................................................................................................303-06-16
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Solenoid Burn off reserve 0.8 - 1.4mm
Solenoid Pre-stressed tension of 12 ± 3N
reset spring for moving contact
Solenoid Pre-stressed tension of 19N
contact pressure spring
Solenoid Pre-stressed tension of 45 ± 7N
plunger spring with 9mm plunger
clearance
Solenoid Total spring force 113N
Commutator Runout 0.1mm
Commutator minimum size 31.2mm
Commutator laminations runout 0.5mm
Starter current draw
Load =<300A
No Load =<8-A
Description Nm
Starter Retaining bolts 21 - 27
G86721 en 01/2003 2003.0 BA Falcon

Starting System — 6 Cylinder (Bosch) battery

inhibitor switch (auto trans)
The starting system includes the permanent magnet
electrical circuitry incorporating the ignition switch,
gear-reduction starter with a solenoid-actuated drive,
BEM and EEC V (’smartshield’), starter diode and
the battery, a remote control starter switch (part of the resistor. (Refer schematics section of this
ignition switch), the neutral start switch (automatic
manual).
transmission), the starter relay, the heavy circuit
wiring, the body electronics module (BEM) and the Operation
power train control module (PCM).
Turning the ignition to the IGN or ACC position
Turning the ignition switch to the START position
activates the BEMs ’smartshield’ system (Refer to
actuates the starter relay, through the starter control Section 419-10.) and disarms the engine
circuit. The starter relay then connects the battery to
immobilisation. If the inhibitor switch is closed, the
the starter solenoid, causing it to energize.
circuit is completed and current flows through the
When the starter solenoid is energized, a magnetic starter relay. This, in turn, completes the circuit from
field is created in the solenoid windings. The iron the battery to the starter solenoid. This connects the
plunger core is drawn into the solenoid coil and a battery to the starter motor. The starter utilizes an
lever connected to the drive assembly engages the integral positive engagement drive.
drive pinion gear into the flywheel ring gear. When the
The electrical circuit also incorporates a starter diode
plunger is pulled all the way in, its contact disk closes
and starter resistor connected to ground. This
the circuit between the battery and motor feed completes the starter solenoid circuit through ground
terminals. This sends current to the motor and the
after the solenoid is switched off to prevent any
drive pinion gear cranks the flywheel to start the
voltage surges at the solenoid caused by back EMF.
engine. When current flows to the motor, the solenoid
pull-in coil is bypassed and the hold-in coil keeps the Roadside Service
drive pinion gear engaged with the flywheel until the
ignition switch is released from the START position. Jump Starting
An overrunning clutch in the drive assembly protects
To avoid damage to the vehicle and battery or the
the starter from excessive speeds during the brief
possibility of personal injury, follow these instructions
period before the driver releases the ignition switch
from the START position (as the engine starts). and precautions:
General Service CAUTION: Hydrogen and oxygen gases are

produced during normal battery operation. The
Description gas mixture can explode if flames, sparks, or
cigarettes are brought near the battery in an
The function of the starting system is to crank the enclosed space, always provide ventilation and
engine at a high enough speed to permit it to start. shield your eyes.
The system contains the following components: Keep out of reach of children. Batteries contain
starter motor and solenoid sulphuric acid. Avoid contact with skin, eyes or
clothing. Also, shield your eyes when working
near the battery to protect against possible
splashing of the acid solution. In case of acid
contact with skin, eyes or clothing, flush
immediately with water for a minimum of fifteen
minutes. If acid is swallowed, drink large
quantities of milk or water, followed by milk of
magnesia, a beaten egg, or vegetable oil. Call a
physician immediately.
NOTE: If instructions are not observed, damage to
electronic components may result. Ensure the battery
to be used for boosting is 12-volt and that the
negative terminal is grounded.
Remove the filler vent caps from both batteries and
place damp cloth over batteries. If the booster battery
Item Description is installed in another vehicle, do not allow the two
1 Terminal 30 vehicles to touch. Turn off all unnecessary electrical
loads. Select neutral gear on manual transmission, or
2 Terminal 50 ’P’ (Park) position in automatic transmission, and
3 Magnets engage the parking brake on both vehicles.
starter relay
G86729 en 01/2003 2003.0 BA Falcon

Connecting and Starting Procedure

Connect the jumper leads in the exact sequence as
illustrated.
Connect end of jumper lead to the positive (+)

terminal of the discharged battery. (Red lead if
coloured).
Connect the other end of the same jumper lead to
the positive (+) terminal of the booster battery.
Connect end of second jumper lead (Black if
coloured) to the negative (-) terminal of the
booster battery.
Connect the other end of the second jumper lead
to the engine of the vehicle with the discharged
battery - NOT TO THE NEGATIVE TERMINAL
OF THE DISCHARGED BATTERY.
Take care that the jumper clamps do not touch each
other or any metal on either vehicle, and are clear of
cooling fans and drive belt.
Do not lean over the battery when making
connections.
Engine Starting
First start the engine in the vehicle with the booster
battery and let it run for a few minutes. Then start the
engine in the vehicle with the discharged battery.
Leave the jumper leads connected until the engine
reaches idle speed (at least 1 minute) – otherwise
damage to the electrical system may occur.
Switch heater fan to boost position to ‘load’ the
vehicle’s electrical system prior to disconnecting the
jumper cables.
Disconnect the cables in reverse order.
Do not disconnect or change over the discharged
battery while the engine is running – damage to the
electrical system may occur.
WARNING: Jump starting could be

dangerous if done incorrectly.
Do not attempt a jump-start if the discharged
battery is frozen or if the battery fluid level is low,
as the battery may rupture or explode.
G86729 en 01/2003 2003.0 BA Falcon

Starting System
Symptom Chart
Symptom Chart - Starting System

Starter Motor Cranks Slowly Loose connections in starter solenoid GO to Pinpoint Test A.
battery feed or ground circuit.
Undercharged battery. (Battery acid in
all cells should have a specific gravity
reading greater than 1.20, with all cells
within 10 points variation).
Malfunctioning starter motor.
Voltage drop on power cable.
Starter Motor Does Not Crank But Loose or corroded connections at GO to Pinpoint Test B.
Starter Solenoid Operates starter solenoid.
Undercharged battery
Main power cable open circuit.
Starter Motor Does Not Crank and Loose or corroded battery cable GO to Pinpoint Test C.
Starter Solenoid Does Not Click connections.
Undercharged battery.
Faulty TR/NDS (neutral drive switch).
Faulty ignition circuit grounds.
Poor earth circuit.
Starter Motor Spins But Does Not Malfunctioning starter drive. GO to Pinpoint Test D.
Crank Engine Damaged flywheel.
Unusual Starter Motor Noise During Starter motor improperly mounted. GO to Pinpoint Test E.
Starter Motor Overrun Malfunctioning starter motor.
Improper starter drive engagement to
flywheel.
Starter Motor Remains Engaged and Battery cable touching solenoid GO to Pinpoint Test F.
Runs with Engine S-terminal (defective or mispositioned
battery cable).
Shorted turns in starter solenoid.
Starter Motor Noisy in Operation Worn or damaged ring gear. Inspect ring gear repair or replace as
Drive end bush or commutator end required.
bush dry/not lubricated. Clean and lubricate bushes as
Excessive clutch dust (Manual required.
Transmission)
Pinpoint Tests
PINPOINT TEST A : THE STARTER MOTOR CRANKS SLOWLY

A1 CHECK BATTERY CONNECTIONS
Inspect the battery terminals for loose or corroded connections. Yes
Go to A2
Test voltage drop between battery negative terminal to case of starter
motor, should be < 300mV. No
Are the battery terminals clean and tight? CLEAN and TIGHTEN battery cable
connections.
G86730 en 01/2003 2003.0 BA Falcon


A2 CHECK BATTERY
Check the battery state of charge. Yes
Go to A3
Battery acid in all cells should have a specific gravity reading greater
than 1.20, with all cells within 10 points variation. No
Load test the battery. CHARGE or REPLACE the battery.
Is the battery OK?
A3 CHECK STARTER MOTOR CONNECTIONS

Inspect the starter motor terminals for loose or corroded connections. Yes
Go to A4
Test voltage drop between battery postive terminal to solenoid main
terminal, should be <350mV. No
Are starter motor terminal connections clean and tight? CLEAN and TIGHTEN starter motor
connections.
A4 CHECK STARTER MOTOR

Check the starter cranking current draw, using a suitable digital Yes
multimeter and current clamp or by following starter load test REMOVE starter and test.
procedure detailed in Components Tests of this section. REPAIR or REPLACE.
Is the current draw lower than Specification? No
Go to A5
A5 CHECK CURRENT DRAW

Remove the stater motor and check the starter current draw with no Yes
load, using a suitable digital multimeter and current clamp or by Engine has excessive friction. Refer to Section
following starter no load test procedure detailed in this section. 303-01.
Is the current draw to Specification? No
Test starter REPAIR or REPLACE.
PINPOINT TEST B : STARTER MOTOR DOES NOT CRANK BUT STARTER SOLENOID OPERATES
B1 CHECK STARTER MOTOR CONNECTIONS

Inspect the starter motor terminals for loose or corroded connections. Yes
Go to B2
Are starter motor terminal connections clean and tight?
No
CLEAN and TIGHTEN starter motor
connections.
B2 CHECK BATTERY
Go to B3
Is the battery OK?
B3 CHECK SOLENOID
By-pass the solenoid with a heavy jumper cable. Yes
REPLACE solenoid.
Does the engine crank now?
No
Go to B4
G86730 en 01/2003 2003.0 BA Falcon


B4 CHECK STARTER ENGAGEMENT
Yes
Is the starter engagement firm? Engine locked up. Refer to Section 303-01.
No
Remove starter and test.
REPAIR or REPLACE.
PINPOINT TEST C : THE STARTER MOTOR DOES NOT CRANK/THE SOLENOID DOES NOT CLICK

C1 CHECK BEM SMARTLOCK STATE
Use WDS to monitor the theft status (THEFT _ S) PID. Yes
Go to C2
With the ignition switched on is the BEM status “moblised”?
No
Refer Section 419-10 (BEM).
C2 CHECK FUSES
Ensure vehicle is in Park or Neutral (Auto. Trans.). Yes
REPLACE and RETEST.
Check all fuses in the vehicle.
Check all fuses in the vehicle. No
Go to C3
C3 CHECK ENGINE ENABLE INPUT

Use WDS to monitor the engine enable input signal No (ATS) EEC Yes
PID. Problem exists in ‘Smartshield’ system or
communication between EEC and BEM.
With the ignition switched on is the ATS signal being received by
the EEC? No
Go to C4
C4 CHECK BATTERY CONNECTIONS

Inspect the battery terminals for loose or corroded connections. Yes
Go to C5
Are the battery terminals clean and tight?
No
CLEAN and TIGHTEN battery cable
connections.
C5 CHECK BATTERY
Go to C6
Is the battery OK?
C6 CHECK POWER SUPPLY TO STARTER MOTOR

Key in OFF position. Yes
Go to C9
Disconnect the starter motor solenoid terminal 50 (connector C-11).
Key in START position. No
Go to C7
Measure the voltage at Connector C-11
Is the voltage greater than 10 volts?
G86730 en 01/2003 2003.0 BA Falcon


C7 CHECK POWER SUPPLY TO STARTER MOTOR
With the vehicle in park and the handbrake on, bridge the starter relay Yes
across its switching circuit (relay pins 30 AND 87) with a heavy Go to C10
jumper cable.
No
Does the starter crank now? Go to C8
C8 CHECK THE STARTER CIRCUIT

Check continuity of circuit from fuse block to starter relay and from Yes
starter relay to starter motor solenoid. Go to C9
Is the circuit OK? No
Rectify and Retest.
C9 CHECK THE SOLENOID

With the vehicle in park and the handbrake on, bridge the starter Yes
motor battery connection to the solenoid terminal. REPLACE solenoid. Retest.
Does the engine crank? No
No Test starter motor.
REPAIR or REPLACE.
C10 CHECK POWER BETWEEN IGN & STARTER RELAY

With ignition switched to the start position, check the voltage at the Yes
starter motor relay (winding input). Go to C11
Is there greater than 8 volts? No
Check continuity of circuit from fuse through
ignition switch to relay.
Rectify and Retest.
C11 CHECK EEC STARTER RELAY SWITCHING

Use the WDS to monitor the starter relay enable starter signal Yes
(ENABLE_ S) EEC PID. Go to C12
With the ignition switched to the start postion is the signal “ No
ON”? Perform further EEC diagnostic tests.
C12 CHECK STARTER CIRCUIT

Ensure vehicle is in Park or Neutral (Auto. Trans.). Yes
Replace starter motor.
Check continuity of circuit from, EEC;
Starter relay No
Inhibitor switch Rectify and Retest.
Ground
Is the circuit OK?
PINPOINT TEST D : THE STARTER SPINS BUT THE ENGINE DOES NOT CRANK

D1 CHECK BATTERY
Go to D2
Is the battery OK?
No
CHARGE or REPLACE the battery.
G86730 en 01/2003 2003.0 BA Falcon


D2 CHECK FLYWHEEL
Remove the starter motor. Refer to procedure in this section. Yes
REPLACE as necessary.
Inspect the starter drive and flywheel for damage.
Is the starter drive or flywheel damaged? No
Perform Bench Test procedures this section.
PINPOINT TEST E : UNUSUAL STARTER NOISE DURING STARTER OVERRUN

E1 CHECK STARTER MOTOR MOUNTING
Inspect the starter motor mounting. Yes
Go to E2
Check the starter motor mounting bolts for looseness.
Is the starter motor mounted properly? No
REMOUNT or REPLACE the starter motor.
E2 CHECK STARTER DRIVE ENGAGEMENT

Remove the starter motor. Yes
PERFORM the Bench Test procedures in this
Inspect the starter drive and flywheel for damage. Refer to inspection section.
Are the starter drive and flywheel OK? No
REPLACE as necessary.
PINPOINT TEST F : STARTER MOTOR REMAINS ENGAGED AND RUNS WITH ENGINE
F1 CHECK STARTER MOTOR TERMINALS

Inspect the starter motor connectors for corrosion and incorrect Yes
installation. PERFORM the Bench Test procedures in this
section.
Are the starter motor connectors clean and installed properly?
No
CLEAN or ADJUST starter motor connectors.
Component Tests starter switch, and determine exact reading on

voltmeter.
Starter Motor Load Test NOTE: Ensure ignition switch is in the off position
Conduct this test if the starter cranks slowly and it is and the solenoid terminal 50 connector has been
desired to compare current draw to specifications. removed so that the engine does not start.
This test is performed with the starter motor fitted to 4. Disconnect battery to vehicle cables and reduce
the vehicle. resistance of carbon pile until voltmeter indicates
1. Connect the starter motor tester equipment to the the same reading as that obtained while the
vehicle’s battery. Ensure that current is not starter cranked the engine. The ammeter will
flowing through the ammeter and heavy duty indicate starter current draw under load. Check
carbon pile rheostat portion of starter tester this value with value listed in specifications.
circuit, (rheostat at maximum counter clockwise
position). Starter Motor No Load Test
2. Disconnect the push on connector at the starter The starter motor no load test will uncover such
solenoid (terminal 50) and connect a remote conditions as open or shorted windings, rubbing
control starter switch from the positive battery armature, and bent output shaft. The starter can be
terminal to solenoid terminal 50. tested, at no load, on the test bench only.
3. Place transmission in neutral or park. With the 1. Clamp the starter motor securely in a starter test
ignition off crank the engine using the remote bench.
G86730 en 01/2003 2003.0 BA Falcon

2. Connect Starter Tester to a fully charged battery starter motor should operate smoothly. Determine
(Specific Gravity > 1260) and connect the battery the exact reading on the voltmeter.
positive to the battery supply (terminal 30) of the NOTE: The duration of this test should be as
starter motor and battery negative to the starter short as possible.
motor case. Starter motor connection cables
should be large enough to carry high currents, 5. Disconnect starter from battery then reduce
(equivalent to those used on the vehicle). resistance of rheostat until voltmeter indicates the
same reading as that obtained while the starter
3. Connect a remote starter switch between the was running. The ammeter will indicate starter no
solenoid terminal 50 and the power supply on load current draw. Refer to specifications for a
terminal 30. comparative value.
4. Ensure that no current can flow through the 6. If the current exceeds Specification, check for
ammeter (rheostat at maximum counter clockwise rubbing armature, bent output shaft, binding
position). Engage the remote starter switch, the bearings, or shorts in armature or brush
pinion should shift to the crank position and the assembly.
Starter Solenoid Armature

Inspect the solenoid for damage and test the winding The commutator should be examined for any sign of
dc resistance. burned or darkened segments as this is usually an
indication of open circuited windings. Check for short
Hold-in Winding 1.16 - 1.3 Ohms.
circuits using an armature growler or similar tester.
Pull-in Winding 0.248 - 0.281 Ohms. Test the insulation resistance to earth using a megger
Test temperature +20°C or similar tester. A reading 1 MegaOhm or greater
During hold in and pull in tests the solenoid is held should be expected.
vertically, ie plunger uppermost. It is recommended
that a rubber band be installed to prevent the plunger
from flinging out during testing.
G86730 en 01/2003 2003.0 BA Falcon

Inhibitor Switch Test

On vehicles equipped with an automatic transmission,
apply the brakes and attempt to start the engine while
moving the selector lever through all ranges. This may
determine if the problem is caused by a maladjusted
or defective neutral-start switch. Refer to Section
307-01 for the adjustment of this switch.
G86730 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
2. Press the plunger fully home, it will be held by the

Starting System hold-in winding.
Cleaning Components 3. Now decrease the voltage until the winding will no
longer hold the plunger.
CAUTION: The Armature, solenoid switch Brushes and brush holder Inspection
and drive assembly components must not be 1. Check the brush holder for shorts to ground using
cleaned with spirit based agents, only clean rags an insulation tester with a minimum AC voltage of
and compressed air must be used. 40 volts.
NOTE: All other mechanical components may be 2. Ensure that the brushes move freely in their
cleaned using non volatile or low inflammable agents holders and that the brushes are free from chips
in a well ventilated area, it is important that the parts and burn marks.
are thoroughly dried before assembly, take care not to
breath in the vapours. 3. Check brush length if shorter than the minimum
length (7mm) replace the brush set.
Please observe the safety regulations and precautions
issued by the manufacturer of the cleaning agent in Armature Inspection
use. 1. Clean and inspect the armature for broken or
Pull-In Voltage Testing burned insulation and unwelded or open
connections.
1. Using a power supply capable of supplying 30 2. Inspect armature shaft and bearing surfaces for
amperes, set the voltage to 3.0 volts. A battery scoring and excessive wear.
and variable resistor may also be used.
3. Check commutator for runout using a dial
2. Connect the solenoid. Connect a 12 volt test lamp indicator. If commutator is rough, or out of round,
between terminal 30 (main battery supply input) turn it down to Specification or replace.
and +12 volt supply and a voltmeter between
terminal 50 and ground.
Item Description
3. Fully press in solenoid plunger until lamp lights. 1 Rotate armature chafts on bearing
Allow the plunger to spring out by approximately surfaces
8-10mm and hold in this position. 2 Dial indicator
4. Slowly increase the voltage on terminal 50 until 3 “V” blocks
the plunger pulls in; note voltmeter reading. At the
same time the lamp must light fully (main contact Machining and undercutting the commutator
continuity). 1. If worn segments are evident on the commutator it
NOTE: The voltage should be between 3.0 - 6.5 must be machined until the working surface is
volts. Test duration should NOT exceed 2 clean, note that the minimum size for the
seconds. commutator is 31.2mm. When machining the
Hold-In Voltage Testing armature it must not be held by the laminations.
The Armature must be held at the drive end and
NOTE: The voltmeter reading, this is the release supported at the commutator end bearing surface.
voltage which should be between 0.2 - 2.0 volts.
1. Set the power supply to 12 volts, connect the
positive lead to terminal 50 of the solenoid and
connect the negative lead to the case of the
solenoid.
G86731 en 01/2003 2003.0 BA Falcon

2. It is recommended that the commutator be turned 2. Examine drive end housing mounting surfaces
in two stages, that is pre turning and finish and threaded holes for damage.
turning. In the pre turning stage the commutator is Drive shaft and planetary assembly inspection
undercut to a maximum depth of 0.8mm.
NOTE: It is most important to use dust extraction 1. Carefully examine the assembly for signs of wear
when undercutting commutators. or cracking.
2. If worn replace the whole planetary drive. The
3. After undercutting the commutator place the planetary gear hub and bush may be replaced
armature in the lathe and finish cut using a fine separately if required.
tool. The cut should be no more than 0.03mm.
After turning, brush out the commutator slots 3. To replace the hub remove the circlip and thrust
using a stiff brush and polish surface if necessary. washer and withdraw the planetary shaft. To
reassemble reverse the procedure.
NOTE: Runout should be less than 0.1mm for the
commutator and 0.5mm for the laminations. NOTE: The planetary gears are pre lubricated, a
small amount of light oil may be used to lubricate
Drive end and commutator end bushes the armature spigot bushing prior to reassembly.
NOTE: Replace bushes whenever excessive The helix for the drive assembly must be
armature shaft side play is evident. If bushes are lubricated with lithium based grease only.
excessively worn the starter motor is likely to operate Drive assembly inspection
inefficiently or the armature may foul the pole pieces.
1. Inspect the pinion for signs of wear or chipped
1. Remove both the commutator end housing and teeth.
drive end bush by carefully tapping out with a 2. Rotate the pinion by hand and check for any signs
mandrel. Be sure that the commutator end of roughness or slipping, examine the pinion bush
cover/drive end housing is well supported. for wear or scoring, if in doubt replace the drive
This can be achieved by soaking the bushes over assembly.
night in mineral oil. If time does not permit over
night soaking oil can be forced into the bush by Contact burn off reserve testing
placing a thumb over one end of the bush and 1. Press the plunger until the contacts close, this will
filling it with oil. Using the other thumb press firmly be indicated when the test lamp comes on.
until the oil is visible on the outer surfaces of the
2. It must be possible to push the plunger another
bush.
1mm or more towards the magnetic core. If less
NOTE: Note that the bushings used in starter than 1 mm the solenoid must be replaced.
motors are made from porous sintered metal and
as such they will hold oil to provide lubrication. It Interwinding short circuit testing
is important that the bushes are pre lubricated 1. A 24 volt supply is required for this test. Apply
prior to fitting. positive supply to terminal 30 (main battery supply
2. New bushes may be pressed or tapped into input) and negative to the casing.
position using a suitably sized shouldered 2. Press the plunger fully home.
mandrel. Do not ream bushes after installation as 3. Release the plunger, it should return to it’s rest
the self lubricating qualities will be impaired. position by the action of the return spring. If it
does not the windings have inter winding short
circuits.
NOTE: When the solenoid is connected in this
way the windings are differentially compounded,
that is, their fields are in opposition to each other.
Drive end housing & Commutator end cover

inspection
1. Inspect the housing and cover for damage, wear
or cracking.
G86731 en 01/2003 2003.0 BA Falcon

Starter Motor
Removal
1. Disconnect Battery Negative Ground Cable.
2. Raise vehicle on hoist.
3. Disconnect starter cable and solenoid connector.
4. Remove starter retaining bolts and withdraw
starter.
Installation
1. Position starter and install retaining bolts. Torque
to Specification.
2. Install starter cable and solenoid connection.
3. Lower Hoist.
4. Reconnect Battery Negative Ground Cable.
G86732 en 01/2003 2003.0 BA Falcon

Starter Motor
G86733 en 01/2003 2003.0 BA Falcon

Item Description 5. Using a pair of circlip pliers expand the stop ring
and remove it from the planetary drive shaft taking
1 Drive end shield
care not to damage the shaft.
2 Solenoid
6. Carefully remove any burrs from the planetary
3 Parts set, solenoid drive shaft before removing the drive assembly,
4 Overrunning clutch drive failure to do so will damage the drive assembly
5 Fork bearing internal bush.
6 Epicycloidal gear train Solenoid Switch
7 Gear hub
1. Disconnect the main braided cable from the short
8 Closure cap
threaded terminal (13mm spanner).
9 Hexagon screw 2. Remove the 3 mounting screws withdraw the
10 Sintered - Metal bushing solenoid, disengage the plunger from the fork
11 Commutator end shield lever and remove complete with the plunger and
12 Brush holder spring.
NOTE: Solenoid position relative to drive end
13 Armature
housing.
14 Pole housing
15 Needle bushing Drive End Housing
1. Loosen and remove through bolts (7mm socket).
Starter Drive Assembly
2. Withdraw the drive end housing complete with the
Special Tool(s) planetary gear assembly, drive assembly and fork
lever from the armature gear taking care not to
Bosch fixture disengage the cover plate.
KDAL 5047
Armature
Special Tool(s)
Bosch fixture
KDAW 9999
Bosch fixture
KDAL 5028
Bosch tool
KDAL 5048
1. Clamp the mounting lug of the drive end housing
in the vice using soft jaws.
2. Remove the rubber sealing block. Remove the
planetary drive assembly, fork lever and planetary
drive from the drive end housing.
3. Ease fork lever from the drive assembly. In order 1. Clamp the pole housing in a vice using soft jaws
to avoid damage to the planetary gears when or Bosch clamping fixture KDAW 9999.
removing the stop ring use Bosch fixture KDAL 2. Remove the screws and the dust cover cap from
5047 this supports the output shaft and prevents the commutator end cover.
the shock being absorbed by the planetary gear
hub. 3. Remove the rubber ring, circlip and adjustment
washers.
4. Using Bosch striking sleeve KDAL 5028 and a
non metallic hammer, with a sharp tap drive back 4. Slide commutator end cover from armature shaft.
the stop ring retainer. 5. Using special Bosch tool KDAL 5048, slide tool
Alternatively clamp the protruding end of the onto the armature shaft until it contacts the face of
planetary drive shaft in a vice (using soft jaws) the commutator.
and prise the stop ring retainer towards the drive
assembly.
G86733 en 01/2003 2003.0 BA Falcon

6. Gently push the tool until the annular flange

contacts the brushplate, the armature may now be
withdrawn. The tool will support the brushes in
their holders until the armature needs to be
reinserted.
7. Remove the armature thrust washer.
G86737 en 01/2003 2003.0 BA Falcon

303-12-1 Intake Air Distribution and Filtering 303-12-1
SECTION : 303-12 Intake Air Distribution and

Filtering
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-12-2
Intake Air Distribution and Filtering .......................................................................................303-12-3
Intake Air Distribution and Filtering ......................................................................................303-12-3
The Intake Air System ..........................................................................................................303-12-3
Intake Air Distribution and Filtering .......................................................................................303-12-4
GENERAL PROCEDURES
Cleaning and Inspection .......................................................................................................303-12-5
Air Cleaner Body — I6 Engine ..............................................................................................303-12-6
Air Cleaner Element — I6 and V8 Engines ..........................................................................303-12-6
Engine Air Ducting — I6 and V8 Engines .............................................................................303-12-6
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Air cleaner bolt 9
Air cleaner intake pipe screw 2.5
Air cleaner assembly screw 12
Air cleaner intake manifold duct –
screw
Air cleaner to intake manifold duct 1.5
clamp
G93830 en 01/2003 2003.0 BA Falcon

Intake Air Distribution and Filtering The air cleaner assembly is secured to the LH fender
inner panel with three insulator mountings. The top
All engines are equipped with dry type air cleaners cover is attached to the air cleaner tray by four spring
that have serviceable PET(plastic fibre) filtering clips.
elements. Air enters the air cleaner from the front
grille, through a duct above the radiator shroud, and I6
then passes through the filter element. Dust particles
are trapped in the filter element as the air passes
through it. After leaving the filter element, the air
passes through an intake duct into the throttle body.
Intake Air Distribution and Filtering
The air intake system consists of the following
components:
air cleaner
air cleaner element
mass air flow (MAF) sensor
air cleaner outlet tube
inlet tube
resonator V8
The Intake Air System
filters intake air with a replaceable air cleaner
element.
measures intake Air Temperature and manifold
absolute pressure.
I6
V8
G93831 en 01/2003 2003.0 BA Falcon

Intake Air Distribution and Filtering

For diagnosis and testing of the intake Air
temperature and Manifold absolute pressure sensor,
G93832 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Cleaning and Inspection

Air Cleaner Element
The PET plastic fibre filter element must not be
cleaned with a solvent or cleaning solution. Also, oil
must not be added to the surfaces of the filter element
or air cleaner body. The element should be cleaned
by tapping it lightly on a horizontal surface or using
compressed air. Direct a stream of compressed air
through the element in the opposite direction to intake
air flow, that is, from the inside outward. Extreme care
must be exercised to prevent rupture of the element
material.
Inspection
Hold the filter in front of a light and carefully inspect it
for any splits or cracks. If the filter is split or cracked,
replace it.
Body and Cover
Clean the air cleaner body and the cover with a
solvent or compressed air. Wipe the air cleaner dry if
a solvent is used. Inspect the air cleaner body and
cover for distortion or damage at the gasket mating
surfaces. Replace the cover or body if they are
damaged beyond repair.
G93833 en 01/2003 2003.0 BA Falcon

Air Cleaner Body — I6 Engine

Removal
1. Remove the retaining screws from the front sheet
metal crossmember. Detach the air intake tube
from the front crossmember and air cleaner body.
2. Back off the air cleaner lid to flexible air duct tube
worm drive clamp until loose on its collar.
3. Remove the three air cleaner mounting screws
and remove the air cleaner assembly.
Installation
1. Position the air cleaner assembly to the fender
inner panel and install the three mounting screws.
2. Slide the flexible air duct forward into the air
cleaner lid and tighten the air cleaner lid worm
drive clamp.
3. Attach the air intake tube to the lower air cleaner
body, position on front sheet metal and install
retaining screws.
Air Cleaner Element — I6 and V8

Engines
Removal
1. Release the spring clips and lift the air cleaner
cover away.
2. Remove the air filter element.
Installation
1. Install the air cleaner element into the air cleaner
body.
2. Install the cover and air duct assembly. Secure
the cover retaining clips (ensuring tights seal of
mating surfaces).
Engine Air Ducting — I6 and V8

Engines
Removal
1. Back off the air cleaner lid worm drive clamp until
loose on its collar.
2. Remove screws from plastic air duct above
engine intake manifold.
3. Slide air duct rearwards out of air cleaner.
4. Slide air duct off throttle body and remove from
engine bay.
Installation
1. Position duct assembly in engine bay.
2. Position duct and rubber collar onto throttle body.
3. Slide the duct forward into the air cleaner lid.
4. Install duct to inlet manifold screws.
5. Tighten the air cleaner lid worm drive clamp.
G93839 en 01/2003 2003.0 BA Falcon

303-14-1 Powertrain Control Management 303-14-1
SECTION : 303-14 Powertrain Control Management

CONTENTS PAGE
General Information ...............................................................................................................303-14-4
Precautions ..........................................................................................................................303-14-4
Special Notes .......................................................................................................................303-14-4
PCM Systems ........................................................................................................................303-14-8
System Overview .................................................................................................................303-14-8
Control Systems .....................................................................................................................303-14-8
Fuel System .........................................................................................................................303-14-8
Fuel tank ..............................................................................................................................303-14-8
Fuel pump ............................................................................................................................303-14-8
Fuel Supply and Return Lines .............................................................................................303-14-9
Fuel Filters ...........................................................................................................................303-14-9
Fuel Rail ...............................................................................................................................303-14-9
Fuel Injector .........................................................................................................................303-14-9
Fuel Pressure Regulator ....................................................................................................303-14-10
Intake Air System ...............................................................................................................303-14-10
Air Mass Measurement System .........................................................................................303-14-10
Variable Camshaft Timing ..................................................................................................303-14-11
5.4L, 3 Valve V8 Engine ....................................................................................................303-14-11
Intake Manifold Charge Control (IMCC) (I6 only) ..............................................................303-14-12
Ignition System ...................................................................................................................303-14-12
Spark Advance Map ...........................................................................................................303-14-13
Engine Cooling System ......................................................................................................303-14-13
Evaporative Emission System ...........................................................................................303-14-13
Positive Crankcase Ventilation ..........................................................................................303-14-13
Catalyst and Exhaust System ............................................................................................303-14-13
Air Conditioning System .....................................................................................................303-13-14
Traction Control ..................................................................................................................303-14-14
Automatic Transmission Control ........................................................................................303-14-14
Control Software ..................................................................................................................303-14-15
Powertrain Control Module Memory ..................................................................................303-14-15
Operating Strategies ..........................................................................................................303-14-15
Operating Modes ................................................................................................................303-14-16
Normal Mode ......................................................................................................................303-14-16
Crank Mode ........................................................................................................................303-14-17
Under-Speed Mode ............................................................................................................303-14-17
Open Loop .........................................................................................................................303-14-17
Closed Loop .......................................................................................................................303-14-17
Powertrain Control Hardware ...............................................................................................303-14-18
Powertrain Control Module ................................................................................................303-14-18
Module Programming .........................................................................................................303-14-18
General Procedures .............................................................................................................303-14-19
General Procedures ..........................................................................................................303-14-19
Power and Ground Signals ................................................................................................303-14-19
Inputs ...................................................................................................................................303-14-20
Crankshaft Position Sensor (CKP) .....................................................................................303-14-20
Temperature and Manifold Absolute Pressure Sensor ......................................................303-14-21
Trimming Sensors ................................................................................................................303-14-23
Camshaft Position Sensor .................................................................................................303-14-23
01/2003 2003.0 BA Falcon

(Continued)
Cylinder Head Temperature Sensor ..................................................................................303-14-24

Engine Oil Temperature Sensor ........................................................................................303-14-25
Engine Oil Pressure Sensor ...............................................................................................303-14-26
Boost Pressure Sensor, I6 Turbo Engine ..........................................................................303-14-26
TAS ......................................................................................................................................303-14-27
Failure Mode ......................................................................................................................303-14-27
Feedback Inputs ..................................................................................................................303-14-27
Heated Exhaust Gas Oxygen Sensor ................................................................................303-14-27
Knock Sensor .....................................................................................................................303-14-30
Feed Forward Inputs ............................................................................................................303-14-30
Transmission Range Sensor (TRS-A1) .............................................................................303-14-30
Transmission Range Sensor (TRS-A2) .............................................................................303-14-31
Power Steering Pressure Switch .......................................................................................303-14-32
Vehicle Speed ....................................................................................................................303-14-33
Electronic Throttle Control Inputs .........................................................................................303-14-34
Pedal Position Sensor ........................................................................................................303-14-34
Throttle Position Sensor .....................................................................................................303-14-35
Clutch Engagement Switch, Manual Transmission ............................................................303-14-36
Brake Switches ..................................................................................................................303-14-36
Reverse Gear Switch .........................................................................................................303-14-37
Speed Control Range Switch Assembly ............................................................................303-14-37
Air Conditioner Inputs ..........................................................................................................303-14-38
Air Conditioner Demand .....................................................................................................303-14-38
Air Conditioner Relay .........................................................................................................303-14-38
Air Conditioner Pressure Transducer .................................................................................303-14-39
Transmission Inputs .............................................................................................................303-14-39
Transmission Fluid Temperature Sensor ...........................................................................303-14-39
Output Actuators ..................................................................................................................303-14-40
Fuel Pump ..........................................................................................................................303-14-40
Fuel Injectors 1-8 ...............................................................................................................303-14-41
Ignition Coils .......................................................................................................................303-14-43
Actuators ..............................................................................................................................303-14-44
Intake Manifold Charge Control .........................................................................................303-14-44
Electro Drive Fans .............................................................................................................303-14-45
Variable Camshaft Timing ..................................................................................................303-14-46
Electronic Throttle Body .....................................................................................................303-14-54
Evap Canister Purge Solenoid ...........................................................................................303-14-55
Turbocharger Westgate Control .........................................................................................303-14-55
Transmission Outputs ..........................................................................................................303-14-56
Shift Solenoid 1 ..................................................................................................................303-14-56
Shift Solenoid 2 ..................................................................................................................303-14-57
Shift Solenoid 3 ..................................................................................................................303-14-57
Shift Solenoid 4 ..................................................................................................................303-14-57
Variable Pressure Solenoid 5 ............................................................................................303-14-58
Power Control Solenoid 6 ..................................................................................................303-14-58
Lock up Solenoid 7 ............................................................................................................303-14-59
LPG Fuel System Outputs ...................................................................................................303-14-59
LPG Prime Solenoid PRIME ..............................................................................................303-14-59
Gas Cut-out Solenoid GCO ...............................................................................................303-14-60
LPG Stepper Motor A-D .....................................................................................................303-14-60
Control Area Network (CAN) ..............................................................................................303-14-61
Smartshield Security ..........................................................................................................303-14-63
Diagnosis .............................................................................................................................303-14-65
Diagnosis ..........................................................................................................................303-14-65
01/2003 2003.0 BA Falcon

(Continued)

Powertrain Control Management .........................................................................................303-14-71
Powertrain Control Management .......................................................................................303-14-71
GENERAL PROCEDURES
Powertrain Control Module ................................................................................................303-14-101
VCT Solenoid Valve ..........................................................................................................303-14-101
Crankshaft Position (CKP) Sensor (I6 Engine) ..................................................................303-14-103
Crankshaft Position (CKP) Sensor (V8 Engine) ................................................................303-14-103
Camshaft Position Sensor (I6 Engine) ...............................................................................303-14-103
Camshaft Position Sensor (V8 Engine) .............................................................................303-14-103
Knock Sensor (I6 Engine) ..................................................................................................303-14-103
Cylinder Head Temperature (CHT) Sensor (I6 Engine) .....................................................303-14-104
Cylinder Head Temperature (CHT) Sensor (V8 Engine) ...................................................303-14-104
Throttle Position (TP) Sensor (I6, LPG & Turbo Engines) .................................................303-14-104
Throttle Position (TP) Sensor (V8 Engine) ........................................................................303-14-105
Powertrain Control Module (PCM) (I6 Engine) ..................................................................303-14-105
HEGO Sensor (I6 & V8 Engines) .......................................................................................303-14-106
HEGO Sensor (Turbo) .......................................................................................................303-14-107
Boost Pressure Sensor (Turbo Engine) .............................................................................303-14-107
Turbocharger Wastegate Control Solenoid ........................................................................303-14-107
Reverse Gear Switch .........................................................................................................303-14-107
Temperature and Manifold Absolute Pressure (T-MAP) Sensor .......................................303-14-108
Fuel Rail (I6 Engine) ..........................................................................................................303-14-108
Fuel Rail (V8 Engine) .........................................................................................................303-14-108
Brake Switches .................................................................................................................303-14-109
Clutch Engagement Switch, (Manual Transmission) ........................................................303-14-109
Pedal Position Sensor ........................................................................................................303-14-109
Air Conditioning Relay .......................................................................................................303-14-110
Air Conditioner Pressure Transducer .................................................................................303-14-110
Transmission Fluid Temperature Sensor ..........................................................................303-14-110
Fuel Pump .........................................................................................................................303-14-110
Transmission Range Sensor (TRSA1) .............................................................................303-14-110
Transmission Range Sensor (TRSA2) .............................................................................303-14-110
Phaser removal .................................................................................................................303-14-110
OCV removal ....................................................................................................................303-14-110
CID sensor removal ..........................................................................................................303-14-110
VCT oil filter removal ..........................................................................................................303-14-110
EVAP Canister Purge Solenoid .........................................................................................303-14-110
Power Steering Pressure Switch .......................................................................................303-14-110
01/2003 2003.0 BA Falcon

General Information
This section describes the operation and components
of the Powertrain Control Module (PCM). The system
is designed to provide optimal performance and
emission control. Modifying the system or substituting
non-Ford components may have an adverse effect on
drivability and emissions. Diagnosis of the system
requires special tools and training. Maintenance of the
PCM system should be performed by Ford trained
technicians.
Precautions
The fuel supply lines retain pressure that must be
relieved before servicing the fuel system. Leaking fuel
poses a potential fire hazard.
The spark ignition system produces high voltages.
Use care to avoid personal injury.
When the ignition is ON, the electric engine cooling
fans can start at any time. Keep clear of the fans to
avoid entanglement and personal injury.
With the engine running, there are rotating
components within the engine compartment. Use
extreme care to avoid entanglement and personal
injury.
Some components in the engine compartment are
HOT.
The cooling system contains hot liquid under
pressure. Allow the engine to cool to ambient
temperature before removing the cooling system cap.
Do not reconnect a PCM to the vehicles wiring
harness with the ignition turned ON.
Special Notes
With this issue of the Falcon Workshop Manual,
some terminologies in this section for PCM
components now reflect Ford’s Global Naming
Conventions. The full title of the component is
spelt out in full the first time it is mentioned in a
section. The acronym for the component is shown
in brackets and, where applicable, the previous
acronym is shown in Chevrons. Elsewhere in the
section, only the acronym is used.
Information in this section regarding the Traction
Control System is only applicable where fitted.
Information in this section regarding LPG applies
only to Ford Factory fitted LPG systems.
Installation of after-market LPG systems may
operate differently from that described here.
Information in this section regarding Air
Conditioning and Automatic Climate Control Air
Conditioning is only applicable where fitted.
G98119 en 01/2003 2003.0 BA Falcon

PCM Control Components, I6 Engine
G98119 en 01/2003 2003.0 BA Falcon

Item Description
1 Transmission Range Sensor (TR)
2 Vehicle Speed Sensor (VSS) (where fitted)
3 Cylinder Head Temperature (CHT)
4 Camshaft Position Sensors (CMP)
5 Reverse Gear Switch (RGS)
6 Throttle Body
7 Throttle Position Sensor (TP)
8 Powertrain Control Module (PCM)
9 Evaporator Canister Purge Solenoid
(EVAP)
10 Temperature and Manifold Absolute
Pressure (T-MAP) Sensor
11 Air Conditioner Refrigerant Pressure
12 Intake Manifold Runner Control (IMCC)
13 Fuel Injector (INJ1-6)
14 Knock Sensor (KS)
15 Crankshaft Position Sensor (CKP)
16 Oil Pressure Switch and Engine Oil
Temperature
17 Variable Cam Timing (VCT) Solenoid
18 Power Steering Pressure Switch (PSP)
19 Heated Exhaust Gas Oxygen Sensor
(HEGO)
20 Power Distribution Box, PCM Relay, Fuel
21 Coil On Plug (1-6)
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PCM Control Components, V8 Engine
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Item Description A sophisticated diagnostics system monitors the PCM

and the interfacing components, compensating for
1 Transmission Range Sensor (TR)
faults and wear during operation. The diagnostics are
<PRNDL>
accessed using the WDS tester.
2 Vehicle Speed Sensor (VSS) (where fitted)
3 Cylinder Head Temperature (CHT) Control Systems
4 Reverse Gear Switch (RGS) Fuel System
5 Throttle Position
The fuel system supplies the fuel injectors with filtered
6 Throttle Body Sensor (TP)
fuel at a controlled pressure. The Powertrain Control
7 Temperature and Manifold Absolute Module (PCM) controls the fuel pump and the on/off
Pressure T-MAP duration (pulse width) and timing of the fuel injectors.
8 Powertrain Control Module (PCM)
Fuel Injection
9 Evaporator Canister Purge Solenoid
(EVAP) The PCM electronic fuel injection system supplies the
10 Heated Exhaust Gas Oxygen Sensors correct amount of fuel to the engine as required for
the operating conditions. Each cylinder has an
(HEGO1-2)
individual fuel injector controlled sequentially to inject
11 Oil Pressure Switch the fuel at the optimum point in the engine cycle. The
12 Fuel Injector (INJ1-8) Powertrain Control Module (PCM) adjusts the fuel
13 Camshaft Position Sensor (CMP) injection pulse width, delivering a precise quantity of
fuel into the intake ports. Fuel is injected into the
14 Crankshaft Position Sensor (CKP) cylinders in the same sequence as the ignition firing
15 Engine Oil Temperature Sensor order. As the fuel is injected into a close port, the
16 Air Conditioner Refrigerant Pressure period that each charge remains in the port is even for
17 Power Distribution Box, PCM Relay, Start all cylinders, ensuring optimum mixture throughout the
Enable Relay, Fuel Pump Relay engine.
18 Coil On Plug (1-8) Fuel System Components
The fuel system consists of the following components.
PCM Systems
Fuel Tank
System Overview Fuel Pump
The Powertrain Control Module (PCM) manages the Fuel Supply and Return Lines
powertrain, providing optimal performance, maximum Fuel Filter
fuel economy and minimal exhaust emissions. Fuel Rail
The PCM system manages the following: Fuel Injector
Fuel Injection Fuel Pressure Regulator
Ignition
Fuel tank
Throttle
Variable Camshaft Timing The fuel tank is located at the rear of the vehicle and
contains a store of fuel to operate the engine. The fuel
Automatic Transmission Gear Shift
tank is described in more detail in Section 310-00,
Fuel Pump Fuel System - General Information.
Air-Conditioning
Fuel pump
Evaporative Emissions
Vehicle Immobilisation The fuel pump assembly is mounted inside the fuel
tank within a reservoir. The reservoir maintains a pool
Engine Cooling of fuel at the pick-up point and prevents fuel
Powertrain Electric’s Diagnostics starvation during hard acceleration, braking and
Turbocharger (where fitted) cornering. To enhance engine start-up, the fuel pump
LPG (where fitted) has a discharge check valve that maintains pressure
in the fuel lines after the ignition has been turned
At each engine revolution the PCM monitors driving OFF.
conditions through signals and switches situated on
the powertrain. Optimal air, fuel, ignition and camshaft When the ignition switch is in the ON position, the
PCM power relay is energised. The PCM ignition
settings for the current driving conditions are then
power relay provides power to the PCM and the fuel
calculated by the PCM using algorithms and look up
tables stored in memory. pump relay. The fuel pump relay is then energised by
the PCM under certain conditions.
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The PCM monitors the Crankshaft Position Sensor within a special fitting on the fuel rail pipe. An o-ring
(CKP) signal to determine engine speed. Once the on the fuel injector prevents leakage around the joint.
engine is running the PCM will keep the fuel pump On I6 engines the injectors are secured and oriented
relay energized until the engine stops. If the engine with a clip.
does not start after two seconds, the PCM disengages
the fuel pump relay.
Fuel Supply and Return Lines
Fuel is routed to the fuel rail from the fuel tank along
the supply pipe. Excess fuel from the fuel pressure
regulator is returned to the fuel tank through the
return line. The fuel lines are described in more detail
in Section 310-00, Fuel System - General Information.
Fuel Filters
To prevent the fuel injectors becoming clogged or
contaminated with foreign material, the fuel system
contains four levels of filtering:
Fuel Pump: A filter screen is mounted on the
intake side of the fuel pump. The filter is part of Item Description
the assembly and cannot be replaced separately. 1 Fuel Injector
Fuel Filter Assembly: The fuel filter assembly is 2 Injector Seat
located in the fuel supply line between the fuel
pump and the fuel rail. The fuel filter assembly 3 Clip
must be periodically replaced according to the
maintenance schedule. Fuel Injector
Fuel Pressure Regulator: A filter is located on the
inlet side of the fuel pressure regulator. The filter CAUTION: The fuel injectors pulse open
is part of the assembly and cannot be replaced momentarily using a signal from the PCM.
separately. Applying battery voltage directly to the fuel
injector’s electrical connector terminals will
Fuel Injectors: A mesh screen on the inlet side of damage the internal solenoid.
the fuel injector prevents foreign debris and
materials from entering the fuel injector The fuel injector is a solenoid-operated valve that
mechanism. The filter is part of the assembly and meters fuel flow to the engine. The injector is opened
cannot be replaced separately. and closed a constant number of times per crankshaft
revolution by the Powertrain Control Module (PCM).
Fuel Rail The length of time the injector is held open and the
fuel rail pressure controls the amount of fuel admitted
Fuel from the supply line is conveyed to the fuel to the engine. The fuel injectors are described in more
injectors through the fuel rail and excess fuel is detail under Components in this section.
returned to the fuel tank via the fuel pressure
regulator and return line. Each fuel injector seats
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Fuel Injector Fuel Pressure Regulator

The fuel pressure regulator is attached to the outlet
side of the fuel rail and controls the pressure within
the fuel rail. Fuel is delivered to each injector at the
same pressure to ensure the volume of fuel injected is
equal for each cylinder.
The regulator is a diaphragm-operated relief valve.
One side of the diaphragm senses fuel pressure, and
the other side is connected to the intake manifold
vacuum. Fuel pressure is established by a spring
pre-loading applied to the diaphragm. Balancing one
side of the diaphragm with manifold vacuum
maintains a constant pressure across the fuel
injectors. Excess fuel is bypassed through the
regulator and returned to the fuel tank. Fuel pressure
is high when engine vacuum is low.
Intake Air System
The intake air system provides clean air to the engine,
optimises airflow and is designed to minimise
induction noise. The intake air system consists of:
Air Cleaner Assembly
Inlet Ducting
Electronic Throttle Body
Inlet Manifold
Air Cleaner Assembly
The air cleaner assembly is an essential component
of the intake air system. The air cleaner assembly
houses a disposable air filter element that removes
Item Description dust from the intake air. The air cleaner element must
1 O-ring be periodically replaced according to the maintenance
schedule.
2 Filter
3 Adjusting Sleeve Air Mass Measurement System
4 Weld The I6 and V8 engines use the “speed density” fuel
5 Shells (2 of) injection system. In this system, the PCM has stored
6 Weld in its memory the theoretical mass of intake air that
will be drawn into the engine at any given speed of
7 Weld
operation. Using the engine speed sensor (Crankshaft
8 Support Ring Position CKP) signal, the Intake Air Temperature and
9 O-ring Manifold Absolute Pressure sensor (T-MAP), the PCM
10 Seat & Spray Plate Assy. can compute the intake air mass, and from it the fuel
required to be injected into the engine for combustion.
11 Tube Assy. This amount of fuel injected is further corrected by
12 Needle, Ball & Armature Assy. feedback information obtained from the Heated
13 Spring Oxygen Sensor (HEGO) sensor, providing close loop
control of fuel injection. A further feature of this
14 Coil & Bobbin Assy.
system is the ability to ‘re-calibrate’ itself for changes
15 Plastic Body in fuel requirements as the engine wears and the
sensors age. This is known as adaptive strategy or
learning and is an additional function derived from
HEGO sensor information.
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two ports in the Phaser, one port will retard the cam
timing (‘Retard port’) and the other will advance the
timing (‘Advance port’). An Oil Control Valve (OCV),
one for each camshaft, is used to control the flow of
oil into the retard and advance ports of both cams.
The OCV is controlled by the PCM.
The PCM uses a pulse width modulated (PWM)
voltage or ‘Duty Cycle’ (DC) to control each OCV to
attain the desired camshaft angle. VCT1 output
controls the inlet camshaft OCV. VCT2 controls the
exhaust camshaft OCV.
A 3 + 1 tooth wheel on the front of each camshaft with
an associated sensor mounted on the intake and
exhaust sides of the cylinder head are used to
calculate the ‘Actual cam angle’ for both camshafts.
Intake Air Ducting The two sensors are called, intake cam position or
‘CID1’ and exhaust cam position or ‘CID2’. Intake and
The intake air ducting connects the air filter assembly exhaust cam positions are calculated separately.
to the throttle body. The ducts prevent entry of foreign
material to the air intake system after the air filter. The The PCM uses engine rpm, throttle position and
design minimises restriction and is tuned to reduce engine load to determine the optimum camshaft
intake noise. timing setting or ‘Desired Cam Angle’ for both
camshafts.
Electronic Throttle Control Once the PCM has determined the Desired Cam
The Electronic Throttle Body (ETB) controls the Angle, it will control the Duty Cycle output VCT1 and
amount of air admitted to the engine by restricting the VCT2, to the intake and exhaust OCVs based on the
air intake with a throttle plate. difference between the Desired Cam Angle and the
Actual Cam Angle. This difference is called the Cam
The accelerator pedal position sensor (APPS) senses
Angle Error. The Cam Angle Error for each cam is
the driver’s acceleration request to the PCM. The
calculated individually and used to control both
PCM processes this information into an output signal
camshafts independently to a single Desired Cam
for the ETB. The electric motor in the ETB moves the
Angle.
throttle plate through a gear set. The throttle plate is
adjusted and monitored by the PCM in a closed An engine oil temperature sensor, which measures oil
control loop. The TP sensor provides the PCM with temperature in the oil gallery, is used to compensate
feedback on the actual position of the throttle plate. for Phaser response with changing oil viscosity at
different temperatures.
The electronic throttle body and the Positive
Crankcase Ventilation (PCV) provides airflow during 5.4L, 3 Valve V8 Engine
idle. The PCM trims the throttle continuously to
maintain the proper idle speed under all conditions The 5.4, 3V, V8 Engine is fitted with variable inlet and
from cold start to normal operating temperatures. It exhaust camshaft timing on each cylinder head bank.
also compensates for additional loads such as The camshaft on each bank is variable over a
air-conditioning and power steering. The idle speed is 60-degree crank angle using two separate hydraulic
not manually adjustable. ‘Phasers’, which are integral with the Bank1 and
Bank2 camshaft drive sprockets.
Inlet Manifold The camshaft timing is controlled by directing oil
The inlet manifold is an aluminium casting, which under pressure (from the engine oil pump) into one of
directs the intake air to the inlet ports on the cylinder two ports in the Phaser, one port will retard the cam
head. timing (‘Retard port’) and the other will advance the
Variable Camshaft Timing one for each camshaft, is used to control the flow of
oil into the retard and advance ports of both cams.
I6 Engine
The OCV is controlled by the PCM.
The I6 Engine is fitted with variable inlet and exhaust The PCM uses a pulse width modulated (PWM)
camshaft timing. Both camshafts are variable over a voltage or ‘Duty Cycle’ (DC) to control each OCV to
60-degree crank angle. This is achieved by two attain the desired camshaft angle. VCT1 output
separate hydraulic mechanisms called ‘Phasers’, controls the inlet RH Bank OCV. VCT2 controls the
which are integral with the intake and exhaust LH Bank camshaft OCV.
camshaft drive sprockets.
A 4 + 1 tooth wheel on the front of each camshaft with
The camshaft timing is controlled by directing oil an associated sensor mounted on the intake and
under pressure (from the engine oil pump) into one of exhaust sides of the cylinder head are used to
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calculate the ‘Actual cam angle’ for both camshafts.

The two sensors, CID1 and CID2 measure the
camshaft angle on Bank 1 and Bank 2 respectively.
The PCM uses engine rpm, throttle position and
engine load to determine the optimum camshaft
timing setting or ‘Desired Cam Angle’ for both
camshafts.
Once the PCM has determined the Desired Cam
Angle, it will control the Duty Cycle output VCT1 and
VCT2, to the intake and exhaust OCVs based on the
difference between the Desired Cam Angle and the
Actual Cam Angle. This difference is called the Cam
camshafts independently to a single Desired Cam
Angle.
An engine oil temperature sensor in the engine sump
is used to compensate for Phaser response with
changing oil viscosity at different temperatures.
Intake Manifold Charge Control (IMCC) (I6
only)
To improve engine torque over the entire engine
operating range, the I6 engine has an Intake Manifold
Charge Control (IMCC) system, which contains two
air runners for each cylinder. A butterfly valve situated
in the intake runner for each cylinder controls the
effective length of the intake path. The Powertrain
Control Module (PCM) controls operation of the IMCC
system.
At low engine speeds a long intake path improves In normal operation, below approximately 3,800 RPM,
volumetric efficiency, while at higher engine speeds a the butterfly valves are closed, causing the intake air
short intake path provides better efficiency. Changing to follow the longer path into the engine. At higher
the effective length of the intake air path improves engine speeds, above approximately 3,800 RPM, the
drivability and engine power throughout the engines butterfly valves open allowing the intake air to follow a
operating range. The lengths of the runners are shorter path into the engine. A vacuum actuator
designed to suit the Ram Air Effect of the I6 engine. operates the butterfly valves. The Powertrain Control
Module (PCM) controls vacuum to the actuator via a
solenoid valve.
NOTE: On I6 Turbo engines, there are no butterfly
valves.
Ignition System
The ignition Coil-On-Plug (COP) assembly consists of
a coil mounted on top of a spark plug. For each of the
engine’s cylinders, there is a corresponding COP
assembly.
Individual low side coil drives in the PCM control the
COP’s that ignites the air-fuel mixture within the
cylinders. The COP’s provide a controlled high
voltage spark to each spark plug at the correct time
under all engine operating conditions.
The ignition system comprises:
Individual coil drives: one per cylinder
Spark Plugs
Crankshaft Position Sensor (CKP) input
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Camshaft Position Sensors (Cylinder The powertrain control module (PCM) controls the
Identification) (CID1 & 2) Evaporative (EVAP) Canister Purge solenoid. The
solenoid controls the flow of vapours from the carbon
Spark Advance Map canister to the intake manifold for combustion during
The Powertrain Control Module (PCM) memory various engine operating modes. The EVAP canister
contains a complex spark advance map to ensure purge solenoid is a normally closed valve.
optimum ignition timing under all conditions. The ideal Canister purge occurs at all engine operating
advance is applied ensuring the best possible conditions including idle and after engine warm-up.
performance, economy and minimal emissions. The solenoid valve purges continuously until the EGO
sensor detects no more fuel vapours. The solenoid
Spark Plugs valve then shuts down for a two minute period before
Spark plugs are described in Section 303-07. starting the purge cycle again.
Engine Cooling System Positive Crankcase Ventilation

The engine cooling system is described in Section The Positive Crankcase Ventilation (PCV) system
303-03A. The Powertrain Control Module (PCM) cycles crankcase gases back through the engine
controls operation of the Electro Drive Fans 1-2 where they are burned during the combustion
(EDF1-2). The PCM operates both fans at low or high process. The PCV valve regulates the amount of
speeds through relays depending on engine ventilating air entering the intake air system and
temperature load and A/C System pressure. The PCM prevents any backfire from reaching the crankcase.
uses the Cylinder Head Temperature Sensor (CHT)
and Air Conditioner Refrigerant Pressure Transducer
Catalyst and Exhaust System
(ACPT), Vehicle Speed and Air Conditioner Control The exhaust system carries engine emissions from
Relay, B2 (ACR) signals to calculate the cooling the engine through the exhaust manifold, engine pipe,
requirements, then switches the fan relays and catalytic converter to the atmosphere. The
accordingly. exhaust system is described in Section 309-00. A
The PCM transmits CHT information to the instrument Heated Exhaust Gas Oxygen Sensor (HEGO) is
cluster temperature gauge and the Climate Control air mounted before the catalytic converter. The catalytic
conditioning on the CAN line. converter reduces the concentration of carbon
monoxide, unburned hydrocarbons and oxides of
Engine Cooling Strategy (excludes LPG) nitrogen in the exhaust emissions to an minimum
The I6 and V8 engine cooling strategy ensures the level.
continued operation of the engine in the event of Heated Oxygen Sensors
coolant loss or extremely high temperatures. If the
engine temperature exceeds approximately 120 The Heated Exhaust Gas Oxygen Sensor (HEGO)
degrees, to maintain a safe engine operating provides the Powertrain Control Module (PCM) with a
temperature, the fuel injectors are sequentially shut voltage level that relates to the oxygen content of the
off to allow each cylinder to be cooled by the intake exhaust gas.
air. The engine may run rough when operating in
overheat management strategy mode. The jewel in
the cluster will light when the PCM senses that the
engine has exceeded a safe operating temperature.
The jewel will flash when fail-safe cooling strategy no
longer can keep the engine running. Shortly
afterwards, the engine will shutdown.
Evaporative Emission System
The Evaporative Emission System prevents fuel
vapours from the fuel tank being vented to the
atmosphere. Fuel vapours from the fuel tank are
collected in a carbon canister while the engine is not
running. The vapours remain trapped within the
canister until it is purged to the inlet manifold, where
the vapours are burnt as part of the normal Item Description
combustion process.
1 Fuel Injector
The Powertrain Control Module (PCM) monitors
several system inputs to determine when purging the 2 HEGO Sensor
vapours will have minimum impact on engine
operation.
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Catalytic Converter from the ASR on the CAN line, it reduces engine
torque by retarding ignition timing, inhibiting injector
A catalyst is a material that initiates and increases a operation, closing the throttle plate and leaning the
chemical reaction without itself being consumed. The air-fuel ratio.
catalytic converter minimises the concentration of
toxic gases released to the atmosphere from the The system continues to monitor for wheel slip. When
exhaust system. It contains a catalyst in the form of a traction is restored, engine torque can be returned to
specially treated honeycomb structure saturated with normal levels.
catalytically active precious metals. As the exhaust Automatic Transmission Control
gases come in contact with the catalyst, they are
changed into mostly harmless products. The catalyst The Powertrain Control Module (PCM) controls the
initiates and speeds up heat producing chemical automatic transmission gear shift. The PCM
reactions of the exhaust gas components so they are calculates the shift points and controls the
used up as much as possible. The catalytic reaction transmission according to driving conditions, engine
only occurs when the air fuel/ratio is near the load and throttle demand. The PCM controls or
stoichiometry point. monitors the following automatic transmission
functions:
Air Conditioning System Transmission Range Sensor (TR) <PRNDL>
The PCM controls the air conditioning compressor Transmission Fluid Temperature Sensor (TFT)
clutch relay on and off in response to the AC Clutch <TOT>
request sent on the CAN by the Climate Control HIM Shift Solenoid 1 (SS1) <GSS1>
Module. The Climate Control HIM Module determines
the operational state of the AC compressor needed to Shift Solenoid 2 (SS2) <GSS2>
maintain a desired evaporator air temperature based Shift Solenoid 3 (SS3) <MCS1>
on the comfort temperature selected by the driver and Shift Solenoid 4 (SS4) <MCS2>
passenger.
Variable Pressure Solenoid 5 (VPS)
When the compressor is commanded to turn on, the
PCM utilizes and Air Conditioner Refrigerant Pressure Power Control Solenoid 6 (PCS)
Transducer (ACPT) input (B15), and the Air Lock Up Solenoid 7 (LUS)
conditioning Evaporator Air Temperature (AEAT) data Operation, maintenance and the control strategy for
on the CAN to monitor the Air Conditioner system the transmission are described in Section 307-01,
performance. Automatic Transmission.
In the event of overheating or a low refrigerant charge Electronic Sport Shift
condition, the Powertrain Control Module (PCM) shuts
down the air conditioning compressor to prevent The electronic sports shift feature allows driver control
damage. of the automatic transmission.
A malfunction of the air conditioning system is The TRS-A1 <PRNDL> sensor on the side of the
detected by the failure of an individual sensor or by a transmission housing senses the sport-shift selection
combination of factors calculated from the combined of “P”, “R”, “N” and “D” position. The resistance of the
outputs of ACPT and AEAT being out of range over a sensor changes for each position and is measured by
period of time. The failure mode can be accessed the PCM as a voltage on the TRS-A1 input.
through the diagnostic connector using the WDS The sport shift manual, tip-up and tip-down position is
tester. sensed by the TRS-A2 sensor, a printed circuit board
Traction Control with 3 Hall-effect switches in the T-bar console. The
sport shift lever contains a magnet in its base that
On vehicles fitted with the Traction Control System, activates the appropriate Hall-effect switch in different
the Traction Control (ASR) module works with the shift position. The switches are resistively multiplexed
Powertrain Control Module (PCM) to minimise wheel together and are read as a voltage by the PCM on the
slippage. The ASR monitors the speed of each wheel TRS-A2 input.
using wheel sensors on each wheel. Wheel spin is
detected when one of the rear wheels is spinning or Column Shift Auto
accelerating faster than the front or opposite side Vehicles fitted with column shift automatics use the
wheel. When spin occurs, the ASR module works to same TRS-A1 <PRNDL> sensor on the side of the
stop wheel spin by, if necessary, momentarily transmission as the electronic sport shift. The column
applying the brake of the spinning wheel and signaling shift mechanism moves the sensor through an arc to
the Powertrain Control Module (PCM) to reduce allow selection of “P”, “R”, “N” and “D” as well as the
engine torque to a specific level. “3”, “2” and “1” gear positions.
When the PCM receives a torque reduction message
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Control Software a 14.64:1 air-fuel ratio during closed-loop operation.

The range of LONGFT is from -35%to +35%. The
Powertrain Control Module Memory ideal value is near 0% but variations of +20%are
acceptable. Information gathered at different engine
The Powertrain Control Module (PCM) uses flash speeds and loads is stored in the adaptive fuel tables
Electrically Erasable and Programmable Read Only for later use in fuel calculations.
Memory (EEPROM) to store the software code
SHRTFT and LONGFT work together. If the HEGO
required to control the powertrain. EEPROM can be indicates the engine is running rich the PCM will
electrically erased and reprogrammed without
correct the rich condition by moving SHRTFT in the
removing the PCM from the vehicle.
negative range (less fuel to correct for a rich
Operating Strategies combustion). If after a certain amount of time
SHRTFT is still compensating for a rich condition, the
Adaptive Idle Air Control Strategy PCM adapts, moving LONGFT into the negative
range to compensate and allows SHRTFT to return to
The adaptive idle air control strategy is designed to
a value near 0%.
adjust the idle calibration to correct for wear and
ageing of components. When engine conditions meet As the fuel control and air metering components age
the adaptive strategy-learning requirement, the and vary from nominal values, the adaptive fuel
strategy monitors the engine and determines the strategy learns corrections while in closed-loop fuel
values required for ideal idle calibration. The adaptive control. The corrections are stored in a table that is a
strategy stores these values within a table in memory function of engine speed and load. The tables reside
for later reference. This table is used by the PCM for in Keep Alive Memory (KAM) and are used to correct
correction factors when controlling idle speed. The fuel delivery during open and closed-loop operation.
adaptive idle table is stored in Keep Alive Memory As changing conditions continue the individual cells
(KAM) and retains the learned values even after the are allowed to update for that speed load point. If,
engine is turned OFF. A Diagnostic Trouble Code during the adaptive process, both SHRTFT and
(DTC) is output when the adaptive strategy has LONGFT reach their high or low limit and can no
reached its limits. longer compensate, a Diagnostic Trouble Code (DTC)
Whenever an idle air control system component is is reported.
renewed or cleaned, or a repair affecting idle is Whenever an injector or the fuel pressure regulator is
performed, the KAM should be reset to ensure the idle renewed, the Keep Alive Memory (KAM) should be
strategy does not use the previous adaptive values. reset to delete the existing adaptive values. The
Re-training the PCM is described in the ‘Resetting system will generate new values for the replaced
The Powertrain Control Module’ section. component. Refer to the ‘Resetting The Powertrain
Control Module’ section.
Adaptive Fuel Control Strategy
Failure Mode Effects Management
The fuel control system uses the adaptive fuel table to
compensate for normal variability of the fuel system Failure Mode Effects Management (FMEM) is a
components caused by wear or ageing. During Powertrain Control Module (PCM) strategy that
closed-loop operation, if the fuel system is biased lean maintains vehicle operation if one or more of the
or rich, the adaptive fuel table will shift the fuel major input sensors fail.
delivery calculations to remove the bias. The fuel When an input sensor is out of limits, an alternative
system monitor has two means of adapting; Short strategy is initiated by the PCM. A fixed value is
Term Fuel Trim (SHRTFT) and Long Term Fuel Trim substituted for the faulty one. The PCM then
(LONGFT). In both cases the range is displayed as a continues to monitor the incorrect sensor input. If the
percentage on the WDS tester. sensor later operates within limits, the PCM returns to
Short Term Fuel Trim (SHRTFT) is a parameter that the normal engine operation.
indicates short-term fuel adjustments. The Powertrain This mode allows the PCM to compensate for any of
Control Module (PCM) calculates the SHRTFT from the four major sensor or sensor circuit failures by
Heated Exhaust Gas Oxygen Sensor (HEGO) inputs either inferring sensor values from remaining
to maintain a 14.64:1 air-fuel ratio during closed-loop operational sensors or by using calibrated default
operation. A negative percentage means that the values.
HEGO is indicating a rich mixture and the PCM is T-MAP sensor failure
attempting to lean the mixture. Ideally, SHRTFT
should remain near 0% but has the ability to adjust TP sensor failure
from between -25%to +35%. ECT sensor failure
Long Term Fuel Trim (LONGFT) indicates long-term IAT sensor failure
fuel adjustments. LONGFT is also referred to as
adaptive fuel control. LONGFT is calculated by the
PCM using information from the SHRTFT to maintain
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Speed Limiting Strategy The road speed limit varies according to model. The
engine speed is limited to approximately 6,000 RPM
NOTE: In some cases, excessive engine or road (I6) and 5,300RPM (V8). On automatic transmission
speed may be caused by loss of traction due to wheel vehicles, selecting the T-bar in NEUTRAL, “N”
slippage on loose surfaces such as; sand, gravel, wet position limits the engine speed to approximately
roads, mud, snow or ice. 3,000 RPM. Engine and vehicle speed limiting is
Over-revving of the engine in park, neutral or while nominally controlled by reducing throttle opening to an
driving may also cause the PCM to initiate its speed appropriate level. Speed overshoots beyond these
limiting strategy. limits are controlled by momentarily disabling the fuel
To prevent damage to the powertrain components, injectors.
the Powertrain Control Module (PCM) reduces the Operating Modes
throttle and disables the fuel injectors whenever the
engine or road speed reaches specific limits. Once The mode used by the Powertrain Control Module
the speed is reduced to below the set limit, normal (PCM) to control the fuel injection and ignition
operation will resume. Diagnostic Trouble Code (DTC) systems depends on the operating conditions.
P1270 is reported if the engine or road speed exceed Operating modes are shown in the diagram below,
the limit. No repair is required. However, the DTC and are described in the following section.
should be cleared and the driver informed of the
engine and road speed limits applicable to the vehicle.
Normal Mode Engine Speed Limiting Strategy to prevent damage to

the powertrain.
In normal operating mode the PCM controls the
powertrain in all operating conditions. Normal mode Start-Up Mode
commences when the engine is started, either cold or In Start-Up Mode the PCM starts the engine and
hot, then continues throughout the entire range of
manages the engine until it reaches Run Mode. The
engine operation. Normal mode is made-up of two
Start-Up strategy manages the transition between
parts: Start-Up Mode and Run Mode. Each mode has cranking, start-up, cold running and normal engine
further sub-modes that control the powertrain under
operation. The PCM uses several phases to reach
specific conditions. If engine or vehicle speed
Run mode.
exceeds the specified limit, the PCM will initiate the
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Crank Mode During rapid throttle opening, the PCM will provide
acceleration enrichment by applying additional pulses
Crank Mode provides the engine with the correct to the injectors (increasing injection frequency).
parameters for rapid, “no touch” start-up. Crank mode
occurs when the ignition switch is moved to the Open Loop
START position and the engine speed is below 200
There are two basic modes of fuel injection control:
RPM. In Crank Mode the ignition timing is set to 10
…BTDC, and the injector pulse width is determined by Open Loop and Closed Loop. The PCM will operate in
Open Loop depending on the driver’s throttle
the signal from the Cylinder Head Temperature
demand, measured by the Throttle Position Sensor
Sensor (CHT).
(TP) <TPS> or when the Heated Exhaust Gas
Whilst cranking, all the injectors fire simultaneously on Oxygen Sensor (HEGO) sensor has not reached
the rising edge of every internal PIP signal. With each operating temperature.
opening, each injector supplies 1/6th (I6) or 1/8th (V8)
of the fuel required for one cycle. The PCM will operate the engine in Open Loop mode
during warm engine start-up, engine warm-up, part
Once engine speed reaches approximately 240 RPM, throttle mode and wide open throttle conditions.
the PCM will enter under-speed mode.
In Open Loop Mode, the PCM updates the adaptive
To assist in clearing a flooded condition, the PCM fuel strategy tables stored in memory. The adaptive
disables the fuel injectors if the throttle is held wide fuel strategy is described in the ‘Adaptive Fuel
open during Crank mode. Strategy’ section.
Under-Speed Mode Start-Up and Idle
Under-speed Mode assists the transition from Crank During Crank Mode and under-speed mode the
mode to Run mode and prevents stall. Under-speed engine operates in Open Loop mode. The PCM varies
mode occurs once the engine fires, indicated by an the air-fuel ratio (fuel mixture) to maintain the engine
engine speed of more than 200 RPM. Once the speed or assist in warm-up. During cold start and
engine fires, the PCM switches to sequential fuel warm-up the fuel mixture is enriched to promote easy
injection, using Crankshaft Position Sensor (CKP) and starting and smooth idle.
the Camshaft Position Sensors (Cylinder As the engine warms to normal operating
Identification) (CMP) <CID> to synchronise the fuel
temperature, the fuel injector pulse width is gradually
injection and ignition timing. The injector pulse width
reduced, bringing the mixture with the normal
is switched to use the values stored in the adaptive operating range. Once the engine is running at normal
fuel strategy tables and trimmed by input from various
operating temperature the PCM will switch to Closed
sensors. Ignition timing is held at 10…BTDC and the
Loop Mode once the engine has been idling for
Electronic Throttle Control (ETC) controlling the air approximately 60 seconds. The engine normally
intake to maintain idle speed.
operates in Closed Loop Mode when the throttle is
When operating in sequential injection mode, the closed.
PCM delivers the correct amount of fuel to the port
above each intake valve, once every 720… of engine Wide Open Throttle
revolution. The PCM will maintain Under-speed mode Wide Open Throttle (WOT) mode is used to enrich the
until the engine speed reaches or exceeds 400 RPM, mixture according to the driver’s throttle demand.
and until the engine reaches normal operating Wide Open Throttle is indicated when the Throttle
temperature, at which time the PCM will switch to Run Position Sensor (TP) <TPS> signal exceeds
mode. approximately 4 volts. Under these conditions, the
Run Mode Powertrain Control Module (PCM) enters Wide Open
Throttle mode, enriching the mixture to obtain
The Powertrain Control Module (PCM) switches from maximum performance. The EVAP Canister Purge
Under-speed to Run mode when engine speed is Solenoid (EVAP) <CANP>is turned OFF during WOT
greater than 400 RPM. Once the engine and Heated mode.
Exhaust Gas Oxygen Sensor HEGO) have reached
normal operating temperature, the PCM operates in Closed Loop
Run Mode and selects either Open or Closed Loop There are two basic modes of fuel injection control:
operation according to the throttle position and driving
Open Loop and Closed Loop. The PCM will operate in
conditions.
Closed Loop depending on the driver’s throttle
In addition to the control sequences for Under-speed demand, measured by the Throttle Position Sensor
mode, in Run mode the ignition timing is varied by the (TP) <TPS> and when the engine and the Heated
PCM to suit engine load and demand. The engine will Exhaust Gas Oxygen Sensor (HEGO) sensor has
operate in Open or Closed Loop mode according to reached operating temperature.
the signal from the Throttle Position Sensor (TP)
Closed Loop Mode controls exhaust emissions of
<TPS>.
hydrocarbon (HC), carbon monoxide (CO) and
G98122 en 01/2003 2003.0 BA Falcon

nitrogen oxide (NOX) gasses, while providing Module Programming

excellent fuel economy, optimal power and
performance. The system regulates emissions and Special Tool(s)
fuel economy by controlling the air-fuel ratio at the
optimum level during different driving conditions. Worldwide Diagnostic System
(WDS)
Within the closed loop system, deviations from the —
optimal air-fuel ratio are measured. The PCM
monitors the signal from the HEGO sensor, then
adjusts fuel-air mixture to maintain the correct ratio.
The principle is based on measuring the residual
oxygen content in the exhaust with a HEGO sensor.
The oxygen content of the exhaust is a measure of Principles of Operation
the air-fuel ratio being provided to the engine. Where
PCM modules must be programmed as part of the
the air-fuel ratio deviates from the stoichiometric point
of 14.64:1, the sensor voltage output changes repair procedure. If this procedure is not followed the
sharply. The PCM evaluates the change and adjusts module will not function correctly and may set a
the injector pulse width to maintain the air fuel ratio number of DTCs, including P1639, which indicate that
within the stoichiometric point. In Closed Loop Mode, some necessary data has not been programmed into
the module.
the air-fuel ratio is kept at the optimum for all driving
conditions. PCMs should not be exchanged between vehicles. In
This precise control of the fuel-air ratio allows a most cases the parameter values or settings are
catalytic converter to be used in the exhaust system unique to that vehicle, and if not set correctly will
to burn-up the harmful particles and maintain the cause malfunctions or faults.
lowest exhaust emissions. WDS will automatically attempt to retrieve the module
After the HEGO has reached operating temperature, configuration information from all modules, and from a
the PCM selects Closed Loop Mode during closed backup location in the PCM when the vehicle ID is
throttle or part throttle operation. carried out. If the module and the PCM do not contain
correct information the diagnostic tool will display a list
Closed Throttle Mode of items that you will need to manually configure. The
diagnostic tool will program the module based on the
Closed Throttle Mode occurs whenever there is no
data you enter.
demand on the throttle. This occurs during idle,
coasting and deceleration. The PCM is able to detect There are three different methods that are used for
a closed throttle condition by monitoring the signal module programming:
from the Throttle Position Sensor (TP) <TPS>. programmable module installation (PMI)
The PCM controls idle speed, injector pulse width and module reprogramming
ignition timing in Closed Throttle Mode to maintain the programmable parameters
correct air-fuel ratio.
Some modules do not support all three methods.
Under periods of prolonged idle, the PCM will exit
closed loop mode and hold the mixture slightly richer Programmable Module Installation (PMI)
than the stoichiometric point to enhance idle quality.
The programmable module installation (PMI) method
During deceleration at engine speeds above is used when a new PCM module is installed on the
approximately 2,000 RPM, the injectors are shut off. vehicle. The diagnostic tool automatically obtains any
At engine speeds below 2,000 RPM, the fuel injectors available module option content information for the old
are re-enabled. PCM during the vehicle ID routine that runs when the
diagnostic tool is initially connected to the vehicle. It is
Powertrain Control Hardware important that you connect WDS to the vehicle and
allow it to identify the vehicle and obtain configuration
Powertrain Control Module data prior to removing the old PCM.
The centre of the PCM system is a microprocessor
controlled Powertrain Control Module (PCM).
Module Programming
Depending on model, the PCM has 92 or 122 Calibration update is used to install a new calibration
electrical connector pins through which it receives and strategy into a module. The updates are usually
input from sensors and other electronic components. issued to fix a concern in the module software and
Based on information received and programmed into would normally be addressed by another technical
its memory, the PCM generates output signals to service bulletin (TSB).
control the engine and transmission through various
relays, solenoids and actuators.
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Vehicle Identification (VID) Block Keep Alive Power (KAPWR) when the ignition key is
in the OFF position so that this information is not lost.
The PCMs contain a memory area called a vehicle KAPWR is routed through a fuse, situated in the
identification (VID) block. The VID block is used to instrument panel.
store powertrain configuration information.
The PCM VID block contains the factory settings for If the PCM power supply is interrupted then the PCM
the configurable modules unless the PCM is flashed may lose the "Keep Alive Memory" data. The KAM
with a new calibration in which case some PCM data retention time for the PCM depends on the
parameters may be modified. module temperature during the period without power
(e.g. battery disconnected).
General Procedures
Vehicle Reference Voltage
General Procedures Vehicle Reference Voltage (VREF) is a positive 5.0
Volt output from the PCM used by 3-wire sensors.
Tire Size and Axle Ratio
Signal Return
Using the WDS, select Module Configuration and
Programming, then follow the screen prompts. The Signal Return (SIGRTN) is a dedicated ground
circuit used by engine sensors.
Tire Size, Axle Ratio and Option Index
Feature Falcon Power Ground
Tire Size 215/60R16 Power Ground (PWRGND) is an electric ground
225/50R17 return for the Powertrain Control Module (PCM).
245/40R18 Power Supply
235/45R17 The PCM’s power relay voltage supply (VPWR) is
255/60R16 controlled by the PCM’s power sustain (PWRSTN)
215/55R16 output circuit. The PWRSTN output turns on
immediately when the ignition is “ON” and maintains
Axle Ratio 3.23 power to the PCM power relay for a further 1 second
3.45 after key-off. This key-off delay enables the PCM to
Speed Control Not Present position the ETC throttle plate close during engine
Present shut down.
Speed Source ABS Only Connections
Other PCM Pin B9….……………………………… IGNSNS
Traction Control PCM Pin B37….…………………………… PWRSTN
Power and Ground Signals PCM Pin B34, B36…………………………… VPWR
Failure Mode
Vehicle Power
TURN-ON If the PCM does not appear to turn on (no engine
crank and no PRNDL display when T-bar is moved),
When the ignition switch is turned to the START or ascertain that the PCM is being correctly powered up.
RUN positions, positive battery voltage (B+) is applied Failure in the IGNSNS and PWRSTN circuit or wiring
to the PCM’s IGNSNS input. The PCM’s PWRSTN circuit will result in no power to the PCM.
output grounds the VPWR relay. Since the other end
of the VPWR relay coil is wired to B+, this energises Testing
the coil and closes the contacts of the PCM power Refer to wiring diagrams 303-14-00/01 (I6) and
relay. This supplies VPWR to the PCM, turning it on. 303-14-00/02 (V8).
TURN-OFF 1. Ensure that the vehicle ignition system and the
When the ignition switch is turned to the OFF or ACC instrument cluster is working correctly by
positions, the PCM’s IGNSNS input reads 0V. The observing the warning lamps on the instrument
PCM turns off the injectors and commands the cluster at the ignition “RUN” position.
electronic throttle to the closed position. 2. Remove the PCM power relay.
Approximately 1 second later, the PWRSTN output
3. While the ignition is in the RUN position, measure
turns off and de-energises the PCM power relay. This
turns off VPWR to the PCM. the voltage of the 4 relay pin and ground. Ensure
that the contact pin 361A and the relay coil pin
Keep Alive Memory 513 measure 12V. Rectify wiring if required.
The PCM stores some information in Keep Alive
Memory (KAM). The KAM remains powered through
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4. Measure the voltage of the relay coil pin 175E to CKP Sensor, I6 Engine
the battery 12V. If this measures 12V, replace the
relay with a known good unit and ensure that the
relay clicks as it is inserted into the relay socket. If
12V is not measured, remove the PCM and probe
the IGNSNS pin for 12V (ensure key is in the
“RUN” position) and check the wiring continuity
between PWRSTN and the relay coil pin 175E.
Rectify wiring if required.
5. Reinstall the PCM power relay.
6. To confirm that the relay circuitry is operational,
ground the PWRSTN pin and ensure that 12 V is
present at the VPWR pins at the PCM.
7. Turn the key to the “OFF” position.
8. Plug the wiring harness to the PCM.
9. Start the vehicle. The CKP signal is produced by an Inductive Pulse
If the PCM is still non-functional, replace the PCM. Generator. Its main components are a reluctor
(toothed wheel on the harmonic balancer) and a
pick-up coil. When the engine rotates, the toothed
Inputs wheel passes the coil pick-up. The strength of the
magnetic field changes from strong to weak, and
Crankshaft Position Sensor (CKP) vice-versa, as the teeth rotate past the pick-up coil.
The Crankshaft Position (CKP) sensor is a magnetic The amplitude and frequency of the CKP signal is
transducer mounted on the front timing cover. A proportional to engine speed. As engine speed
reluctor (tooth wheel) is mounted on the front of the increases, so does the voltage amplitude.
crankshaft internal to the engine. The CKP is the
primary sensor for ignition timing information used by CKP Sensor, V8 Engine
the powertrain control module (PCM).
The reluctor, or trigger wheel, has a total of 35 teeth,
spaced 10 degrees apart with one empty space for a
missing tooth. By monitoring the trigger wheel, the
CKP indicates crankshaft position and speed
information to the PCM.
The PCM uses the CKP signal and the Camshaft
Position Sensor (Cylinder Identification) (CMP) <CID>
signal to determine the position of piston 1 within the
cycle. From this, the PCM calculates spark and fuel
injection timing.
The CKP signal converts the crankshaft position to an
electrical signal as shown below. The analogue AC
voltage CKP signal is converted to a digital PIP signal;
this signal is used internally by the Powertrain Control The reluctor has a missing tooth positioned before
Module (PCM), every rising edge signals that the cylinder No. 1 reaches TDC. The PCM keeps count of
crankshaft is 10° before TDC for a particular cylinder the teeth as they pass the pick-up, using the missing
s compression stroke. tooth as a reference point. The PCM can then
calculate the exact crankshaft position at any time. As
the crankshaft rotates twice between each combustion
stroke, he CKP uses a signal from the CMP sensor to
determine the position within the cycle. On I6 engines
the missing tooth is 60° BTDC, while on V8 engines it
is 90° BTDC.
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Crankshaft Position Sensor Failure Mode

The PCM will not be able to determine the current
engine speed or crankshaft position without the
correct signal from the CKP sensor. If the CKP sensor
fails, or an improper signal is received at the PCM,
fuel pump operation, spark and fuel injection are
suspended.
Testing
Sensor Test
1. Disconnect the harness from the CKP connector.
2. Measure the resistance across the connector
terminals using a suitable multimeter. Replace the
solenoid if not within specification.
Item Description CKP Resistance Specification
280 - 380 Ω
1 Sensor Housing
3. Check the harness for open circuits and short
2 Timing Cover circuits.
3 Soft Iron Core
Temperature and Manifold Absolute
4 Coil Winding
Pressure Sensor
5 Toothed Wheel
6 Permanent Magnet The I6 Temperature And Manifold Absolute Pressure
(T-MAP) sensor is located on the inlet manifold, below
The Coil On Plug (COP) Ignition System uses the the throttle body. The 5.4, 3V V8 T-MAP sensor is
CKP and CMP signals to generate a digital Profile located on the inlet manifold, adjacent to cylinder 8.
Ignition Pick-Up (PIP) signal. The PIP signal produces The 5.4L, 4V, V8 T-MAP sensor is located on the inlet
a rising edge when the crankshaft is at 10º BTDC of manifold, adjacent to throttle body.
any cylinder s compression stroke. The PCM uses the
PIP signal to calculate spark timing. The T-MAP sensor is a combined pressure and
temperature sensor that measures both intake air
Connections temperature and manifold absolute pressure. The
Powertrain Control Module (PCM) uses these signals
PCM Pin A30.................................... CKP Positive
for air mass calculations.
PCM Pin A41.................................... CKP Negative
The T-MAP sensor uses a Piezo resistive sensor and
Circuit outputs a voltage proportional to the manifold
absolute pressure. The voltage increases as manifold
vacuum falls.
A temperature-sensing element is incorporated into
the T-MAP senor to measure the temperature of the
intake air within the manifold. The temperature
element employs a thermistor that is sensitive to
temperature variations. The resistance of the
thermistor decreases as the temperature rises. The
sensor also measures barometric pressure when the
ignition is moving from the ON to the START positions
or whenever the throttle is wide open.
Connections
PCM Pin A38……................…...............MAP Signal
PCM Pin A25……................…...............IAT Signal
Diagnosis PCM Pin A36.....Vehicle Reference Voltage (VREF)
Diagnostic Trouble Codes (DTC) are retrieved through PCM Pin A32......................Signal Return (SIGRTN)
the diagnostic connector using the WDS tester.
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Circuit the operating range, or not present at all, the PCM will
substitute a value proportional to the Throttle Position
Sensor (TP) <TPS> signal and adaptive values stored
within its memory. The appropriate trouble code will
be logged in memory for retrieval during Self-test
mode.
Testing
The T-MAP sensor is tested continuously during
vehicle operation (cont.) and whenever Key On
Engine Off (KOEO) or Key On Engine Running
(KOER) tests are performed.
Testing Manifold Absolute Pressure
1. Connect a WDS tester to the diagnostic
connector.
Diagnosis 2. Check the Manifold Absolute Pressure Sensor
readout on the screen when the engine is at
If the T-MAP sensor is damaged or faulty, but still normal operating temperatures. If the value is
operating within the operating range, no fault code will within specification, then check for other
be logged in memory and value substitution will not Diagnostic Trouble Codes (DTC) or component
take place. Under these conditions the PCM will faults.
increase the injector timing in an attempt to
compensate; causing difficult starting, rough running T-MAP Specification (Normally aspirated engines)
and poor fuel economy. Manifold Pressure Signal Voltage
Incorrect or modified valve timing, worn piston rings or 15 kPa 0.3
an alteration in manifold vacuum (particularly at idle) 30 kPa 1.0
can cause a lower than normal vacuum. 50 kPa 2.0
Diagnostic Trouble Codes (DTC) are retrieved through 70 kPa 3.0
90 kPa 4.0
DTCs applicable to the T-MAP are shown in the
following table. 105 kPa 4.8
DTC Test Mode Condition T-MAP Specification (Turbo)

P0106 KOEO, Throttle MAP circuit Manifold Pressure Signal Voltage
range / 10 kPa 0.3
performance
50 kPa 1.0
problem
100 kPa 1.9
P0107 KOEO, KOER, MAP circuit low
Cont. input 150 kPa 2.8
P0108 KOEO, KOER, MAP circuit high 200 kPa 3.7
Cont. input 3. Check the harness for the conditions described in
P0112 KOEO, KOER Temperature ‘Fault Finding’ in this section if the displayed
circuit range / pressure is not within the expected range.
performance
problem Testing Temperature
P0112 KOEO, KOER, Temperature 1. Connect a WDS tester to the diagnostic
Cont. circuit low input. connector.
P0113 KOEO, KOER, Temperature 2. Check the Intake Air Temperature readout on the
Cont. circuit high screen when the engine is at room temperatures
input. and at normal operating temperatures. If the value
is within specification, then check for other
Failure Mode Diagnostic Trouble Codes (DTC) or component
The Failure Mode Effects Management (FMEM) faults.
strategy will, in most cases, ensure almost normal
operation of the vehicle in the event of a T-MAP
sensor fault or failure. If the T-MAP signal is not within
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Sensor Test CMP Sensor Location, V8 Engine

1. Disconnect the harness from the T-MAP
connector.
sensor if not within specification.
circuits.
T-MAP Resistance Specification
Temperature Resistance, Voltage Nominal
(±3º C.) Nominal
0º 5960 Ω 4.3
10º 3820 Ω 4.0
20º 2500 Ω 3.6
25º 2050 Ω 3.4 Connections
30º 1690 Ω 3.1 PCM Pin 31.......................... CMP1 Sensor Positive
40º 1160 Ω 2.7 PCM Pin 32......... CMP1 Sensor Negative/ SIGRTN
60º 580 Ω 1.8 PCM Pin 33.......................... CMP2 Sensor Positive
PCM Pin 32.......... CM2 Sensor Negative/ SIGRTN
Trimming Sensors
Circuit
Camshaft Position Sensor
The 2 engine Camshaft Position Sensor (Cylinder
Identification) (CMP) <CID1,2> are Variable
Reluctance Sensors. On the I6, the 2 sensors are
located on both sides of the cylinder head rear. On
the V8 the sensors are located on the two engine
front covers. The sensors are used in conjunction with
the CKP to synchronize the ignition system and the
fuel injectors to the firing of each cylinder and to
feedback the camshaft position for VCT control.
The I6 engine uses a 3+1 tooth reluctor wheel on the
inlet camshaft and another on the exhaust camshaft.
The V8 engine uses a 4+1 tooth reluctor wheel for the
camshaft on bank 1 and another on the camshaft on
the bank 2.
Diagnosis
CMP Sensor Location, I6 Engine
Diagnostic Trouble Codes (DTC) are retrieved through
DTCs applicable to the CMP sensor are shown in the
following table.
DTC Test Mode Condition
P0320 Cont. Ignition engine
speed input
circuit
Malfunction
P0340 Cont. CID1 Circuit
malfunction
P1340 Cont. CID2 Circuit
malfunction
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Failure Mode CHT Sensor Location, V8 Engine

Should a CMP signal be missing then the PCM will be
unable to identify the camshaft position and VCT
operation will be disabled. Should both CMP sensors
or signal fail, the PCM will not operate the fuel
injectors sequentially, and the engine may run rough.
Testing
The CMP sensor is tested continuously during vehicle
operation (cont.).
connector.
2. Check the Parameter Identification (PID) value of
the CMP. If the PID value is within specification,
then check for other Diagnostic Trouble Codes
(DTC) or component faults. The CHT sensor measures the cylinder head
temperature for the fail-safe cooling strategy. The
PID Specification PCM also uses this sensor signal in conjunction with
the Intake Air Temperature signal to determine fuel
PID Description requirements and to inhibit activation of some features
CMPFM CMP Failure mode flag that only work properly when the engine is at normal
SYNC CMP and CKP signals are operating temperature. These feature include closed
synchronised loop fuel control and canister purge control.
The sensor employs a thermistor that is sensitive to
Sensor Test temperature variations. The resistance of the
thermistor decreases as the temperature rises.
1. Disconnect the harness from the CMP Sensor
connector. Connections
2. Measure the resistance across the connector PCM Pin A45.................... CHT Temperature Signal
PCM Pin A32.....................Signal Return (SIGRTN)
sesnor if not within specification.
CMP Resistance Specification Circuit
280 - 380 Ω
circuits.
Cylinder Head Temperature Sensor
The Cylinder Head Temperature (CHT) sensor is
mounted at the rear of the cylinder head on the I6 and
between cylinder 3 & 4 on the cylinder head of the V8
engines.
CHT Sensor Location, I6 Engine
Diagnosis
The CHT sensor element is encased is brass for
protection against corrosion. Diagnostic Trouble
Codes (DTC) are retrieved through the diagnostic
connector using the WDS tester.
DTCs applicable to the CHT sensor are shown in the
following table.
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DTC Test Mode Condition Connections

P0116 KOEO, KOER circuit range / PCM Pin A13……..……………… …… EOT Signal
performance PCM Pin A32…..…………. Signal Return (SIGRTN)
problem
P0117 KOEO, KOER, circuit low input Circuit
Cont.
P0118 KOEO, KOER, circuit high input
Cont.
Failure Mode (Petrol Engines only)

The PCM has a Failure Mode Effects Management
(FMEM) strategy mode that, in most cases, will
ensure almost normal operation of the vehicle in the
event of a CHT sensor fault or failure. If the CH
sensor fails or produces an invalid signal, the PCM
will not be able to sense the engine temperature.
Under these conditions, the PCM will substitute the
value from the Intake Air Temperature Sensor (IAT).
During crank mode, the PCM will substitute the IAT
signal for the missing CHT, since both sensors will
have “soaked” to approximately the same Diagnosis
temperature. When the engine is switched OFF, the If the sensor is damaged or faulty, but still operating
whole engine will soak up heat from the cooling within the operating range, no fault code will be
system and reach a similar temperature. When the logged DTCs applicable to this sensor are shown on
engine starts, the PCM will infer a value for the CHT the following table.
of approximately 80º C.
Testing DTC Test Mode Condition
0196 KOEO Engine Oil
The CHT sensor is tested continuously during vehicle Temperature
operation (cont.) and whenever Key On Engine Off Sensor
(KOEO) or Key On Engine Running (KOER) tests are temperature is
performed. inconsistent with
1. Connect a WDS tester to the diagnostic engine
connector. temperature
2. Check the Cylinder Head Temperature readout on
the screen when the engine is at normal operating Failure Mode
temperatures. The Failure Mode Effects Management (FMEM)
PID Description strategy will, in most cases, ensure normal operation
of the vehicle in the event of an EOT sensor failure. If
Cylinder Head 85° to 100° the EOT signal is not within the normal operating
Temperature range, or not present at all, the PCM will substitute a
temperature value calculated from CHT. The
Engine Oil Temperature Sensor appropriate trouble code will be logged in memory for
The Engine Oil Temperature (EOT) sensor is located retrieval during Self-test mode.
on the engine block directly above the engine oil filter
(I6) and on the engine sump on the V8 engine.
Testing
The EOT sensor measures the temperature of the The EOT sensor is tested continuously during vehicle
engine oil for the variable cam timing strategy. operation (cont.) and whenever Key On Engine Off
(KOEO) or Key On Engine Running (KOER) test are
A temperature-sensing element is incorporated into
performed.
the EOT sensor to measure the temperature of the
engine oil within the engine. The temperature element Testing Engine Oil Temperature Sensor
employs a thermistor that is sensitive to temperature 1. Disconnect the EOT sensor wire connector.
variations. The resistance of the thermistor decreases 2. Measure the resistance across the connector
as the temperature rises. terminals using a suitable multimeter. Replace the
sensor if not within specification.
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EOT Resistance Specification Testing

Temperature Resistance, kΩ Voltage Nominal 1. Connect a WDS tester to the diagnostic
(±3º C.) connector.
0º 96 4.5 2. Check the Parameter Identification (PID) value of
20º 37 3.9 the EOP.
25º 30 3.8 PID Specification
30º 24 3.5
40º 16 3.1 PID Description
60º 7.6 2.2 OIL_PRESS Engine Oil Pressure
80º 3.9 1.4 EOP sensor specification
90º 2.8 1.1
100º 2.1 0.9 Oil Pressure PID Count Resistance
Normal Less than 50 Less than 20 Ω
circuits. Low Greater than Greater than
230 100kΩ
Engine Oil Pressure Sensor
Boost Pressure Sensor, I6 Turbo Engine
The I6 Engine Oil Pressure (EOP) switch is located on
the engine block above and right of the engine oil The Boost Pressure Sensor (BPS) is located on the
filter. The V8 engine oil pressure switch is located on aluminium duct between the intercooler and the
the adaptor between the oil filter and the engine throttle body inlet duct.
block. The BPS measures the absolute pressure of the
The EOP sensor switches to ground at normal oil pre-throttle intake system for speed control and
pressures and opens at low engine oil pressure. wastegate control strategy.
Engine oil pressure is not used for powertrain control The pressure-sensing element in the BPS employs a
but is transmitted on the CAN for display on the Piezo resistive sensor that outputs a voltage
instrument cluster to warn the driver the oil pressure is proportional to absolute pressure.
low.
Connections
Connections
PCM Pin C2…………………..Boost Pressure Signal
PCM Pin A26…………………… Pressure Signal PCM Pin C30… Vehicle Reference Voltage (VREF)
Circuit PCM Pin B33..……………. Signal Return (SIGRTN)
EOP Sensor Circuit Circuit
Failure Mode Diagnosis

In the event the EOP sensor fail, the instrument DTCs applicable to this sensor are shown on the
cluster warning lamp will not indicate correctly. following table.
NOTE: The instrument cluster warning lamp glows
regardless of EOP switch status when the engine is
not running.
G98128 en 01/2003 2003.0 BA Falcon

DTC Test Mode Condition the ignition is on, from the Restraint Control Module,
RCM. During a non impact phase, the frequency read
P0236 Cont Boost Pressure
by the PM is 0.8Hz. In the event of an impact that is
Sensor Circuit
registered by the RCM, the RCM changes the
/Range frequency of the TAS signal to 5Hz for 5 cycles only.
Performance
The PCM detects the change in frequency of the TAS
P0237 KOERKOEO Boost Pressure signal and places on the CAN bus in message 427,
Cont Sensor Circuit bit 6, where circumstances allow it, a message to the
Low BEM and the RCM has registered an impact and that
P0238 KOERKOEO Boost Pressure the vehicles doors should be unlocked.
Cont Sensor Circuit
High Failure Mode
If the TAS signal is not within the normal operating
Failure Mode frequency range or not present at all, the PCM sets a
The Failure Mode Effects Management (FMEM) DTC in memory for retrieval during self test mode.
strategy will, in most cases, ensure reasonable The TAS is tested continuously during vehicle
operation of the vehicle in the event of a BPS failure. operation.
If the BPS signal is not within the normal operating DTC Test Mode Condition
range, or not present at all, the PCM will substitute a P1534 Cont TAS signal outside of
default value for pre-throttle absolute pressure and allowable frequency range or
use MAP for boost control. The appropriate trouble not present
code will be logged in memory for retrieval during
Self-test mode. Feedback Inputs
Testing Heated Exhaust Gas Oxygen Sensor
The BPS is tested continuously during vehicle
On I6 engines, there is one Heated Exhaust Gas
operation (cont.) and whenever Key On Engine Off Oxygen (HEGO) sensor mounted in the exhaust
(KOEO) or Key On Engine Running (KOER) tests are
manifold above the engine pipe connection flange. On
performed.
V8 engines, there are two HEGO sensors, one for
Testing Boost Pressure Sensor each bank, mounted in the engine pipe just below the
1. Connect a WDS tester to the diagnostic exhaust manifold. The sensor has a built in heating
connector. element to bring the sensor to its operating
2. Check the Parameter Identification (PID) value of temperature quickly and to prevent it from dropping
the BPS. If the PID value is within specification, below its operating temperature during periods of
(at key-on engine off it should be at atmospheric extended engine idle.
pressure or 1.8 to 2.2 volts) then check for other The PCM uses the HEGO sensor signal to adjust the
Diagnostic Trouble Code (DTC) or component fuel injector pulse width to maintain the air-fuel ratio at
faults stoichiometry. The PCM compares the amount of fuel
that is being used in closed loop operation to the
PID Specification amount of fuel it predicts would be required if there
was no HEGO signal.
PID Description
If there is a difference, the PCM adjusts its ‘Open
TURBO Turbo Boost Pressure Loop’ (ie. no feedback) predicted values to reflect the
actual requirements of the engine as signaled by the
BPS Specification HEGO sensor. These corrections are stored in the
Absolute Pressure (kPa) Signal Voltage (V) KAM for use when the system next operates in the
10 0.3 open loop mode, ie. in cold drive conditions, or wide
50 1.0 open throttle operation. This adaptive learning
enables the PCM to precisely control the air-fuel ratio
100 1.9 and compensate for component wear and injector
150 2.8 fouling. It does this by having one of its electrodes
200 3.7 exposed to the exhaust gas and the other electrode
exposed to normal air. The difference in the level of
TAS oxygen produces a voltage across the electrodes. The
platinum electrodes of the Zirconia element typically
The TAS signal consists of two distinct frequencies, operate only above 350ºC so the HEGO sensor has
one for normal conditions and a higher frequency for heaters permanently switched.
impact event notification. The PCM recieves a
continuous 12 Volt sqare wave signal on pin B6 while
G98129 en 01/2003 2003.0 BA Falcon

HEGO Sensor, Typical. Closed Loop Process
The HEGO detects the amount of unburnt oxygen in Item Description

the exhaust gasses as a measure of the air-fuel ratio.
1 Ideal ratio
Since a single sensor is used for a bank of cylinders
the signal represents the average air-fuel ratio. In 2 Oxygen Sensor Signal Lean
Closed Loop Mode the HEGO sensor provides the 3 Increase Pulse Time
PCM with a signal indicating whether the engine is 4 Ideal Ratio
running ‘rich’ or ‘lean’.
5 Oxygen Sensor Signal Rich
HEGO Sensor Operation 6 Reduce Pulse Time
Connections
PCM Pin B8………..................... HEGO11(I6, V8)
PCM Pin B26……………............ HEGO11(V8)
PCM Pin B33.................…..Signal Return (SIGRTN)
Circuit
The PCM uses the HEGO signals to maintain the

correct air-fuel ratio during closed loop mode by
varying the fuel injector pulse width. In open loop
mode the HEGO signal is disregarded by the PCM.
The PCM also stores values from the sensor in a
look-up table as part of its adaptive strategy. See the
‘Operating Modes’ section.
Diagnosis
DTCs applicable to the HEGO sensors are shown in
the following table.
G98129 en 01/2003 2003.0 BA Falcon

DTC Test Mode Condition HEGO Sensor, I6 Turbo

P0171 KOER I6, bank
1-V8Fuel
System too lean
P0172 KOER I6, bank
1-V8Fuel
System too rich
P0174 KOER V8 bank 2 - Fuel
System too lean
P0175 KOER V8 bank 2- Fuel
System too rich
P1128 Cont Connection for
Bank1 and
Bank2 HEGO
sensors
swapped. Failure Mode
HEGO Sensor, I6 Engines In the event the HEGO fails, the PCM is not able to
operate in Closed Loop Mode. In Open Loop Mode
the PCM will use values stored in its look-up tables.
These values are stored from the adaptive strategy.
As the strategy constantly updates the table, the PCM
should be able to maintain a suitable air-fuel ratio with
a faulty HEGO.
A trouble code for HEGO failure is only logged when
an Key On Engine Running (KOER) self-test is
performed.
Testing
The HEGO sensors are tested continuously during
vehicle operation (cont.) and whenever Key On
(KOER) tests are performed.
HEGO Sensor, V8 Engines
connector.
the HEGO sensor. If the PID value is within
specification, then check for other Diagnostic
Trouble Codes (DTC) or component faults.
PID Specification
PID Description
O2S1 Bank 1 HEGO Voltage
O2S21 Bank 2 HEGO Voltage (V8)
O2S11FM Bank 1 HEGO Failure
O2S21FM Bank 2 HEGO Failure
Item Description Sensor Test
1 HEGO Sensor (LHS only)
1. Disconnect the harness from the HEGO sensor
2 HEGO Sensor (LHS & RHS) connector.
2. Measure the Heater element resistance across
the heater wire terminals using a suitable
multimeter.
HEGO Sensor Heater Resistance
Specification
G98129 en 01/2003 2003.0 BA Falcon

4-8 Ω @20º C. Connections

3. Reconnect the HEGO harness and start the PCM Pin A29.......................Knock Sensor Positive
engine. With the throttle held open to maintain
approximately 2,000 RPM, The HEGO voltage PCM Pin A40.......................Knock Sensor Negative
should be switching between High and Low at Circuit
least once per second; and the rich/lean periods
should be reasonably even. If this does not occur
and the voltage remains constant, either High or
Low, open and close the throttle rapidly and look
for a change in voltage. If the voltage changes
with throttle movement, it indicates that the sensor
is operating correctly but the PCM, is not able to
control the air-fuel ratio.
circuits.
HEGO Sensor Signal Voltage Specification
Diagnosis
DTC applicable to the KS sensor is shown in the
following table.
P0325 Cont. Sensor or circuit
malfunction
Knock Sensor Failure Mode

Should the KS fail, or produce the incorrect signal, the
Sensor Description PCM will log a fault code, then revert to minimum
Vehicles fitted with the I6 engine have a linear Knock ignition advance. The vehicle will otherwise operate
Sensor (KS) located on the left hand side of the as normal, possibly with marginally less performance,
cylinder block, adjacent to cylinder No. 5 to detect and some engine knock may occur under certain
pre-ignition detonation (engine knock) within the conditions.
cylinders. The system detects engine knock by
comparing engine noise at crank angles when Testing
cylinder pressure of the combustion fuel is highest Testing Knock Sensor
with engine noise at quieter portions of the engine
cycle. If the noise is louder, indicating knock, the 1. Disconnect the knock sensor wire connector.
Powertrain Control Module (PCM) retards ignition 2. Measure the resistance across the knock sensor
timing until knocking ceases. connector terminals using a suitable multimeter.
Replace the sensor if not within specification.
The KS is used as a feed-back signal to control
KS Resistance Specification
ignition timing. The KS is a piezo-electric
4 - 6 mΩ
accelerometer comprised of a piezo crystal mounted
in a ceramic case. Whenever the KS detects knock 3. Check the harness for open circuits and short
the PCM retards the ignition timing until the knock circuits.
ceases. The PCM then advances the ignition timing in
small increments until knock is again detected. The Feed Forward Inputs
cycle of retarding and advancing the ignition is
continuous in Closed Loop Mode, and maintains the Transmission Range Sensor (TRS-A1)
ignition at the optimum spark advance for the fuel The automatic Transmission Range Sensor A1
quality. (TRS-A1) <PRNDL>, is incorporated in the inhibitor
The PCM uses the KS to automatically adjust the switch mounted on the side of the transmission case.
engine tune for low octane unleaded fuel or higher The TRS-A1 sensor reports the current gear lever
performance Premium unleaded fuel.
G98129 en 01/2003 2003.0 BA Falcon

selector position to the Powertrain Control Module DTC Test Mode Condition
(PCM). P0708 KOEO, Cont. Circuit high
The TRS-A1 signal is used by the PCM for automatic input
transmission control operations and by the engine
management system to predict an impending increase Failure Mode
in engine load.
In the event the TRS-A1 fails, or the signal is outside
The TRS-A1 is a rheostat that, with the reference the expected range, the PCM will log a fault code,
voltage, produces a voltage proportional to the gear then assume the gear lever selector is in Drive for the
lever selector position. purpose of setting the idle speed.
The TRS-A1 is a Feed Forward sensor that produces
a signal change at the PCM before the actual event Testing
takes place. For example, when moving the gear lever The TRS-A1 sensor is tested continuously during
selector from shifting from Park to reverse, the PCM vehicle operation (cont.) and whenever a Key On
receives the changed signal prior to the engine load Engine Off (KOEO) test is performed.
actually increasing. This allows the PCM sufficient 1. Connect a WDS tester to the diagnostic
time to open the Idle Air Control Valve (IAC) <ISC> connector.
valve and increase the fuel injector pulse width to
compensate for the additional load. 2. Check the Parameter Identification (PID) value of
the TR sensor. If the PID value is within
The Key On Engine Running (KOER) self-test is specification, then check for other Diagnostic
disabled whenever the gear selector is in any gear. Trouble Codes (DTC) or component faults.
KOER self-test is only operational in either the Park or
Neutral positions. PID Specification
Electrical Description PID Description Units
The TRS-A1 is series of stepped resistors that will TR / PRNDL Park/Neutral Position
drop Vehicle Reference Voltage (VREF) in seven Position
distinct steps from Park down to Manual. (PRNDL) sensor
Connections
Sensor Test
PCM Pin B41.................................. TRS-A1 Sensor
1. Disconnect the harness from the TRS-A1 sensor
PCM Pin 45.....................................................VREF connector.
PCM Pin B33.....................Signal Return (SIGRTN) 2. Measure the resistance across the TRS-A1
Circuit sensor connector terminals using a suitable
multimeter. Replace the TRS-A1 sensor if not
within specification.
circuits.
TRS-A1 Resistance Specification
Shift Lever Position Resistance Nominal
Park (P) 17,300 -20,300 Ω
Reverse (R) 10,900 -11,850 Ω
Neutral (N) 6,500 -7,600 Ω
Drive (D) 4,300 - 5,000 Ω
3rd Gear (3) 2,900 -3,400 Ω
2nd Gear (2) 1,850 -2,200 Ω
1st Gear (1) 1,050 -1,270 Ω
DTCs applicable to the TRS-A1 sensor are shown in
the following table. Transmission Range Sensor (TRS-A2)
DTC Test Mode Condition The electronic sport shift manual, tip-up and tip-down
P1705 KOEO Not in Park or position is sensed by 3 Hall-effect switches mounted
Neutral during on a printed circuit board in the T-bar console. The
self-test (Auto) sport shift lever contains a magnet in its base that
P0707 KOEO, Cont. Circuit low input activates the appropriate Hall-effect switch in different
shift position. The switches are resistively multiplexed
G98130 en 01/2003 2003.0 BA Falcon

together and are read as a voltage by the PCM on the Pin-out Sport Shift Voltage
TRS-A2 input. 2 and 3 ESS Lever in 2.6V - 3.3V
Connections “Manual”
Position
PCM Pin B43................................... TRS-A2 Sensor 2 and 3 ESS Lever in 1.5V - 2.0V
PCM Pin B45................... ...............................VREF “Tip +” Position
PCM Pin B33......................Signal Return (SIGRTN) 2 and 3 ESS Lever in 0.5V - 1.3V
“Tip -” Position
Circuit
Pin-out numbers are marked on the back of the white
ESS connector
Power Steering Pressure Switch
NOTE: This circuit must not remain by-passed or
bridged, since steering load applied when cornering
may stall the engine and cause loss of steering
control.
The Power Steering Pressure Switch (PSP) <PSPS>
which is a pressure sensitive switch that detects when
pressure within the power steering system reaches a
specified level. To prevent engine stall and maintain
idle quality during parking manoeuvres the PCM
boosts the engine idle speed by approximately 100
RPM.
Failure Mode The PSP switch is a normally closed pressure switch.
Under no load conditions the switch connects the PSP
In the event the TRS-A2 fails, or the signal is outside pin B31 to Signal Return (SIGRTN). When the power
the expected range, the PCM will log a fault code, and steering load is high, the PSP opens causing 5 volts
then assume the gear lever selector is in the to be detected at PCM Pin.
automatic plane.
Connections
Testing
PCM Pin B31..........................................PSP Signal
The TRS-A2 sensor is tested continuously during
vehicle operation and whenever Key On Engine Off PCM Pin B33......................Signal Return (SIGRTN)
(KOEO) or Key On Engine Running (KOER) tests are Circuit
performed.
Testing TRSA-2 Sensor
1. Connect a WDS tested to the diagnostic
connector.
the sensor. If the PID value is within specification,
then check for other Diagnostic Trouble Code
(DTC) or component faults
PID Specification
PID Description
GLP_D ESS Lever in Auto Position
Manual ESS Lever in “Manual” Position
TP+ ESS Lever in “Tip +” Position
TP- ESS Lever in “Tip -” Position Diagnosis
Pin-out Sport Shift Voltage the diagnostic connector using the WDS tester.
1 and 2 All positions 4.8V - 5.2V
DTCs applicable to the PSP switch are shown in the
2 and 3 ESS Lever in 3.7V - 4.2V following table.
Auto Position
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DTC Test Mode Condition Speed control operation

P1650 KOEO Failure Vehicle speed limiting.
P1651 KOER did not switch Engine fan control
NOTE: A 19-tooth gear is used on the OSS for all
Testing axle and tyre size variants. Alternative OSS gears will
result in vehicle speed calculation errors and must not
The PSP switch is tested whenever Key On Engine
Off (KOEO) or Key On Engine Running (KOER) tests be used.
are performed. When a P1650 and a P1651 DTC is Vehicle speed data is transmitted on the CAN line for
reported after a KOEO and KOER test, check the the speedometer, odometer, trip computer and
PSP for correct operation. air-conditioner functions.
Switch Test Connections
1. Disconnect the PSP connector harness. PCM Pin B7…………….Vehicle Speed Signal VSS
2. Using a multimeter with suitable connectors, PCM Pin B45…. Vehicle Reference Voltage (VREF)
measure the resistance if the PSP Switch. PCM Pin B33..……………. Signal Return (SIGRTN)
3. Start and run the engine.
4. Actuate the PSP switch by turning the steering VSS Installation
wheel and releasing. Ensure that the switch
resistance conforms to specifications. If the switch
is within specifications, check the wiring for open
and short circuits.
Steering PSP Resistance PSP voltage
Steering turned Greater than 4.5 - 5.2V
10kΩ
Steering Less than 10Ω 0.0 - 1.0V
released
Vehicle Speed
The PCM determines the vehicle speed from 3
sources depending on vehicle option. Vehicle speed
source, tyre rotations per mile, axle ratio is Diagnosis
programmed into the PCM using the WDS tester (see
‘Module Configuration’ in this section). If the sensor is damaged or faulty, but still operating
within the operating range, no fault code will be
Option VSS input Signal Type logged
ABS Connected to Square wave DTCs applicable to this sensor are shown on the
ABS speed frequency signal following table.
output pin (0V to 5 V)
Traction Control Not used CAN signal DTC Test Mode Condition
None Connected to Square wave P0500 KOEO Cont Missing/erratic
output shaft frequency signal speed signal
speed sensor in (0V to 5V) from ABS, ASR
the transmission or OSS
housing
Failure Mode
Output Shaft Speed (OSS) Sensor Failure of the vehicle speed sensor signal source will
The output shaft speed sensor is used in vehicles result in normal engine running but no speedometer
without the ABS or traction controlled option. It is a readout, no speed control operation. Automatic
gear driven Hall effect sensor mounted in the transmission will default to 3rd gear when DRIVE is
transmission extension. The output signal frequency is selected.
proportional the output shaft speed. The PCM Testing
calculates vehicle speed using this signal and the
programmed axle ratio and tyre rotation per mile. 1. Check that the instrument cluster is working
correctly by observing warning lamps, tachometer,
The PCM uses vehicle speed signal to control: fuel and temperature gauges. Rectify before
Automatic transmission gear shifts continuing.
G98130 en 01/2003 2003.0 BA Falcon

2. Where ABS and traction control is fitted, ensure Circuit

that the warning lights are not illuminated. Rectify
before continuing.
connector.
4. Check the check the Output Shaft Speed and the
Vehicle Speed on the WDS screen. If these reads
0, check the electrical connections between the
PCM and the vehicle speed source.
5. If vehicle speed is inaccurate, reconfigure the
PCM VID block as detailed in the Module
Configuration section.
PID Specification
PID Description
AXLE Axle Ratio used by the PCM
Diagnosis
TIRE SIZE Tire size used by the PCM - revs
DTCs applicable to this sensor are shown on the
per mile
following table.
Vehicle Speed Output (VSOUT) DTC Test Mode Condition
The PCM transmits a 12V square wave vehicle speed P2122 KOEO Cont PPS1 fails - Out-of-range
output signal on the VSOUT pin for the satellite low
navigation system. This pin may be used to drive
P2123 KOEO Cont PPS1 fails - Out-of-range
other devices such as taximeters. The recommended
high
load for this pin is 4.7 to 15 k Ω to ground.
P2124 KOEO Cont PPS1 fails - intermittent,
Connections Out-of-range
PCM Pin B7…………………………………. VSOUT P2138 KOEO Cont PPS1 fails - In-range
P2139 (one sensor disagrees)
Electronic Throttle Control Inputs P2127 KOEO Cont PPS2 fails - Out-of-range
low
Pedal Position Sensor
A triple output Throttle Position Sensor (TPS) is used high
to provide pedal position signal to the PCM. It has an P2129 KOEO Cont PPS2 fails - intermittent,
8-way electrical connector providing 3 independent Out-of-range
potentiometer signals.
P2138 KOEO Cont PPS2 fails - In-range
Connections P2140 (one sensor disagrees)
PCM Pin B17………….……………… PPS1 Signal P2132 KOEO Cont PPS3 fails - Out-of-range
low
PCM Pin B18………….……………… PPS2 Signal
PCM Pin B19………….……………… PPS3 Signal high
PCM Pin B20………….…………..…… PPSVREF1 P2134 KOEO Cont PPS3 fails - intermittent,
PCM Pin B28………….…………….…. PPSVREF2 Out-of-range
PCM Pin B21…………………………….PPSRTN1 P2139 KOEO Cont PPS3 fails - In-range
PCM Pin B29……………………………. PPSRTN2 P2140 (one sensor disagrees)
P2110 KOEO Cont Two or three PPS fail
(pedal position > or = no
pedal)
Failure Mode
The Failure Mode Effects Management (FMEM)
strategy will, in most cases, ensure normal operation
of the vehicle if one of the PPS potentiometers fail.
The ETC warning light will flash. If two or more
sensors fail, the ETC will default to limp home part
G98130 en 01/2003 2003.0 BA Falcon

throttle mode. The appropriate trouble code will be Circuit

logged in memory for retrieval during Self-test mode.
Testing
The PPS sensor is tested continuously during vehicle
operation (cont.) and whenever Key On Engine Off
performed.
Testing Pedal Position Sensor
connector.
the PPS. If the PID value is within specification,
then check for other Diagnostic Trouble Code
(DTC) or component faults
PID Specification Diagnosis

PID Description DTCs applicable to this sensor are shown on the
APP_F Accelerator Pedal Position Status following table
APP_MODE Pedal position mode: -1=pedal not DTC Test Mode Condition
depressed, 0=pedal partially P0122 KOEO Cont. TP1-NS fails -
depressed, 1=pedal fully depressed Out-of-range low
APP1 Voltage of the Pedal Position Sensor P0123 KOEO Cont. TP1-NS fails -
number 1 (PPS1) at the PCM Out-of-range high
connector pin, relative to signal return
(SIGRTN) P0124 KOEO Cont. TP1-NS fails -
intermittent, Out-of-range
APP2 Voltage of the Pedal Position Sensor
number 2 (PPS2) at the PCM P0221 KOEO Cont. TP2-PS fails -
connector pin, relative to signal return Out-of-range at
(SIGRTN) commanded settings
APP3 Voltage of the Pedal Position Sensor P0222 KOEO Cont. TP2-PS fails -
number 3 (PPS3) at the PCM Out-of-range low
connector pin, relative to signal return P0223 KOEO Cont. TP2-PS fails -
(SIGRTN) Out-of-range high
P0224 KOEO Cont. TP2-PS fails -
Throttle Position Sensor intermittent, Out-of-range
A dual (opposing slope) output Throttle Position P1124 KOEO,KOER Throttle Out Of Self-test
Sensor (TPS) is used to provide feedback to the Range
Powertrain Control Module (PCM). It has a four way P2111 Cont. Throttle Actuator Control
electrical connector providing 5v supply, a return and System - Higher throttle
two output signals. The TPS is replaceable in service opening than driver
and simply bolts onto the ETB in one orientation only demand
by way of a locating pin on the TPS.
P2112 Cont. Throttle Actuator Control
Connections System - Lower throttle
opening than driver
PCM Pin A44…………………………… TP1 Signal demand
PCM Pin A16…………………………… TP2 Signal P2135 KOEO Cont. Sensor disagreement, in
PCM Pin A21………………………..…. TPS_VREF range
PCM Pin A22……………………………. TPS_RTN P0124 KOEO Cont. Intermittent sensor
P0224 disagreement, in range
P0124 KOEO Cont. Both TPS fail -
P0224 Out-of-range intermittent
G98131 en 01/2003 2003.0 BA Falcon

Failure Mode Connections

The Failure Mode Effects Management (FMEM) PCM Pin B5……………………………………. CES
strategy will, in most cases, ensure normal operation
of the vehicle if one of the TPS potentiometers fails. Circuit
The ETC warning light will flash. If both sensors fail,
the ETC will default to limp home part throttle mode.
The appropriate trouble code will be logged in
memory for retrieval during Self-test mode.
Testing
The TPS sensor is tested continuously during vehicle
operation (cont.) and whenever Key On Engine Off
performed.
Testing Throttle Position Sensor
connector.
the TPS. If the PID value is within specification,
then check for other Diagnostic Trouble Code Failure Mode
(DTC) or component faults. Failure of clutch switch in the open circuit position will
inhibit speed control operation. A shorted CES will
PID Specification result in engine flaring to a high engine rpm when the
clutch pedal is depressed with the speed control
PID Description
engaged.
ETC_ACT The actual throttle angle in degrees
as determined from the throttle Testing
sensor inputs. Testing Clutch Engagement Switch
TP1 Voltage of the Electronic Throttle 1. Connect a WDS tester to the diagnostic
Control (ETC) Throttle Position connector.
Sensor number 1 (TPS1) at the PCM
connector pin, relative to signal return 2. Check the Parameter Identification (PID) value of
(TPS_RTN) the CES while depressing and releasing the
clutch pedal.
TP2 Voltage of the Electronic Throttle
Control (ETC) Throttle Position PID Description
Sensor number 2 (TPS2) at the PCM CPP Clutch Pedal Depressed
connector pin, relative to signal return
(TPS_RTN) Brake Switches
Clutch Engagement Switch, Manual The PCM monitors the brake pedal position using two
Transmission switches - the Brake On-Off (BOO) switch and the
Redundant Brake Switch (RBS). Both switches are
The PCM monitors clutch engagement using the mounted on the pedal assembly and are directly
Clutch Engagement Switch (CES). The CES is actuated by the brake pedal. When the brakes are
mounted on the pedal assembly and is actuated by applied, the PCM cancels speed control operation.
the clutch pedal in the released position. When the BOO is a normally-open switch that switches 12V to
clutch is applied, the PCM cancels speed control the PCM’s BOO input when the brakes are applied.
operation. RBS is a normally-closed switch that switches 12V to
the PCM’s RBS input when the brakes are released.
BOO is designed to switch to 12V before RBS breaks
the circuit to 12V. If the RBS 12V circuit breaks
without the BOO switching to 12V, the speed control
cannot be engaged or re-engaged until the next
key-on.
G98131 en 01/2003 2003.0 BA Falcon

Connections gear selection. When 12V is sensed on RGS, engine

torque is limited to a suitable value for reverse gear
PCM Pin B25……………………………………. BOO operation. The switch status is transmitted on the
PCM Pin B32……………………………………. RBS CAN for the optional reverse parking sensor.
Circuit Connections
PCM Pin B30…………………………………. RGS
Diagnosis
Ensure that the reverse lamps operate correctly.
Rectify before continuing.
following table.
P0812 KOEO Cont Reverse switch or
circuit faulty
Failure Mode
The ETC will implement reverse gear torque limiting
under the following conditions:
Diagnosis
RGS switch short circuit fault;
Ensure that the brake lamps operate correctly before
RGS wire open circuit;
continuing.
Both reverse lamps are faulty.
following table. Testing
DTC Test Mode Condition Testing Reverse Gear Switch
P1572 KOEO Cont. Brake switch circuit 1. Ensure that the reverse lamps operate correctly.
faulty Rectify before continuing.
Failure Mode connector.
Failure of either brake switch will inhibit speed control 3. Check the Parameter Identification (PID) value of
operation. TRANS_GEAR while selecting reverse gear.
Testing PID Specification
The BOO and RBS switches are tested continuously PID Description
during vehicle operation (cont.) and whenever Key On
Engine Off (KOEO) or Key On Engine Running TRANS_GEAR Transmission Gear state
(KOER) test are performed.
Speed Control Range Switch Assembly
Testing Brake Pedal Switches
1. Connect a WDS tester to the diagnostic The Speed Control Range Switch Assembly (SCRSA)
connector. is located right side of the steering wheel airbag. The
switches are resistively multiplexed and connect to
2. Check the Brake ON/OFF status on the WDS the steering wheel clock spring wiring to the PCM.
screen and the Parameter Identification (PID) Each switch connects a specific resistor value to
value of the BPA. If these are correct, check for ground and produces a distinctive voltage level signal
other Diagnostic Trouble Code (DTC) or at the SCRSA input. The PCM uses the SCRSA
component faults. signal to determine driver command of the speed
PID Specification control system.
PID Description
BPA Redundant Brake Pedal Switch
Status
Reverse Gear Switch

The PCM monitors the reverse gear switch (RGS) on
manual transmission vehicles to check for reverse
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Connections Switch Specification

PCM Pin B16…………………………………SCRSA Switch Voltage Range Resistance (±
PCM Pin B33…………………………………SIGRTN (V) 5% Ω)
Circuit Default (none) 4.5 - 4.8 4,330
RES COAST 4.0 - 4.3 1,630
SET + 3.2 - 3.8 810
SET - 2.1 - 3.0 420
CRUISE 0 - 0.4 0
Air Conditioner Inputs

Air Conditioner Demand
The Powertrain Control Module (PCM) controls
operation of the air conditioning compressor clutch.
When an Air Conditioner Demand (ACD) signal is
received by the PCM on the CAN, it energises the
ACR to engage the air conditioning compressor.
Failure Mode
Air Conditioner Relay
In the event the SCRSA fails, or the signal is outside
the expected range, the PCM will log a fault code. The Powertrain Control Module (PCM) energises the
Some or all of the speed control functions will not be Air Conditioning Relay (ACR) whenever air
available. conditioning is required. The air conditioning relay
then energises the air conditioning compressor clutch.
Testing
Connections
The SCRSA is tested continuously during vehicle
operation (CONT) and whenever a Key On Engine Off PCM Pin B2.......................................... ACR Signal
(KOEO) test is performed. Circuit
connector.
2. Monitor the speed control switch status on the
WDS screen
3. Operate the speed control switches in sequence.
4. Check the Parameter Identification (PID) value for
each of the status as the button is pressed. If the
PID value is within specification, then check for
other Diagnostic Trouble Code (DTC) or
component faults
PID Specification
PID Description
SCCS_NULL Speed Control Range Switch in
“NULL” state Diagnosis
SCCS_CANCEL Speed Control Range Switch Diagnostic Trouble Codes (DTC) are retrieved through
“RESUME / CANCEL” the diagnostic connector using the WDS tester. Fault
SC_ON Speed Control Range Switch “ON Finding Tables for DTCs are in the ‘Diagnosis’
/ OFF” section.
SCCS_TAP_UP Speed Control Range Switch DTCs applicable to the ACR relay are shown in the
“SET +” following table.
SCCS_TAP_DN Speed Control Range Switch
“SET -”
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DTC Test Mode Condition DTC Test Mode Condition

P1465 KOEO, Cont. Circuit malfunction P0532 KOEO, Cont. ACPT sensor circuit low
P1463 Cont. Insufficient pressure input
change when AC P0533 KOEO, Cont. ACPT sensor circuit high
compressor commanded input
on. P0534 Cont. Air conditioning
refrigerant charge loss or
Testing A/C system blockage
The AC relay is tested continuously during vehicle P1463 Cont. Insufficient pressure
operation (cont.) and whenever a Key On Engine Off change when AC
(KOEO) test is performed. compressor commanded
on.
Relay Test
1. Remove the AC relay from its socket in the Testing
relay/fuse box adjacent to the battery. The ACPT sensor is tested continuously during
2. Check the condition of the relay vehicle operation (cont.) and whenever a Key On
3. Check the harness for open circuits and short Engine Off (KOEO) test is performed.
circuits. 1. Connect a WDS tester to the diagnostic
connector.
Air Conditioner Pressure Transducer 2. Start and run the engine. Engage the
The Air Conditioner Pressure Transducer (ACPT) air-conditioning.
sensor is located on the compressor discharge pipe. 3. Check the Parameter Identification (PID) value of
The Powertrain Control Module (PCM) uses this the ACPT. If the PID value is within specification,
signal to monitor the air conditioner discharge then check for other Diagnostic Trouble Codes
pressure and actuate the air conditioning and cooling (DTC) or component faults.
strategies accordingly.
PID Specification
Connections
PCM Pin B15...................................... ACPT Signal PID Description
PCM Pin A36.....Vehicle Reference Voltage (VREF) ACP A/C pressure
PCM Pin A32......................Signal Return (SIGRTN) 4. Check the harness for open circuits and short
circuits.
Circuit
Transmission Inputs
Transmission Fluid Temperature Sensor
The Transmission Fluid Temperature (TFT) sensor is
located in a harness within the Automatic
Transmission oil pan. The TFT measures the
temperature of the oil in the automatic transmission
sump. The Powertrain Control Module (PCM) uses
the TFT signal to vary shift pressures in response to
the transmission oil temperature for consistent and
smooth shifts. It is also used to indicate transmission
overheat conditions.
The TFT sensor uses a thermistor that is sensitive to
temperature variations. The resistance of the
thermistor decreases as the temperature of the
Diagnosis transmission oil increases.
the diagnostic connector using the WDS tester. Fault
Finding Tables for DTCs are in the ‘Diagnosis’
section.
DTCs applicable to the ACPT sensor are shown in the
following table.
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Connections Output Actuators

PCM Pin A37......................................... TFT Signal
Fuel Pump
PCM Pin A32......................Signal Return (SIGRTN)
The Fuel Pump (FP) is powered by the fuel pump
Circuit relay situated in the power distribution box on the right
hand side of the engine compartment. The PCM and
the PCM Power Relay control operation of the Fuel
Pump.
The fuel pump is a two-stage turbine pump. The first
stage is a low-pressure impeller pump. As it rotates,
the impeller draws fuel from the tank. Fuel is then
forced into the second high pressure stage. The
second stage is a gear type pump. As the inner gear
rotates, it carries fuel around with the rotor,
pressurising it and directing fuel into the outlet. This
two stage system eliminates vapour bubbles and
ensures the fuel is supplied at the correct pressure.
The large number of low volume chambers within the
gear pump produces smooth pressure characteristics
with minimal pressure pulsation resulting in quiet
operation.
Diagnosis
The fuel pump relay winding is supplied with power
DTCs applicable to the TFT sensor are shown in the when the ignition is switched to the ON position. The
following table. FP relay switches battery voltage to the Fuel Pump
DTC Test Mode Condition when the coil is energised by the PCM Power Relay
and grounded by the PCM. When the ignition is first
P0712 KOEO, Cont. TFT circuit low input switched ON, the PCM will operate the fuel pump for
P0713 KOEO, Cont. TFT circuit high input one second. If no CKP signal is received at the PCM,
the PCM will open the ground circuit, switching OFF
Testing the fuel pump relay. This ensures that if the engine
The TFT sensor is tested continuously during vehicle stalls, for any reason, fuel pump operation will cease
operation (cont.) and whenever a Key On Engine Off immediately.
(KOEO) test is performed. Connections
Testing Engine Oil Temperature Sensor
PCM Pin B27.................... Fuel Pump Relay (FP)
1. Disconnect the Automatic transmission harness
connector. Circuit
2. Locate the TFT sensor pins on the harness.
3. Using a suitable measure the resistance of the
TFT sensor. Replace the sensor if not within
specification.
TFT Specification
Temperature Resistance Voltage Nominal
(±3º C.) Nominal
10º 3800 Ω 4.0
20º 2500 Ω 3.5
30º 1700 Ω 3.1
40º 1200 Ω 2.7
60º 600 Ω 1.9
80º 320 Ω 1.2
100º 190 Ω 0.8 Diagnosis
120º 110 Ω 0.5 Diagnostic Trouble Codes (DTC) are retrieved through
4. Check the harness for open circuits and short Finding Tables for DTCs are in the ‘Diagnosis’
circuits.
section.
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DTCs applicable to the fuel pump relay are shown in Fuel Injector Cross Section, Typical
P0230 KOEO, Cont. Relay primary circuit
malfunction
Failure Mode
If the Fuel Pump, Fuel Pump Relay or PCM Power
Relay fail, the fuel pump will not operate.
Testing
The fuel pump relay is tested continuously during
vehicle operation (cont.) and whenever a Key On
Engine Off (KOEO) test is performed.
1. Remove the relay from its socket in the relay/fuse
box adjacent to the battery.
2. Check the condition of the relay. Replace the
relay if faulty.
circuits.
Fuel Injectors 1-8
The fuel injectors are electronically operated valves,
which deliver a metered amount of atomised fuel to
the engine. The injectors are conventional solenoid
operated injectors with a pintle type nozzle. The
injector orifice is a fixed size and the fuel supply
pressure to the injector is regulated by the fuel
pressure regulator. Fuel flow to the engine, and thus
the air-fuel ratio, is controlled by how long the injector
solenoid is energised. The Injector Pulse Width is the Item Description
time the solenoid is energised. 1 O-ring
Vehicles fitted with the I6 engine use 6 fuel injectors 2 Filter
(INJ1-6),while V8 engines have 8 injectors
3 Adjusting Sleeve
(INJ1-8),one for each cylinder.
4 Weld
CAUTION: The fuel injectors pulse open 5 Shells (2 of)
momentarily using a signal from the PCM. 6 Weld
Applying battery voltage directly to the fuel
7 Weld
injector’s electrical connector terminals will
damage the internal solenoid. 8 Support Ring
Battery voltage is applied to the positive side of the 9 O-ring
injector solenoid coil via the PCM Power Relay. The 10 Seat & Spray Plate Assy.
negative side of the injector solenoid is grounded, as 11 Tube Assy.
required, by the Powertrain Control Module (PCM).
12 Needle, Ball & Armature Assy.
The strategy the PCM uses to control the air-fuel ratio
is described in Control Systems. 13 Spring
14 Coil & Bobbin Assy.
15 Plastic Body
Connections (I6)
PCM Pin A14................................. Injector 1
PCM Pin A7................................... Injector 2
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PCM Pin A3................................... Injector 6 DTC Test Mode Condition

Connections (V8) P0207 KOEO, Cont. INJ7 circuit malfunction
P0208 KOEO, Cont. INJ8 circuit malfunction
PCM Pin A3................................... Injector 2 Failure Mode
PCM Pin A8................................... Injector 3 Should a fuel injector fail the engine may run rough, a
PCM Pin A10................................. Injector 4 Diagnostic Trouble Code (DTC) will be logged in
PCM Pin A4................................... Injector 5 memory for the failed injector and subsequent
unexpected changes in the air-fuel ratio.
In the unlikely event that all the fuel injectors fail
simultaneously, the vehicle will not run. The
PCM Pin A42................................. Injector 8 appropriate DTC will be reported to indicate failure of
the individual fuel injectors.
Circuit
Testing
The fuel injectors are tested continuously during
Injector Fouling
Over time, sulphur and other trace elements in petrol
can build-up on the injector spray plate and around
the nozzle. The quality of the fuel plays an important
part in minimising this fouling of the fuel injectors.
Fouling affects both the spray pattern and the volume
of fuel injected. Incorrect spray pattern will cause poor
atomisation and vaporisation of the fuel, which results
in poor combustion, rough idle and high hydrocarbon
and carbon monoxide emissions.
Maintenance Fouling of the fuel injectors is a common condition
The fuel rail must be removed to replace the fuel that should be suspected if the engine is running
injectors. The procedure is described in Fuel Rail in rough or hesitation during cold acceleration.
the ‘Removal and Installation’ section. The fuel
injectors have a fixed orifice size and cannot be Injector Test
adjusted 1. Disconnect the harness from the fuel injector
NOTE: If any, or all, of the fuel injectors are replaced, connector.
the Keep Alive Memory (KAM) must be reset to 2. Measure the resistance across the fuel injector
ensure the adaptive idle strategy does not use the connector terminals using a suitable multimeter.
previous adaptive values. Refer to Resetting The Replace the fuel injector if not within specification.
Powertrain Control Module. Repeat the procedure for each fuel injector.
Fuel Injector Solenoid Resistance
Diagnosis Specification
Diagnostic Trouble Codes (DTC) are retrieved through 13.5 to 16.0 Ω
the diagnostic connector using the WDS tester. Fault 3. Turn the ignition key to the ON position. Do not
Finding Tables for DTCs are in the ‘Diagnosis’ start the engine. Positive power should be applied
section. to the fuel injectors from the PCM Power Relay.
DTCs applicable to the fuel injectors are shown in the 4. On the harness, measure the voltage between the
following table. positive connector terminal (red wire) and ground
using a suitable multimeter. Repeat the procedure
DTC Test Mode Condition for each fuel injector.
P0201 KOEO, Cont. INJ1 circuit malfunction Fuel Injector Voltage Specification
P0202 KOEO, Cont. INJ2 circuit malfunction 12 Volts DC
P0203 KOEO, Cont. INJ3 circuit malfunction 5. Check the harness for open circuits and short
P0204 KOEO, Cont. INJ4 circuit malfunction circuits.
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Fuel Injector Testing Circuit
CAUTION: Care should be taken to avoid

damaging the fuel injector tip.
1. Remove the fuel injector and place in a clean
plastic bag to avoid contamination. Number each
bag to identify the cylinder location of the injector
spray plate.
2. Visually examine each fuel injector filter basket
and protection sleeve for damage and
contaminants using a suitable magnifying glass.
NOTE: The injector spray pattern cannot be
tested on the vehicle.
3. Mount the injector in a suitable commercial
injector tester and inspect the spray pattern in
accordance with the operating instructions.
Diagnosis
4. Replace the injector if poor atomisation is found,
ie: streaming, uneven spray pattern or dribbling. Diagnostic Trouble Codes (DTC) are retrieved through
Ignition Coils Finding Tables for DTCs are in the ‘Diagnosis’
section.
The ignition system is described in Control Systems
section. DTCs applicable to the ignition coils are shown in the
following table.
Connections (I6)
DTC Test Mode Condition (I6) Condition (V8)
PCM Pin A35................................. Ignition Coil 1
P0351 KOEO, Ignition Coil 1 Ignition Coil 1
PCM Pin A24................................. Ignition Coil 2 KOER Cont Primary / Primary /
PCM Pin A12................................. Ignition Coil 3 Secondary Secondary
PCM Pin A23................................. Ignition Coil 4 Circuit Failure Circuit Failure
PCM Pin A46................................. Ignition Coil 5 P0352 KOEO, Ignition Coil 5 Ignition Coil 3
KOER Cont Primary / Primary /
PCM Pin A34..................................Ignition Coil 6
Secondary Secondary
Connections (V8) Circuit Failure Circuit Failure
PCM Pin A35................................. Ignition Coil 1 P0353 KOEO, Ignition Coil 3 Ignition Coil 7
PCM Pin A24................................. Ignition Coil 2 Secondary Secondary
PCM Pin A12................................. Ignition Coil 3 Circuit Failure Circuit Failure
PCM Pin A1................................... Ignition Coil 4 P0354 KOEO, Ignition Coil 6 Ignition Coil 2
PCM Pin A46................................. Ignition Coil 5 KOER Cont Primary / Primary /
Secondary Secondary
Circuit Failure Circuit Failure
PCM Pin A11..................................Ignition Coil 8 KOER Cont Primary / Primary /
Secondary Secondary
Secondary Secondary
P0357 KOEO, Ignition Coil 4
KOER Cont Primary /
Secondary
Circuit Failure
P0358 KOEO, Ignition Coil 8
KOER Cont Primary /
Secondary
Circuit Failure
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Actuators Connections
Intake Manifold Charge Control PCM Pin B3......................................... IMCC Signal
PCM Pin B34........................Vehicle Power (VPWR)
On I6 engines (except Turbo), the intake manifold has
an Intake Manifold Charge Control (IMCC) <BBM> Circuit
system. The IMCC housing is an aluminium casting,
situated below the plenum chamber. It has two intake
air passages for each cylinder. The PCM opens
vacuum control solenoid allowing the vacuum to pass
to the vacuum actuator drawing the valve plates
closed or releasing the vacuum allowing the actuator
to push the valve plates open. The direct mounted
vacuum actuator system and its return springs are
located within the vacuum actuator assembly.
The IMCC system is also described in Control
Systems. The IMCC solenoid controls the vacuum
signal line to the manifold servo control diaphragm.
The solenoid is mounted on the front of the PCM
bracket.
IMCC Solenoid Specification
Engine Solenoid PCM Pin Butterfly Diagnosis
Speed Condition B3 Voltage Valves
400 to ON 12 Volts Closed the diagnostic connector using the WDS tester. Fault
3,800 RPM Finding Tables for DTCs are in the ‘Diagnosis’
above OFF 0 Volts Open section.
3,800 RPM DTCs applicable to the IMCC solenoid are shown in
IMCC Solenoid Location the following table.
P1520 KOEO, Cont. circuit malfunction
Failure Mode
During self-test the PCM checks the electrical
continuity of the IMCC circuit. If the circuit fails the
self-test a DTC will be logged in the PCM memory.
Should either the IMCC electrical or vacuum circuit
fail, then the IMCC butterflies will remain open
throughout the entire engine operating range. This will
result in a noticeable lack of power and torque when
operating the engine between 400 to 3,800 RPM.
Testing
The IMCC solenoid is tested continuously during
Whenever the ignition key is in the ON position,
positive power should be applied to the IMCC
solenoid from the PCM Power Relay.
connector.
2. Initiate an Output Circuit Check as described in
Diagnosis.
the IMCC. If the PID value is within specification,
(DTC) or component faults.
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Sensor Test Connections

4. Disconnect the engine harness from the IMCC PCM Pin B24................................................EDF1-2
solenoid electrical connector. PCM Pin B35............................….................EDF1-2
5. Connect the multimeter across the IMCC solenoid
terminals and measure the resistance of the coil. Circuit
IMCC Resistance Spesification
50 to 100 Ω
circuits.
Electro Drive Fans
Electro Drive Fans 1 & 2 provide air flow over the
radiator to remove heat from the engine coolant.
Operation of the fans is controlled by the PCM.
EDF1 and EDF2 PCM outputs control three relays to
operate two electric cooling fans on the radiator.
The relays are wired to switch the fans in series and
parallel combinations to provide low and high speed
operation as shown in the following table.
Fan Speed EDF1 EDF2
Off OFF OFF
Low Speed ON OFF
High Speed ON ON
Diagnosis
section.

P1474 KOEO EDF1 Fan Control Relay
Circuit
P1479 KOEO EDF2 Fan Control Relay
Circuit
Failure Mode
The PCM tests the EDF relay circuits during self test.
If any circuit fails the test, then a Diagnostic Trouble
Code (DTC) will be logged in the PCM memory.
Testing
1. Initiate an Output Circuit Check as described in
Diagnosis.
2. Check the operation of the cooling fan EDF1-2.
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3. Check the harness for open circuits and short The camshaft timing is controlled by directing oil
circuits. under pressure (from the engine oil pump) into one of
4. Further testing of EDF1-2 is described in Section two ports in the Phaser, one port will retard the cam
303-03, Engine Cooling. timing (‘Retard port’) and the other will advance the
Variable Camshaft Timing one for each camshaft is used to control the flow of oil
into the retard and advance ports of both cams. The
I6 Engine OCV is controlled by the PCM.
The I6 Engine is fitted with variable inlet and exhaust The PCM uses a pulse width modulated (PWM)
camshaft timing. Both camshafts are variable over a voltage or ‘Duty Cycle’ (DC) to control each OCV to
60-degree crank angle. This is achieved by two attain the desired camshaft angle. VCT1 output
separate hydraulic mechanisms called ‘Phasers’, controls the Bank1 camshaft OCV. VCT2 controls the
which are integral with the intake and exhaust Bank2 camshaft OCV.
camshaft drive sprockets. A 4 + 1 tooth wheel on the front of each camshaft with
The camshaft timing is controlled by directing oil an associated sensor mounted on the intake and
under pressure (from the engine oil pump) into one of exhaust sides of the cylinder head are used to
two ports in the Phaser, one port will retard the cam calculate the ‘Actual cam angle’ for both camshafts.
timing (‘Retard port’) and the other will advance the The two sensors, CID1 and CID2 measure the
timing (‘Advance port’). An Oil Control Valve (OCV), camshaft angle on Bank 1 and Bank2 respectively.
one for each camshaft is used to control the flow of oil The PCM uses engine rpm, throttle position and
into the retard and advance ports of both cams. The engine load to determine the optimum camshaft
OCV is controlled by the PCM. timing setting or ‘Desired Cam Angle’ for both
The PCM uses a pulse width modulated (PWM) camshafts.
voltage or ‘Duty Cycle’ (DC) to control each OCV to Once the PCM has determined the Desired Cam
attain the desired camshaft angle. VCT1 output Angle, it will control the Duty Cycle output VCT1 and
controls the inlet camshaft OCV. VCT2 controls the VCT2, to the intake and exhaust OCVs based on the
exhaust camshaft OCV. difference between the Desired Cam Angle and the
A 3 + 1 tooth wheel on the front of each camshaft with Actual Cam Angle. This difference is called the Cam
an associated sensor mounted on the intake and Angle Error. The Cam Angle Error for each cam is
exhaust sides of the cylinder head are used to calculated individually and used to control both
calculate the ‘Actual cam angle’ for both camshafts. camshafts independently to a single Desired Cam
The two sensors are called, intake cam position or Angle.
‘CID1’ and exhaust cam position or ‘CID2’. Intake and An engine oil temperature sensor, which measures oil
exhaust cam positions are calculated separately. temperature in the oil sump, is used to compensate
The PCM uses engine rpm, throttle position and for Phaser response with changing oil viscosity at
engine load to determine the optimum camshaft different temperatures.
timing setting or ‘Desired Cam Angle’ for both
camshafts. Modes of Operation
Once the PCM has determined the Desired Cam 1. Start-Up Mode
Angle, it will control the Duty Cycle output VCT1 and
In this mode the VCT phasers will be in the fully
VCT2, to the intake and exhaust OCVs based on the
advanced position or locked position. The Camshafts
difference between the Desired Cam Angle and the
Actual Cam Angle. This difference is called the Cam are locked mechanically by a hydraulic ‘Locking Pin’
which forms part of the phaser. The VCT1 and VCT2
duty cycle sent to the oil control valves will be 0%.
camshafts independently to a single Desired Cam Exit from startup mode is within 10 seconds of
starting.
Angle.
An engine oil temperature sensor, which measures oil 2. Idle Mode
temperature in the oil gallery of the engine block, is At idle, the VCT Phasers are in the locked fully
used to compensate for Phaser response with advance position as per Start-Up Mode. Exit from Idle
changing oil viscosity at different temperatures. Mode occurs when the engine speed is above 1,050
5.4 L, 3 Valve V8 Engine RPM and the throttle is open.
The 5.4, 3V, V8 Engine is fitted with variable inlet and 3. Normal Drive Mode
exhaust camshaft timing on each cylinder head bank . In this mode of operation the camshaft timing angle is
The camshaft on each bank is variable over a controlled to a Desired Cam Angle which is
60-degree crank angle using two separate hydraulic determined by, Engine Speed, Engine Load, Throttle
‘Phasers’, which are integral with the Bank1 and Position. In this condition the PCM VCT1 and VCT2
Bank2 camshaft drive sprockets. output duty cycle will be between 20% and 80% (0.2
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to 0.8) supplied to the OCVs. VCT Sensor Location

4. Engine Shut down Mode
When the vehicle is keyed off, (normally from idle) the
VCT Phasers will remain in the Locked position.
5. Oil Overheat mode

If the oil temperature becomes excessively high
engine speed at which the VCT system enters Drive
Mode will become higher. See specifications in this
section.
6. System Malfunction Mode

If a critical sensor or the VCT system fails the VCT
system will be set to the fully advanced locked
position. The VCT1 and VCT2 Duty cycle to the OCVs
will be set to 0%.
Diagnosis
7. Oil Control Valve Cleaning Mode Diagnostic Trouble Codes (DTC) are retrieved through
The VCT system has an automatic Valve Cleaning the diagnostic connector using the WDS tester. Fault
Mode that is designed to keep the valve free of oil Finding Tables for DTCs are in the ‘Diagnosis’
deposits and build up. This mode is activated when section.
the throttle is closed during normal driving. DTCs applicable to the VCT solenoid are shown in the
Connections following table.
PCM Pin A5…………………………………….VCT1 DTC Test Type Description of test

PCM Pin A6…………………………………….VCT2 P0340 KOER Cont Camshaft Position
Sensor CID1 (I6
Circuit Intake Cam, V8 Bank
1)
P1340 KOER Cont Camshaft Position
Sensor CID2 (I6
Exhaust Cam, V8
Bank 2)
P1380 KOEO Cont Camshaft Position
Actuator, VCT1
Circuit (I6 Intake
OCV, V8 Bank 1
OCV)
P1385 KOEO Cont Camshaft Position
Actuator, VCT2
Circuit (I6 Exhaust
OCV, V8 Bank 2
OCV)
Maintenance P1381 Cont Camshaft Position
Maintenance of the VCT solenoid and mechanisms Timing Over
are described in the Variable Camshaft Timing Advanced (I6 Intake
section. cam, V8 Bank 1)
P1386 Cont Camshaft Position
Timing Over
Advanced (I6
Exhaust Cam, V8
Bank 2)
P1383 Cont Camshaft Position
Timing Over
Retarded (I6 Intake
cam, V8 Bank 1)
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DTC Test Type Description of test PID Description

P1388 Cont Camshaft Position VCTADV cam_angle_0; The actual position
Timing Over in crankshaft degrees of the right
Retarded (I6 Exhaust or number 1 camshaft for VCT
Cam, V8 Bank 2) (Variable Camshaft Timing),
where zero is the base camshaft
Critical Sensors timing. A decrease corresponds to
If the following sensors malfunction the VCT system an advance of the camshaft
will be disabled. timing, while an increase
corresponds (I6 Intake Cam, V8
Sensor Description Bank 1)
CHT Cylinder head temperature sensor VCTADV2 cam_angle_1; The actual position
EOT Engine Oil Temperature Sensor in crankshaft degrees of the left or
number 2 camshaft for VCT
MAP Manifold Absolute Pressure Sensor (Variable Camshaft Timing),
ACT Air Charge Temperature Sensor where zero is the base camshaft
TP Throttle Position Sensor timing. A decrease corresponds to
an advance of the camshaft
Check the relevant sections in this chapter to ensure
timing.(I6 Exhaust Cam, V8 Bank
these sensors are operating correctly, Before 2)
Performing any other diagnosis on the VCT system.
VCTADVERR cam_err_0; How far the actual
Specifications / Modes of operation I6 V8, 3V position of the right camshaft is
Cam Angle at fully advanced -10° 0° advanced (+) or retarded (-) in
Position crankshaft degrees from the
Cam Angle at Fully Retarded 50° 60° desired position for VCT (Variable
Position Camshaft Timing ). (I6 Intake
Cam, V8 Bank 1)
VCT Activation RPM VCTADVERR2 cam_err_1; How far the actual
Oil Temperature I6, 4V V8, 3V position of the left or number 2
Normal 1000 RPM 1100 RPM camshaft is advanced (+) or
130° 1250 RPM 1100 RPM retarded (-) in crankshaft degrees
from the desired position for VCT
140° 1500 RPM 1100 RPM (Variable Camshaft Timing ). (I6
150° VCT off 1100 RPM Exhaust Cam, V8 Bank 2)
Failure Diagnosis Solenoid Test

If a fault develops in the VCT control system or a 1. Disconnect the wiring harness from the VCT
critical sensor, The VCT outputs from the PCM are solenoid.
disabled (the VCT system is turned off) and the 2. Using a suitable multimeter, measure the
appropriate trouble code will be logged in memory for
resistance of the solenoid coil across the
retrieval during Self-test mode.
terminals.
VCT PID Specification
PID Description
VCT1 cam_dc_0; Duty cycle of the VCT
(Variable Camshaft Timing)
solenoid output (I6 Intake Cam,
V8 Bank 1)
VCT2 cam_dc_1; Duty cycle of the VCT
(Variable Camshaft Timing)
solenoid output (I6 Exhaust Cam,
V8 Bank 2)
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VCT Solenoid Resistance Specification

I6 7.0 Ω - 9.0 Ω
V8, 3V 8.0 Ω - 10.0 Ω
Circuit
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G98133 en 01/2003 2003.0 BA Falcon

Flow Problem Possible Cause Possible solution DTCs Additional comments

Chart that may
Output be set
Number
1 VCT controller not Throttle pedal is not
Check for correct
at idle mode. fully closed. throttle pedal
operation.
Engine RPM is to Check and rectify
high for entry into air leaks, throttle
VCT idle mode. malfunction and
other problems that
allow engine to idle
to be excessively
high.
2 Engine idle rough OCV is Remove valve, P1383 Ref: OCV Cleaning
and/or high RPM contaminated, perform cleaning P1388 Procedure
idle. One camshaft jammed or faulty. procedure and
is retarded when the inspect.
its OCV duty is PCM VCT output 1 or Check and repair P1383 Check by
equal to zero. 2 wiring is shorted to wiring/PCM. P1388 disconnecting both
ground. (This P0340 OCVs and re-running
problem will power P1340 ‘VCT TEST1 IDLE’ in
up one of the OCVs). the diagnostic flow
chart.
VCT Phaser is Remove and P1383 Most problems can
jammed or faulty. replace Phaser. P1388 be attributed to the
OCV, ensure that the
OCV is checked and
cleaned before
replacing Phaser Ref:
Engine Section
303-01a, b & c.
Engine performance Camshaft or CID Check camshaft Ref: Engine Section
and/or Idle quality is timing is incorrect or and engine timing 303-01a, b & c.
poor. Camshaft is slipped, moved or including CID
not at ‘Locked damaged. timing.
position’ when the
OCV duty cycles are
=0
G98133 en 01/2003 2003.0 BA Falcon


Chart that may
Output be set
Number
3 Engine stalls or runs VCT OCV or CID Check for correct P1383 This will only be a
poorly when throttle sensor wiring is OCV wiring P1388 problem if the engine
is opened. Engine connected back the orientation. P1381 wiring has been
operates normally front. P1386 removed and
for only 10sec after replaced, or the
start. history of the vehicle
NOTE: Engine may is not known.
recover 5sec after Open circuit/faulty Check VCT1 and P1381
throttle is opened OCV wiring. VCT2 wiring. P1386
when the PCM P0340
Identifies a problem, P1340
turns VCT off and One OCV is jammed Remove and clean P1381 Ref: OCV Cleaning
sets a DTC. in the fully closed the OCV that is P1386 Procedure.
position. jammed or replace
faulty valve.
Oil supply or filter Check the oil filter P1381 Ref: Engine Section
blocked on one in #1 cam cap. P1386 303-01a, b & c.
camshaft.
VCT Phaser stuck in Replace VCT P1381 This is not a very
locked position i.e. Phaser. P1386 common fault ensure
locking pin jammed. that the oil supply,
Phaser is therefore OCV, wiring and
unable to move when PCM are operating
a duty cycle is correctly before
applied to the OCV. replacing Phaser.
Ref: Engine Section
303-01a, b & c for
Phaser replacement.
G98133 en 01/2003 2003.0 BA Falcon


Chart that may
Output be set
Number
4 Cam_dc_0_ or OCV blocked, Remove OCV, P1381 Ref: OCV Cleaning
Cam_dc_1 is high, jammed, worn or perform cleaning P1386 Procedure.
cam retard is slow faulty. procedure, inspect
or cam error is and re-install.
large. Blocked VCT oil Remove OCVs and P1381 Ref: Engine Section
filter/s in #1 cam cap, cam caps inspect P1386 303-01a, b & c.
or blocked oil supply. and clean oil filters,
oil galleries and
OCV. Re-install
and re-test.
Cam_dc_0_ or OCV worn or faulty. Check condition of P1388 Ref: Engine Section
Cam_dc_1_ is low OCVs P1383 303-01a, b & c.
But not zero, cam Phaser return spring Check condition of P1388 Ref: Engine Section
error is large and is broken or faulty. Phaser return P1383 303-01a, b & c.
negative. spring.
Cam friction is high. Check cam, journal P1388 Ref: Engine Section
and valve train P1383 303-01a, b & c.
condition.
When throttle is A ‘Critical Sensor’ Run KOEO, KOER P1388 Stop engine, check
opened Both has failed and check DTCs P1383 stored DTCs, and
Cam_dc_ are = 0, Check stored P1381 clear. Re-run flow
i.e. has been VCT is Failed PCM VCT P1386 chart tests.
outputs or wiring, i.e. DTCs for failed
disabled P0340 Check DTCs that
OCVs not connected VCT outputs.
P1340 indicate that the
or wiring damaged. P1380 listed ‘critical
Failed CID/Cam Check CID P1385 sensors’ have failed.
position sensor or sensors, MAP NOTE: During a test
Wiring associated wiring, EOT if a fault is found the
and stored DTCs ACT VCT will be disabled
VCT control system Check OCVs, CHT and the stored DTC
unable to move associated wiring, TP is set.
camshafts to desired and stored DTCs
position.
5 Poor VCT Oil condition is poor Change oil and oil P1388 Ref: Engine Section
performance. and/or engine oil filter filter. P1383 303-01a, b & c.
Causing poor is blocked. P1381
drivability. Engine P1386
runs well during Engine oil pressure is Check oil pressure P1388
cruise conditions. low. is within P1383
specification. P1381
P1386
G98133 en 01/2003 2003.0 BA Falcon


Chart that may
Output be set
Number
6 Poor VCT VCT oil filters are Check and clean P1381 Ref: Engine Section
performance. blocked. filters in cam P1386 303-01a, b & c.
Causing poor journal caps.
drivability. Engine Oil control valve is Check OCV P1381 Ref: Engine Section
runs well during faulty/Worn out. condition and P1386 303-01a, b & c.
cruise conditions. replace as P1388
necessary. P1383
VCT Phasers are Check Phasers P1381 Ref: Engine Section
worn/Faulty. and replace as P1386 303-01a, b & c.
necessary. P1388
P1383
#1 camshaft journal Check journal P1381 Ref: Engine Section
clearances are too clearances are P1386 303-01a, b & c.
high. within specification. P1388
P1383
Electronic Throttle Body Diagnosis
The PCM processes accelerator pedal and speed DTCs applicable to this output are shown on the
control demand for the Electronic Throttle Body following table
(ETB). The electric motor in the ETB moves the
throttle plate through a gear set. The plate is adjusted DTC Test Mode Condition
and monitored by the PCM in a closed control loop. P2100 KOEO Cont. Throttle Actuator Control
The TP sensor provides the PCM with feedback on Motor Circuit/Open
the actual position of the throttle plate. P2101 KOEO Cont. Throttle Actuator Control
Motor Circuit
CAUTION: The Electronic Throttle Body Range/Performance
(ETB) must NOT be dismantled. No adjustments P2102 KOEO Cont. ETB motor current is
can be made to the ETB. The only serviceable lower than expected
item on the ETB is the Throttle Position Sensor
(TPS), which can be replaced. P2103 KOEO Cont. ETB motor current is
higher than expected
NOTE: The preset stop-screw must not be adjusted
as it is factory set and bonded tight. Adjustment will P2105 Cont. Throttle Actuator Control
likely cause failure. System - Forced Engine
Shutdown
Connections P2107 Cont. Throttle Actuator Control
System - Forced Engine
PCM Pin A27…………………………………..ETCP
into guard mode
PCM Pin A28…………………………………..ETCN
P2110 Cont ETC in Guard Mode.
Circuit (Limp home mode)
System - Higher throttle
opening than driver
demand
System - Lower throttle
opening than driver
demand
Failure Mode
If a fault develops in the electronic throttle control
system, a standby function is carried out. The plate is
spring loaded to a slightly open position allowing
enough air to pass to provide limited engine
operation. This spring-loaded position is preset during
G98133 en 01/2003 2003.0 BA Falcon

manufacture and must not be adjusted in service. EVAP Solenoid Location, I6

When operating in this mode, rpm-limiting by cylinder
cutout will occur and the warning light will be set. The
appropriate trouble code will be logged in the memory
for retrieval during Self-test mode.
Testing
1. Measure the resistance of the electronic throttle
motor
ETC Motor Resistance Specification
3 to 5 Ω
Evap Canister Purge Solenoid
The Evaporator Canister Purge Solenoid (EVAP)
<CANP> controls purging of vapours from the carbon
canister to the air intake system. The canister stores
fuel vapours from the fuel tank. The Powertrain EVAP Solenoid Location, V8
Control Module (PCM) monitors several systems to
determine when to purge these vapours into the
intake manifold with minimum impact on engine
operation.
The positive side of the EVAP solenoid is connected
to Vehicle Power (VPWR). The PCM completes the
electrical circuit by grounding the solenoid coil in a 10
Hz duty cycle. Once purge is initiated, the duty will
gradually increase with engine speed to slowly draw
the canister vapours in the intake manifold.
Connections
PCM Pin B22....................................EVAP Solenoid
PCM Pin B34........................Vehicle Power (VPWR)
Circuit Diagnosis
section.
DTCs applicable to the EVAP solenoid are shown in
P0443 KOEO, Cont. circuit malfunction
Testing
1. Check the operation of the EVAP solenoid.
2. Measure the resistance of the solenoid.
EVAP Solenoid Resistance Specification
50 to 70 Ω
circuits.
Turbocharger Westgate Control
The PCM measures the boost pressure of the
turbocharger using the boost pressure sensor (BPS).
Boost pressure is controlled to a set pressure, which
is dependent upon the engine load, temperature and
RPM. The control system increases engine intake
pressure by diverting excess pressure away from the
G98133 en 01/2003 2003.0 BA Falcon

wastegate actuator, through a wastegate solenoid cycle) allowing minimum mechanical boost to be
valve mounted underneath the battery. The solenoid delivered. The minimum mechanical boost is
is controlled by the PCM’s TURBO output. controlled by the spring-loaded position of the
wastegate actuator. This is preset during manufacture
Connections and must not be adjusted in service. If the boost
PCM Pin C21………………………………. TURBO pressure is still higher than desired, torque limiting by
cylinder cutout will occur. The appropriate trouble
Circuit code will be logged in memory for retrieval during
Self-test mode.
Testing
The TURBO solenoid output is tested continuously
during vehicle operation (cont.) and whenever Key On
(KOER) test are performed.
Testing TURBO control solenoid output
connector.
the WGATE. If the PID value is within
specification, then check for other Diagnostic
Trouble Code (DTC) or component faults
Diagnosis PID Specification

DTCs applicable to this output are shown on the PID Description
following table. WGATE Turbocharger Wastegate Control
P0243 KOEO, KOER Wastegate Solenoid Transmission Outputs
Cont. Circuit Malfunction
If several Diagnostic Trouble Code (DTC) applicable
P1227 Cont Wastegate Control to transmission are present, check for a short circuit to
System Failed closed - Vehicle Power (VPWR) or ground, or moisture in the
Over Pressure transmission harness connector.
P1228 Cont Wastegate Control
System Failed Open - Shift Solenoid 1
Under Pressure Shift Solenoid 1 (SS1) <GSS1> is used on vehicles
The P1227 and P1228 codes are total system fitted with automatic transmission to control shifting of
performance codes, and may relate to a mechanical the gear ratios.
fault in the control system if P0243, P0236, P0237 The solenoid is wired to 12V within the transmission.
and P0238 have not been set, possible causes are: The PCM applies 0 Volts to energise the coils of SS1
Blocked or restricted wastegate solenoid ports as required for gearshift operation.
Damaged or missing hose(s) between wastegate The automatic transmission gear shift strategy is
solenoid and turbo compressor or wastegate described in Section 307-01, Automatic Transmission.
actuator.
Connections
Failed wastegate actuator diaphragm,
Stuck open/closed wastegate valve (in turbine PCM Pin A19......................................SS1 Solenoid
housing). Diagnosis
Loose, blocked or damaged hoses from turbo
compressor outlet to throttle body Diagnostic Trouble Codes (DTC) are retrieved through
Damaged intercooler Finding Tables for DTCs are in the ‘Diagnosis’
Blocked or restricted intake to turbo compressor section.
Failure Mode DTCs applicable to the SS1 solenoid are shown in the
following table.
If a fault develops in the turbo wastegate control
system, a standby function is carried out. The
wastegate solenoid is forced fully open (0% duty
G98133 en 01/2003 2003.0 BA Falcon

DTC Test Mode Condition Testing

P0752 KOEO, KOER Shift Solenoid 1 (SS1) Solenoid Test
Cont (Auto) stuck on
P0753 KOEO, KOER Shift Solenoid 1 (SS1) 1. Disconnect the harness from the transmission
Cont electrical problem connector.
Testing terminals using a suitable multimeter. Replace the
Solenoid Test
SS2 Solenoid Resistance Specification
1. Disconnect the harness from the transmission 23 -45 Ω
connector. 3. Check the harness for open circuits and short
2. Measure the resistance across the connector circuits.
solenoid if not within specification. Shift Solenoid 3
SS1 Solenoid Resistance Specification Shift Solenoid 3 (SS3) <MCS1> is used on vehicles
23 -45 Ω fitted with automatic transmission to control shifting of
3. Check the harness for open circuits and short the gear ratios.
circuits. The solenoid is wired to 12V within the transmission.
The PCM applies 0 Volts to energise the coils of SS3
Shift Solenoid 2 as required for gearshift operation.
Shift Solenoid 2 (SS2) <GSS2> is used on vehicles The automatic transmission gear shift strategy is
fitted with automatic transmission to control shifting of described in Section 307-01, Automatic Transmission.
the gear ratios.
Connections
The solenoid is wired to 12V within the transmission.
The PCM applies 0 Volts to energise the coils of SS2 PCM Pin A17.......................................SS3 Solenoid
as required for gearshift operation.
Maintenance
The automatic transmission gear shift strategy is
described in Section 307-01, Automatic Transmission. DTCs applicable to the SS3 solenoid are shown in the
following table.
Connections
PCM Pin A20.......................................SS2 Solenoid
P0762 KOEO, KOER Shift Solenoid 3 (SS3)
Circuit Cont (Auto) stuck on.
P0763 KOEO, KOER Shift Solenoid 3 (SS3)
Cont <MCS1> electrical
problem
Testing
Solenoid Test
1. Disconnect the harness from the transmission
connector.
SS3 Solenoid Resistance Specification
23 - 45 Ω
DTCs applicable to the SS2 solenoid are shown in the 3. Check the harness for open circuits and short
following table. circuits.
DTC Test Mode Condition Shift Solenoid 4

P0757 KOEO, KOER Shift Solenoid 2 (SS2) Shift Solenoid 4 (SS4) <MCS2> is used on vehicles
Cont (Auto) stuck on. fitted with automatic transmission to control shifting of
P0758 KOEO, KOER Shift Solenoid 2 (SS2) the gear ratios.
Cont electrical problem The solenoid is wired to 12V within the transmission.
The PCM applies 0 Volts to energise the coils of SS4
as required for gearshift operation.
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The automatic transmission gear shift strategy is Connections

described in Section 307-01, Automatic Transmission.
PCM Pin A39......................................VPS Solenoid
Connections
Circuit
PCM Pin A18.......................................SS4 Solenoid
Circuit
DTCs applicable to the VPS solenoid are shown in the

following table.
DTCs applicable to the SS4 solenoid are shown in the DTC Test Mode Condition
following table. P1746 KOEO, KOER Solenoid 5 (SS5) <VPS>
DTC Test Mode Condition Cont open circuit fault
P0768 KOEO, KOER Shift Solenoid 4 (SS4) P1747 KOEO, KOER Solenoid 5 (SS5) <VPS>
Cont <MCS1> electrical Cont short circuit fault
problem P1748 KOEO, KOER Solenoid 5 (SS5) <VPS>
Cont circuit fault
Testing
Testing
Solenoid Test
Solenoid Test
1. Disconnect the harness from the transmission
connector. 1. Disconnect the harness from the transmission
2. Measure the resistance across the connector connector.
terminals using a suitable multimeter. Replace the 2. Measure the resistance across the connector
solenoid if not within specification. terminals using a suitable multimeter. Replace the
SS4 Solenoid Resistance Specification solenoid if not within specification.
23 -45 Ω SS5 Solenoid Resistance Specification
3. Check the harness for open circuits and short 3.8-6.2 Ω
circuits. 3. Check the harness for open circuits and short
circuits.
Variable Pressure Solenoid 5
Power Control Solenoid 6
Variable Pressure Solenoid 5 (VPS) is used on
vehicles fitted with automatic transmission to control Power Control Solenoid 6 (PCS) is used on vehicles
the pressure to the clutches and bands for automatic fitted with automatic transmission to control line
gear shift. pressure in the automatic transmission.
The solenoid is wired to 12V within the transmission. The solenoid is wired to 12V within the transmission.
The PCM applies a PWM current to energise the coils The PCM applies 0 Volts to energise the coils of SS1
of VPS as required for gearshift operation. as required for gearshift operation.
The automatic transmission gearshift strategy is The automatic transmission gearshift strategy is
described in Section 307-01, Automatic Transmission. described in Section 307-01, Automatic Transmission.
G98136 en 01/2003 2003.0 BA Falcon

Connections Connections
PCM Pin A2.........................................PCS Solenoid PCM Pin A43......................................LUS Solenoid
Circuit Circuit
Maintenance Diagnosis
Maintenance, removal and installation of PCS is Diagnostic Trouble Codes (DTC) are retrieved through
described in Section 307-01, Automatic Transmission. the diagnostic connector using the WDS tester. Fault
DTCs applicable to the PCS solenoid are shown in Finding Tables for DTCs are in the ‘Diagnosis’
the following table. section.

P0773 KOEO, KOER Shift Solenoid 6 (SS6) P0743 KOEO, KOER Lock Up Solenoid 7
Cont <PCS> electrical problem Cont (LUS) fault
Testing Testing
Solenoid Test Solenoid Test
1. Disconnect the harness from the transmission 1. Disconnect the harness from the transmission
connector. connector.
2. Measure the resistance across the connector 2. Measure the resistance across the connector
terminals using a suitable multimeter. Replace the terminals using a suitable multimeter. Replace the
solenoid if not within specification. solenoid if not within specification.
PCS Solenoid Resistance Specification LUS Solenoid Resistance Specification
23 -45 Ω 23 -45 Ω
3. Check the harness for open circuits and short 3. Check the harness for open circuits and short
circuits. circuits.
Lock up Solenoid 7 LPG Fuel System Outputs

Lock Up Solenoid 7 (LUS) is used on vehicles fitted LPG Prime Solenoid PRIME
with automatic transmission to control the automatic
transmission torque converter lock-up clutch. The LPG prime solenoid primes the LPG hoses and
The Powertrain Control Module (PCM) applies 12 the intake manifold with gas the facilitate engine
starting.
Volts to energise the coils of LUS as required.
The automatic transmission gear shift strategy is
described in Section 307-01, Automatic Transmission.
G98137 en 01/2003 2003.0 BA Falcon

Connections Connections
PCM Pin C21............................…….. PRIME PCM Pin C7..............................Gas Cut-Out (GCO)
Circuit Circuit
Diagnosis Diagnosis
Diagnostic Trouble Codes (DTC) are retrieved through Diagnostic Trouble Codes (DTC) are retrieved through
the diagnostic connector using the WDS tester. Fault the diagnostic connector using the WDS tester. Fault
Finding Tables for DTCs are in the ‘Diagnosis’ Finding Tables for DTCs are in the ‘Diagnosis’
section. section.
DTCs applicable to the GCO relay are shown in the DTCs applicable to the GCO relay are shown in the
following table. following table.
P1213 KOEO, Cont. PRIME circuit malfunction P1182 KOEO, Cont. relay circuit malfunction
Testing Failure Mode

Solenoid Test Should the GCO relay fail for any reason, LPG mode
will not be available.
1. Remove the connector to the PRIME solenoid on
the LPG converter. Testing
2. Measure the resistance across the PRIME Relay Test
solenoid using a suitable multimeter.
Prime Solenoid Resistance Specification 1. Remove the GCO Relay.
10-14 Ω 2. Measure the resistance across the GCO relay coil
3. Check the harness for open circuits and short terminals using a suitable multimeter.
circuits. GCO Relay Coil Resistance Specification
60-120 Ω
Gas Cut-out Solenoid GCO 3. Check the harness for open circuits and short
In vehicles fitted with Ford factory SF LPG systems, circuits.
three solenoids control LPG flow from the tank to the
converter unit. The three solenoids are controlled by LPG Stepper Motor A-D
the Gas Cut-Out (GCO) relay. The GCO relay is LPG Stepper Motor A -D (GSCA-D) signals are used
energised by the PCM, energising the solenoid control by the Powertrain Control Module (PCM) to control
relay, which then energises to activate the Tank the air-fuel ratio when running in LPG mode. The LPG
Lock-off, Engine Bay Lock-off and Idle Circuit Stepper Motor moves in discrete steps from 0 (fully
solenoids on the LPG fuel line. These solenoids are open) to 216 (fully closed).
open when.
Connections
PCM Pin C24.............LPG Stepper Motor A (GSCA)
PCM Pin C25.............LPG Stepper Motor B (GSCB)
PCM Pin C26….........LPG Stepper Motor C (GSCC)
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PCM Pin C27............LPG Stepper Motor D (GSCD) DTCs applicable to GSMA-D are shown in the
following table.
Circuit
P1159 LPG fault
Testing
GSMA-D are tested whenever an LPG test is
performed.
connector.
the GSM. If the PID value is within specification,
(DTC) or component faults.
PID Specification
LPG Stepper Motor Location PID Description Units

LPG SMP LPG Stepper Motor 100 - 160
Position Steps
Control Area Network (CAN)

CAN is a bi-directional bus used in the vehicle for
intermodule communications. A DLC connector in the
fuse panel allows a WDS to be connected to the CAN
for module diagnostics.
CAN-H and CAN-L is a balanced pair of twisted wire
on the CAN network. It is terminated at the PCM on
one end and the instrument cluster on the other. In
between the PCM and the instrument cluster are other
modules that tap off or daisy chains the CAN-H and
CAN-L wires on the wiring harness. CAN-H and
CAN-L signals are complementary for EMC. A level of
Diagnosis fault tolerance is provided should either line be
Diagnostic Trouble Codes (DTC) are retrieved through shorted to ground or 12V. The PCM and the
the diagnostic connector using the WDS tester. Fault instrument cluster must be connected for the CAN to
Finding Tables for DTCs are in the ‘Diagnosis’ function.
section.
G98137 en 01/2003 2003.0 BA Falcon

CAN Wiring Diagram
Signal Name Receiving ECU

Traction Body Audio/ Instrument Heater WDS
Control Electronics Climate Cluster Integrated Tester
Module Module Control Module
Module
AC Compressor Clutch R
status
AC Shed Load R R
Speed control Telltale R
Engine Coolant Temperature R R R
Engine RPM R R R R
Engine Temperature R
Warning
Engine Type R R R
Engine Torque R
ETC Warning Lamp R
Fuel Usage R
Log DTC R R R
ODO Count R
Oil Pressure Warning R
Smartshield Security Codes R R
Smartshield Warning Lamp R
Gear Position/ ratio R R R
Throttle position R
G98137 en 01/2003 2003.0 BA Falcon

Signal Name Receiving ECU

Traction Body Audio/ Instrument Heater WDS
Control Electronics Climate Cluster Integrated Tester
Module Module Control Module
Module
Transmission Fault R
Transmission Gear
Transmission Mode R
Transmission Overheat R
Transmission Type R R
Vehicle speed R R R R
Diagnostics R
The PCM receives the following data from CAN for its
operation:
Signal Name Transmiting ECU Function
Body Heater Instrument Traction WDS
Electronics Integrated Cluster Control Tester
Module Module
Desired Torque T Reduce engine torque to
Command the commanded level
during traction control
events
Evaporator T AC compressor protection
temperature calculations
Blower voltage T Cooling system load
calculation to determine
appropriate electro-drive
fan speed
A/C Clutch request T Turns the AC compressor
on and off to control the
evaporator temperature
Park brake on T Cancels speed control
Wheel Speed T Vehicle speed calculation
Immobilization Codes T Smartshield Security
Diagnostics T Diagnostic Function
Connections Smartshield Security
PCM PinB13………………….… …..……. CAN-H The PCM forms part of the Smartshield immobilisation
PCM Pin B14……………………………… CAN-L system with the BEM, instrument cluster.
Diagnosis Smartshield system diagram

section.
DTCs applicable to the CAN are shown in the
following table.
U1900 KOEO, KOER CAN Communication Bus
Cont Fault - Receive Error
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At key-on, the PCM transmit a code on the CAN line DTC Test Condition Action required
to the BEM to determine if the vehicle should be Mode
mobilized. The BEM will only respond with a correct
B2139 KOEO PCM or BEM Re-install
code if the key transponder is recognized. The PCM
immobilizes the engine if it does not receive the Cont substituted on original
vehicle components or
correct response code. The PCM immobilizes the car
BEM does not perform a
by deactivating:
recognise Parameter
fuel injectors ignition key Reset
ignition system operation to
fuel pump train the
immobilization
starter motor
system
The PCM controls the illumination of the Smartshield Check BEM
warning indicator on the instrument cluster using the DTCs
CAN line. At key-off, the instrument cluster
B2141 KOEO Incomplete Check KAPWR
automatically flashes the warning jewel once every 2
Cont PCM/BEM to PCM, BEM,
seconds. At key-on, the PCM commands the warning training. and CAN lines
jewel to illuminate for 2 seconds for system prove out.
then perform
The lamp is commanded to flash if the system is
Parameter
immobilized. The lamp extinguishes after 2 seconds if Reset
the system is operational.
Operation
Radio Security Code again.
The PCM transmits a unique PCM ID code on the P1260 KOEO Vehicle Check other
CAN for the radio’s security system to discourage Cont Immobilized. DTCs.
theft. U1147 KOEO Unsuccessful Check BEM
Cont PCM/BEM ID and CAN
Connections training operation
The PCM Smartshield System operates by
communicating codes on the CAN line with the BEM, Failure Mode
the audio system and the instrument cluster. Failure in any part of the Smartshield Security System
will result in no vehicle operation.
Maintenance
Replacement of the PCM, BEM and keys will require Start Relay
a “Parameter Reset ” to be performed. The Smartshield and Smart Start function of the PCM
1. Connect a WDS tester to the Data Link Connector strategy control the START relay. The START relay is
(DLC). enabled when the Smartshield immobilisation system
is not immobilised. After the vehicle starts, the START
2. Turn the ignition to the RUN/START position
relay is de-energise to prevent unintended starter
3. Select “Service Bay Function” and follow the motor operation.
menu directions to select “Parameter Reset”
4. Select “Enter Security Access” from the menu.
Connections
5. There is a 10-minute access delay. PCM PinB4………………….… …..…….STRTEN
6. Select “Parameter Reset” from the menu. Testing
7. When the BEM is trained correctly, the door locks
1. Observe that the Smartshield warning lamp
will cycle twice. operates for 2 seconds when the ignition is key is
8. Remove the WDS tester. turned from the OFF to the RUN position. If the
9. Cycle the ignition key OFF then RUN/START. Smartshield warning lamp flashes, refer to the
10. Verify that the Smartshield indicator turns on for 2 Smartshield section in this group.
seconds and the vehicle will start. 2. Attempt to start the vehicle in the “P” and “N”
Replacement of the PCM will also require the audio positions.
system to be trained to the new PCM ID code. This 3. Check that condition of the start relay located in
procedure can be carried out by using the WDS the fuse/relay box adjacent to the battery.
tester. 4. Check the harness for open circuits and short
circuits.
Diagnosis
DTCs applicable to the PCM Smartshield system are
shown on the following table.
G98137 en 01/2003 2003.0 BA Falcon

Diagnosis operation are logged in Keep Alive Memory (KAM) for

later retrieval.
Diagnosis On-demand tests are initiated as required to diagnose
faults or check vehicle condition. During on-demand
Diagnostic System tests, the Powertrain Control Module (PCM) checks
A sophisticated on-board diagnostic system is various sensors and circuits for faults or malfunctions.
integrated into the PCM software to monitor input and
Continuous Testing
output components.
The Powertrain Control Module (PCM) checks that Continuous testing occurs throughout normal vehicle
sensors and calculated values are within specified operation. Testing commences 4 seconds after the
operating parameters. The test varies according to the ignition key is moved to the ON position. Continuous
diagnosis mode and the component. Where a value testing does not occur whenever on-demand tests are
falls outside of parameters, a Diagnostic Trouble being performed.
Code (DTC) is reported and logged in the PCMs When the Powertrain Control Module (PCM) detects a
memory for retrieval. Components and circuits are fault or malfunction a Diagnostic Trouble Code (DTC)
tested in various ways depending on the hardware, is reported and stored in the PCMs Keep Alive
function, and type of signal. Memory (KAM) memory. KAM has its own power
Analogue inputs are typically checked for open or supply that retains the codes even after the ignition is
short circuits, and out-of-range values. Outputs are switched OFF. DTCs can be retrieved by the
checked for open or short circuits by monitoring the Worldwide Diagnostic System (WDS) testing tool.
circuit associated with the output driver when the Continuous DTCs can be retrieved or cleared at any
output is energised or de-energised. Some outputs time using the WDS, independently of on-demand
are also monitored for the proper function by DTCs.
measuring the reaction of the control system to a To eliminate the storage of transient conditions,
given output command. continuous fault codes are filtered. Only DTCs present
Diagnostic Connector for a specific duration are stored in memory.
NOTE: Disconnecting the battery will clear the KAM
Diagnostics on the PCM are accessed through the and all DTCs stored in memory.
diagnostic connected, situated in the fuse
compartment below and to the right of the steering Once a DTC is stored, it remains in memory until
column. Connect a Worldwide Diagnostic System manually cleared or the PCM is disconnected from the
(WDS) tester to retrieve any Diagnostic Trouble battery supply. If a stored continuous DTC does not
occur for 80 subsequent key-ons, then the code is
Codes (DTC), initiate self-testing diagnostics, retrieve
Parameter Identification (PID) values or reset the erased from memory.
Keep Alive Memory (KAM) or adaptive values. When a DTC is reported from a major input or output
sensor or circuit, the PCM will log the DTC. A Failure
Diagnostic Connector Location
Mode Effects Management (FMEM) flag is set
internally in the PCM, which then,if necessary, will
implement a FMEM strategy to allow continued
operation of the vehicle.
The PCM performs the following continuous tests:
Analogue/Digital Limit Check
Air Conditioning System Tests
CMP Test
EDIS Test
CMP Test
VSS Test
Auto Transmission Test
Traction Control Test
Diagnostic Modes Output Circuit Check
The PCM powertrain control management system has Setting Of Failure Mode (FMEM) flags
two diagnostic modes: Continuous Testing and Servicing Warm-up Counters
On-Demand Tests. Fault Filter Calibration
Continuous testing occurs during normal vehicle
operation. Faults or malfunctions which occur during Analogue/Digital Limit Check
The Analogue/Digital Limit Check tests the limits and
G98137 en 01/2003 2003.0 BA Falcon

range of some analogue sensors. The check tests for VSS Test
short or open circuit sensors and performs a range The Vehicle Speed Sensor Test checks the Vehicle
test on each sensor to ensure it is within the expected Speed Sensor (VSS) signal and circuit.
operating range.
DTC P0500 is reported if the VSS sensor or its circuit
Range checks are only performed where the sensor has malfunctioned.
or circuit passes the limit test.
The following sensor signal limits are checked during Automatic Transmission Tests
the Analogue/Digital Limit Check and associated The Auto Transmission Tests check the operation and
Diagnostic Trouble Codes (DTC) are reported if items circuit continuity of the Transmission Range Sensor
tested are not within specification. Note that the (TRS-A1) <TRS>, (SS1-4, VPS, LUS and PCS).
VPWR test is designed to check continuity of the
DTC P0706 is reported if the TR signal is either out of
PCMs internal power circuit (IVPWR). VPWR does
range or demonstrates a performance problem. DTC
not test battery voltage. P0753 is reported if SS1 or its circuit have failed.
Temperature and Manifold Absolute Pressure
DTC P0758 is reported if SS2 or its circuit have failed.
(T-MAP)
Throttle Position Sensor (TP) <TPS>
Air Conditioner Refrigerant Discharge
Temperature (ACRT) DTC P0748 is reported if Variable Pressure Solenoid
5 (VPS) or its circuit have failed.
Transmission Fluid Temperature Sensor (TFT)
<TOT> DTC P0778 is reported if Power Control Solenoid 6
(PCS) or its circuit have malfunction.
Transmission Range Sensor (TR) <TRS>
DTC P0743 is reported if the Lock Up Solenoid 7
Knock Sensor (KS) (LUS) or its circuit have failed.
Vehicle Power (VPWR)
Solenoids Electrical Fault Logic
Air Conditioning System Tests
When a transmission solenoid electrical fault is
Air Conditioning Compressor Integrity Failure detected, the fault is latched:- remains set until next
The Air Conditioning Compressor Integrity Failure test key-on event.
checks the status of the air conditioning compressor Intermittent faults that do not trigger the latch
clutch and reports a fault if the clutch does not mechanism are not reported.
engage, the clutch slips or the compressor output is
insufficient. Output Circuit Check
The Output Circuit Check tests some outputs for a
DTC P1463 is reported if there is insufficient pressure
short or open circuit.
change in the air conditioning pressure sensor.
The following sensor signal limits are checked during
Air Conditioning Low Refrigerant Charge the Output Circuit Check and associated Diagnostic
The Air Conditioning Low Refrigerant Charge test Trouble Codes (DTC) are reported if items tested are
checks the air conditioning charge and reports a fault not within specification.
where the charge is below the specific limit, or if there Electro Drive Fan 1 (EDF1)
is an A/C system blockage.
Electro Drive Fan 2 (EDF2)
DTC P0534 is reported if there is an air conditioning Fuel Pump (FP)
refrigerant charge loss or blockage.
Air Conditioning Request (ACR)
COP Test Evaporative Canister Purge Solenoid (EVAP)
The COP Test checks the test checks the continuity of <CANP>
the ignition coil circuits and verifies if a coil has fired Variable Cam Timing (VCT),
since the test was last performed. Intake Manifold Runner Control (IMRC) <BBM>
CMP Test Fuel Injectors 1-8 (INJ1-8)
The CMP Test checks the Camshaft Position Sensor Each time the engine is re-started from cold the
(Cylinder Identification) (CMP) <CID> signal and warm-up counter is incremented by one. If the fault
circuit. causing fault the code is not present after 80 warm-up
cycles, the code is erased from memory.
DTC P0340 is reported if the CMP sensor or its circuit
have malfunctioned. Fault Filter Calibration
DTC P0320 is reported if duration between CMP Each continuous fault code has a fault filter to avoid
signal is greater than a specified value. setting a DTC for transient (seen only for a split
G98137 en 01/2003 2003.0 BA Falcon

second) error conditions. When a particular fault All other on-demand tests are done with key on
occurs during operation the corresponding fault filter engine running, and the vehicle stationary.
increments a background counter by one. For each Key On Engine Off (KOEO) and Key On Engine
key-on event the code is not present, the counter is Running (KOER) tests can only be run once during
reduced by one. If the counter reaches a specified each key on event. The ignition key must be moved to
limit, then a DTC is logged. Continuous DTCs stay in the OFF position before the tests can be re-initiated.
memory until cleared by Servicing Warm-up Counters
or manually using the (WDS) tester, or by resetting Key On Engine Off (KOEO) test
the Keep Alive Memory (KAM).
NOTE: On manual transmission vehicles, the clutch
On-Demand Testing pedal must be depressed during the whole test.
On-demand testing is initiated to diagnose faults or The Key On Engine Off (KOEO) on-demand self-test
check operating conditions. On-demand Testing can is a functional test of the powertrain control system.
only commence 4 seconds after the ignition key is The test checks various sensors and circuits with the
moved to the ON position. Continuous testing does ignition key in the ON position and the engine off:-not
not occur whenever on-demand tests are being running. For a fault to be detected during this test the
performed. fault must be present at the time the test is initiated or
When the Powertrain Control Module (PCM) detects a running. Once a fault is detected a Diagnostic Trouble
fault or malfunction a Diagnostic Trouble Code (DTC) Code (DTC)will be logged in the Powertrain Control
is reported and stored in the PCMs Keep Alive Modules (PCM)memory and output to the Diagnostic
Memory (KAM) memory. KAM has its own power Link Connector (DLC) for retrieval by a Worldwide
supply that retains the codes even after the ignition is Diagnostic System (WDS) tester to the diagnostic
switched OFF. DTCs can be retrieved by the tool.
Worldwide Diagnostic System (WDS) testing tool. KOEO test is performed only once for each key on
On-demand DTCs can be retrieved or cleared at any event. The ignition must be switched to the ON
time using the WDS, independently of continuous position for at least 4 seconds; do not move the
DTCs. ignition switch to the START position. When the
conditions for KOEO test initiation are met, and the
If an on-demand test is requested and conditions are
test has not already been performed during the
not correct for the test to run, a “conditions not
current key on session, the PCM performs the
correct” message is displayed on the WDS. following tests:
On-demand test fault codes are only returned to the
PCM Processor and ROM/RAM Test
WDS tester if the test completes normally.
On-demand tests exit the checking procedure under Analogue/Digital Limit and Range Check
the following conditions: Vehicle State Check
The test completes normally or runs to completion Electronic Immobilisation Check
without interruption unless: Output Circuit Check
The test is aborted by the operator; “Cancel” Engine Cooling Fans Check
command is issued from the WDS
The WDS test equipment is unplugged from the PCM Processor and ROM/RAM test
vehicle before the test procedure is complete PCM Processor and ROM/RAM Test checks the PCM
Operational or vehicle conditions change so that Central Processing Unit (CPU), Random Access
conditions needed to continue the test are no Memory (RAM), Keep Alive [Memory] Power
longer met. (KAPWR) and Read Only Memory (ROM) checksum.
The time taken to run the test exceeds a pre-set If any item fails the test, a Diagnostic Trouble Code
limit for the test. (DTC) is logged in memory and displayed on the
Worldwide Diagnostic System (WDS) tester.
There are seven on-demand test modes. Each is
described in further detail in the following sections. DTC P0603 is reported if the KAPWR has been reset
since the last key on event
Key On Engine Off (KOEO)
DTC P0605 is reported if the ROM checksum test fails
Key On Engine Running (KOER)
DTC P0606 is reported if either the CPU or RAM
Throttle Test check fails
Ignition Timing Test
Analogue/Digital Check
Cylinder Contribution Test
Output Test Mode (OTM) The Analogue/Digital Limit Check tests the limits and
range of some analogue sensors. The check tests for
LPG System Test, I6 engines, where fitted short or open circuit sensors and performs a range
The KOEO and OTM tests are done with key on, test on each sensor to ensure it is within the expected
engine off. operating range. Range checks are only performed
G98137 en 01/2003 2003.0 BA Falcon

where the sensor or circuit passes the limit test. The 1. Turning the steering wheel to open the Power
following sensor signal limits are checked during the Steering Pressure Switch (PSP) <PSPS>.
Analogue/Digital Limit Check and associated 2. Depressing the brake pedal.
Diagnostic Trouble Codes (DTC) are reported if items
tested are not within specification. Once a fault is detected a Diagnostic Trouble Code
(DTC) will be logged in the Powertrain Control
Temperature and Manifold Absolute Pressure Modules (PCM) memory and outputs it to the
(T-MAP) Diagnostic Link Connector (DLC) for retrieval by a
Throttle Position Sensor (TP) <TPS> Worldwide Diagnostic System (WDS) tester to the
Air Conditioner Pressure Transducer (ACPT) diagnostic tool.
(ACRT) KOER test is performed only once for each key on
Transmission Fluid Temperature Sensor (TFT) event. The ignition must be switched to the ON
<TOT> position for at least 4 seconds before a new test can
be initiated. The test is initiated by the WDS when the
Transmission Range Sensor (TR) <TRS> vehicle stationary, engine running, transmission in
Vehicle Power (VPWR) either Park or Neutral, as appropriate; and test has
Vehicle State Check not already been performed during the current key on
session:
The Vehicle State Check tests that the Power Initialisation
Steering Pressure (PSP)switch is not active, that no
Air Conditioner Demand (ACD) is present during Analogue/Digital Limit Check
KOEO, I6 engines, and for the Transmission Range High/Low Idle Speed Test
Sensor (TR) <PRNDL> (automatic transmission only) Fuel Ramp Lean/Rich Test
is in either Park or Neutral. Spark Advance Test
DTC P1650 is reported the PSP is active PSPS Operated Check I6 engines
DTC P1705 is reported if the TR is in any position
other than Park or Neutral Initialisation
Output Circuit Check The Initialisation phase prepares the vehicle for
KOER test by switching off Evaporative Canister
The Output Circuit Check tests some outputs for a Purge Solenoid (EVAP) <CANP>, switching off any
short or open circuit. The outputs are turned off before Air Conditioner Demand (ACD)Spark advance
the check; each output is then switched on in turn for feedback is normally enabled during KOER testing,
50 milliseconds during the test. except during the Spark Advance, Ignition Timing and
The following sensor signal limits are checked during Cylinder Contribution tests. During these tests spark
the Output Circuit Check and associated Diagnostic advance feedback is disabled and the timing is fixed.
Trouble Codes (DTC) are reported if items tested are
Analogue/Digital Limit Check
not within specification.
Electro Drive Fan 1 (EDF1) The Analogue/Digital Limit Check tests the limits and
range of some analogue sensors that are not covered
Electro Drive Fan 2 (EDF2)
by Key On Engine Off test. The check tests for short
Fuel Pump (FP) or open circuit sensors and performs a range test on
Air Conditioning Request (ACR) each sensor to ensure it is within the expected range
Evaporative Canister Purge Solenoid (EVAP) under actual engine operating conditions. Range
<CANP> checks are only performed where the sensor or circuit
passes the limit test.
Variable Cam Timing (VCT)
The following sensor signal limits are checked during
Intake Manifold Runner Control (IMRC) <BBM>. the Analogue/Digital Limit Check and associated
Diagnostic Trouble Codes (DTC) are reported if items
Key On Engine Running (KOER) test
tested are not within specification.
The Key On Engine Running (KOER) on-demand
The Cylinder Head temperature Sensor (CHT)
self-test is a functional test performed with the engine
operating in normal conditions and temperatures. The Temperature and Manifold Absolute Pressure
test checks various sensors and circuits with the (T-MAP)
ignition key in the ON position and the engine Throttle Position Sensor (TP) <TPS>
on:-running. For a fault to be detected during this test
the fault must be present at the time the test is High/Low Idle Speed Test
initiated or running. This test calls for some operator The High/Low Idle Speed Test checks that the
intervention to test additional sensor information. This Electronic Throttle Control (ETC) can properly control
includes the idle speed. The test increases then decreases the
idle speed and measures the change in engine speed.
G98137 en 01/2003 2003.0 BA Falcon

DTC P0507 is reported if the idle speed is higher than table.

the expected low idle speed
Output Test Mode States
DTC P0506 is reported if the idle speed is lower than
the expected high idle speed State Description
Fuel Ramp Lean/Rich Test All On The following outputs are switched on (engine
cooling fans off): Air Conditioning Clutch Relay (ACR),
The Fuel Ramp Lean/Rich Test varies the Fuel evaporative Emission Canister Purge (EVAP), Starter
Injector Pulse Width and measures the Heated Relay (START), Fuel Pump (FP) relay, Intake
Exhaust Gas Oxygen Sensors (HEGO) signal to Manifold Charge Control (IMCC) and Variable Cam
detect if the Powertrain Control Module (PCM) can Timing (VCT)* All Off The outputs listed above, and
successfully control the air fuel ratio between lean and engine cooling fans, are switched off.
rich.
If DTC P0131 or P0151, V8 engine, HEGO sensor Fans Low The engine cooling fans (EDF1-2) are
switched on at low speed; all other outputs above
short circuit is already set, the Fuel Ramp Lean/Rich
switched off. Fans High The engine cooling fans
Test will not be performed.
(EDF1-2) are switched on at high speed; all other
I6 Engines outputs above switched off.
DTC P0172 is reported if the air fuel ratio is too rich LPG System Test
during the lean phase of the test
The LPG System Test checks the operation of the
DTC P0171 is reported if the air fuel ratio is too lean complete LPG fuel control system on vehicles with
during the rich phase of the test Ford Factory Fitted LPG systems.
V8 Engines The PCM uses the Heated Exhaust Gas Oxygen

Sensor (HEGO) signal to detect that a change in the
DTC P0172 is reported if the air fuel ratio is too rich
air fuel ratio occurs when the LPG stepper motor is
on cylinder bank 1 during the lean phase of the test
actuated. The LPG stepper motor is ramped lean and
DTC P0175 is reported if the air fuel ratio is too rich then rich to force a change in the HEGO output. The
on cylinder bank 2 during the lean phase of the test test will fail if the system fails to switch either lean or
DTC P0171 is reported if the air fuel ratio is too lean rich within a set time or if the RPM drops below its
on cylinder bank 1 during the rich phase of the test predefined limits. A failure in this test can be caused
by faulty stepper motor, wiring, PCM, HEGO sensor
DTC P0174 is reported if the air fuel ratio is too lean or LPG converter.
on cylinder bank 2 during the rich phase of the test
Code P1159 is reports a fuel stepper motor
Power Steering Pressure Switch Operated malfunction if the air fuel ratio cannot be changed by
Check the PCM during the test.
A requirement of KOER test is that the test operator Ignition Test
moves the steering wheel to either left or right hand
The Ignition Test sets the ignition spark advance to a
extreme lock to operate the Power Steering Pressure
fixed value so that ignition timing can be manually
Switch (PSP) <PSPS>. checked using a timing light. Fixed timing mode stays
The PCM checks that the power steering pressure in effect for 2 minutes or less if cancelled from the
switch changes state during the KOER test. WDS. Fixed timing can be performed more than once
DTC P1651 is reported if the PSP does not change during the same Key On Engine Running (KOER) test
state during the test. session.
Output Test Mode No fault codes are reported from the ignition test.
The Output Test Mode (OTM), No. 84, allows some Parameter Identification
Powertrain Control Module (PCM) outputs to be
A Parameter Identification (PID) represents an internal
switched on and off manually using the Worldwide
Powertrain Control Module (PCM) parameter. PIDs
Diagnostic System (WDS) tester. Either an audible
sound or visually verification of a device can confirm accessed using the Worldwide Diagnostic System
(WDS) tester are displayed as parameter names with
its operation. The OTM may be performed more than
operating values of analogue and digital
once during a KOEO event. TM can only be entered
with the key in the ON position and the engine off:-not inputs/outputs, calculated values and system status
information.
running. There are no fault codes reported following
this test. The test will time out and abort if the test The WDS PID data monitor and record data function
time in any one state exceeds a specified limit. can display values and data dynamically during
normal running and can also record the data for
Once OTM has been entered, there are 4 states that detailed diagnosis.
can be manually selected, as shown in the following
G98137 en 01/2003 2003.0 BA Falcon

Input PID values can immediately confirm the status

of a sensor and its associated circuit to the Powertrain
Control Module (PCM). Similarly output PID values
can monitor the operation of an output device or
signal being sent from the PCM.
Use of PIDs minimises the need to perform pin out
tests. Circuit continuity and a sensor’s actual
operating value can be read directly from the WDS.
PIDs can optimize diagnostic time by quickly
identifying faulty components or circuits.
G98137 en 01/2003 2003.0 BA Falcon

Powertrain Control Management Diagnostic Communications

The PCM communicates with the Worldwide
Powertrain Control Management Diagnostic System (WDS) tester through the
Diagnostic Trouble Codes diagnostic connector using the Control Area Network
(CAN).
The PCM diagnostic system monitors the condition of
various sensors and circuits associated with control of Resetting The Powertrain Control Module
the powertrain. A Diagnostic Trouble Code (DTC) is NOTE: Do not disconnect the battery to clear the
reported and logged in memory to identify the specific Keep Alive Memory (KAM) or Diagnostic Trouble
area where a fault has been reported to the Codes (DTC) unless absolutely necessary.
Powertrain Control Module (PCM). Disconnecting the battery will clear the PCM memory,
Retrieving Diagnostic Trouble Codes including the adaptive values.
Diagnostic data is accessible with the Worldwide Clearing Diagnostic Trouble Codes (DTC)
Diagnostic System (WDS) tester to assist in
Once a system fault has been rectified, the diagnostic
diagnosing faults and operating conditions on the
trouble codes must be cleared from the PCM memory
vehicle. The system is accessed through the
diagnostic connector situated in the fuse box, below using the Worldwide Diagnostic System (WDS) tester.
and to the right of the steering column. 1. Connect the Worldwide Diagnostic System (WDS)
The functions and operation of the WDS are tester to the diagnostic connector.
described in the Worldwide Diagnostic System (WDS) 2. Initiating Retrieve/Clear Continuous DTCs.
Tester Instruction Manual. 3. After the codes appear on the screen, press
“CLEAR”, to erase DTCs from memory.
4. Verify the codes have been erased by test-driving
the vehicle and then repeat Step 2.
DTC Description Possible Causes

A979 AC Compressor Clutch Refer to AC section
KOEO, KOER cycling due to ACPT cutout.
Cont
B2139 Incorrect BEM Response IMMOBILIZATION SYSTEM ACTION REQUIRED
KOEO, Cont. Code. CONDITION Perform a Parameter Reset
PCM or BEM substituted on operation to train the
vehicle immobilization system
BEM does not recognise Check BEM DTCs
ignition key
B2141 Incomplete PCM/BEM IMMOBILIZATION SYSTEM ACTION REQUIRED
KOEO, Cont. training. CONDITION Check KAPWR to PCM, BEM
Unsuccessful PCM/BEM ID operation, and CAN line
training operation then perform
Parameter Reset operation
again
P0107 Temperature And SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, ManifoldAbsolute Pressure Sensor damaged or faulty Improper connection, signal
Cont. (T-MAP) circuit low input open circuit or shorted to
DTC P0107 is reported if the ground, low Vehicle
manifold pressure sensor in Reference Voltage (VREF),
the T-MAP Sensor is less VREF open circuit
than the self- test range. OTHER CONDITION
Manifold pressure has
changed but signal from
Throttle Position Sensor (TP)
<TPS> remains steady, PCM
damaged or faulty
G98120 en 01/2003 2003.0 BA Falcon


P0108 Temperature And MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER, ManifoldAbsolute Pressure Vacuum leak at manifold, Improper connection, signal
Cont. (T-MAP) circuit high input sensor loose or not installed shorted to Vehicle Power
DTC P0108 is reported if the on manifold (VPWR), high Vehicle
manifold pressure sensor in SENSOR CONDITION Reference Voltage (VREF)
the T- MAP Sensor is Sensor damaged or faulty OTHER CONDITION
greater than the self-test Manifold pressure has
range. changed but signal from
Throttle Position Sensor (TP)
<TPS> remains steady, PCM
damaged or faulty
P0112 Intake air temperature signal SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, (T-MAP sensor) circuit low Faulty or malfunctioning Improper connection,
Cont. input. sensor incorrect Reference Voltage
DTC P0112 is reported if the (VREF), sensor signal or
air temperature signal is less Signal Return (SIGRTN)
than the self-test range. shorted to ground
OTHER CONDITION
Extreme low ambient
temperature, faulty or
damaged PCM
P0113 Intake air temperature signal MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER, (T- MAP) Clogged air filter Improper connection,
Cont. DTC P0113 is reported if the SENSOR CONDITION incorrect Reference Voltage
air temperature signal is Faulty or malfunctioning (VREF),T-MAP sensor signal
greater than the self-test sensor shorted to VREF or Vehicle
range. Power (VPWR), T-MAP
sensor signal open circuit,
Signal Return (SIGRTN) open
circuit
OTHER CONDITION
Extreme high ambient
temperature, PCM damaged
or faulty
P0121 Throttle Position Sensor (TP) MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER <TPS> circuit range/ Binding or bent throttle shaft Improper connection,
performance problem throttle plate below closed corrosion on contacts or
DTC P0121 is reported if the position, throttle plate or base connectors, Reference
TP sensor signal is out of idle screw maladjustment, TP Voltage (VREF) too low, TP
the self-test range. sensor not properly secured sensor signal or VREF open
or loose circuit, TP signal shorted to
SENSOR CONDITION Signal Return (SIGRTN) or
TP sensor loose or incorrectly ground
installed. TP sensor damaged OTHER CONDITION
or faulty; corrosion on TP PCM faulty or damaged.
sensor brush, contaminated
TP sensor brush
P0122 Throttle Position Sensor SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, (TP1) circuit low input TP1 sensor faultyor damaged. Improper connection,
Cont. DTC P0122 is reported if the Check Throttle Position corrosion on contacts or
TP sensor signal is less than Sensor Connector. connectors, Reference
the self-test range. Voltage (VREF) too low, TP
sensor signal or VREF open
circuit, TP signal shorted to
Signal Return (SIGRTN) or
ground
OTHER CONDITION
PCM damaged or faulty
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER, (TP1) circuit high input TP1 sensor faulty or Improper connection, TP
Cont. DTC P0123 is reported if the damaged. Check Throttle sensor signal shorted to
TP sensor signal is greater Position Sensor Connector. Reference voltage (VREF) or
than the self-test range. Vehicle Power (VPWR),
circuit, Reference Voltage
(VREF) shorted to Vehicle
Power (VPWR)
P0124 Throttle/Pedal Position SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, Sensor Intermittent TP1 sensor faulty or Improper connection, TP
Cont. DTC P0124 is reported if the damaged. Check Throttle sensor signal shorted to
TP sensor signal is Position Sensor Connector. Reference voltage (VREF) or
intermittent Vehicle Power (VPWR),
Power (VPWR)
P0171 Fuel System too lean (I6, FUEL SYSTEM CONDITION INTAKE AIR CONDITION
KOEO, KOER bank 1-V8) External leak at fuel injectors, Defective positive crankcase
Cont DTC P0171 is reported to externally leaking fuel ventilation system, faulty
indicate the air fuel ratio is pressure regulator, leaking Evaporative Purge (EVAP)
incorrect, too lean. The fuel rail, inadequate pressure Canister or Solenoid
adaptive fuel control strategy from fuel pump, fuel injectors ELECTRICAL CONDITION
has reached the limit of contaminated with foreign Heated Exhaust Gas Oxygen
available mixture correction. material, blocked or restricted Sensor (HO2S) signal shorted
fuel filter to ground; moisture in
harness connectors, blown
CAUTION: A leaking HO2S heater fuse
fuel system poses a OTHER CONDITION
potential fire hazard. Leaking exhaust system; leak
SENSOR CONDITION at manifold slip joint, leaking
Sensor damaged or faulty joint between engine pipe and
catalyst converter, leak at
engine pipe to manifold joint,
damaged or leaking exhaust
P0172 Fuel System too rich (I6, FUEL SYSTEM CONDITION INTAKE AIR CONDITION
KOEO, KOER bank 1- V8) Internally leaking fuel Faulty or damaged
Cont DTC P0172 is reported to injectors, damaged fuel Evaporative Canister Purge
indicate the air fuel ratio is pressure regulator, obstructed Solenoid (EVAP) <CANP>,
incorrect, too rich. The fuel return line, low or no EVAP canister saturated with
adaptive fuel control strategy vacuum to fuel pressure fuel
has reached the limit of regulator; leaking, damaged ELECTRICAL CONDITION
available mixture correction. or missing vacuum hose to Heated Exhaust Gas Oxygen
fuel pressure regulator. Sensor (HO2S) signal shorted
to Vehicle Power (VPWR),
CAUTION: A leaking blown HO2S heater fuse.
potential fire hazard. Restricted exhaust system,
SENSOR CONDITION Engine Cylinder Head
Sensor damaged or faulty Temperature Sensor (CHT) or
cooling system fault
G98120 en 01/2003 2003.0 BA Falcon


P0174 Fuel System too lean (bank FUEL SYSTEM CONDITION INTAKE AIR CONDITION
KOEO, KOER 2-V8) External leak at fuel injectors, Defective positive crankcase
Cont DTC P0174 is reported to externally leaking fuel ventilation system, faulty
indicate the air fuel ratio is pressure regulator, leaking Evaporative Purge (EVAP)
incorrect, too lean. The fuel rail, inadequate pressure Canister or Solenoid
adaptive fuel control system from fuel pump, fuel injectors ELECTRICAL CONDITION
has reached the limit of contaminated with foreign Heated Exhaust Gas Oxygen
available mixture correction. material, blocked or restricted Sensor (HO2S) signal shorted
P0175 Fuel System too rich (bank FUEL SYSTEM CONDITION INTAKE AIR CONDITION
KOEO, KOER 2-V8) Internally leaking fuel faulty or damaged
Cont DTC P0175 is reported to injectors, damaged fuel Evaporative Canister Purge
indicate the air fuel ratio is pressure regulator, obstructed Solenoid (EVAP) <CAN> P,
incorrect, too rich. The fuel return line, low or no EVAP canister saturated with
adaptive fuel control system vacuum to fuel pressure fuel
has reached the limit of regulator; leaking, damaged ELECTRICAL CONDITION
available mixture correction. or missing vacuum hose to Heated Exhaust Gas Oxygen
potential fire hazard. restricted exhaust system,
Sensor damaged or faulty. Temperature Sensor (CHT) or
P0196 ngine Oil Temperature SENSOR CONDITION ELECTRICAL CONDITION
KOER Sensor Circuit Sensor damaged or faulty; Improper wiring connection to
Range/Performance sensor. EOT wiring circuit
EDTC P0196 is reported if shorted to VPWR, VREF or
the EOT Sensor temperature PWRGND.
is inconsistent with engine OTHER CONDITION
temperature. CHT sensor faulty.
P0201 Injector Circuit / Open - ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER Cylinder 1 Improper connection, injector Faulty fuel injector; fuel
Cont DTC P0201 is reported if the shorted to ground or Vehicle injector field coil not
fuel injector for cylinder 1 is Power (VPWR), short or open continuous
malfunctioning or fails the circuit in injector coil
KOEO self-test
KOEO self-test
G98120 en 01/2003 2003.0 BA Falcon


KOEO self-test
KOEO self-test
KOEO self-test
KOEO self-test
KOEO self-test
P0221 TP2-PS fails - Out-of-range MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER, at commanded settings. Binding or bent throttle shaft Improper connection,
Cont. DTC P0221 is reported if the throttle plate below closed corrosion on contacts or
TP sensor signal is invalid atposition, throttle plate or base connectors, Reference
the commanded throttle idle screw maladjustment, TP Voltage (VREF) too low, TP
position. sensor not properly secured sensor signal or VREF open
or loose circuit, TP signal shorted to
SENSOR CONDITION Signal Return (SIGRTN) or
TP sensor loose or incorrectly ground
installed. TP sensor faulty or OTHER CONDITION
damaged. TP sensor PCM damaged or faulty
damaged or faulty; corrosion
on TP sensor brush,
contaminated TP sensor
brush
KOEO, KOER, (TP2) circuit low input TP sensor loose or incorrectly Improper connection,
Cont. DTC P0222 is reported if the installed.TP sensor faulty or corrosion on contacts or
TP sensor signal is less than damaged. Check Throttle connectors, Reference
the self- test range. Position Sensor Connector. Voltage (VREF) too low, TP
sensor signal or VREF open
circuit, TP signal shorted to
Signal Return (SIGRTN) or
ground
OTHER CONDITION
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER, (TP2) circuit high input TP sensor loose or incorrectly Improper connection, TP
Cont. DTC P0223 is reported if the installed. TP sensor faulty or sensor signal shorted to
TP sensor signal is greater damaged. Check Throttle Reference voltage (VREF) or
than the self-test range. Position Sensor Connector. Vehicle Power (VPWR),
Power (VPWR)
OTHER CONDITION
P0224 Throttle/Pedal Position SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, Sensor Intermittent TP sensor loose or incorrectly Improper connection, TP
Cont DTC P0224 is reported if the installed. TP sensor faulty or sensor signal shorted to
TP sensor signal is damaged. Check Throttle Reference voltage (VREF) or
intermittent Position Sensor Connector. Vehicle Power (VPWR),
Power (VPWR)
OTHER CONDITION
P0230 Fuel Pump (FP) relay ELECTRICAL CONDITION RELAY CONDITION
KOEO, KOER primary circuit malfunction Improper connection, fuel Open circuit to fuel pump
Cont DTC P0230 is reported if a pump circuit open or shorted relay, open circuit within fuel
malfunction develops in the circuit between fuel pump pump relay improper
fuel pump, fuel pump relay relay and FP, Vehicle Power connection to fuel pump relay
or fuel pump circuit (VPWR) open circuit to fuel OTHER CONDITION
pump, fuel pump circuit PCM damaged or faulty
shorted to VPWR
P0236 Turbo Charger Boost Sensor SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER, Circuit Range/Performance Sensor damaged or faulty. Intermittent electrical
Cont. connection to T-MAP sensor.
Intermittent short circuit to
VPWR, VREF or PWRGND.
SIGRTN shorted to
PWRGND.
KOEO, KOER, Circuit Low Sensor damaged or faulty. Improper connection, signal
Cont. shorted to Vehicle Power
(VPWR), high Vehicle
Reference Voltage (VREF)
KOEO, KOER, Circuit High Sensor damaged or faulty. Improper connection, signal
Cont. shorted to Vehicle Power
P0320 Engine Speed Input Circuit ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER DTC P0320 is reported if Improper connection, short or Interference from on
Cont duration between two open circuit in harness boardtransmitter such as a
successive PIP signals is SENSOR CONDITION two way radio, faulty or
greater than specified value Faulty Crankshaft Position damaged PCM
resulting in a possible engine Sensor (CK), faulty or
stall or misfire damaged reluctor (toothed
wheel)
G98120 en 01/2003 2003.0 BA Falcon


P0325 Knock Sensor (KS) circuit ELECTRICAL CONDITION SENSOR CONDITION
KOEO, KOER malfunction Improper connection, open or Sensor damaged or faulty.
Cont DTC P0325 is reported if the short circuit, KS shorted to General background noise not
KS is out of the self-test ground, KS shorted to Vehicle within expected range
range. Power (VPWR) OTHER CONDITION
P0340 Camshaft Position Sensor MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER CID1 (I6 Intake Cam, V8 Inlet camshaft (I6) or Bank1 Improper connection to CID1
Cont Bank 1) (V8) camshaft incorrectly Sensor.
installed. Reluctor incorrectly
installed on camshaft
Sensor loose or incorrectly
secured.
SENSOR CONDITION
Sensor damaged or faulty;
P0351 I6 Engine IGNITION SYSTEM OTHER CONDITION
KOEO, KOER Ignition Coil 1 CONDITION Crankshaft Position Sensor
Cont Primary/Secondary Circuit Fouled spark plugs, incorrect (CKP) or reluctor (toothed
Failure spark plug gap, worn or wheel) faulty or damaged,
V8 Engine damaged spark plugs, faulty PCM
Ignition Coil 1 excessive carbon deposits on
Primary/Secondary Circuit spark plugs, coil faulty or
Failure. damaged
ELECTRICAL CONDITION
coil signal shorted to ground,
Vehicle Power (VPWR) or
Signal Return (SIGRTN),
faulty or improper coil signal
connection, improper signal
from Crankshaft Position
Sensor (CKP) to PCM, wiring
fault.
Failure. damaged
fault.
G98120 en 01/2003 2003.0 BA Falcon


Failure. damaged
fault.
Failure. damaged
Coil signal shorted to ground,
fault.
Failure. damaged
fault.
G98120 en 01/2003 2003.0 BA Falcon


Failure. damaged
fault.
P0357 V8 Engine IGNITION SYSTEM OTHER CONDITION
Failure. spark plug gap, worn or wheel) faulty or damaged,
damaged spark plugs, faulty PCM
excessive carbon deposits on
spark plugs, coil faulty or
damaged
fault.
P0358 V8 Engine IGNITION SYSTEM OTHER CONDITION
Failure. spark plug gap, worn or wheel) faulty or damaged,
damaged spark plugs, faulty PCM
excessive carbon deposits on
spark plugs, coil faulty or
damaged
fault.
P0443 Evaporative Emission SOLENOID CONDITION ELECTRICAL CONDITION
KOEO, KOER System Purge Control Solenoid open or short circuit Improper connection, CANP
Cont Valve Circuit malfunction output wiring shorted to
Ground.
G98120 en 01/2003 2003.0 BA Falcon


P0500 Vehicle Speed signal fault ASR Equipped Vehicle OSS Equipped Vehicle
KOEO, KOER DTC P0500 is reported if the Check ASR warning lamp. Check VSS wiring between
Cont vehicle speed signal is not Rectify ASR faults if required. PCM and OSS on
received at the Powertrain Check other DTCs. Rectify as transmission for open circuit,
Control Module (PCM). required. short circuit to VPWR and
The signal may be missing ABS Equipped Vehicle Ground.
or intermittent. Check ABS warning lamp. Check condition of OSS and
Rectify ABS faults if required. driven gears
Check VSS wiring between OTHER CONDITION
PCM and ABS module for PCM VID block incorrectly
open circuit, short circuit to configuredPCM damaged or
VPWR and Ground. faulty
P0503 Vehicle Speed signal fault ASR Equipped Vehicle OSS Equipped Vehicle
KOEO, KOER DTC P0503 is reported if the Check ASR warning lamp. Check VSS wiring between
Cont vehicle speed signal is not Rectify ASR faults if required. PCM and OSS on
received at the Powertrain Check other DTCs. Rectify as transmission for open circuit,
Control Module (PCM). required. short circuit to VPWR and
The signal may be missing ABS Equipped Vehicle Ground.
or intermittent. Check ABS warning lamp. OTHER CONDITION
Rectify ABS faults if required. PCM damaged or faulty
Check VSS wiring between
PCM and ABS module for
open circuit, short circuit to
VPWR and Ground.
P0505 Idle Air Control System MECHANICAL CONDITION ELECTRICAL CONDITION
KOER DTC P0506 is reported if the Extreme blockage of the air Electronic throttle body wiring
idle speed cannot be inlet system or air cleaner. open circuit or, short circuit to
controlled to a specified Improper adjustment of VPWR or Ground
speed during self-test throttle stop screw. Damaged OTHER CONDITION
throttle stop screw; faulty PCM damaged or faulty
throttle body or gasket.
Throttle body loose; sticking
or binding throttle plate;
Faulty or damaged positive
crankcase ventilation system,
leaking o-ring at fuel injector.
Vacuum leak in manifold; hole
in inlet manifold, damaged
gasket at inlet manifold,
damaged, broken or missing
vacuum hose.
P0532 Air Conditioner ELECTRICAL CONDITION AIR CONDITIONING
KOEO, Cont. PressureTransducer (ACPT) Improper connection, Air SYSTEM
sensor circuit low input Conditioner Pressure Refer to Section 412-03,
DTC P0532 is reported if the Transducer (ACPT) sensor AirConditioning for air
ACPT sensor is less than open circuit or shorted to conditioner diagnosis
the self- test range. ground. OTHER CONDITION
KOEO, KOER PressureTransducer (ACPT) Improper connection, Air SYSTEM
Cont sensor circuit low Input Conditioner Pressure Refer to section 412-03, Air
DTC P0532 is reported if the Transducer (ACPT) shorted to Conditioning for air
ACPT sensor is greater than ground or SIGRTN conditioner diagnosis
the self-test range. OTHER CONDITION
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER PressureTransducer (ACPT) Improper connection, Air SYSTEM
Cont sensor circuit high input Conditioner Pressure Refer to section 412-03, Air
DTC P0533 is reported if the Transducer (ACPT) shorted to Conditioning for air
ACPT sensor is greater than Vehicle Power (VPWR), conditioner diagnosis
the self-test range. Vehicle Reference Voltage OTHER CONDITION
(VREF) PCM damaged or faulty
P0534 A/C Refrigerant Charge Loss AIR CONDITIONING Refer to section 412-03.
KOEO, KOER SYSTEM
Cont Insufficient gas charge in A/C
system or A/C system
blockage.
P0562 Battery / System voltage low ELECTRICAL CONDITION CHARGING SYSTEM
KOEO, Cont. DTC P0562 is reported if the Improper connections at Faulty charging system. Refer
battery voltage is below 9.0 battery or ground, faulty or to Group 13, Charging
Volts damaged battery System for diagnosis
P0563 System Voltage High ELECTRICAL CONDITION CHARGING SYSTEM
KOEO, Cont. DTC P0563 is reported if the Improper connections at Faulty charging system. Refer
battery voltage is above 16.0 battery or ground, faulty or to Group 13, Charging
Volts damaged battery System for diagnosis
P0602 Powertrain Control Module POWERTRAIN CONTROL
KOEO, KOER Vehicle ID block MODULE CONDITION
Cont Programming Error VID block is not configured
correctly. Refer to PCM
configuration section
SENSOR CONDITION
P0603 Keep Alive Memory (KAM ELECTRICAL CONDITION OTHER CONDITION
KOEO, Cont test failed. Internal control Improper connection; Keep PCM has been disconnected
module failure Alive Power (KAPWR) open from wiring harness;
DTC P0603 is reported if the circuit to PCM, PCMfusible intermittent connection at
KAM has been reset since link blown battery
the last key on event
KOEO Read Only Memory (ROM) MODULE CONDITION
Error Faulty Powertrain Control
DTC P0605 is reported if the Module (PCM), ROM has
ROM checksum test fails failed
KOEO (PCM) Central Processing MODULE CONDITION
Unit (CPU) fault Faulty PCM: -RAM, or CPU
DTC P0606 is reported if has failed
either the CPU or Read Only
Memory (RAM) check fails
P0707 Transmission Range Sensor ELECTRICAL CONDITION SENSOR CONDITION
KOEO, KOER (TRSA1) <PRNDL> sensor Improper connection; TR Faulty sensor, moisture in
Cont circuit low input (Auto) sensor shorted to ground sensor
DTC P0707 is reported if the AUTOMATIC
TSA1 sensor signal is less TRANSMISSION
than the self-test range. Refer to Group 7, Automatic
Transmission for more
information on the
transmission control system.
G98120 en 01/2003 2003.0 BA Falcon


P0708 Transmission Range Sensor ELECTRICAL CONDITION SENSOR CONDITION
KOEO, KOER (TRSA1) <PRNDL> circuit Improper connection; TRSA1 Faulty sensor, moisture in
Cont high input (Auto) sensor shorted to Vehicle sensor
DTC P0708 is reported if the Power (VPWR) or Vehicle AUTOMATIC
TRSA1 sensor signal is Reference Voltage (VREF), TRANSMISSION
greater than the self-test sensor open circuit Refer to Group 7, Automatic
range. Transmission for more
information on the
P0712 Transmission Fluid ELECTRICAL CONDITION SENSOR CONDITION
KOEO, KOER TemperatureSensor (TFT) Improper connection; TFT Faulty sensor, moisture in
Cont <TOT> sensor circuit low sensor shorted to ground sensor
input (Auto) AUTOMATIC
DTC P0712 is reported if the TRANSMISSION
TFT sensor is less than the Refer to Group 7, Automatic
self-test range. Transmission for more
information on the
P0713 Transmission Fluid ELECTRICAL CONDITION SENSOR CONDITION
KOEO, KOER Temperature Sensor (TFT) Improper connection; TFT Faulty sensor, moisture in
Cont <TOT> sensor circuit high sensor shorted to Vehicle sensor
input (Auto) DTC P0713 is Power (VPWR) or Vehicle AUTOMATIC
reported if the TFT sensor is Reference Voltage (VREF), TRANSMISSION
greater than the self-test sensor open circuit Refer to Group 7, Automatic
range. Transmission for more
information on the
P0743 Lock Up Solenoid 7 (LUS) ELECTRICAL CONDITION AUTOMATIC
KOEO, KOER (Auto) fault Improper connection; LUS TRANSMISSION
Cont DTC P0743 is reported if shorted to Vehicle Power Faulty solenoid
LUS or its circuit have failed (VPWR), Vehicle Reference Refer to Group 7, Automatic
Voltage (VREF) or ground, Transmission for more
solenoid open circuit information on the
P0752 Shift Solenoid 1 (SS1) (Auto) AUTOMATIC
KOEO, KOER stuck on. TRANSMISSION
Cont DTC P0752 is reported if SS1 hydraulic fault
SS1 solenoid is stuck on Refer to Group 7,
AutomaticTransmission for
more information on the
P0753 Shift Solenoid 1 (SS1) ELECTRICAL CONDITION AUTOMATIC
KOEO, KOER electrical problem Improper connection; SS1 TRANSMISSION
SS1 or its circuit have failed (VPWR), Vehicle Reference Refer to Group 7, Automatic
SS2 solenoid is stuck on Refer to Group
7,AutomaticTransmission for
more information on the
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER electrical problem Improper connection; SS2 TRANSMISSION
SS3 solenoid is stuck on Refer to Group 7, Automatic
information on the
KOEO, KOER <MCS1> electrical problem Improper connection; SS3 TRANSMISSION
KOEO, KOER <MCS1> electrical problem Improper connection; SS4 TRANSMISSION
KOEO, KOER <PCS> electrical problem Improper connection; SS6 TRANSMISSION
P0812 Reverse Gear Input Circuit ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER Improper connection; RGS Both reverse lamps faulty.
Cont wiring open circuit or shorted Check reverse lamp operation
SWITCH CONDITION
Manual transmission reverse
gear switch faulty. Check
reverse lamp operation
P0826 Electronic sport shift Switch Check DTC0827 and 0828 OTHER CONDITION
KOEO, KOER Input Circuit Performance SENSOR CONDITION This DTC is not applicable to
Cont ESS switching detected when column-shift automatic.
TRSA-1 <PRNDL> is not in
“DRIVE” position. TRS-A2
printed circuit board loose or
incorrectly installed in ESS
shift assembly.
P0827 Electronic sport shift ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER Switch Input Circuit Low Improper connection, signal This DTC is not applicable to
Cont shorted to PWRGND or column-shift automatic.
SIGRTN
SENSOR CONDITION
Sensor damaged or faulty
G98120 en 01/2003 2003.0 BA Falcon


P0828 Electronic sport shift ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER Switch Input Circuit High Improper connection, signal This DTC is not applicable to
Cont shorted to Vehicle Power column-shift automatic.
SENSOR CONDITION
P1001 KOER Not Able to Complete, OTHER CONDITION
KOER KOER Aborted Check other DTCs and re-run
test.
P1124 Throttle Position Sensor OTHER CONDITION
KOEO, KOER A Out Of Self Test Range Driver pressed on accelerator
pedal or throttle position at
unexpected position during
self-test. Key-off, Key-on and
Re-run test.
NOTE: If throttle system in
RPM guard mode during
KOER test, it is likely that you
will get this P-code.
Additionally if engine stops
while in RPM guard and
KOEO test run w/o cycling
ignition, it is likely to get this
P-code despite foot off pedal
during this test.
P1128 Upstream HO2S Sensors ELECTRICAL CONDITION
KOEO, KOER Swapped (V8 only) Connection for Bank1 and
Cont DTC P1128 is reported if the Bank2 HO2S sensors
Bank 1 and Bank2 HO2S swapped.
sensors are swapped.
P1130 Lack Of HO2S11 Switches - FUEL SYSTEM CONDITION INTAKE AIR CONDITION
KOEO, KOER Fuel Trim At Limit External leak at fuel injectors, Defective positive crankcase
Cont externally leaking fuel ventilation system, faulty
pressure regulator, leaking Evaporative Purge (EVAP)
fuel rail, inadequate pressure Canister or Solenoid
from fuel pump, fuel injectors ELECTRICAL CONDITION
contaminated with foreign Heated Exhaust Gas Oxygen
material, blocked or restricted Sensor (HO2S) signal shorted
fuel filterInternally leaking fuel to ground or VPWR; moisture
injectors, damaged fuel in harness connectors, blown
pressure regulator, obstructed HO2S heater fuse
fuel return line, low or no OTHER CONDITION
vacuum to fuel pressure Leaking exhaust system; leak
regulator; leaking, damaged at manifold slip joint, leaking
or missing vacuum hose to joint between engine pipe and
fuel pressure regulator. catalyst converter, leak at
CAUTION: A leaking damaged or leaking exhaust
fuel system poses a
potential fire hazard.
SENSOR CONDITION
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER Sensor Indicates Lean External leak at fuel injectors, Defective positive crankcase
KOEO, KOER Sensor Indicates Rich Internally leaking fuel Faulty or damaged
Cont injectors, damaged fuel Evaporative Canister Purge
pressure regulator, obstructed Solenoid (EVAP) <CANP>,
fuel return line, low or no EVAP canister saturated with
vacuum to fuel pressure fuel
regulator; leaking, damaged ELECTRICAL CONDITION
or missing vacuum hose to Heated Exhaust Gas Oxygen
KOEO, KOER Fuel Trim At Limit External leak at fuel injectors, Defective positive crankcase
fuel filter to ground or VPWR; moisture
Internally leaking fuel in harness connectors, blown
injectors, damaged fuel HO2S heater fuse
pressure regulator, obstructed OTHER CONDITION
fuel return line, low or no Leaking exhaust system; leak
vacuum to fuel pressure at manifold slip joint, leaking
regulator; leaking, damaged joint between engine pipe and
or missing vacuum hose to catalyst converter, leak at
fuel pressure regulator. engine pipe to manifold joint,
CAUTION: A leaking
fuel system poses a
potential fire hazard.
SENSOR CONDITION
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER Sensor Indicates Lean External leak at fuel injectors, Defective positive crankcase
Cont Sensor Indicates Rich Internally leaking fuel Faulty or damaged
injectors, damaged fuel Evaporative Canister Purge
pressure regulator, obstructed Solenoid (EVAP) <CANP>,
fuel return line, low or no EVAP canister saturated with
vacuum to fuel pressure fuel
regulator; leaking, damaged ELECTRICAL CONDITION
or missing vacuum hose to Heated Exhaust Gas Oxygen
P1159 LPG Stepper Motor A-D FUEL SYSTEM CONDITION LPG SYSTEM
LPG (GSCA- D) fault (I6 LPG) Improper connection; Refer to the LPG section of
DTC P1159 is reported if GSCA-D open circuit, shorted this manual for details on the
GSCA-D fails the self-test or to Vehicle Power (VPWR) or Ford factory fitted LPG
if the air fuel ratio cannot be ground systems
changed by the PCM during
the test
P1182 Gas Cut-Out Solenoid ELECTRICAL CONDITION LPG SYSTEM
KOEO, KOER (GCO) relay circuit Improper connection; GCO Refer to the LPG section of
Cont malfunction, I6 engine solenoid open circuit, shorted this manual for details on the
DTC P1182 is reported if the to Vehicle Power (VPWR) or Ford factory fitted LPG
GCO solenoid or its circuit ground, blown fuse systems
have failed
P1183 Engine Oil Temperature SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER Sensor Circuit Sensor damaged or faulty. Improper connection. Sensor
Cont DTC P1183 is reported if the wiring open circuit or short
sensor voltage is out of circuit to VPWR or PWRGNF,
range VREF or SIGRTN.
G98120 en 01/2003 2003.0 BA Falcon


P1184 Engine Oil Temperature SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER Sensor Out Of Self Test Sensor damaged or faulty. Improper connection. Sensor
Cont Range wiring open circuit or short
DTC P1184 is reported if the circuit to VPWR or PWRGND,
sensor voltage is out of VREF or SIGRTN.
range during self test OTHER CONDITION
Engine cold or overheated
during self-test. Operate
engine to normal operating
temperature and re-run test.
P1213 LPG Prime Solenoid Circuit ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER DTC P1213 is reported if the Improper connection. PCM damaged or faulty
Cont LPG prime solenoid is Solenoid wiring open circuit or
malfunctioning short circuit to VPWR or
PWRGND.
P1227 Wastegate Control System TURBOCHARGER
KOEO, KOER Failed closed - Over CONDITION
Cont Pressure Blocked or restricted
wastegate solenoid ports.
Damaged or missing hose(s)
between wastegate solenoid
and turbo compressor or
wastegate actuator.
Failed wastegate actuator
diaphragm,Stuck open/closed
wastegate valve (in turbine
housing).
Loose, blocked or damaged
hoses from turbo compressor
outlet to throttle body.
Damaged intercooler.
Blocked or restricted intake to
turbo compressor.
P1228 Wastegate Control System TURBOCHARGER
KOEO, KOER Failed Open - Under CONDITION
Cont Pressure Blocked or restricted
wastegate solenoid ports.
Damaged or missing hose(s)
between wastegate solenoid
and turbo compressor or
wastegate actuator.
Failed wastegate actuator
diaphragm,Stuck open/closed
wastegate valve (in turbine
housing).
Loose, blocked or damaged
hoses from turbo compressor
outlet to throttle body.
Damaged intercooler.
Blocked or restricted intake to
turbo compressor.
P1260 Theft Detected, Vehicle SMARTSHIELD CONDITION
KOEO, KOER Immobilized A theft condition has been
Cont DTC P1260 is reported if the detected. The PCM has
Smartshield immobilization immobilised the vehicle.
system is in an immobilised Refer to DTC B2139, 2141
state and U1147 for diagnosis.
G98120 en 01/2003 2003.0 BA Falcon


P1270 Engine RPM or Vehicle OTHER CONDITION
KOEO, KOER Speed Limiter Reached Driver induced condition
Cont DTC P1270 is reported if the NOTE: This code can also
engine rpm limit or vehicle get set if forced shutdown is
speed limit has been activated after RPM guard
reached, resulting in torque mode (P2105 and P2110)
intervention by the PCM.
P1285 Cylinder Head Over ENGINE CONDITION ELECTRICAL CONDITION
KOEO, KOER, temperature Condition Engine over-heated Improper connection. Sensor
Cont. DTC P1285 is reported if the SENSOR CONDITION wiring open circuit or short
CHT sensor indicates Sensor damaged or faulty. circuit to VPWR or VREF.
over-temperature
P1288 Cylinder Head Temperature SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER Sensor Out Of Self Test Sensor damaged or faulty. Improper connection. Sensor
Range wiring open circuit or short
DTC P1288 is reported if the circuit to VPWR or PWRGND,
CHT sensor temperature is VREF or SIGRTN.
out of range during self test. OTHER CONDITION
Engine too hot or cold during
self-test. Operate engine to
normal operating temperature
and re-run test.
KOER Cont Sensor Circuit High Input Sensor damaged or faulty. Improper connection. Sensor
DTC P01289 is reported if wiring open circuit or short
the CHT sensor signal is circuit to VPWR or VREF.
greater than the self-test OTHER CONDITION
range. Engine is at extreme low
temperature
KOEO, KOER Sensor Circuit Low Input Sensor damaged or faulty. Improper connection. Sensor
Cont DTC P0190 is reported if the wiring short circuit to
CHT sensor signal is lower PWRGND or SIGRTN.
than the self-test range.
P1299 Cylinder Head Over ENGINE CONDITION ELECTRICAL CONDITION
KOEO, KOER Temperature Protection Engine over-heating Improper connection. Sensor
Cont Active SENSOR CONDITION wiring open circuit or short
DTC P1299 is reported if the Sensor damaged or faulty; circuit to VPWR or VREF.
PCM is activating the
fail-safe cooling strategy.
P1340 Camshaft Position Sensor MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER CID2 (I6 Exhaust Cam, V8 Exhaust camshaft (I6) or Improper connection to CID12
Cont Bank 2) Bank2 (V8) camshaft Sensor.
incorrectly installed. Reluctor
incorrectly installed on
camshaft
Sensor loose or incorrectly
secured.
SENSOR CONDITION
Sensor damaged or faulty;.
P1380 Camshaft Position Actuator, ACTUATOR CONDITION ELECTRICAL CONDITION
KOEO, KOER VCT1 Circuit (I6 Intake OCV, Oil control valve solenoid Improper connection Sensor
Cont V8 Bank 1 OCV) open circuit or short circuit circuit open circuit or shorted
to VPWR or PWRGND.
OTHER CONDITION
G98120 en 01/2003 2003.0 BA Falcon


P1381 Camshaft Position Timing MECHANICAL CONDITION
KOEO, KOER Over Advanced (I6 Intake Camshaft incorrectly installed.
Cont cam, V8 Bank 1)
KOEO, KOER Over Retarded (I6 Intake Camshaft incorrectly installed.
Cont cam, V8 Bank 1)
P1385 Camshaft Position Actuator, ACTUATOR CONDITION ELECTRICAL CONDITION
KOEO, KOER VCT2 Circuit (I6 Exhaust Oil control valve solenoid Improper connectionSensor
Cont OCV, V8 Bank 2 OCV) open circuit or short circuit circuit open circuit or shorted
to VPWR or PWRGND.
OTHER CONDITION
KOER Cont Over Advanced (I6 Exhaust Camshaft incorrectly installed.
Cam, V8 Bank 2)
KOER Cont Over Retarded (I6 Exhaust Camshaft incorrectly installed.
Cam, V8 Bank 2)
P1463 A/C Pressure Sensor AIR CONDITIONER SENSOR CONDITION
KOER Cont Insufficient Pressure Change Refer to the Air Conditioner ACPT sensor damaged or
when AC compressor section of this manual. faulty
commanded on ELECTRICAL CONDITION OTHER CONDITION
ACR relay coil open circuit or PCM damaged or faulty
short circuit. Relay not Compressor or Compressor
inserted correctly into socket. clutch fault
PCM wiring to relay open or
shorted to ground.
P1465 AC Compressor Relay ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER, AC Relay coil open circuit or PCM damaged or faulty
Cont short circuit. Relay not
inserted correctly into socket.
shorted to ground.
P1474 EDF1 Fan Control Relay ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER, EDF1 Relay coil open circuit PCM damaged or faulty
Cont or short circuit. Relay not
shorted to ground.
P1479 EDF2 Fan Control Relay ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER, EDF2 Relay coil open circuit PCM damaged or faulty
Cont or short circuit. Relays not
shorted to ground.
P1506 Idle Air Control Over Speed Refer to other DTCs for
KOEO, KOER Error diagnosis.
Cont
P1507 Idle Air Control Under Speed Refer to other DTCs for
KOEO, KOER Error diagnosis.
Cont
P1534 Restraint Deployment Faulty RCM, check Section
Cont Indicator Circuit 501-20b, open circuit TAS
signal to pin B6 of PCM
G98120 en 01/2003 2003.0 BA Falcon


P1549 Intake Manifold ELECTRICAL CONDITION OTHER CONDITION
KOEO, KOER Communication Control IMCC control signal open Faulty or damaged IMCC
Cont Circuit (IMCC) <BBM> circuit circuit, IMCC signal shorted to solenoid, faulty or damaged
malfunction, I6 engine Vehicle Power (VPWR) or PCM
DTC P1549 is reported to ground, loose or improper
indicate a fault in the IMCC harness connections,
circuit. intermittent short to VPWR or
PWRGND.
P1565 Speed Control Command SWITCH CONDITION ELECTRICAL CONDITION
KOEO, KOER Switch Out Of Range High Speed control switch Improper connection, ground
Cont DTC P1565 is reported if the assembly damaged or faulty circuit open circuit;
SCRS-A sensor signal is SCRS-A signal wire open
greater than the self-test circuit or short circuit to VREF
range. or VPRWR
P1566 Speed Control Command SWITCH CONDITION ELECTRICAL CONDITION
KOEO, KOER Switch Out Of Range Low Speed control switch SCRS-A signal wire short
Cont DTC P1566 is reported if the assembly damaged or faulty circuit to PWRGND or
SCRS-A sensor signal is SGRTN
greater than the self-test
range.
P1572 Brake Pedal Switch Circuit MECHANICAL CONDITION ELECTRICAL CONDITION
KOEO, KOER DTC P1572 is reported if the Brake switch bracket loose or Improper connection to BOO
Cont BOO and RBS brake switch distorted. and RBS switch. Fusible link
status are different when the SWITCH CONDITION to RBS blown. Switch wiring
brake pedal is depressed. BOO or RBS switch damaged open circuit or short circuit to
or faulty VPWR or PWRGND
OTHER CONDITION
No speed control option fitted
to vehicle. This DTC is not
applicable to vehicles without
speed control.
P1635 Tire/Axle Out of Acceptable PCM CONDITION
KOEO, KOER Range VID block incorrectly
Cont DTC P1572 is reported if the configured.
tyre and axle data entered
into the VID block is out of
range
P1639 Vehicle ID Block Corrupted, PCM CONDITION
KOEO, KOER Not Programmed VID block incorrectly
Cont DTC P1572 is reported if the configured
VID block is corrupted not
programmed
P1650 Power Steering Pressure ELECTRICAL CONDITION MECHANICAL CONDITION
KOEO Switch (PSP) <PSPS> Improper connection, PSP Refer to Group 3 Suspension,
failure open circuit Steering, Wheels & Tyre for
DTC P1650 is reported if the SENSOR CONDITION power steering information
PSP has failed in the open Sensor damaged or faulty. OTHER CONDITION
position Switch contacts may be stuck PCM damaged or faulty
open, improper operation
threshold of switch.
G98120 en 01/2003 2003.0 BA Falcon


P1651 Power Steering Pressure ELECTRICAL CONDITION MECHANICAL CONDITION
KOER Switch (PSP) <PSPS> did Improper connection, PSP Power steering fluid low or
not switch, 6 engine shorted to Vehicle Power loss, mechanical or hydraulic
DTC P1651 is reported if the (VPWR) fault in power steering
switch fails in the closed SENSOR CONDITION system.
position. This code is also Faulty or malfunctioning Refer to Group 3 Suspension,
reported if the PSP does not sensor, switch contacts may Steering, Wheels & Tyres for
change state during KOER be stuck closed, improper power steering information
self-test operation threshold of switch OTHER CONDITION
Steering wheel was not
moved during KOER self-test,
Faulty or damaged PCM
P1703 Brake Switch Out Of Self MECHANICAL CONDITION ELECTRICAL CONDITION
KOER Test Range Brake switch bracket loose or Improper connection to BOO
distorted. and RBS switch. Fusible link
SWITCH CONDITION to RBS and/or BOO blown.
BOO or RBS switch damaged Switch wiring open circuit or
or faulty short circuit to VPWR or
PWRGND
OTHER CONDITION
Brake switch was not
depressed and released
during KOER self-test.
No speed control option fitted
to vehicle. This DTC is not
applicable to vehicles without
speed control.
P1705 Not in Park or Neutral during TEST CONDITION OTHER CONDITION
KOEO self- test (Auto) Transmission was not in Park Faulty TR sensor or wiring
DTC P1705 is reported if the or Neutral positions during the
Transmission Range Sensor Key On Engine Off self-test.
(TRS-A1) <PRNDL> is in Move the gear selector to
any position other than Park either Park or Neutral and
or Neutral re-run the test
P1708 Clutch Switch was not TEST CONDITION OTHER CONDITION
KOEO depressed during self-test Clutch pedal was not Faulty CES switch or wiring
(Manual) depressed during the Key On
DTC P1708 is reported if the Engine Off self-test. Depress
Clutch Engagement Switch the clutch pedal and re-run
(CES) indicates that the the test
clutch pedal was not
depressed
P1709 Not in Park or Neutral during TEST CONDITION OTHER CONDITION
KOEO self- test (Auto) Transmission was not in Park Faulty TR sensor or wiring
DTC P1709 is reported if or Neutral positions during the
theTransmission Range Key On Engine Off self-test.
Sensor (TRS-A1) <PRNDL> Move the gear selector to
is in any position other than either Park or Neutral and
Park or Neutral re-run the test
P1746 Solenoid 5 (SS5) <VPS> ELECTRICAL CONDITION AUTOMATIC
KOEO, KOER open circuit fault Improper connection; SS5 TRANSMISSION
Cont DTC P1746 is reported if shorted to PWRGND, Faulty solenoid
SS5 or its circuit have failed solenoid open circuit Refer to Group 7, Automatic
information on the
G98120 en 01/2003 2003.0 BA Falcon


KOEO, KOER short circuit fault Improper connection; SS5 TRANSMISSION
Cont DTC P1747 is reported if shorted to VPWR, solenoid Faulty solenoid
SS5 or its circuit have failed short circuit Refer to Group 7, Automatic
information on the
KOEO, KOER circuit fault Improper connection; SS5 TRANSMISSION
Cont DTC P1748 is reported if shorted to VPWR or Faulty solenoid
SS5 or its circuit have failed PWRGND, solenoid open Refer to Group 7, Automatic
circuit or short circuit Transmission for more
information on the
P2100 Throttle Actuator Control ELECTRONIC THROTTLE OTHER CONDITION
KOEO, KOER Motor Circuit /Open CONDITION Refer to other DTCs for
Cont Motor open circuit. Check diagnosis.
Throttle Motor Connector.
This code may also get set by
entry into RPM Guard mode
(P2110).
P2101 Throttle Actuator Control OTHER CONDITION
KOEO, KOER Motor Circuit PCM damaged or faulty
Cont Range/Performance
P2102 ETB motor current is lower ELECTRONIC THROTTLE ELECTRICAL CONDITION
KOEO Cont than expected CONDITION Improper ETB wiring
ETB motor faulty.Throttle connection
Damaged. Check Throttle OTHER CONDITION
Motor Connector. PCM damaged or faulty
SENSOR CONDITION
TP sensor incorrectly installed
P2103 ETB motor current is higher ELECTRONIC THROTTLE ELECTRICAL CONDITION
KOEO Cont than expected CONDITION Improper ETB wiring
ETB motor faulty. Throttle connection
Damaged. Check Throttle OTHER CONDITION
Motor Connector. PCM damaged or faulty
ETB HARDWARE
Check ETB for Stuck Throttle
Plate.
SENSOR CONDITION
TP sensor incorrectly installed
P2105 Throttle Actuator Control Refer to other DTCs for
KOEO, KOER System - Forced Engine diagnosis.
Cont Shutdown
P2107 Throttle Actuator Control Refer to other DTCs for OTHER CONDITION
KOEO, KOER System - Internal TPPC diagnosis. This code may PCM damaged or faulty.
Cont Fault also get set by entry into RPM
Guard mode (P2110).
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P2110 Throttle Actuator Control SENSOR CONDITION OTHER CONDITION
KOEO, KOER System - Forced Limited Accelerator pedal and/or PCM damaged or faulty.
Cont RPM throttle position sensor
damaged or faulty. Throttle
motor damaged or
connector/wiring faulty. Check
other DTCs.
ETB HARDWARE
Check ETB for Stuck Throttle
Plate.
P2111 Throttle Actuator Control ETB HARDWARE
KOEO, KOER System - Higher throttle Check ETB for Stuck Throttle
Cont opening than driver demand Plate.
Refer to other DTCs for
diagnosis.
P2112 Throttle Actuator Control ETB HARDWARE
KOEO, KOER System - Lower throttle Check ETB for Stuck Throttle
Cont opening than driver demand Plate.
Refer to other DTCs for
diagnosis.
P2122 Pedal Position Sensor SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER (PPS1) Low Input Accelerator Pedal Sensor Improper connection to PPS.
Cont damaged or faulty. Check PPS wiring open circuit or
Connector. short circuit to PWRGND or
SIGRTN.
KOEO, KOER (PPS1) High Input Accelerator Pedal Sensor Improper connection to PPS.
Connector. short circuit to VPWR or
VREF.
KOEO, KOER (PPS1) Intermittent Input Accelerator Pedal Sensor Improper connection to PPS.
Connector. short circuit to VPWR, VREF,
PWRGND or SIGRTN.
SIGRTN.
VREF.
PWRGND or SIGRTN.
SIGRTN.
G98120 en 01/2003 2003.0 BA Falcon


VREF.
PWRGND or SIGRTN.
P2135 Throttle Position Sensor 1 & SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER 2 Voltage Correlation Fault Throttle Position Sensor Improper connection to TPS.
Cont damaged or faulty. Check TPS wiring open circuit or
PWRGND or SIGRTN.
OTHER CONDITION
P2138 Pedal Position Sensor 1 and SENSOR CONDITION ELECTRICAL CONDITION
KOEO, KOER 2 correlation fault Accelerator Pedal Sensor Improper connection to PPS.
connector. short circuit to VPWR, VREF,
PWRGND or SIGRTN.
OTHER CONDITION
connector. short circuit to VPWR, VREF,
PWRGND or SIGRTN.
OTHER CONDITION
Cont damaged or faulty. PPS wiring open circuit or
short circuit to VPWR, VREF,
PWRGND or SIGRTN.
OTHER CONDITION
U1147 Invalid or Missing Data for IMMOBILIZATION SYSTEM ACTION REQUIRED
KOEO, KOER Vehicle Security. CONDITION Check BEM and CAN line
Cont PCM did not receive the operation.
correct response codes from
the BEM
U1900 CAN Communication Bus Missing CAN messages from ELECTRICAL CONDITION
KOEO, KOER Fault - Receive Error HIM, instrument cluster, BEM CAN wiring open circuit or
Cont and/or traction control (where short circuit to VPWR, VREF,
fitted) PWRGND or SIGRTN.
Check other DTCs
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Glossary
ABS acronym for Anti-lock Brake System. Prevents wheel lockup during an emergency stop
by modulating brake pressure. Allows the driver to maintain steering control and stop
the vehicle in the shortest possible distance under most conditions
APPS acronym for Accelerator Pedal Position Sensor. The pedal position sensor has 3
independent outputs, APPS1, APPS2 and APPS3
APPSVREF acronym for Accelerator Pedal Position Sensor VREF. A 5V supply. Two are used for
the pedal sensor
APPSRTN acronym for Accelerator Pedal Position Sensor Return. A 0V supply. Two are used for
the pedal sensor
ASR acronym for Acceleration Slip Control system. Also known as the traction control
system
Absolute The pressure referenced to a perfect vacuum
Pressure
ACC acronym for Air Conditioning Clutch in this section
ACD acronym for Air Conditioner Demand.
ACP acronym for Air Conditioning Pressure
ACPT acronym for Air Conditioner Pressure Transducer
ACR acronym for Air Conditioning Clutch Relay
Actuator A mechanism for moving or controlling something indirectly instead of by hand
AEAT acronym for Air Conditioner Evaporator Temperature
Air Conditioning A vehicular system that modifies the passenger compartment environment by cooling
and drying the air
Analogue Signals are signals that vary within a certain range (ie.0 - 5 volts). An analogue signal is
infinitely variable within the rage. The Throttle Position Sensor (TP) produces an
analogue signal
ATDC acronym for After Top Dead Centre
Base Timing Spark advance in degrees before top dead centre of the base engine without any
control from the PCM
Battery An electrical storage device designed to produce a DC voltage by means of an
electrochemical reaction
BBM acronym for Broad Band Manifold, see IMCC
BEM acronym for Body Electronic Module
BFS acronym for Blower Fan Speed
Blower A device designed to supply a current of air at a moderate pressure. A blower usually
consists of an impeller assembly,a motor and a suitable case. The blower case is
designed as part of the ventilation system
BOO Acronym for the Brake On Off Switch.
BPS acronym for Boost Pressure Sensor. Measures the boost pressure of the turbocharger.
BTDC acronym for Before Top Dead Centre - relating to the position of the piston within the
cylinder
Camshaft A shaft on which phased cams are mounted. The camshaft is used to regulate the
opening and closing of the intake and exhaust valves
CAN Acronym for Control Area Network. An intermodule communications network comprising
a twisted pair wire, CAN-H and
CAN-L which have complementary output.
Canister A device designed to hold dry material. An evaporative emission canister contains
activated charcoal that absorbs fuel vapours and holds them until the vapours can be
purged at an appropriate time
Canister Purge Controls purging of the EVAP canister
CASEGN acronym for PCM Case Ground
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Catalytic An in-line exhaust system device used to reduce the level of engine exhaust emissions
Converter
CD1..8 acronym for Coil Driver. The PCM’s Coil On Plug output drivers.
CHT acronym for Cylinder Head Temperature sensor.
Circuit A complete electrical path or channel, usually includes the source of electrical energy.
Circuit may also describe the electrical path between two or more components. May
also be used with fluids, air or liquids
CKP acronym for Crankshaft Position Sensor
Closed Loop A control system that uses a signal from an oxygen sensor mounted in the exhaust
system to control the ratio of air and fuel provided to the engine. Also known as the
Lambda loop
Clutch A mechanical device that uses mechanical, magnetic or friction type connections to
facilitate engaging or disengaging of two shafts or rotating members
CMP acronym for Camshaft Position. Indicates camshaft position. Provides camshaft position
information for fuel injection synchronisation
CO Carbon Monoxide. A colourless, odourless, gas toxic gas formed by combustion within
the cylinder
CO2 Carbon Dioxide. A colourless, odourless, incombustible gas formed during combustion
Coil A device consisting of windings of conductors around an iron core, designed to
increase the voltage and for use in a spark ignition system
Continuous The portion of KAM used to store DTCs generated during Continuous Memory Self-Test
Memory
Continuous A continuous test of the EEC system conducted by the PCM whenever the vehicle is
Memory Self-Test operating
Control A means or a device to direct and regulate a process or guide the operation of a
machine, apparatus system
Coolant A fluid used for heat transfer. Coolants usually contain additives such as rust inhibitors
and antifreeze
Crankshaft The part of an engine that converts the reciprocating motion of the pistons to rotary
motion
Data General term for information, usually represented by numbers, letters, or symbols
Digital Digital signals have only one of two values, either on or off. Some systems measure the
duration between the on and off signals to determine a value. The vehicle speed sensor
(VSS)is produces a digital signal
DLC acronym for Data Link Connector. Connector providing access and/or control of the
vehicle information, operating conditions, and diagnostic information
DTC acronym for Diagnostic Trouble
Code An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic
System
EDF1 acronym for Electro Drive Fan 1. Controls the engine cooling fans at low Speed
EDF2 acronym for Electro Drive Fan 2. Controls the engine cooling fans at high Speed
EMC acronym for Electro-Magnetic Compatibility
Engine A machine designed to convert thermal energy into mechanical energy to produce force
or motion
EOT acronym for Engine Oil Temperature
ETB acronym for Electronic Throttle Body
ETC acronym for Electronic Throttle Control.
ETCN acronym for Electronic Throttle Control Negative. The negative of the ETC motor.
ETCP acronym for Electronic Throttle Control Positive. The positive of the ETC motor.
EVAP acronym for Evaporative Emission Evaporative Emission (EVAP) - A system to prevent
fuel vapour from escaping into the atmosphere. Typically includes a charcoal canister to
store fuel vapours
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Fan A device designed to supply a current of air. A fan may also have a frame, motor, wiring
harness and the like
FEPS acronym for Flash EEPROM Power Supply
FMEM acronym for Failure Mode Effects Management. An alternative vehicle operation
strategy that protects vehicle function from the adverse effect of a system failure
FP acronym for Fuel Pump. A pump used to deliver fuel to the engine
Freeze Frame A block of memory containing the vehicle operating conditions for a specific time
Fuel Any combustible substance burned to provide heat or power. Typical fuels include
gasoline and diesel fuel. Other types of fuel include ethanol, methanol, natural gas,
propane or in combination
Fuel Rich/Lean A qualitative evaluation of air-fuel ratio based on an A/F ratio known as stoichiometry or
14.64:1. In the EEC system, rich/lean is determined by a voltage signal from the H02S.
An excess of oxygen (lean) is indicated by an H02S voltage of less than 0.4 volts; a
rich condition is indicated by an H02S voltage of greater than 0.6 volts
GCO acronym for Gas Cut-out
GLVL acronym for Gas Tank Level Sensor
GLVL-RTN acronym for Gas Tank Level Sensor Return
GRND Ground. The ground, or common side of a DC electrical circuit
GSCA-D acronym for LPG Stepper Motor A to D
Hall Effect A process where current is passed through a small slice of semi-conductor material at
the same time as a magnetic field to produce a small voltage in the semi-conductor
HC Hydrocarbon. A compounds that contains only carbon and hydrogen
HO2S acronym for Heated Oxygen Sensor. An Oxygen Sensor (02S) that is electrically heated
Hz Hertz. The measure of a frequency - equal to one cycle per second. Defined by
Heinrich Rudolf Hertz
IAC acronym for Idle Air Control. Electrical control of throttle bypass air
IAT acronym for Intake Air Temperature. The temperature of the intake air
IDM acronym for Ignition Diagnostic Monitor
Ignition System used to provide high voltage spark for internal combustion engines
IGNSNS Acronym for Ignition Sense input.
IMCC acronym for intake Manifold Charge Control
INJ1-8 acronym for Fuel Injectors 1 to 8
Injector A device for delivering metered pressurised fuel to the intake system or the cylinders
Intake Air Air drawn through a cleaner and distributed to each cylinder for use in combustion
Intermittent A fault that may not be present or identifiable at the present time
KAM acronym for Keep Alive Memory. A portion of the memory within the PCM that must
maintain power even when the vehicle is not operating
KAPWR acronym for Keep Alive memory Power. Dedicated, unswitched power circuit that
maintains KAM
Knock The sharp metallic sound produced when two pressure fronts collide in the combustion
chamber of an engine
KOEO acronym for Key On Engine Off Self-Test. A test of the EEC system conducted by the
PCM with power applied and the engine at rest
KOER acronym for Key On Engine Running Self-Test. A test of the EEC system conducted by
the PCM with the engine running and the vehicle at rest
KS acronym for Knock Sensor. Detects engine knock
L Litres
Lean excess air (or too little fuel) in the air- fuel ratio being supplied to the combustion
process
LONGFT acronym for Long Term Fuel Trim
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LPG acronym of Liquefied Propane Gas. Used as an alternative to petroleum fuel in

combustion engines
LUS acronym for Lock up Solenoid
M/T Manual Transmission
Manifold A device designed to collect or distribute fluid, air or the like
MAP acronym for Manifold Absolute Pressure. The absolute pressure of the intake manifold
air
Module A self-contained group of electrical/electronic components, which is designed as a
single renewable unit
Multiplexing the simultaneous transmission of two or more signals over a single circuit. The EEC-V
uses multiplexing to communicate with the NGS
NC acronym for Normally Closed electrical Contact
NO acronym for Normally Open electrical Contact
NOx Oxides of Nitrogen
OCV acronym for Oil Control Valve. Also known as a Camshaft Position Actuator. Used on
the VCT to control oil pressure to the phaser.
OHC acronym for Overhead Camshaft. An engine configuration that uses a camshaft
positioned above the valves Open Circuit - A circuit which does not provide a complete
path for flow of current
OSS acronym for Output Shaft Speed Sensor. A sensor which provides driveshaft speed
information
PCM acronym for Powertrain Control Module
PCS acronym for Power Control Solenoid
PCV acronym for Positive Crankcase Ventilation. Positive ventilation of crankcase emissions
Phaser a mechanism used on VCT to vary camshaft angle
PID acronym for Parameter Identification. Identifies an address in memory which contains
vehicle operating information
PIP acronym for Profile Ignition Pick-up. Provides crankshaft or camshaft position
information for ignition synchronisation
Power Steering A system which provides additional force to the steering mechanism, reducing the
driver’s steering effort
Powertrain The elements of a vehicle by which motive power is generated and transmitted to the
driven axles
PSPS acronym for Power Steering Pressure Switch. Indicates the pressure in the power
steering system
Pulse Width a continually changing digital signal turned on and off or a percentage of the available
Modulation on pulse off cycle time. A signal on for 30% and off 70% of the time is a 30% On PWM
signal
PRIME acronym for the LPG PRIME solenoid.
Pump A device used to raise, transfer, or compress fluids by suction, pressure or both
PWRGND Power Ground. The main ground circuit in the EEC-V system
PWRSTN acronym for Power Sustain. A PCM output that powers the VPWR relay on for a short
delay after the ignition is keyed OFF.
Relay A generally electromechanical device in which connections in one circuit are opened or
closed by changes in another circuit
RBS acronym for Redundant Brake Switch used for the cruise control feature
RGS Acronym for the Reverse Gear Switch used on manual transmissions.
Rich an inadequate amount of air (or too much fuel) in the air-fuel ratio being supplied to the
combustion process
RPM Engine speed in revolutions per Minute
SCRSA Acronym for Speed Control Range Sensor (Analogue signal).
Short Circuit An undesirable connection between a circuit and any other point
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SHRTFT acronym for Short Term Fuel Trim

Signal A fluctuating electric quantity, such as voltage or current, whose variations represent
information
SIGRTN acronym for Signal Return. A dedicated sensor ground circuit that is common to two or
more sensors
Solenoid A device consisting of an electrical coil which, when energised, produces a magnetic
field in a plunger that is pulled to a central position. A solenoid may be used as an
actuator in a valve or switch
Speed The magnitude of velocity (regardless of direction)
SS x acronym for Shift Solenoid. A device that controls shifting in an automatic transmission
STRTEN Acronym for Start Enable relay output.
Switch A device for making, breaking, or changing the connections in an electrical circuit
System A group of interacting mechanical or electrical components serving a common purpose
Tachometer A meter that provides a measure of engine speed in RPM
TAS Acronym for Travel Assistance Service, the signal recieved by the PCM from the
Restraint Control Module, RCM, when it detects deployment level impact events.
TDC acronym for Top Dead Centre - relating to the position of the piston within the cylinder
Test A procedure whereby the performance of a product is measured under various
conditions
TFT acronym for Transmission Fluid Temperature. Indicates temperature of transmission
fluid
Throttle A valve for regulating the supply of a fluid, usually air or an air-fuel mix, to an engine
Timing Relationship between spark plug firing and piston position usually expressed in
crankshaft degrees before (BTDC) or after (ATDC) top dead centre of the compression
stroke
T-MAP acronym for Temperature and Manifold Absolute Pressure Sensor
TP acronym for Throttle Position sensor. Indicates the position of the throttle plate. The TP
sensor assembly has two independent sensor outputs
TPS_VREF acronym for Throttle Position sensor VREF. The 5V supply for the sensor
TPS_RTN acronym for Throttle Position sensor RTN. The 0V supply for the sensor
TRS-A1 acronym for Transmission Range Sensor - (Analogue signal) 1. The transmission
mounted sensor gear position.
TRS-A2 acronym for Transmission Range Sensor - (Analogue signal) 2. The centre console
mounted electronic Sport Shift sensor.
Transient Remaining only for a brief time
Transmission A device which selectively increases or decreases the ratio of relative rotation between
its input and output shafts.
TURBO acronym for Turbocharger
Variable A process of passing a magnetic field through wire windings and inducing a voltage
Reluctance
Valve A device by which the flow of liquid, gas, vacuum, or loose material in bulk may be
started, stopped or regulated by a movable part that opens, shuts or partially obstructs
one or more ports or passageways. A “Valve” is also the moveable part of such a
device
VCT acronym for Variable Camshaft Timing
VPS acronym for Variable Pressure Control Solenoid 5
VPWR acronym for Vehicle Power. A switched circuit that provides power to the EEC system.
Compare “Battery Positive Voltage (B+).”
VREF acronym for Reference Voltage. A dedicated circuit that provides a 5.0 volt signal used
as a reference by certain sensors
G98120 en 01/2003 2003.0 BA Falcon

VSOUT acronym for Vehicle Speed Output. An output which provides speed information as a
frequency signal proportional to vehicle speed
VSS acronym for Vehicle Speed Sensor. A sensor which provides vehicle speed information
WOT acronym for Wide Open Throttle. A condition of maximum airflow through the throttle
body
The glossary is a list of technical terms or acronyms
and their definitions. It is not intended to be a
dictionary of components and their functions. If a
detailed description of a specific component is
desired, refer to the related Workshop Manual Group.
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GENERAL PROCEDURES
Powertrain Control Module 3. Locate 565B-W (Black wire with white stripe) and
splice the wire at the back of connector C-119.
Accessing vehicle speed signal for installation of Refer to Connector Views chapter 700-07-00-9.
taximeters
CAUTION: Vehicle speed signal must NOT be

accessed via the ABS system as this may
compromise system integrity.
NOTE: The Power Control Module (PCM) generates
the vehicle speed signal which can be accessed by
taximeters. The B36VSOUT is a pulsed 12V signal of
approximately 5000 pulses/km which is used by
SATNAV (Refer to chapter 419-07 for further
SATNAV information) to measure speed. This
outputted signal should be accessed by taximeters to
monitor vehicle speed.
1. Remove outer front LHS scuff plate.
4. Check integrity of taximeter. Taximeters to be
used with the PCM should have an input
resistance to ground of between 4.7kOhm and
15kOhm
5. Re-install scuff plates.
Intake Manifold Charge Control

Adjustment
1. Using a suitable vacuum pump and gauge, apply
a 40kPa vacuum to IMCC actuator.
2. Adjust IMCC set screw to achieve the specified
clearance between the set screw and the actuator
arm.
IMCC Clearance Specification
2. Remove inner front LHS scuff plate.
This will expose the B36VSOUT wiring which 1. 0.65 - 0.80 mm
includes the 565B-W wire and C-119 connector.
VCT Solenoid Valve

Cleaning Procedure
Items required.
1. Aerosol can of suitable cleaning fluid such as CO
electrical cleaning fluid, Compressed air or
similar.
2. Clean Rag.
3. Wiring Loom.
G98141 en 01/2003 2003.0 BA Falcon

4. 12V Vehicle Battery.

5. Safety Glasses.
Procedure.
1. Remove jammed Oil Control Valve (OCV) Ref.
Engine Section 303-01a, b & c.
2. Place valve on a clean cloth.
3. Connect 12V onto valve through a push button
momentary switch.
4. Hold valve upright on clean cloth.
5. Spray cleaning Fluid into ports of valve while
pressing momentary switch 3 - 4 times per
second.
6. Clean down the center of the valve using a similar
process.
7. Repeat process until the obstruction is removed.
8. Re-fit valve and test.
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Crankshaft Position (CKP) Sensor (I6 Camshaft Position Sensor (I6 Engine)
Engine) Removal
Removal 1. Remove the camshaft position (CMP) sensor.
1. Remove the crankshaft position (CKP) sensor. 1. Disconnect the electrical connector
1. Disconnect the electrical connector 2. Remove the retaining bolt
2. Remove the retaining bolt 3. Remove the sensor
3. Remove the sensor
Installation
NOTE: Be sure the sensor wiring is routed away from 1. To Install, reverse the removal procedure.
the battery cable.
Camshaft Position Sensor (V8 Engine)
Installation
Removal
1. To Install, reverse the removal procedure.
Crankshaft Position (CKP) Sensor (V8 additional information, refer to Section 414-01.
Engine) 2. Disconnect the camshaft position (CID) sensor
electrical connector.
Removal 3. Unscrew the retaining bolt and remove the CID
1. Remove the A/C compressor. For additional sensor.
2. Remove the crankshaft position (CKP) sensor.
1. Disconnect the electrical connector
2. Remove the bolt
3. Remove the sensor
Installation
Knock Sensor (I6 Engine)

Removal
Installation 1. Disconnect the knock sensor (KS) electrical
1. To Install, reverse the removal procedure. connector.
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2. Remove the bolt and the KS. 4. Remove the CHT sensor.
1. To Install, reverse the removal procedure. 1. To Install, reverse the removal procedure.
Cylinder Head Temperature (CHT) Throttle Position (TP) Sensor (I6, LPG
Sensor (I6 Engine) & Turbo Engines)
Removal Removal
1. Disconnect the cylinder head temperature (CHT) 1. Ensure the ignition has been switched off and the
sensor electrical connector. battery disconnected. For additional information,
2. Using a ring spanner, remove the CHT sensor. refer to Section 414-01.
2. Remove the inlet duct from the throttle body.
3. Remove the TP sensor.
1. Disconnect the electrical connector from the
TP sensor by sliding the red locking tab out
and pressing the clip release.
2. Remove the 2 TP sensor retaining bolts.
3. Remove the TP sensor from the throttle body.
I6 & Turbo
Installation
Cylinder Head Temperature (CHT)

Sensor (V8 Engine)
Removal
2. Disconnect the electrical connector and remove
the alternator.
3. Disconnect the CHT sensor electrical connector.
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LPG Engine 7. Remove the throttle TP sensor.

1. Remove the 2 TP sensor retaining bolts.
2. Remove the TP sensor from the throttle body.
Installation
1. Fit the new bolts provided with the new TP sensor
and tighten them to 2 - 4Nm. Installation
2. Reconnect the electrical connector ensuring there 1. Fit the new TP sensor to the throttle body,
is a positive “click” as the safety clip engages. ensuring that the locating pin on the TP sensor
3. Slide the red locking tab into position. aligns with the hole in the throttle body.
4. Refit the inlet duct to the throttle body. 2. Fit the new bolts provided with the new TP sensor
5. Reconnect the battery. and tighten them to 2 - 4Nm.
6. Switch on the ignition then fully depress the 3. Refit the gasket and the throttle body to the inlet
accelerator pedal and release it. manifold and tighten the bolts to 8 -12Nm.
7. Perform key-on, engine-off test to ensure no TP 4. Reconnect both electrical connectors ensuring
sensor codes are present. there is a positive “click” as the safety clips
8. Start the car and ensure normal operation. engage.
5. Slide the red locking tabs into position.
Throttle Position (TP) Sensor (V8 6. Refit the inlet duct to the throttle body.
Engine) 7. Reconnect the battery.
Removal 8. Switch on the ignition then fully depress the
accelerator pedal and release it.
1. Ensure the ignition has been switched off and the
battery disconnected. For additional information, 9. Perform key-on, engine-off test to ensure no TP
refer to Section 414-01. sensor codes are present.
2. Remove the inlet duct from the throttle body. 10. Start the car and ensure normal operation.
3. Disconnect the 4 way electrical connector from Powertrain Control Module (PCM) (I6
the TP sensor by sliding the red locking tab out
and pressing the clip release. Engine)
4. Disconnect the 2 way electrical connector from The PCM is installed in the engine compartment on
the throttle body motor by sliding the red locking the bracket over the front nearside strut tower. Three
tab and pressing the clip release. security bolts secure the PCM to the PCM bracket.
5. Remove the 4 bolts retaining the throttle body to Removal
the inlet manifold. 1. Ensure the ignition has been switched off and the
6. Note the throttle body orientation, then remove battery disconnected. For additional information,
the throttle body, being careful with the gasket. refer to Section 414-01.
2. Use a small high-speed grinding tool with a small
circular grinding disc to cut slots on the 3 security
bolts holding the PCM to the bracket.
CAUTION: This operation produces
sparks and debris that can cause fire and
personal injury.
Perform this operation in a well-ventilated
area.
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Ensure that that there are no fuel leaks in 9. Torque the security bolts on the PCM until the
the engine compartment, the engine, fuel heads break off.
injectors and fuel lines.
Ensure that there are no flammable liquids
HEGO Sensor (I6 & V8 Engines)
and fumes present in the work area. Eg Removal
solvents, inks, paints, thinners, cleaning
fluids, open fuel containers etc. 1. Remove the HEGO sensor.
Use necessary precautions to confine 1. Disconnect the electrical connector
debris from the grinder. 2. Remove the screws
Use protective goggles and gloves for 3. Using a 22mm ring spanner, remove the
personal safety. sensor
3. Use a blade screwdriver to unscrew the security I6 Engine
bolts.
4. Release the wiring harness locking bar and
remove the harness from the PCM.
V8 Engine
Item Description
1 PCM Module
2 Security bolt
5. Remove the PCM.
Installation
1. Secure the wiring harness to the correct PCM
connector pockets. They are keyed so that they
only fit one way and both the A and B pocket
connectors are different.
2. For new PCMs, perform the Module Configuration
operation in the "Module Programming" section.
3. For new PCMs, perform the Parameter Reset Item Description
operation as detailed in this section to re-train the 1 HEGO Sensor (LHS only)
Smartshield security system. 2 HEGO Sensor (LHS & RHS)
4. For new PCMs, retrain the audio system to the
new PCM ID code. This procedure can be carried Installation
out by using the WDS tester. 1. To Install, reverse the removal procedure.
5. Temporarily secure the PCM to the bracket with NOTE: Make sure the thread is cleaned and that a
new security bolts. DO NOT BREAK THE HEADS suitable anti-seize compound is applied to the thread
OFF YET. before installing the sensor.
6. Clear the PCM fault codes NOTE: Make sure the sensor’s flylead is routed away
7. Remove the WDS and test-drive the vehicle. from the steering intermediate shaft. Check for any
8. Reconnect the WDS tester and run a KOEO and exhaust leakage around the sensor.
KOER test on the PCM. Rectify faults if required.
G98151 en 01/2003 2003.0 BA Falcon

HEGO Sensor (Turbo) Installation

1. Push the BPS into the aluminum duct.
Removal
2. Refit the retaining bolt and tighten.
1. Remove the HEGO sensor.
3. Reconnect the harness to the BPS.
1. Disconnect the electrical connector
2. Remove the screws Turbocharger Wastegate Control
3. Using a 22mm ring spanner, remove the Solenoid
sensor
Removal
I6 Engine 1. Remove the Wastegate Control Solenoid.
1. Disconnect the electrical connector.
2. Slide solenoid up and away from its retaining
bracket.
Installation
NOTE: Make sure the thread is cleaned and that a
suitable anti-seize compound is applied to the thread
before installing the sensor. Installation
NOTE: Make sure the sensor’s flylead is routed away
from the steering intermediate shaft. Check for any Reverse Gear Switch
exhaust leakage around the sensor.
Removal
Boost Pressure Sensor (Turbo Engine) 1. Remove the Reverse Gear Switch
Removal 1. Disconnect the electrical connector
1. Disconnect the wire harness from the BPS 2. Remove the retaining bolt
connector. 3. Remove the sensor
2. Unscrew the retaining bolt.
3. Gently pull the sensor out vertically from the
aluminum duct.
Installation
G98156 en 01/2003 2003.0 BA Falcon

Temperature and Manifold Absolute Fuel Rail (I6 Engine)

Pressure (T-MAP) Sensor
Removal
Removal 1. Ensure the area of the fuel rail and intake
1. Remove the Electronic Throttle Body and then manifold injectors are clean of all dirt, grit etc.
disconnect the engine wiring harness from the Prior to the removal of injectors.
T-MAP connector. 2. Relieve fuel system residual pressure.
2. Remove the two screws securing the T-MAP 3. Remove intake air duct.
sensor to the inlet manifold.
4. Disconnect the wiring harness from the fuel
3. Carefully withdraw the sensor from the manifold. injectors at the connector.
4. Plug the aperture in the inlet manifold to prevent 5. Tag and disconnect fuel supply and return lines at
the ingress of foreign material. the quick-connect fittings.
Installation 6. Disconnect vacuum hose from pressure regulator.
1. Install new o-rings on the T-MAP sensor, if 7. Disconnect the wiring loom from the fuel rail.
necessary.
8. Remove the screws attaching the fuel rail
2. Install the T-MAP sensor into the inlet manifold brackets to the intake manifold.
with the connector at the bottom.
9. Remove the fuel injector to fuel rail retaining clips
3. Align the holes and install the T-MAP sensor and withdraw each injector. Place each injector in
retaining screws. Tighten the screws to 3Nm. a clean plastic bag to prevent the injectors from
4. Reconnect the harness to the T-MAP sensor. being contaminated with foreign material. Number
5. Run the engine and check for vacuum leaks each bag according to injector position. Plug the
around the sensor. Rectify any leaks found. apertures in the intake manifold to prevent the
ingress of foreign material.
I6 Engine
Installation
1. Ensure the fuel rail injector mounting apertures
are clean, smear the fuel injector sealing rings
with a light coating of engine oil. DO NOT use
petroleum jelly. Insert the injectors into the fuel rail
and install retaining clips.
2. Ensure the intake manifold injector apertures and
the fuel injector tips are clean, smear the injector
sealing rings with a light coating of engine oil. DO
NOT use petroleum jelly. Insert the injectors into
the manifold and position the fuel rail, install the
retaining screws and torque screws to 19Nm.
3. Attach the injector wiring loom at the fuel rail and
connect the injector clamp.
4. Reconnect the fuel supply and return lines as
V8 Engine tagged.
5. Start and run engine. Check for any leaks. Rectify
any faults found.
Fuel Rail (V8 Engine)

Removal
1. Ensure the area of the fuel rail and intake
manifold injectors are clean of all dirt, grit etc.
Prior to the removal of injectors.
2. Relieve fuel system residual pressure.
3. Remove intake air duct from the air cleaner and
throttle body.
4. Disconnect wiring connectors from the Throttle
Position Sensor (TP) <TPS> and Idle Air Control
Valve (IAC) <ISC>sensors.
5. Disconnect vacuum hoses and lines from the PCV
system and fuel pressure regulator.
G98156 en 01/2003 2003.0 BA Falcon

6. Disconnect the throttle cable from the throttle Brake Switches

linkage.
7. Remove the upper intake manifold. Refer to Section 206-06 for more information.
8. Tag and is connect the fuel supply and return Clutch Engagement Switch, (Manual
lines using quick-connect fittings.
Transmission)
9. Disconnect the fuel injector wiring connectors.
10. Remove the screws securing the fuel rail. Removal
11. Remove the fuel rail and injectors as an 1. Gently twist the switch 45 degrees anti clockwise.
assembly. 2. Withdraw the switch from the bracket.
12. Remove the fuel injector from the fuel rail. Place
each injector in a clean plastic bag to prevent the
injectors from being contaminated with foreign
material. Number each bag according to injector
position. Plug the apertures in the intake manifold
to prevent the ingress of foreign material.
Installation
1. Ensure the fuel rail injector mounting apertures
are clean, smear the fuel injector sealing rings
with a light coating of engine oil. DO NOT use
petroleum jelly. Insert the injectors into the fuel
rail.
2. Ensure the intake manifold injector apertures and
the fuel injector tips are clean, smear the injector
sealing rings with a light coating of engine oil. DO 3. Unplug the wire harness connector from the
NOT use petroleum jelly. Insert the injectors into switch.
the manifold and position the fuel rail, press down Installation
on the fuel rail and install the retaining screws.
Torque screws to 12Nm. 1. Plug the wire harness connector to the switch.
3. Connect the fuel supply and return lines. 2. Insert the switch into to the bracket.
4. Install the upper intake manifold as described in 3. While pushing the switch home into the bracket,
Group 8-3, Eight Cylinder Engine. gently twist the switch 45 degrees clockwise to
lock the switch into the bracket.
5. Connect PCV hoses and all vacuum lines.
6. Connect throttle cable to the throttle linkage. Pedal Position Sensor
7. Connect wiring connectors to the TP and ISC Removal
sensors. Refer to Adjustable pedal section.
8. Install intake air duct to the air cleaner and throttle Installation
body. Refer to Adjustable pedal section.
9. Start and run engine. Check for any leaks. Rectify
any faults found.
G98162 en 01/2003 2003.0 BA Falcon

Air Conditioning Relay Phaser removal

Refer to Sections 412-03 & 412-04. Refer to Section 303-01a for more information.
Air Conditioner Pressure Transducer OCV removal

Refer to Section 412-03. Refer to Section 303-01a for more information.
Transmission Fluid Temperature CID sensor removal

Sensor Refer to Section 303-01a for more information.
VCT oil filter removal
Fuel Pump Refer to Section 303-01a for more information.
EVAP Canister Purge Solenoid
Transmission Range Sensor (TRSA1)
Transmission Range Sensor (TRSA2)

Intake Manifold Charge Control

IMCC Installation
Power Steering Pressure Switch

PSP Switch Location, I6
Item Description
1 Vacuum motor
2 Intake manifold
G98162 en 01/2003 2003.0 BA Falcon

PSP Switch Location, V8
G98169 en 01/2003 2003.0 BA Falcon

307-01-1 Automatic Transmission 307-01-1
SECTION : 307-01 Automatic Transmission

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................307-01-3
Automatic Transmission .........................................................................................................307-01-4
BTR Model 93/97LE Automatic transmission general description .......................................307-01-4
The Electronic Control System ..........................................................................................307-01-10
Adaptive Shift Strategy ......................................................................................................307-01-13
Automatic Transmission .......................................................................................................307-01-38
Electronic Control System ..................................................................................................307-01-38
Symptom Chart ..................................................................................................................307-01-38
GENERAL PROCEDURES
Hydraulic System .................................................................................................................307-01-45
Fluid Level ............................................................................................................................307-01-45
Fluid leakage checks ...........................................................................................................307-01-45
Fluid Leakage Converter Area .............................................................................................307-01-45
Gear shift Cable check .........................................................................................................307-01-46
Initial Engagement check .....................................................................................................307-01-46
Transmission operation checks - Test preparation ..............................................................307-01-46
Stall test, Engine speed .......................................................................................................307-01-46
Green Transmission Strategy (Retraining for new Automatic Transmission) ......................307-01-47
Line Pressure Boost Check .................................................................................................307-01-47
Road testing .........................................................................................................................307-01-47
Road Test ............................................................................................................................307-01-47
Air Pressure checks .............................................................................................................307-01-48
Transmission fluid level adjustment .....................................................................................307-01-49
Filling a drained/dry transmission and convertor to determine the correct fluid level ..........307-01-50
Gear shift cable adjustment .................................................................................................307-01-51
Band adjustment ..................................................................................................................307-01-51
Oil cooler flushing ................................................................................................................307-01-51
Inhibitor Switch .....................................................................................................................307-01-53
Radiator Oil Cooler ..............................................................................................................307-01-53
Oil Cooler Tube ....................................................................................................................307-01-53
Gear Shift — Column Shift ..................................................................................................307-01-54
Gear Shift — Floor Mounted ................................................................................................307-01-56
Cross Shaft Seals ................................................................................................................307-01-58
Mass Damper / Extension Housing .....................................................................................307-01-58
Speedometer drive gear (Non-ABS vehicles only) ..............................................................307-01-59
Extension housing seal .......................................................................................................307-01-60
Extension housing bush .......................................................................................................307-01-60
Oil Pan and Filter .................................................................................................................307-01-60
01/2003 2003.0 BA Falcon

(Continued)
Valve Body Assembly ..........................................................................................................307-01-60

Front Servo ..........................................................................................................................307-01-61
Rear Servo ...........................................................................................................................307-01-61
Transmission ........................................................................................................................307-01-62
DISASSEMBLY
Transmission ........................................................................................................................307-01-67
Transmission Case ..............................................................................................................307-01-67
Forward Clutch Cylinder ......................................................................................................307-01-69
C3 Clutch Cylinder ...............................................................................................................307-01-70
Planet Carrier & Centre Support ..........................................................................................307-01-71
Pump ....................................................................................................................................307-01-71
Valve Body ...........................................................................................................................307-01-71
ASSEMBLY
Transmission ........................................................................................................................307-01-73
Output Shaft & Gear Assembly ............................................................................................307-01-76
Rear Band ............................................................................................................................307-01-78
Rear Servo ...........................................................................................................................307-01-78
Planet Carrier and Centre Support ......................................................................................307-01-78
Extension Housing ...............................................................................................................307-01-79
Front Servo ..........................................................................................................................307-01-79
Front Band ...........................................................................................................................307-01-79
C2/C4 Clutch ........................................................................................................................307-01-79
C3 Clutch, Reverse Sun Gear & Forward Sun Gear Assembly ..........................................307-01-83
C1 Clutch Overdrive Shaft & Input Shaft .............................................................................307-01-85
Clutch ...................................................................................................................................307-01-86
Pump Cover & Converter Support .......................................................................................307-01-87
Valve Bodies ........................................................................................................................307-01-94
Oil Filter and Pan Assembly ................................................................................................307-01-99
Torque Converter & Housing .............................................................................................307-01-100
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Oil Specification
Automatic Transmission CASTROL TQ-95
Fluid
NOTE: When adding fluid use only CASTROL TQ-95
ATF. The use of incorrect fluids will cause a reduction
in performance and durability of the transmission.
Description Nm
Transmission Assembly Screws
T. C. housing to case M12 x 32 54-68
Extension housing to case - M93 M12 54-68
x 32
Extension housing to case - M97 M8 x 35-40
25
Rear servo cover to case M8 x 25 30-35
Pan to case M6 x 16 4-6
Cooler connector 40-45
Valve body to case M6 x 26 8-13
Valve body to case M6 x 45 8-13
Detent spring M8 x 16 20-22
Centre support to case M10 x 34 20-27
Cam plate to case M8 x 16 16-22
Position sensorswitch 10-24 x 13 4-6
Shipping strap to converter housing - 11-16
M93, M8 x 13 OR M8 x 30 (TAPTITE)
M97, M8 x 13
M97, M8 x 50
Shipping cap - cooler connector M16 0.15-0.35
Service fill plug M20 30-35
Pump Cover Assembly Screws
Pump to pump cover M8 x 55 24-27
Pump to pump cover M8 x 40 24-34
Pump cover to case M8 x 58 24-34
Pump cover plate to pump cover M6 x 13-16
16
Pump cover plate to crescent M6 x 54 13-16
Valve Body Body Assembly Screws
Upper valve body to lower M6 x 30 11-16
Line pressure plug M6 4-7
Solenoids (ON/OFF & VPS including 8-12
S7) M6 x 16
G73080 en 01/2003 2003.0 BA Falcon

Automatic Transmission gear states or modes, Park, Reverse, Neutral, Drive

(Adaptive Mode), Manual ‘3’, Manual ‘2’ and Manual
BTR Model 93/97LE Automatic ‘1’.
transmission general description Shift scheduling is controlled by the Adaptive (mode)
Shift Schedule or the Performance (mode) Shift
The Model 93/97LE is an electronically controlled four Schedule System. The Adaptive mode monitors how
speed transmission with overdrive fourth gear and a the driver uses the throttle and adjusts the shift
torque converter lockup clutch. strategy to meet driving requirements. The
Of primary significance is the microprocessor based Performance mode is optimised to achieve maximum
control system which employs a single proportional vehicle performance. In certain vehicles this mode is
solenoid multiplexed to three regulator valves to optimised for towing operations instead.
control all shift feel aspects. This solenoid is The 93LE (6 cylinder) and 97LE (8 cylinder)
controlled as a function of transmission sump transmissions are controlled by Powertrain Control
temperature to maintain consistent shift feel Module (PCM). The PCM utilizes throttle position,
throughout the operating range. engine speed, engine torque, transmission range
Transmission gear state is selected by the driver via sensor, transmission output speed, transmission
the position selector. There are two sump temperature and communication to the engine
vehicle/transmission position selector mechanism controller inputs, to control all shift feel and shift
variants available, these are Sequential Sports Shift schedule aspects.
and Column Shift. A reverse lockout feature is also incorporated into the
The Sequential Sports Shift variant has the following transmission design. This feature is intended to
selection of gear states or modes: Park, Reverse, protect the transmission from being exposed to
Neutral, Drive (Adaptive Mode), Performance Mode, excessive torque in the event that Reverse gear is
‘+’ and ‘-’ in Sequential Sports Shift Mode. The engaged at speed.
Column Shift variant has the following selection of
G73081 en 01/2003 2003.0 BA Falcon

Model 93LE Automatic Transmission (Non-ABS shown)
G73081 en 01/2003 2003.0 BA Falcon

Model 97LE Automatic Transmission
G73081 en 01/2003 2003.0 BA Falcon

Electronic Control In the case where Reverse is selected inappropriately,

solenoids 1 and 3 both have the supply output
This system is comprised of various input sensors, a pressure exhausted, the RLO spring biases the RLO
PCM and seven solenoids. The PCM simply reads the valve to the B2 band exhausted position, reverse oil is
inputs and activates the outputs as per the software prevented from feeding the B2 band.
and table values stored in the Read Only Memory
(ROM). Mechanical Arrangement
The PCM drives the hydraulic valve body via the The mechanical arrangement consists of four clutch
seven electromagnetic solenoids. Six of the seven assemblies, two bands, two sprag (or one way)
solenoids are ON/OFF solenoids used to: boost the clutches and a planetary gear set.
line pressure, operate shift valves and turn on and off
two regulator valves to control shift feel. The seventh Power Flow
solenoid is the proportional or Variable Pressure First gear is accomplished by applying the C2 clutch
Solenoid (VPS). and regulating the front band off, the reaction torque
Hydraulic Control is taken by the 1-2 One Way Clutch (OWC). The C2
clutch is applied in all forward gears.
The hydraulic control system consists of a primary
regulator valve for line pressure, a solenoid supply The 1-2 shift is accomplished by applying the B1 band
and overrunning the 1-2 OWC (Only the outer B1
regulator, a lockup clutch regulator valve, a band
servo apply area is used).
apply regulator valve, a clutch apply regulator valve, a
servo exhaust valve, C1 bias valve for converter The 2-3 shift is accomplished by applying the C1
lockups, a 4-3 sequence valve, three shift valves, a clutch concurrent with releasing the B1 band.
manual valve and the previously mentioned solenoids. The 3-4 shift is accomplished by applying the B1 band
All upshifts are accomplished by simultaneously and overrunning the 3-4 OWC. (Both inner and outer
switching: a shift valve or valves, the band and/or B1 servo apply areas are used).
clutch regulator valve and controlling the VPS output The C3 clutch and the B2 band are applied to
pressure. The event is completed by switching the accomplish Reverse. (Both inner and outer B2 servo
regulator off concurrent with sending the VPS to apply areas are used).
maximum pressure. The C4 clutch is applied in Sequential Sports
All downshifts are accomplished by simultaneously Shift/manual ranges 3, 2 and 1 to provide engine
switching on one or both of the regulators and braking. In addition the C4 clutch is applied in
controlling the VPS output pressure. The event is Adaptive and Performance mode for 2nd and 3rd
completed by concurrently; switching the regulator off, gears to prevent objectionable ‘freewheel’ coasting.
switching the shift valve and sending the VPS to Note in Auto 1st the C4 clutch is applied but due to
maximum pressure. The exception to this is a the B2 band not being applied the 1-2 OWC is able to
downshift to Auto 1st where the VPS is reduced to overrun this enables the vehicle to ‘freewheel’.
minimum pressure while switching the shift valve, the B2 band is applied in Sequential Sports Shift/manual
regulator remains on while in Auto 1st. range 1 to achieve engine braking shift. The servo is
Neutral to ‘D’ shifts while the vehicle speed is below a dual area design which allows smooth overrun shifts
approximately 6 km/hr results in a shift to Garage 1st at high vehicle speeds without the addition of a
to improve garage shift quality. Above 6 km/hr the regulator valve (i.e. servo is applied with line
transmission shifts to Auto 1st. Garage 1st is identical pressure). Only the inner B2 area is used for manual
to Auto 1st hydraulically except solenoid 1 is 1st.
energised, this results in the C4 clutch not being The B1 servo is also a dual area design to provide
supplied with oil. additional clamping force on the B1 band in fourth
Downshifts to Manual 1st gear state are accomplished gear.
in the same manner as other downshifts, however the The mechanical arrangement utilizes non-asbestos
gear state is achieved by exhausting the output friction materials for all members. These paper
pressures of solenoids 1, 2 & 3. This results in the 1-2 composites were selected based upon their
Shift Valve toggling to the Manual 1st position performance with a specially formulated Automatic
supplying oil to the C4 clutch and B2 band. Transmission Fluid.
The Reverse gear state is accomplished by the driver
positioning the manual valve into the reverse position, Converter Lockup Clutch
the manual valve supplies oil to the C3 clutch and to The Converter Lockup Clutch is a conventional clutch
the reverse lockout valve (RLO). To obtain Reverse with a spring damper arrangement to reduce engine
gear state either solenoids 1 or 3 supply output torsional disturbances. Located in the torque
pressure to the RLO valve, this biases the valve to the converter, its function is to couple the turbine (driven
B2 Band applied position where reverse oil is fed to member) to the impeller (drive member) to eliminate
the B2 band. slippage. It is generally functional in 3rd gear and 4th
G73081 en 01/2003 2003.0 BA Falcon

gear. The apply schedule and feel are modulated with The Torque Converter - 97LE
throttle position, engine torque and vehicle speed.
To enable lockup at high engine torque, line pressure
is supplied to the converter clutch regulator valve.
The Torque Converter - 93LE
Item Description
1 Turbine
2 Impeller
3 Stator
Item Description 4 Thrust Bearing
1 Turbine 5 Stator One Way Clutch
2 Impeller 6 Converter Cover
3 Stator 7 Clutch Plate
4 Thrust Bearing 8 Torsion Damper Springs
5 Stator One Way Clutch 9 Preload Spring
6 Converter Cover 10 Turbine Hub
7 Clutch Plate 11 Clutch Hub
8 Torsion Damper Springs 12 Friction Surface
9 Preload Spring
10 Turbine Hub Diagnostics
11 Clutch Hub Diagnostic activities of the control module are divided
12 Friction Surface into two categories.
Real-Time Self Check
This is an automatic monitoring of all inputs and
outputs for malfunctions during normal operation of
the vehicle.
If any INPUTS malfunction, the transmission assumes
one of a number of ‘temporary limp home’ (default)
G73081 en 01/2003 2003.0 BA Falcon

modes until the malfunction ceases, at which time the performed. This feature is to improve garage shift
unit will return to normal operation either while driving quality.
or after the module is re-initialised (vehicle turned off RANGE ‘D’ (ADAPTIVE MODE): Auto 1st, 2nd, 3rd
and restarted). and 4th gear operation. 1-2, 2-3, 3-4, 4-3, 4-2, 4-1,
If solenoids 1 to 6 OUTPUTS malfunction the 3-2, 3-1 and 2-1 shifts are all available as a function
transmission assumes a ‘permanent limp home’ of vehicle speed, throttle position and the time rate of
mode. Even if the output malfunction corrects itself, change of the throttle position (forced downshift,
the module must be re-initialised to return to normal inhibited upshifts). Lockup clutch available in 3rd and
operation. The exception to this is a hydraulic 4th.
solenoid 1 or 3 fault where normal operation is not RANGE ‘PERF’ (PERFORMANCE MODE): Auto 1st,
restored until reverse is successfully engaged at 2nd, 3rd and 4th gear operation. 1-2, 2-3, 3-4, 4-3,
vehicle startup. 4-2, 4-1, 3-2, 3-1, and 2-1 shifts are all available as a
If solenoid 7 output malfunctions then this solenoid is function of vehicle speed, throttle position and the
disabled resulting in the torque converter always time rate of change of the throttle position (forced
unlocked. downshift, inhibited upshifts). Lockup clutch available
in 3rd and 4th. In some vehicle this mode is replaced
Limp Home Mode with Towing mode.
There are now a number of ‘Limp Home’ modes Range ‘+’ (MANUAL ‘2’, ‘3’, ‘4’): This position initiates
available depending on the type of fault which has an upshift. Each gear state has a vehicle speed
occurred. The target gear state in most cases is third range, if the target gear is outside of this range an
gear, if solenoid 2 is faulty above a certain speed upshift is inhibited. Lockup clutch available in third
fourth gear is the target gear state. Several Limp and fourth, application.
Home modes will result in the speed limiting of the RANGE ‘-’ (MANUAL ‘1’, ‘2’, ‘3’): This position
vehicle, in the event of a speedo fault the vehicle will initiates a downshift. Each gear state has a vehicle
be limited to 140 km/hr, a solenoid 1 to 6 fault will limit speed range, if the target gear is outside of this range
to 120 km/hr and multiple solenoid 1 to 6 faults will a downshift is inhibited. Lockup clutch available in 3rd.
limit to 45 km/hr. These speeds are approximate and Manual 1st is only available by this means.
depend on the vehicle axle/wheel configuration.
2. Column Shift Selector Lever
Limp Home modes that noticeably limit driveability
also result in the PRNDL display being flashed. A seven position detent mechanism is featured to
Reverse gear is available. select ranges ’1’, ’2’, ’3’, ’D’, ’N’, ’R’, ’P’.
Range ‘1’ (MANUAL ‘1’): Manual 1st gear only with
Active Diagnostics an inhibited engagement as a function of excess
This aspect is dedicated for service technician use. vehicle speed. Manual 1st is only available in this
Error codes are displayed by digital output to the range.
diagnostic terminals. RANGE ‘2’ (MANUAL ‘2’): Auto 1st and 2nd gear
operation with an inhibited engagement of second at
Selector Lever Positions high vehicle speed.
1. Sequential Sports Shift Selector Lever RANGE ‘3’ (MANUAL ‘3’): Auto 1st, 2nd and 3rd gear
A four position detent mechanism is used to select operation with an inhibited 3rd gear engagement at
ranges ‘D’, ‘N’, ‘R’, ‘P’. In the ‘D’ position, Adaptive high vehicle speed. Lockup clutch available in 3rd.
mode is selected. The lever can then be moved to the RANGE ‘D’: Auto 1st, 2nd, 3rd and 4th gear
left to obtain the ‘PERF’ range, or Performance mode. operation. 1-2, 2-3, 3-4, 4-3, 4-2, 4-1, 3-2, 3-1, and
In this position the lever can be nudged up for ‘-’ or 2-1 shifts are all available as a function of vehicle
down for ‘+’, this initiates Sequential Sports Shift speed, throttle position and the time rate of change of
mode. A spring returns the lever to the central the throttle position (forced downshift, inhibited
position, the transmission will remain in Sequential upshifts). Lockup clutch available in 3rd and 4th.
Sports Shift mode until the lever is moved back to ‘D’. RANGE ‘N’ (NEUTRAL): No bands or clutches are
RANGE ‘P’ (PARK): No bands or clutches are engaged. The inhibitor switch will allow engine start.
engaged. The transmission output shaft is locked. The During a N-D or N-PERF shift and while the vehicle is
inhibitor switch will allow engine start. stationary, a N-Garage 1st-Auto 1st shift will be
RANGE ‘R’ (REVERSE): Reverse gear operation, performed. This feature is to improve garage shift
when selected outside appropriate vehicle and engine quality.
speed limits reverse is inhibited. Reversing lights on. RANGE ‘R’ (REVERSE): Reverse gear operation,
RANGE ‘N’ (NEUTRAL): No bands or clutches are when selected outside appropriate vehicle and engine
engaged. The inhibitor switch will allow engine start. speed limits reverse is inhibited.. Reversing lights on.
During a N-D or N-PERF shift and while the vehicle is
stationary, a N-Garage 1st-Auto 1st shift will be
G73081 en 01/2003 2003.0 BA Falcon

RANGE ‘P’ (PARK): No bands or clutches are for manual 1st. Both areas are applied for reverse
engaged. The transmission output shaft is locked. The operation.
inhibitor switch will allow engine start.
The Electronic Control System
Friction Members
The transmission control unit is combined within the
All friction materials are non-asbestos. Powertrain Control Unit (PCM).
‘C1’ CLUTCH: 3-4 clutch . . . engaged in third and Input signals received from the pedal position sensor,
fourth gears. ignition system, speedometer transducer, range
‘C2’ CLUTCH: Forward clutch . . . engaged in all sensor, transmission temperature sensor and the
forward gears. Sequential Sports Shift selector switch are processed
by the PCM to provide output signals to control the
‘C3’ CLUTCH: Reverse clutch . . . engaged in reverse
gear only. shift schedule, shift feel and line pressure.
This control is achieved by the use of six ON/OFF
‘C4’ CLUTCH: Overrun clutch . . . primary function is
to provide engine braking in manual 1st, 2nd and 3rd. solenoids and one proportional or variable pressure
In 2nd and 3rd gears to prevent objectionable solenoid.
‘freewheel coasting’. The PCM has a diagnostic ‘Self Test’ capability
whereby any malfunctions are recorded in the
‘B1’ BAND: 2-4 band . . . engaged in second and
fourth gears. There are two apply areas on the servo memory. The Diagnostic Test Codes (DTC’s) codes
piston. The outer area is applied in second gear. Both are displayed by digital output at the diagnostic
terminals and may be read by the technician with the
areas are applied in fourth gear.
Worldwide Diagnostic System (WDS) tester. Refer to
‘B2’ BAND: Low/reverse band. There are two apply chapter 303-14 for PCM diagnostics.
areas on the servo piston. The inner area is applied
G73081 en 01/2003 2003.0 BA Falcon

Solenoids Engine Speed

The engine speed signal is taken from the tachometer
signal line.
Road Speed
The road speed signal is taken from the speedometer
transducer to speedometer line (ABS model only). On
non-ABS models, the speed signal is taken from the
speedometer transducer on the output shaft.
Transmission Sump Temperature
This sensor takes the form of a thermistor located in
the solenoid wiring loom within the transmission.
Above certain temperatures, overheat strategies are
invoked as indicated in the table below.
Item Description Temp (°C) Overheat Strategy
1 Exhaust 115 Fan engaged.
2 Line 500 No driver alert.
Solenoids Nos. 1 to 6 are mounted in the valve body. 120 In Adaptive mode,
Solenoid No. 7 is mounted in the pump cover. power shift schedule
is selected.
Solenoids 1 and 2 are normally open ON/OFF Engine temperature
solenoids that combine with other solenoids to set the jewel will appear.
selected gear. PRNDL indicator will
Solenoids 3 and 4 are normally open ON/OFF flash.
solenoids that combine to control shift quality 125 Torque converter
sequencing. They also combine with other solenoids lock-up invoked in
to obtain certain gear states. 2nd, 3rd and 4th
Solenoid 5 is a variable pressure solenoid (VPS) that gears above certain
ramps the pressure during gear changes to control calibratable shaft
shift quality. It is also used to obtain certain gear speed points.
states in combination with other solenoids. 135 Vehicle restricted to a
Solenoid 6 is a normally open ON/OFF solenoid that calibratable constant
sets the high/low level of line pressure. torque.
Solenoid 7 is a normally open ON/OFF solenoid that
controls the application of the converter clutch. Transmission Range Sensor
Accelerator Pedal Position (APP) Sensor The transmission range TR sensor is incorporated in
the inhibitor switch mounted on the side of the
The APP is part of the Electronic Throttle Control ETC transmission case and provides discrete resistance
system. ETC provides direct throttle control by values indicating the gear selected by the gear shift
eliminating the throttle cable. A spring is contained in lever.
the APP to proved pedal resistance. The APP
contains three potentiometers: one reverse slope full
ratio, one forward slope full-ratio and one forward
slope half-ratio. This allows an accurate picture of
both the accelerator pedal position and rate of change
to be sent to the PCM, while providing a failsafe
backup if one of the potentiometers fails. The APP is
not serviceable, if faulty replace the APP as an
assembly.
G73081 en 01/2003 2003.0 BA Falcon

Temperature Sensor Location in Solenoid Loom
G73081 en 01/2003 2003.0 BA Falcon

Adaptive Shift Strategy Override Function

The PCM features an adaptive shift strategy, which is The adaptive shift strategy allows for an immediate
controlled by the software within the PCM. By change to maximum performance shifting when the
continuously monitoring the driver’s accelerator inputs pedal application is greater than 85%. When the pedal
(via the Throttle Position Sensor - measuring throttle falls below 85%, the adaptive shift level will return to
position and rate of change, and vehicle speed-VSS), the level used prior to the 85% pedal application.
the PCM determines the driving style being used and
modifies the gearshift points to suit that style. Kickdown Strategy
The PCM selects from 6 graduated shift maps. The A ‘kickdown’, or forced downshift feature, is controlled
maps are selected automatically by the PCM by the PCM. The PCM reads pedal position, rate of
dependent on the driving style being used at the time. pedal application, engine speed and road speed
signals to determine and select the required gear.
Keep alive memory data retention
The 93/97LE PCM contains a ‘Keep Alive Memory’
capability. When in Adaptive Mode, this enables the
module to maintain a score of various engine/
transmission parameters and optimise the
transmission shift points.
The Keep Alive Memory also stores the fault data for
service technician use in diagnosis. This data is
stored for 40 warm up cycles of the PCM. (Warm =
transmission temp. > 50°C)
If the power supply to the PCM is interrupted the PCM
may lose the data in the ’Keep Alive Memory’.
The Shift maps are essentially sets of tables which The data retention time for the PCM depends on the
dictate the speeds at which the transmission will module temperature during the time that the power
change gear, based on vehicle speed and throttle supply is interrupted (e.g. battery disconnected).
position.
Engine Idle Up Strategy
Operation To ensure sufficient pump capacity the PCM controls
The PCM monitors what pedal position is used for the engine idle at different transmission oil
upshifts and/or downshifts and compiles a composite temperatures.
score which reflects a particular driver’s behaviour. If
the composite score is higher than the current “library”
The Shift Pressure Control System
score then it will move to the next more aggressive Variable Pressure Solenoid (VPS) Multiplexing
“shift map”, or vice versa. System
There are two parameters that the adaptive shift Friction element shifting pressures are controlled by
routine continuously monitors to determine the best the variable pressure solenoid No. 5. Line pressure is
suited “shift map” to suit the driver’s driving completely independent of shift pressure.
behaviour.
Parameters monitored are as follows: VPS pressure is supplied continuously to the
converter clutch regulator valve and is multiplexed to
1. Shift Scoring the clutch and band regulator valves during timed
gearshifts.
The "Shift Scoring" parameter is used to record and
monitor the position of the pedal at the start of a shift. The multiplexing is carried out by two normally open
The PCM does this using the APP signal. on/off solenoids. These on/off solenoids act via a
plunger to apply either VPS outlet pressure or Line
2. Launch Scoring 500 reference pressure to one end of the regulator
The “Launch Scoring” parameter is used to record valve. The other end of the regulator valve is fed with
and monitor the pedal position each time the vehicle band or clutch feed-back pressure.
is accelerated from rest. The PCM does this using the Except when in Auto 1st , Manual 1st or RLO gear
pedal position sensor and vehicle speed sensor (APP state, under steady state conditions the band and
vs VSS). clutch regulator valve solenoids are switched off. This
applies full Line 500 pressure to the plunger and
because Line 500 pressure is always greater than S5
pressure, it squeezes the S5 oil from between the
regulator valve and the plunger. The friction elements
G73081 en 01/2003 2003.0 BA Falcon

are then fed oil pressure equal to Line 500 multiplied hence controls the shift pressures. It is also
by the regulator valve amplification ratio. When a utilised to obtain Auto 1st, Garage 1st and 3rd
gearshift is not in progress the VPS current is set to Limp Home.
200 mA which gives a pressure of approximately 450 S7 - Lock up solenoid LUS switches converter
kPa. clutch on or off, solenoid on applies the clutch.
When a shift is initiated the required on/off solenoid is
switched on cutting the supply of Line 500 oil to the Variable Pressure Solenoid (VPS) Operation
plunger. At the same time the VPS pressure is Solenoid S5 is a proportional or variable pressure
reduced to the ramp start value and assumes control solenoid that provides the signal pressure to the
of the regulator valve by pushing the plunger away clutch and band regulator valves thereby controlling
from the valve. The VPS then carries out the required shift pressures.
pressure ramp and the timed shift is completed by A variable pressure solenoid produces an oil pressure
switching off the on/off solenoid and returning the
inversely proportional to the current applied.
VPS to the standby pressure.
During a gearshift the PCM applies a progressively
This system enables either the band or clutch or both increasing or decreasing (ramped) current to the
to be electrically selected for each gearshift. The solenoid. Current applied will vary between a
multiplexing arrangement also increases transmission minimum of 0.2 amps and a maximum of 1.275 amps.
reliability since it requires both the VPS and one on/off
solenoid to fail before a friction element burn-up can Increasing current decreases output (S5) pressure.
occur. Decreasing current increases output (S5) pressure.
Line 500 pressure, 480 kPa, is the reference pressure
The converter clutch regulator valve is permanently for the VPS.
connected to the VPS but its regulated outlet pressure
is only fed to the torque converter when the lock up S5 output pressure has a maximum value of
solenoid LUS S7 is activated. approximately 450 kPa.
The VPS has been fitted with nose filters to prevent When the VPS is on standby (i.e. no gearshift is
the ingress of contaminants resulting in solenoid taking place), the VPS current is set at 0.2 amps
stiction and hence further increase the overall system giving maximum output pressure. This current may be
reliability. lower when the lockup clutch is applied in high
performance vehicles.
Solenoid Shifting Sequence
Solenoid Valve Symbols (On/Off Solenoids)
Tables 1 and 2 outline the usage of solenoid numbers
S1, S2, S3, S4, S5 and S7 in each gear position and The solenoid symbol shown adjacent to each solenoid
during gear shifts. on the hydraulic system schematics indicates the
state of the oil flow through the solenoid valve with the
In brief: power On or Off.
S1 & S2 - determine static gear position by Both halves of the symbol are identical, only the
operating the shift valves. spring end is labeled.
S3 - Switches the clutch regulator valve off or on. In the example illustrated:
It is also utilised to obtain Reverse, RLO, Manual
1st, Garage 1st and 2nd No Engine Braking. POWER ON Line 500 port is closed. The S1 port
is open to exhaust at the solenoid valve.
S4 - Switches the band regulator valve off or on. It
POWER OFF The exhaust port is closed. The S1
is also utilised to obtain Auto 1st, Garage 1st and
3rd Limp Home. port is open to Line 500.
S5 - Variable pressure solenoid VPS provides the
signal pressure to the clutch, band regulator and
G73081 en 01/2003 2003.0 BA Falcon

On/Off Solenoid
Solenoid Logic States For Model 93/97LE

GEAR STATE ELECTRICAL SHIFT SOLENOID STATES
S1 S2 S3 S4 S5 S7 MODE³
PARK ON OFF OFF OFF X OFF NORMAL
REVERSE ON² OFF OFF OFF X OFF NORMAL
REVERSE LIMP HOME OFF OFF OFF OFF X OFF LIMP HOME
RLO ON OFF ON OFF X OFF NORMAL
NEUTRAL ON OFF OFF OFF X OFF NORMAL
MANUAL 1ST ON ON ON OFF X OFF Sequential
Sports Shift/M1
AUTO 1ST OFF ON OFF ON 1000mA OFF NORMAL
GARAGE 1ST ON ON OFF ON 1000mA OFF GARAGE
2ND (ENGINE BRAKING) OFF ON OFF OFF X OFF NORMAL
2ND LOCKED OFF ON OFF OFF STANDBY ON LIMP HOME
2ND NO ENGINE BRAKING ON ON OFF OFF X OFF LIMP HOME
3RD (ENGINE BRAKING)¹ OFF OFF OFF OFF X OFF NORMAL
3RD LOCKED OFF OFF OFF OFF STANDBY ON NORMAL
3RD LIMP HOME OFF OFF OFF ON 1000mA OFF LIMP HOME
4TH (ENGINE BRAKING) ON OFF OFF OFF X OFF NORMAL
4TH LOCKED ON OFF OFF OFF STANDBY ON NORMAL
¹ Power down gear state. mode refers to the situation where a system or
² In Reverse S1 and S3 states are inverted each sub-system has been detected as being faulty and the
engagement into Reverse, solenoid status needs to transmission software has been put into this mode for
be recorded into history so that it is not reset at key protection.
off.
³ Mode is broken down into four modes, normal which
refers to the normal state which the driver selects
using either the T-Bar or Column Shift Selector Lever.
This covers all normal driving modes. Sequential
Sports Shift (T-Bar) or M1 (Column Shift) modes are
the specific modes where Manual 1st is selected.
Garage mode is a transient mode used when shifting
from N to D and the vehicle is stationary. Limp Home
G73081 en 01/2003 2003.0 BA Falcon

Solenoid Operation During Gearshifts 93LE

Shift To Initiate Shift Typical S5 Current Ramp To Complete Shift
1-2 S1 OFF 700 mA to 550 mA S4 OFF
S4 ON
S2 OFF S4 OFF
S3 ON
S4 ON
S3 ON S4 OFF
S4 OFF
S3 ON S4 OFF
S4 ON
3-4 S1 ON 600 mA to 450 mA S4 OFF
S4 ON
3L-4L S1 ON 600 mA to 450 mA S4 OFF
S4 ON
4-3 KD S4 ON 750 mA to 950 mA S1 OFF
S4 OFF
S2 ON
S3 OFF
4-1 KD S3 ON 400 mA to 900 mA S2 ON
S4 ON S3 OFF
S4 OFF
3-2 KD S4 OFF
@20 kph S2 ON 500 mA to 300 mA
@100 kph 700 mA to 600 mA
S4 ON S2 ON
S3 OFF
S4 OFF
S4 OFF
CONV. CLUTCH S7 ON S7 OFF
ON 700 mA to 500 mA
OFF 700 mA to 900 mA
3L-4 S1 ON 600 mA to 450 mA S4 OFF
S4 ON S7 OFF
KD .... Power on Kickdown Shift
L ...... Locked
S4 ON
S2 OFF S4 OFF
S3 ON
S4 ON
G73081 en 01/2003 2003.0 BA Falcon


S3 ON S4 OFF
S4 OFF
S3 ON S4 OFF
S4 ON
3-4 S1 ON 600 mA to 400 mA S4 OFF
S4 ON
S4 OFF
S2 ON
S3 OFF
S4 ON S3 OFF
S4 OFF
3-2 KD S2 ON S4 OFF
@60 kph 450 mA to 350 mA
@100 kph 600 mA to 500 mA
S4 ON S2 ON
S3 OFF
S4 OFF
S4 OFF
CONV. CLUTCH S7 ON S7 OFF
ON 600 mA to 400 mA
OFF 700 mA to 1000 mA
3L-2 KD S2 ON 400 mA to 300 mA S4 OFF
S4 ON S7 OFF
S7 ON
S7 ON S4 OFF
S7 OFF
3L-1 KD S3 ON 775 mA to 900 mA S1 ON
S4 ON S2 ON
S7 ON S3 OFF
S4 OFF
S7 OFF
4L-1 KD S3 ON 650 mA to 900 mA S2 ON
S4 ON S3 OFF
S7 ON S4 OFF
S7 OFF
S7 ON S2 ON
S3 OFF
S7 OFF
3L-4 S1 ON 550 mA to 350 mA S4 OFF
S4 ON S7 OFF
S7 ON
G73081 en 01/2003 2003.0 BA Falcon


3L-4L S1 ON 500 mA to 300 mA S4 OFF
S4 ON S7 ON
S7 ON
KD .... Power on Kickdown Shift
L ...... Locked
Power Flow and Hydraulic Systems

Schematics
Power Flow - Neutral and Park
No clutches or bands are engaged in Neutral or Park prevented from entering the Drive circuit by the
therefore there is no drive input to the planetary gear Manual Valve.
set. All Clutch and Band circuits are open to exhaust.
In Park the transmission is mechanically locked by
engaging a case mounted pawl with teeth on the
output shaft ring gear.
Control
Solenoid 1 is switched ON, solenoid 2 is switched
OFF. Line (pump) pressure is applied to the Primary
Regulator Valve and to the Solenoid Supply Valve.
The Converter, Oil Cooler and lubrication circuits are
charged from the Primary Regulator Valve.
The Line 500 circuit is charged from the Solenoid
Supply Valve. The S5 circuit is charged by the
Variable Pressure Solenoid - S5. Line pressure is
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - Neutral and Park
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — Reverse
Drive is via the input shaft and the forward clutch preventing reverse pressure from applying the B2
cylinder to the hub of the C3 clutch. The C3 clutch is band.
engaged and drives the reverse sun gear in a
clock-wise direction. The B2 band is engaged and
holds the planetary gear carrier stationary causing the
long pinion to rotate anticlockwise about its axis on
the pinion shaft. The long pinion drives the internal
ring gear in the same direction. The internal ring being
splined to the output shaft drives it in an
anti-clockwise or reverse direction.
Control
Solenoid 2 is switched OFF.
In any given reverse engagement S1 and S3 have
opposite states (for example S1 ON, S3 OFF). Each
subsequent reverse engagement changes the
ON/OFF state of S1 and S3 (eg S1 OFF, S3 ON).
Thus oil pressure from EITHER S1 OR S3 pilots the
Reverse Lockout (RLO) valve into the B2 band
applied position.
Reverse (Line) pressure oil is routed from the Manual
valve direct to the C3 clutch and through the RLO
valve to both the inner and outer apply areas of the
rear servo piston for B2 band application. All other
clutch and band apply circuits are open to exhaust.
To obtain the RLO state, solenoids 1 and 3 are
switched ON to exhaust tracks S1 and S3. The RLO
spring biases the RLO valve to the lockout position
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - Reverse
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — Sequential Sport Shift 1 /

Manual 1
Drive is via the input shaft to the forward clutch

cylinder. The C2 clutch is engaged to drive the
forward sun gear via the 3-4 OWC. The B2 band and
the 1-2 OWC are engaged to hold the planetary gear
carrier stationary. The forward sun gear drives the
short pinion anti-clockwise. The short pinion drives the
long pinion clockwise. The long pinion rotating about
its axis drives the internal ring gear and the output
shaft in a clockwise or forward direction. The C4
clutch provides engine braking by by-passing the 3-4
OWC on overrun.
Control
Solenoids 1, 2 and 3 are switched ON. The 1-2, 2-3,
3-4 shift valves are held in their first gear positions by
Line 500 pressure. Drive (Line pressure) oil from the
Manual valve applies the C2 clutch. Lo-1st (Line
pressure) oil is routed through the 1-2 shift valve to
the C4 clutch and to the inner apply area of the rear
servo piston for B2 band application.
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - Sequential Sports Shift 1 / Manual 1
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — Auto 1
Drive is via the input shaft to the forward clutch deadheads 2nd oil and the Band Apply Feed (BAF)
cylinder. The C2 clutch is engaged to drive the circuit is exhausted.
forward sun gear via the 3-4 OWC. The forward sun Drive (Line pressure) is routed through the 3-4 shift
gear drives the short pinion anti-clockwise. The short valve to apply to C4 clutch.
pinion drives the long pinion clockwise. The 1-2 OWC
prevents the planetary gear carrier from rotating under
reaction force and the long pinion rotates on its axis
driving the internal ring gear and output shaft in a
clockwise or forward direction. There is no engine
braking on overrun.
Control
Solenoids 1 and 3 are switched OFF. Solenoids 2 and
4 are switched ON. VPS is set to minimum pressure
(approximately 0 kPa). Drive (Line pressure) oil from
the Manual valve applies the C2 clutch.
When solenoid S1 switches OFF, S1 oil pressure,
derived from Line 500 moves the 3-4 shift valve to the
left. At the same time S1 and S3 oil is directed to the
1-2 shift valve moving it to its second gear position.
2nd oil (Line pressure) from the 1-2 shift valve is
directed to the Band Apply Regulator (BAR) valve and
to the 2-3 shift valve.
When solenoid S4 switches ON, the pressure behind
the BAR piston is exhausted, S5 pressure is minimum
allows the BAR spring to bias the BAR valve to the
exhaust position. In this position the BAR valve
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - Auto 1st
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — D2 and Sequential Sport Shift

2/Manual 2
Drive is via the input shaft and forward clutch cylinder, only 2.32 times Line 500 pressure less 237 kPa (946
Clutch C2 is applied to drive the forward sun gear via kPa), to the Band Apply Feed (BAF) circuit.
the 3-4 OWC. The forward sun gear drives the short Band Apply Feed oil is directed to:
pinion anti-clockwise. The short pinion drives the long
the outer apply area of the front servo piston
pinion clockwise. The B1 band is applied holding the
reverse sun gear stationary therefore the long pinion the 3-4 shift valve for use when the transmission
‘walks’ around the reverse sun gear taking the internal is shifted to fourth gear
ring gear and output shaft with it in a clockwise or the 1-2 shift valve to provide an exhaust port
forward direction. The C4 clutch is applied to by-pass when the transmission is shifted to first gear.
the 3-4 OWC and provide engine braking on overrun. the 1-2 shift valve to provide an exhaust port
Control when the transmission is shifted to first gear.
Solenoids 1, 3 and 4 are switched OFF. Solenoid 2 is Drive (Line pressure) is routed through the 3-4 shift
switched ON. Drive (Line pressure) oil from the valve to apply to C4 clutch.
Manual valve applies the C2 clutch.
When solenoid S1 switches OFF, S1 oil pressure,
derived from Line 500 moves the 3-4 shift valve to the
left. At the same time S1 and S3 oils are directed to
the 1-2 shift valve moving it to its second gear
position.
2nd oil (Line pressure) from the 1-2 shift valve is
directed to the Band Apply Regulator valve and to the
2-3 shift valve.
The Band Apply Regulator valve supplies 2nd oil,
regulated to a pressure 1.8 times Line 500 pressure
less 191 kPa for the BAR spring (724 kPa) or for XR8
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - D2 and Sequential Sports Shift / Manual 2
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — D3 and Sequential Sport Shift

3/Manual 3
Drive is via the input shaft to the forward clutch the 1-2 shift valve to provide an exhaust port
cylinder. Clutch C2 is engaged to drive the forward when the transmission is shifted to first gear.
sun gear via the 3-4 OWC. Clutch C1 is engaged to the 3-4 shift valve for use when the transmission
drive the planet carrier. Because the forward sun gear is shifted to fourth gear.
and the planet carrier are driven clockwise at the
2nd oil at the 2-3 shift valve is directed to the 3rd oil
same speed there is no relative motion between the
circuit. 3rd oil from the 2-3 shift valve is directed to the
sun gear and the pinions. The ring gear and output
shaft are driven in a clockwise or forward direction atClutch Apply Regulator valve and to the 4-3 sequence
input shaft speed. The C4 clutch is applied to by-pass valve.
the 3-4 OWC and provide engine braking on overrun. Clutch Apply Feed oil is directed to:
the C1 clutch
Control
the 4-3 sequence valve
Solenoids S1, S2, S3 and S4 are switched OFF. With
solenoids 1 and 2 switched OFF the 2-3 and 3-4 shift At the 4-3 sequence valve the CAF oil is directed, as
valves are held in third gear position by Line 500 Band 1 Release Feed (B1R-F) oil, through the 3-4
pressure. The 1-2 shift valve is held in third gear shift valve to the spring end of the 4-3 sequence valve
position by S1-S2-S3 oil pressure. 2nd oil (Line and to the release side of the front servo piston to
hold Band 1 OFF. Drive oil (Line pressure) from the
pressure) from the 1-2 shift valve is directed to the
Band Apply Regulator valve and to the 2-3 shift valve. 3-4 shift valve applies the C4 clutch.
less 191 kPa for the BAR spring (724 kPa) or for XR8
only 2.32 times Line 500 pressure less 237 kPa (946
kPa), to the Band Apply Feed (BAF) circuit.
Band Apply Feed oil is directed to:
the outer apply area of the Front Servo.
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - D3 and Sequential Sports Shift 3 / Manaul 3
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — D4 and Sequential Sports Shift

4/Manual 4
Drive is via the input shaft to the forward clutch less 191 kPa for the BAR spring (724 kPa) or for XR8
cylinder. The C1 clutch is applied to drive the planet only 2.32 times Line 500 pressure less 237 kPa (946
carrier clockwise. The B1 band is applied to hold the kPa), to the Band Apply Feed (BAF) circuit.
reverse sun gear stationary. As the planet carrier Band Apply Feed oil is directed to:
turns, the long pinion ‘walks’ around the stationary
the outer apply area of the front servo piston.
reverse sun gear and rotates around its axis driving
the internal ring gear and output shaft in a clockwise the inner apply area of the front servo piston via
or forward direction at a speed faster than the input the 3-4 shift valve.
shaft i.e. in overdrive ratio. The forward sun gear is the 1-2 shift valve to provide an exhaust port
also driven faster than the input shaft and overruns when the transmission is shifted to first gear. 2nd
the 3-4 OWC. The C2 clutch is engaged to reduce the oil at the 2-3 shift valve is directed to the 3rd oil
speed differential across the 3-4 OWC. circuit. 3rd oil from the 2-3 shift valve is directed
to the Clutch Apply Regulator valve and to the 4-3
Control Sequence valve.
Solenoid S1 is switched ON. The Clutch Apply regulator valve supplies oil,
Solenoid S2 is switched OFF. regulated to a pressure 2.25 times Line 500 pressure
(1100 kPa) (93LE) 2.85 times Line 500 pressure
With solenoid S1 switched ON the 3-4 shift valve is (1375 kPa) (97LE or XR’s), to the Clutch Apply Feed
held in fourth gear position by Line 500 pressure on
(CAF) circuit.
the small end of the valve. With solenoid S2 switched
OFF the 2-3 shift valve is held in fourth gear position Clutch Apply Feed oil is directed to:
by Line 500 pressure on the large end of the valve. the 4-3 Sequence valve
The 1-2 shift valve is held in fourth gear position by the C1 clutch
S2 oil pressure. 2nd oil (Line pressure) from the 1-2
shift valve is directed to the Band Apply Regulator The C2 clutch is applied by Drive oil (Line pressure)
valve and to the 2-3 shift valve. from the Manual valve.
G73081 en 01/2003 2003.0 BA Falcon

Hyadraulic System - D4 and Sequential Sports Shift 4 / Manual 4
G73081 en 01/2003 2003.0 BA Falcon

Power Flow — D2, D3 and D4 Lockup off and allowed to exhaust through the S7 solenoid,
allowing the valve to move to the clutch applied
Drive in this range is the same as for D2, D3 or D4 position.
with the application of the converter Lockup clutch to
provide positive no-slip converter drive. The Converter Clutch Regulator Valve (CCRV)
NOTE: D2 Lockup is only used as an overheat supplies Line oil, regulated to a pressure 1.48 times
reduction strategy when in failure mode. S5 pressure plus 138 kPa (875 kPa), to the Regulated
Apply Feed (BAF) circuit. This is directed by the
CCCV to the apply side of the converter clutch.
Control
Control for this range is the same as for D2, D3 or D4 Converter clutch release oil is exhausted at the
CCCV. Converter Feed oil is re-routed by the CCCV
with the addition of the converter clutch circuit
activated by solenoid S7, as illustrated. When to the oil cooler and lubrication circuit.
solenoid S7 is switched ON, S7 feeds oil to the
Converter Clutch Control Valve (CCCV) is switched
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic System - D2, D3 and D4 Lockup
G73081 en 01/2003 2003.0 BA Falcon

Hydraulic Valves When engine speed increases and the pump provides
an excess of oil the PRV moves to uncover the
Manual Valve converter feed port thereby pressurising the converter.
As engine speed increases further the excess oil
supplied by the pump is diverted back to the pump
suction port as the PRV opens further against spring
force.
1-2 Shift Valve (Manual 1st Shift Valve)
The manual valve is connected to the vehicle selector

mechanism and controls the flow of oil to the forward
and reverse circuits. The manual valve function is
identical in all forward gear positions. Oil is prevented
from entering the forward and reverse circuits when
the manual valve is in the park or neutral position.
This is a two position valve that must be switched to
Primary Regulator Valve the 2, 3 or 4 position in order to get any forward gear
other than Manual 1st. It is used on every Manual
1st-2 and 2-Manual 1st gearshift hence its name.
Drive oil from the manual valve is allowed to pass
through to the 2nd circuit during a Manual 1st-2
gearshift. During a 2-Manual 1st shift the band apply
feed oil is allowed to exhaust via this valve. It also
routes oil to the C4 clutch and the rear band servo.
The switching of this valve is achieved by supplying
pressure from solenoid 1, 2 and/or 3, or exhausting
pressure through solenoid 1, 2 and 3.
2-3 Shift Valve
This valve is used on 2-3 and 3-2 shifts. The
switching of this valve is done directly by solenoid 2
which is located at the end of the 2-3 shift valve.
The function of this valve is to regulate the
When in the 1 and 2 position 2nd oil from the 1-2 shift
transmission line pressure (pump outlet pressure).
valve is prevented from entering the 3rd circuit. When
This valve gives either low, or high, line pressure
the valve is shifted to the 3 and 4 position the 3rd
depending on whether solenoid #6 is switched ON, or
circuit is fed from the 2nd circuit and the transmission
OFF. When the #6 solenoid is switched ‘ON’ S6
will shift to 3rd gear.
pressure is applied to the PRV moving it against
spring pressure and opening the line pressure circuit
to the pump suction port resulting in reduced line
pressure. Low line pressure is used during light
throttle applications and cruising. Heavy throttle
application will cause solenoid #6 to switch ‘OFF’
allowing the PRV to close off increasing line pressure.
This stepped line pressure control does not have a
detrimental effect on shift quality because all shifting
pressures are controlled by separate band and clutch
regulator valves and the output of solenoid #5.
The PRV also regulates the supply of oil to the torque
converter via the converter feed port. The lands on
the PRV are designed such that priority is given to
maintaining line pressure at very low engine speeds.
G73081 en 01/2003 2003.0 BA Falcon

2-3 Shift Valve 4-3 Sequence Valve
This valve switches during 3-4 and 4-3 gearshifts

3-4 Shift Valve although it performs no function during the 3-4 shift.
This valve is used for 3-4 and 4-3 shifts. Switching of It’s sole purpose during the 4-3 shift is to delay the
this valve is done directly by solenoid 1 which is connection of the clutch apply feed circuit (CAF) to the
located at the end of the valve. The function of the B1R circuit until the B1R circuit has been fully
valve during a 3-4 shift is as follows: pressurised by using the 3rd circuit. It prevents
objectionable engine flare at the completion of the 4-3
3-4 Shift Valve gearshift.
B1R Exhaust Valve
exhausts the front band release circuit (B1R)

thereby allowing the application of the band.
connects the inner apply area of the front servo This valve is located in the case directly adjacent to
(B1AI) to the band apply feed circuit (BAF) thus the front servo. Its function is to allow the servo
allowing greater apply forces to the front band. release oil to be rapidly exhausted into the
exhausts the overrun clutch circuit (O.C.) which transmission case during application of the front band
will allow the C4 clutch to release. rather than forcing the oil back into the valve body
and through the 3-4 shift valve. In addition the spring
The exact opposite of the above functions will occur
on one end prevents oil entering the release area of
on a 4-3 downshift. This valve also switches during
the servo until the circuit pressure reaches
Manual 1st-2 and 2-Manual 1st gearshifts where it’s
approximately 70 kPa.
function is to apply the overrun clutch (C4) in 2nd
gear but to release it in Manual 1st gear. Note that the This valve also ensures that C1 pressure has reached
C4 clutch is applied in Manual 1st by the 1-2 shift 70 kPa on a 2-3 shift before B1 is allowed to begin
valve. releasing, thus preventing unwanted engine flare at
the commencement of the gearshift.
G73081 en 01/2003 2003.0 BA Falcon

Converter Clutch Regulator Valve (CCRV) the apply side of the converter. This oil does not
return from the converter because the converter
clutch piston will be sealed against the flat friction
surface of the converter cover. To provide cooler flow
the converter clutch control valve will now direct
converter feed oil from the PRV directly to the cooler
circuit.
The spring on the plug end of this valve ensures that
the valve will remain in the released condition during
engine shutdown, thus limiting the amount of torque
converter draindown that can occur over long periods
of non use.
Solenoid Supply Valve
This valve regulates the pressure of the oil which

applies the converter clutch. Input oil to this valve is
from the Line Pressure and the output pressure is
variable according to the signal pressure from the
solenoid 5 circuit (S5). Converter clutch apply and
release feel is made smooth by electronically varying
the S5 pressure.
The spring on the S5 end of this valve allows the
CCRV to boost its regulator apply feed pressure to a
level above S5 pressure during 3rd locked to 4th
unlocked gearshifts to prevent torque converter clutch
slippage during these shifts.
The load of this spring results in an additional 140
kPa output from this valve during gear changes. This A constant pressure is supplied to all the solenoids by
valve arrangement is common to both 93LE and 97LE this valve. Line pressure is used as the feed oil to this
regulator and the output is termed Line 500 due to its
transmissions.
approximate 500 kPa pressure value.
Converter Clutch Control Valve
Line Pressure Boost Valve
S6 pressure applied to the end of the PRV opposes
spring force and causes LOW line pressure for light
throttle application and cruising.
Heavy throttle application causes the normally open
S6 solenoid to switch OFF closing Line 500 and
opening S6 to exhaust. Removal of S6 pressure from
the PRV results in HIGH line pressure.
Clutch Apply Regulator Valve
The two positions of this valve cause the converter

clutch to be either off or on. The switching of this
valve is governed by the signal pressure from
solenoid 7.
With the valve in the off or released position,
converter feed oil from the PRV is directed to the
release side of the converter. After flowing through the
converter, oil returns to the converter clutch control
valve and is then directed to the cooler.
When the valve is in the applied position, regulated oil
from the converter clutch regulator valve is directed to
G73081 en 01/2003 2003.0 BA Falcon

The clutch apply regulator (CAR) valve is a 2.25:1

(93LE) and 2.85:1 (97LE or XR’s) ratio valve. This
valve provides a regulated pressure to the C1 clutch
and controls the rate of change of state of the clutch
to give the desired shift quality. 3rd oil fed to the valve
is regulated to provide an output pressure (CAF) of
2.25 times the S5 signal pressure or 2.25 times the
Line 500 (93LE) - 2.85 times the S5 signal pressure
or 2.85 times the Line 500 (97LE or XR’s) pressure
depending on the ON/OFF condition of the S3
solenoid.
Band Apply Regulator Valve
The band apply regulator (BAR) valve is a 1.8:1 ratio

valve (2.32:1 in XR8). This valve provides a regulated
pressure to the front servo and controls the rate of
change of state of the front band (B1) to give the
desired shift quality. The BAR spring retained in the
bore of the BAR valve enables the output pressure
(BAF) to be regulated to zero to fully release the front
band. This feature is used in Auto 1st, Garage 1st and
3rd limp home gear states.
2nd oil fed to the valve is regulated to provide a BAF
pressure of 1.8 times the S5 signal pressure or the
Line 500 pressure less 191 kPa (2.32 times S5 or
Line pressure, less 237 kPa in XR8) depending on the
ON/OFF condition of the solenoid S4.
G73081 en 01/2003 2003.0 BA Falcon

Automatic Transmission thoroughly checked to determine the source of the

fault.
Electronic Control System Diagnostic Connector Location
Diagnosis and Testing of the Automatic Transmission
electronic control system is covered in Section 303-14
as part of the Powertrain Control Module Diagnosis
and Testing. The Worldwide Diagnostic System
(WDS) is connected to the vehicle using the
Diagnostic Link Connector (DLC). The WDS retrieves
Diagnostic Trouble Codes (DTC’s), initiate self-testing
diagnostics, review Parameter Identification (PID)
values or reset the Keep Alive Memory (KAM) or
adaptive values.
Component description, maintenance and diagnosis,
(including DTCs and PIDs) for the following
components is found in Section 303-14:
Vehicle Speed Sensor VSS
Transmission Fluid Temperature Sensor TFT Symptom Chart
Transmission Range Sensor TR
Shift Solenoid 1 SS1
Default Transmission Operating Modes
Shift Solenoid 2 SS2 The PCM relies on accurate information from its
inputs and complete control of its outputs to effectively
Shift Solenoid 3 SS3
control the transmission. To ensure that it has both
Shift Solenoid 4 SS4 valid inputs and functioning outputs, the PCM carries
Variable Pressure Solenoid 5 VPS out both hardware and software fault detection
Power Control Solenoid 6 PCS routines. The PCM will respond to any faults detected
by adopting the operating modes which are detailed
Lock Up Solenoid 7 LUS below.
Solenoid 5 has a resistance range of 3.8 to 6.2 ohms The following symptoms of faults are the most
depending on its temperature. All other solenoids obvious results of each fault under "normal"
have a resistance range from 23 to 45 ohms conditions. There is always the possibility that a fault
depending on their temperature. Should a circuit may not be detected. If undetected fault conditions
register a reading outside the above limits the are present, the operation of the transmission is
COMPLETE CIRCUIT including the solenoid and all difficult to predict.
its associated wiring and connectors should be
Default Transmission Operating Modes
Fault Condition Default Operation
Pedal Fault The default pedal position in the event of a pedal sensor fault is
9%. The transmission software will respond normally as if the
pedal is held at 9%.
Engine Speed Fault All shifts will be firm as an engine speed corresponding to peak
engine torques is assumed. If a fault is undetected, the engine
speed is likely to be interpreted as stalled resulting in soft shifting
possibly with an end of shift bump.
G73082 en 01/2003 2003.0 BA Falcon


Vehicle Speed Sensor Fault The PRNDL display will flash, Performance and Sequential
Sports Shift modes will be inhibited and the torque converter will
be unlocked at all times.
If the transmission is in 4th gear at high engine speed it will stay
in 4th gear, otherwise it will shift to 3rd Limp Home gear state.
The vehicle will be speed limited to approximately 140 km/hr.
The reverse lockout feature will only operate above engine
speeds of 3000 ERPM.
In the event of a loss of speed signal the engine speed is used to
estimate vehicle speed.
NOTE: Speedo transducer faults are likely to cause the vehicle’s
speedometer to become inoperative.
Gear Lever Fault (Inhibitor/PRNDL The gear lever is assumed to be in the Drive position, Sequential
switch) Sports Shift and performance modes will be inhibited.
The torque converter will be unlocked at all times.
Transmission Oil Temperature All shifts will be firm until the transmission has warmed up, as a
Sensing FaultTransmission Oil high transmission oil temperature is assumed. If a fault is
Temperature Sensing Fault undetected, the temperature is likely to be evaluated as being
lower than actual resulting in softer shifts with "end bump" (very
firm feel at the end of the shift).
Sequential Sports All shifts will occur as if the mode is set to Adaptive in the
Shift/Performance Mode Setting instance of the Performance mode switch a being faulty.v
Fault All shifts will occur as if the mode is set to Performance in the
instance of the Sequential Sports Shift mode switches being
faulty.
The mode indicator will not respond to changes in the mode
switch setting. If a fault is undetected, the mode as indicated by
the mode indicator is likely to not respond to the mode switch.
G73082 en 01/2003 2003.0 BA Falcon


Battery Voltage Sensing Fault If the battery voltage is too low then:If the battery voltage is too
low then:
Shifts into 1st gear prohibited.
Transmission uses High Line.
If the battery voltage is too high or faulty then:If the battery
voltage is too high or faulty then:
Standby S5 current is set to 0 mA for all gears except Auto
1st.v
ON/OFF Solenoid Electrical Fault If a fault is detected in the electrical circuit of solenoid 1, 3, 4, 5
(Solenoid 1, 3, 4, 5 & 6) or 6 the Fault Detection Strategy puts the transmission into a
Limp Home Mode where: If a fault is detected in the electrical
circuit of solenoid 1, 3, 4, 5 or 6 the Fault Detection Strategy puts
the transmission into a Limp Home Mode where:
The PRNDL display will flash.
The transmission will shift to 3rd Limp Home gear state
Performance and Sequential Sports Shift modes will be
inhibited.
No shift ramps will be available.
Above approximately 90 km/hr the solenoid 6 is switched ON
supplying Low Line Pressure to the transmission to soften
high speed gear shift engagement.
In the case of a single solenoid fault the vehicle will be speed
limited to approximately 120 km/hr, if multiple faults are
present then the vehicle is limited to approximately 45 km/hr.
Engine torque is limited to protect the transmission from stall
starts in 4th.
The reverse lockout feature will not operate in the event of a
solenoid 1 or 3 fault.
ON/OFF Solenoid Electrical Fault If a fault is detected in the electrical circuit of solenoid 2 the Fault
(Solenoid 2) Detection Strategy puts the transmission into a Limp Home Mode
where:
The PRNDL display will flash.
The transmission will shift to 3rd Limp Home gear state if
below 90 km/hr or S3 fault is present, otherwise a shift to 4th
gear will be attempted.
Performance and Sequential Sports Shift modes will be
inhibited.
No shift ramps will be available.
Above approximately 90 km/hr the solenoid 6 is switched ON
supplying Low Line Pressure to the transmission to soften
high speed gear shift engagement.
In the case of a single solenoid fault the vehicle will be speed
limited to approximately 120 km/hr, if multiple faults are
present then the vehicle is limited to approximately 45 km/hr.
Engine torque is limited to protect the transmission from stall
starts in 4th.
The reverse lockout feature will be available.
ON/OFF Solenoid Electrical Fault If Solenoid 7 is found faulty it is disabled resulting in transmission
(Solenoid 7) always unlocked. The transmission does not go into LOS.
G73082 en 01/2003 2003.0 BA Falcon


ON/OFF Solenoid Hydraulic Fault When Reverse is selected solenoid 1 is switched OFF while
(Solenoid 1 & 3) solenoid 3 is switched ON, once a speed signal has been
recognised the solenoid switching state is inverted next time
Reverse is selected. A hydraulic solenoid 1or 3 fault is detected
when Reverse is selected and the engine exceeds the stall speed
while the vehicle is stationary, that is the transmission is
neutralised. The Fault Detection Strategy puts the transmission
into Limp Home Mode as if it had a solenoid 1 or 3 electric circuit
fault as in 9A.
ON/OFF Solenoid Hydraulic Fault Whenever the transmission is in 3rd or 4th gear and is not in the
(Solenoid 2) process of a gear shift the engine speed is monitored to confirm
that it is in a valid vehicle speed range for 3rd and 4th gear
states. In the event that it is not, the Fault Detection Strategy puts
the transmission into Limp Home Mode as if it had a solenoid 2
electric circuit fault as in 9B.
Software Fault The transmission adopts its Limited Operation Strategy of
operation. i.e. 3rd gear, unlocked and high line pressure.
The operation of the PCM under this condition is difficult to
predict. Its operation may be erratic. If a fault is undetected, the
operation of the PCM is likely to be erratic.
Power Supply Fault The transmission adopts its Limited Operation Strategy of
operation. i.e. 3rd gear, unlocked and high line pressure.
If there is an intermittent power supply connection, the PCM will
power-up in fourth gear and then shift to the appropriate gear to
satisfy the conditions present. The power supply is not monitored
for fault evaluation.
If a fault is undetected, the operation of the
transmission is dependent of which solenoid is
actually faulty. The following is a list of characteristics
for different solenoid fault conditions.
Solenoid Fault Transmission Response (when fault undetected)
Solenoid Condition Transmission Operation
1 Always OFF Auto 1st gear instead of Garage
1st 3rd gear instead of 4th.
Manual 1st unavailable.
Reverse Lockout feature not
available.
This results in delayed N-D
engagement.
Always ON Garage 1st gear instead of Auto
1st.
4th gear instead of 3rd.
Loss of engine braking in 2nd
gear.
Loss of Reverse every second
reverse engagement.
This results in a 1 -> 2->4->4 shifts
as the vehicle accelerates from
rest.
2 Always OFF 3rd gear instead of Garage 1st,
Auto 1st and 2nd.
Manual 1st unavailable.
This results in 3 -> 3 -> 3 -> 4
shifts as the vehicle accelerates
from rest.
G73082 en 01/2003 2003.0 BA Falcon

Solenoid Condition Transmission Operation

Always ON 2nd gear instead of 3rd.
Garage 1st gear instead of 4th.
This results in a 1 -> 2 -> 2 -> I
(overrun) downshift as the vehicle
accelerates from rest.
3 Always OFF Manual 1st gear unavailable.
Reverse Lockout feature not
available.
The following shifts become poor:1
-> 3, 1 -> 4, 2 -> 1, 2 -> 3, 4 -> 2, 4
-> 1.
Always ON Manual 1st gear instead of Garage
1st.
Loss of Reverse every second
reverse engagement.The following
shifts become poor:3 -> 4, 4 -> 3, 3
-> 2.
There may be slippage in the
gears during torque converter
locking.
4 Always OFF 2nd gear instead of Garage 1st
and Auto 1st.
rest.
-> 3, 3 -> 2, 3 -> 4, 4 -> 3.
Always ON 2nd gear instead of Garage 1st
and Auto 1st.
rest.
-> 3, 3 -> 2, 3 -> 4, 4 -> 3.
5 Output Pressure High Garage 1st gear and Auto 1st not
available.
All shifts become poor.
Output Pressure Low Torque converter slips during
lockup.
All shifts become poor.
6 Always OFF Line pressure always high.
Torque Converter Blow off valve
noise may be audible at low
speeds and throttle.
Always ON Line pressure always low thus
resulting in risk of slippage in
gears.
7 Always OFF Torque converter always unlocked.
Always ON Torque converter always locked,
engine stall at low speed.
G73082 en 01/2003 2003.0 BA Falcon


Automatic Transmission Connector Switch
Pin Condition Measurable Value Min Max

B34 VPWR A Voltage to GND B1 10V 14V
B46 VPWR A Voltage to GND B1 10V 14V
A43 LUS B Resistance to GND B1 23 Ohm 45 Ohm
A2 PCS B Resistance to pin B46 VPWR 23 Ohm 45 Ohm
B41 PRNDL A Voltage to pin A32, M1* 0.90V 1.10 V
B41 PRNDL A Voltage to pin A32, M2* 1.40V 1.60V
B41 PRNDL A Voltage to pin A32, M3* 1.90V 2.10V
B41 PRNDL A Voltage to pin A32, D 2.40V 2.60V
B41 PRNDL A Voltage to pin A32, N 2.90V 3.10V
B41 PRNDL A Voltage to pin A32, R 3.40V 3.60V
B41 PRNDL A Voltage to pin A32, P 3.9V 4.10V
B41 PRNDL B Resistance to pin A32, M1* 1.0 kOhm 1.4 kOhm
B41 PRNDL B Resistance to pin A32, D 4.5 kOhm 4.9 kOhm
B41 PRNDL B Resistance to pin A32, N 6.8 kOhm 7.2 kOhm
B41 PRNDL B Resistance to pin A32, R 10.6 kOhm 11.2 kOhm
B41 PRNDL B Resistance to pin A32, P 18.6 kOhm 19.0 kOhm
A17 MSC1 B Resistance to pin B46 VPWR 23.0 Ohm 45.0 Ohm
A39 VPS B Resistance to pin B46 VPWR 3.1 Ohm 5.0 Ohm
A37 TFT A Voltage to pin A32 SGRTN 0.25V 4.8V
A37 TFT B Resistance to pin A32 SGRTN 57.0 Ohm 15.5 kOhm
A32 SIGRTN C Resistance to GND B 1 0.0V 1.0V
A19 GSS1 B Resistance to pin B46 VPWR 23.0 Ohm 45 Ohm
A20 GSS2 B Resistance to pin B46 VPWR 23.0 Ohm 45 Ohm
A18 MCS2 B Resistance to pin B46 VPWR 23.0 Ohm 45 Ohm
B43 TRSA_2 A Voltage to pin B33, D 3.94V
B43 TRSA_2 A Voltage to pin B33, S 2.88V
B43 TRSA_2 A Voltage to pin B33, UP 1.83V
B43 TRSA_2 A Voltage to pin B33, DOWN 0.83V
G73082 en 01/2003 2003.0 BA Falcon

*Reading only applicable to column shift.

Conditions
A PCM connected to vehicle wiring harness.
Ignition turned on.
Measurement at pin of vehicle wiring
harness.
B PCM disconnected from vehicle wiring
harness.
Measurement at pin of vehicle wiring
harness.
C PCM disconnected from vehicle wiring
harness.
Measurement at pin of PCM.
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GENERAL PROCEDURES
Hydraulic System 9. If leakage is found at the manual lever shaft,

replace seals that are leaking.
Preliminary inspection 10. Check the front and rear servo covers.
When diagnosing transmission problems, first refer to 11. Fluid leakage from the converter housing may be
the diagnosis guide for detailed information of the caused by engine oil leaking past the rear main
items that could be causing the problem. The bearing or from oil gallery plugs. Be sure to
following preliminary checks should be made in the determine the exact cause of the leak.
order listed.
Converter Area Leakage
1. Check the fluid level. Check the fluid for a burnt
clutch plate odour.
2. Check the manual linkage adjustment.
3. Check engine idle speed.
4. Check electrical connections.
5. Check that the transmission is not in failure mode.
6. Check front and rear band adjustment.
Fluid Level
A fluid level that is too high will cause the fluid to
become aerated. Aerated fluid will cause low line
pressure, and the aerated fluid may be forced out the
vent. Low fluid level can effect the operation of the
transmission and may indicate fluid leaks that could
cause transmission damage.
Fluid leakage checks
1. Check the speedometer transducer installation at
the transmission (if fitted).
2. Leakage at the oil pan seal often can be stopped
by tightening the attaching bolts to the proper
torque.
3. If necessary, replace the seal.
4. Check the fluid plug. If the plug O-ring seal is
leaking, replace the seal.
5. The transmission fluid is water cooled; check the
fluid lines and fittings between the transmission
and the cooler in the radiator tank for looseness,
wear, or damage.
If leakage cannot be stopped by tightening a Fluid Leakage Converter Area
fitting, replace the defective parts. In diagnosing and correcting fluid leaks in the front
6. Check the engine coolant in the radiator. If pump and converter area, use the following
transmission fluid is present in the coolant, the procedures to facilitate locating the exact cause of the
cooler in the radiator tank is probably leaking. leakage. Leakage at the front of the transmission, as
7. The cooler can be further checked for leaks by evidenced by fluid around the converter housing, may
disconnecting the lines at the cooler fittings and have several sources. By careful observation, it is
applying 500 kPa maximum air pressure to the possible, in many instances, to pinpoint the source of
fittings. The radiator cap must be removed when the leak before removing the transmission from the
making this check to relieve the pressure on the vehicle. The paths which the fluid takes to reach the
exterior side of the cooler. bottom of the converter housing are as shown.
If the cooler is leaking and will not hold this 1. Fluid leaking from the front pump seal lip will tend
pressure the radiator must be replaced. The to move along the drive hub and onto the back of
cooler cannot be replaced separately. the impeller housing. In the case of a total seal
8. Leakage in the extension housing area may be failure, fluid leakage past the lip of the seal will be
caused by a worn extension housing bush, seal, deposited on the inside of the converter housing
drive shaft yoke, the housing to case gasket or only, near the outside diameter of the housing.
the speedo transducer (if fitted).
G73085 en 01/2003 2003.0 BA Falcon

2. Fluid leakage from the outside diameter of the front of the flywheel, back of the block (in as far
seal and front pump body will follow the same as possible), and inside the converter housing.
path as leaks from the front pump seal or may run Run the engine until fluid leakage is evident and
down the face of the front pump. the probable source of leakage can be
3. Fluid that leaks by front pump to case bolts will be determined.
deposited on the inside of the converter housing
only. Fluid will not be deposited on the back of the Gear shift Cable check
converter. Correct cable adjustment is necessary to position the
4. Leakage by the front pump to case and O-ring manual valve for proper fluid pressure direction to the
seal may cause fluid to be deposited on the inside different transmission components. Improper
lower part of the converter housing. Engine oil adjustment may cause subsequent transmission
leaks are sometimes improperly diagnosed as failure. Refer to Gear Shift Cable Adjustment for
front pump seal leaks. The following areas of detailed adjustment procedures.
possible leakage should also be checked to
determine if engine oil leakage is causing the Initial Engagement check
problem: Initial engagement checks are made to determine if
Leakage at the rocker arm cover may allow oil initial band and clutch engagements are smooth. Run
to flow over the converter housing or seep the engine until its normal operating temperature is
down between the converter housing and reached. With the engine at kerb idle speed, shift the
cylinder block causing oil to be present in or selector lever from N to D and R. Observe the initial
at the bottom of the converter housing. band and clutch engagements. Band and clutch
Oil gallery plug leaks will allow oil to flow engagements should be smooth in all positions.
down the rear face of the block to the bottom Rough initial engagements are caused by high engine
of the converter housing. idle speed or high line pressures.
Leakage from the crank shaft seal will work Transmission operation checks - Test
back to the flywheel, and then into the preparation
converter housing.
Fluid leakage from other areas, forward of the When testing the transmission, the transmission and
transmission could cause fluid to be present around engine must be at normal operating temperature.
the converter housing due to blow-back or road draft. 1. Check the transmission fluid level.
The following procedure should be used to determine 2. Check the gear shift cable adjustment.
the cause of leakage before any repairs are made:
3. Attach a tachometer to the engine.
5. Remove the transmission plug and note the
colour of the fluid. Original factory fill fluid is dyed 4. Firmly apply the parking brake and start the
red to aid in determining if leakage is from the engine.
engine or transmission. Since road draft may Stall test, Engine speed
cause leaking rocker cover oil to be present on
the transmission, this leakage, if present, should Ensure that the park and service brakes are firmly
be eliminated before performing work on the applied during these tests and the A/C is off. The stall
transmission. test is made in D and R at full throttle, speeds should
6. Remove the converter lower housing cover. Clean agree with the specifications shown in the Converter
off any fluid from the top and bottom of the Stall Speed table. While making this test, do not hold
converter housing, front of the transmission case, the throttle open for more than five seconds at a time.
and rear face of the engine and engine oil pan. Then move the selector lever to Neutral and run
Clean the converter area by washing with suitable engine at 1000 rpm for about 15 seconds to cool the
non-flammable solvent, and blow dry with converter before making the next test. If the engine
compressed air. speed recorded by the tachometer exceeds the
maximum limits specified in the Converter Stall Speed
7. Wash out the converter housing and the front of table, release the accelerator immediately because
the flywheel. Blow all washed areas dry with clutch or band slippage is indicated.
compressed air.
8. Start and run the engine until the transmission Type Stall Speed
reaches its normal operating temperature. 6 Cyl 2000-2200 rpm
Observe the back of the block and top of the 8 Cyl 2000-2400 rpm
converter housing for evidence of fluid leakage.
Raise the car on a hoist and run the engine at fast Stall speed too high
idle, then at engine idle, occasionally shifting to A higher stall speed than that specified indicates that
the drive and reverse ranges to increase the converter is not receiving its required fluid supply
pressures within the transmission. Observe the or that slip is occurring. Excessive engine speed in ‘D’
G73085 en 01/2003 2003.0 BA Falcon

indicates C2 clutch slippage or gear train one way 2. Disconnect the battery for approximately one
clutch slippage. Excessive engine speed in ‘R’ minute.
indicates C3 clutch or B2 band slippage. 3. Reconnect the battery.
Stall speed too low 4. Place the T-bar in the "D" position.
When the stall test speeds are low and the engine is 5. Turn the key to the "RUN" position (Key On
properly tuned, converter stator clutch problems are Engine Off);
indicated. A road test must be performed to determine 6. Leave the T-bar in "D" for at least ten (10)
the exact cause of the trouble. If the stall test speeds seconds after key-on.
are 300 to 400 rpm below the specified values, and
7. Move the T-bar to the "Park" position for at least
the car cruises properly but has very poor
acceleration, the converter stator clutch is slipping. If ten (10) seconds.
the stall test speeds are 300 to 400 rpm below the 8. Move the T-bar to "Neutral" position.
specified values, and the car drags at cruising speeds 9. Ten (10) seconds later, the PRNDL display will
and acceleration is poor, the stator clutch could have fast flash "N" on the display to confirm that the
been installed backwards. Remove the converter and "green" strategy has been activated.
check the stator clutch by replacing with a converter 10. The operation is complete and it is safe to either
known to be operating correctly and retesting. Below key through to start the vehicle, or key off.
standard acceleration in top gear above 50 km/h
combined with a substantially reduced maximum To check whether "green" transmission strategy
speed, indicates that the stator one-way clutch has is active
locked in the engaged condition. This condition will If this procedure is performed when the battery has
also be indicated by the transmission overheating, not been disconnected, or on a key-on cycle other
although the stall speed will remain as specified. than the first after battery is disconnected, it will not
Renew the converter. reset the "green" transmission strategy. Instead it will
NOTE: The torque converter is a sealed unit without a fast flash "N" to indicate if the "green" transmission
drain plug. The unit must not be dismantled. If a strategy is still active, or "N" will remain steady if the
converter is unsatisfactory in any way then it must be strategy has expired (i.e. 1500km/1600km has
replaced. elapsed since vehicle or transmission was new).
Green Transmission Strategy Line Pressure Boost Check

(Retraining for new Automatic This test requires that the vehicle be driven on the
Transmission) road or on a dynamometer whilst monitoring PID
EPCDC with the WDS tester. There should be a sharp
Where a new automatic transmission has been rise in line pressure when solenoid No. 6 switches off
installed, or any of the transmission bands or clutches as the vehicle is gently accelerated in Drive or
have been replaced, the Powertrain Control Module Reverse. This should occur at approximately 8%
(PCM) must be reset for "green" transmission (93LE)/ 10% (97LE) of throttle opening in Drive or 5%
strategy. (93LE)/17% (97LE) of throttle opening in Reverse.
This strategy ensures that the line pressure is Lack of pressure boost: This may be caused by a
regulated to correspond with the lower friction sticking primary regulator valve, a sticking line
coefficient of new clutch material. The strategy pressure boost valve, faulty No. 6 solenoid or faulty
remains in effect for 1,500km for all six cylinder connections or wiring.
variants including SFLPG and Turbo, and 1,600km for
all V8 variants including XR8 and GT. Road testing
Instructions to activate the "green" transmission NOTE: A road test, using the WDS tester, will
strategy determine if the ECU, transmission and converter are
This procedure is now independent of the WDS. It is a functioning correctly. The WDS tester incorporates:
T-Bar sequence that will only work on the first key-on a Parameter Identification PID to monitor the state
cycle after the battery has been disconnected of each ON/OFF solenoid (1, 2, 3, 4, 6 and 7):
NOTE: This reset procedure (Steps 5-9) must be SS1-4, EPC and TCC.
complete within sixty (60) seconds from the first a PID to monitor transmission gear state: GEAR.
Key-On in Step 5.
a PID to monitor the current ramp of the Variable
1. Ensure the ignition is off. Pressure Solenoid (S5): EPCD
G73092 en 01/2003 2003.0 BA Falcon

Diagnosis Guide 2. Drive the vehicle normally.

C1 Clutch Failure Slip or no drive in 3rd Do solenoids 1, 2, 3, 4 & 5 operate in the
or 4th gear correct sequence?
Will drive in 1st Gear Solenoid States
instead of 3rd, and Gear S1 S2
2nd instead of 4th
Auto 1 OFF ON
Normal drive in 1st,
2nd and reverse. 2 OFF ON
C2 Clutch Failure Slip or no forward 3 OFF OFF
drive. 4 ON OFF
Normal reverse.
Do solenoids 3 and 4 operate during
C3 Clutch Failure Slip or no reverse gearshifts?
drive.
Normal forward drive. Does solenoid 5 current ramp during
gearshifts and return to 0.2 amps when shift
C4 Clutch Failure No engine braking in is completed (except in Garage 1& Auto 1)?
Manual 1, D2 or D3.
Is solenoid 6 ON at light throttle and OFF at
B1 Band Failure No 2nd or 4th gear. heavy throttle?
Will operation in 1st
instead of 2nd, and Does solenoid 7 indicate converter clutch
3rd instead of 4th lock-up in 3 and in Drive?
B2 Band Failure No reverse drive. 3. Drive the vehicle at minimum throttle and check
Manual 1 will not have shift speeds in both adaptive and performance
engine braking. modes.
1-2 OWC Slip No drive in D1. 4. Drive the vehicle at 40% throttle opening and
Drive in Manual 1. check shift speeds in both adaptive and
performance modes.
1-2 OWC Seized D1 will have engine
braking. 5. Where safe, and legally permissible, drive the
Transmission will lock vehicle at wide open throttle and check shift
up in other forward speeds in both adaptive and performance modes.
gears with probable 6. Where safe, and legally permissible, check the
gear or friction Sequential Sports Shift / Manual Downshift and
element damage. Kickdown shift speeds. During the road test take
Reverse will function note of the shift quality, abnormal noise and any
normally. evidence of slip or shudder for further
3-4 OWC Slip No drive in D1. investigation.
Probable loss of drive
in Manual 1 because
Air Pressure checks
of C4 clutch burn out. A ‘NO DRIVE’ condition can exist even with correct
3-4 OWC Seized Transmission lock up transmission fluid pressure, because of inoperative
in 4th gear causing clutches or bands. Inoperative bands can be located
probable damage of through a series of checks by substituting air pressure
C1/C2 clutch or B1 for the fluid pressure to determine the location of the
band burn out. malfunction. To make the air pressure checks, drain
the transmission fluid and then remove the oil pan and
Road Test control valve body. The inoperative units can be
located by introducing air pressure into the
1. Check that the engine will only start in Neutral transmission passages leading to the bands.
and Park.
CAUTION: Do not apply air pressure to the
C4 clutch passage as this may dislodge the piston
‘O’ ring.
G73092 en 01/2003 2003.0 BA Falcon

Pressure Apply Ports
Servos Transmission fluid level adjustment

Apply air pressure to the inner passage of each servo.
The band will be seen to tighten around the drum if WARNING: Do not touch a hot exhaust pipe
the servo is operating. Apply air pressure to the outer with your hands or allow transmission fluid to
passage of each servo. Again the band will be seen to contact the exhaust pipe.
tighten around the drum if the servo is operating. NOTE: The transmission is sealed from the factory, oil
While holding air pressure to the outer passage of the level and oil condition checks should only be required
front servo apply air pressure to the release passage when fluid leakage from the transmission or reduced
of the front servo. The air pressure in the release transmission performance has occurred.
passage, aided by the return spring, should release
the front band against the apply pressure. To determine the correct fluid level, proceed as
follows:
1. Place the transmission selector in ‘PARK’ -
Engine switched OFF.
G73093 en 01/2003 2003.0 BA Falcon

2. Raise the vehicle on a hoist or place on a service 4. Partially fill the transmission (if the vehicle is on a
pit. hoist, it should be lowered). Ensure the
3. The transmission sump should be warm to touch park-brake is applied and the selector lever is in
(this indicates that the transmission is at the the ‘PARK’ position. Start the engine and allow to
correct temperature for checking oil level). idle, cycle the transmission selector through all
positions while adding transmission fluid until gear
If the vehicle is at operating temperature - application is felt.
allow the vehicle to cool down for two, but no
greater than four hours (while hot, the ATF Filler Plug Location
level is higher and removing the filler plug
may result in oil being expelled from the filler
hole, this will result in low ATF level).
If the engine is cold - the vehicle should be
driven between 3.5 and 4.5 kilometres at light
throttle so engine does not exceed 2500RPM.
4. Clean all dirt from around the service plug prior to
removing. Allow approx. 3 minutes for
transmission oil drainback. Remove the filler plug
and check the O-ring for damage (replace as
necessary).
5. The correct fluid level is reached when the ATF is
level with the bottom of the filler hole, if the level
is low install the filler pump and add oil to the
correct level. When the level is correct, refit and NOTE : Approx. 9 litres if converter is empty
tighten the filler plug to 30 - 35 Nm. (dry transmission). Approx. 4 litres if converter
is full (Service refill). An additional 0.5 litres
Filling a drained/dry transmission and when gear application is felt as above.
convertor to determine the correct
CAUTION: Be careful not to spill oil
fluid level during the filling procedure.
1. Place the transmission selector in ‘PARK’ - 5. Switch off the engine, remove the oil filler tube
Engine switched OFF. and refit the filler plug (raise the vehicle on the
2. Raise the vehicle on a hoist, or place on a pit (if hoist if required). The plug is to be tightened to
the vehicle is placed on stands, it should be kept 30-35Nm.
level). 6. The vehicle should be driven on light throttle so
3. Clean all dirt from around the service fill plug prior theengine does not exceed 2500RPM for approx.
to removing the plug. Remove the oil service fill 3.5 to 4.5 kilometres.
plug, clean the plug and replace the O-ring as 7. While the engine is idling and with the brake
necessary. Install the oil filler tube into the applied, cycle the transmission selector through
transmission filler hole. all gear positions.
8. Stop the engine and raise the vehicle ensuring
the vehicle is level.
9. Allow the vehicle to sit for 3 minutes after the
engine has been turned off. The transmission
sump should be warm to touch. Remove the filler
plug, the correct level is reached when the
transmission fluid is aligned with the bottom of the
filler hole. If the level is low, add a small quantity
of transmission fluid and recheck.
10. Refit the transmission filler plug and tighten to
30-35 Nm. Clean all transmission fluid from the
transmission.
G73093 en 01/2003 2003.0 BA Falcon

Gear shift cable adjustment Rear Band

For more information, refer to Section 307-05. 1. Measure distance ‘A’ from the Rear Servo Piston
to the inner face of the Transmission Case using
Band adjustment vernier calipers.
Front band 1. Apply air at 650/700 kPa to the Rear Servo
apply area (B2 outer).
1. Measure projection of Front Servo Push Rod from
Transmission Case. 2. Measure travel of the Piston, subtract 3.75mm
and divide the remainder by 2.5 to find Shim
1. Apply air at 650/700 kPa to the Front Servo size.
apply area (B1 outer)
3. Release Air.
2. Measure travel of Push Rod and subtract
3mm to find Shim size. 4. Fit Shim as per 2 below and re-check Piston
travel is 3.75mm ± 0.625mm.
3. Release Air.
NOTE: A minimum of one Shim is required at
4. Fit Shim as per 2 below and re-check Push all times - minimum Shim size is 1mm.
Rod travel is 3 mm ± 0.25mm.
NOTE: A minimum of one Shim is required at 2. Fit the Shim(s) selected to the shank of the
all times - minimum Shim size is 1 mm. Anchor Strut as follows:
1. Inspect Shims for damage, wear or corrosion
2. Fit the Shim(s) selected to the shank of the and replace as necessary.
Anchor Strut as follows:
2. Shims are to be installed between the Case
1. Inspect Shims for damage, wear or corrosion abutment face and the Anchor Strut flange.
and replace as necessary.
3. Shim(s) are to be fitted by hand and under no
2. Shims are to be installed between the Case circumstances to be hammered or forced.
abutment face and the Anchor Strut flange.
4. Shim(s) are to be pressed on by hand until an
3. Shim(s) are to be fitted by hand and under no audible click is heard. The click indicates that
circumstances to be hammered or forced. the Shim is clipped home correctly.
4. Shim(s) are to be pressed on by hand until an 3. The Shim thickness available are:
audible click is heard. The click indicates that
the Shim is clipped home correctly. 1. 1 mm ± 0.05, 2.0mm ± 0.07
3. The Shim thickness available are listed below: 2. 1.2mm ± 0.05, 2.2mm ± 0.08
1. 1 mm ± 0.05, 2.0mm ± 0.07 3. 1.5mm ± 0.06, 2.4mm ± 0.08
2. 1.2mm ± 0.05, 2.2mm ± 0.08 4. 1.8mm ± 0.07, 2.7mm ± 0.09
NOTE: All hardware must be correctly
3. 1.5mm ± 0.06, 2.4mm ± 0.08
installed and torqued to specification.
4. 1.8mm ± 0.07, 2.7mm ± 0.09
Rear Band Adjustment
Front Band Adjustment
Oil cooler flushing

When a clutch or band failure or other internal trouble
has occurred in the transmission, any metal particles
or clutch plate or band material that may have been
carried into the cooler should be removed from the
system by flushing the cooler and lines before the
G73098 en 01/2003 2003.0 BA Falcon

transmission is put back into service. In no case 4. Connect the cooler lines to the transmission.
should an automatic transmission having a clutch or I6 Auto transmission cooling lines
band failure or other internal trouble resulting in fluid
contamination, be put back into service without first
flushing the transmission oil cooler.
1. After installing a new or rebuilt automatic
transmission and converter assembly in the
vehicle, do not connect the cooler lines to the
transmission.
V8 Auto transmission cooling lines
2. Place a pan under the cooler lines.

3. Using an air pressure of 100 kPa and a cleaning
gun charged with clean transmission fluid, flush
the cooler and lines until the fluid from the return
line runs clean.
5. Fill the transmission with the specified Automatic

Transmission Fluid following the procedure
detailed under FILLING A DRY TRANSMISSION
AND CONVERTER in the ADJUSTMENTS
SECTION.
6. Check the system for leaks.
G73098 en 01/2003 2003.0 BA Falcon

Inhibitor Switch 2. Install a new external cross-shaft pin using tool

307-467.
Special Tool(s) CAUTION: When using a pin punch to
Selector shift pin remove/install the external cross shaft pin, be
Remover/Installer sure to support the cross shaft to ensure that
it is not damaged.
3. Install the wiring connector. Check that the 2 pin
plug has the red silicon gasket in place.
Removal
Radiator Oil Cooler
1. Raise the vehicle. When fluid leakage is found at the radiator oil cooler
2. Disconnect the wiring connector. the radiator must be replaced. The oil cooler cannot
NOTE: Be careful not to lose the silicone seal be separated from the radiator for servicing.
contained within the two-pin connector. Oil Cooler Tube
3. Remove the external cross-shaft pin using pin
remover tool 307-467.
WARNING: Tubing and fittings must be free
CAUTION: When using a pin punch to of any kinks or restrictions i.e. flattened areas.
remove/install the external cross shaft pin, be When a fluid cooler steel tube must be replaced, the
sure to support the cross shaft to ensure that replacement tube must be fabricated from the same
it is not damaged. size steel tubing as the original line. Using the old
4. Remove the two screws securing the switch and tube as a guide, bend the new tube as required. Add
remove the switch. the necessary fittings and install the tube. After the
fittings have been tightened, add fluid as needed and
Installation check for leaks. (Replacement tubing must be new
1. Engage the switch with the transmission cross and clean, oxidised tubing is not acceptable).
shaft and install the two screws.
G73101 en 01/2003 2003.0 BA Falcon

Gear Shift — Column Shift

1. For steering column components, refer to Section
211-04.
I6 Steering column components
G73102 en 01/2003 2003.0 BA Falcon

V8 Steering column components
G73102 en 01/2003 2003.0 BA Falcon

Gear Shift — Floor Mounted

Removal
1. Raise the vehicle and disconnect the transmission
shift cable from the lower selector lever.
I6 Floor mount shift components
G73103 en 01/2003 2003.0 BA Falcon

V8 Floor mount shift components
2. Disconnect the four nuts that attach the housing 6. Remove the whole floor shift housing by lifting
to the floorpan. vertically
Installation
1. To install the floor shift housing to the floorpan
reverse the above instructions in order 6, 5, 4.
2. Place the selector lever in the ‘P’ position.
4. Reconnect the four nuts that attach the housing to
the floorpan.
5. Install the shift cable back onto the lower selector
lever.
6. Tighten the lock nut to the required torque to 28
Nm.
7. Lower the vehicle and check transmission
operation in each selector lever detent position.
8. Check that the mode light functions correctly. For
4. Remove the centre console (Refer to section further information, refer to Section 307-05.
307-05).
5. Detach the back light bulb/wiring.
G73103 en 01/2003 2003.0 BA Falcon

Cross Shaft Seals Mass Damper / Extension Housing

Special Tool(s) 93 LE (I6)
Selector shift pin remover and
installer
Manual selector shaft seal

remover

installer
Removal
2. Detach the transmission lever and/or the inhibitor
switch from the cross shaft. For 93LE only the
external cross shaft pin must be removed using
tool 307-467 prior to removing the inhibitor switch.
3. Carefully remove the seal/s from the case using
special tool 307-365.
Installation
1. Cover the shaft with plastic tape to prevent Item Description
damage to the seal and using special tool 1 Nut M8
307-366 drive the new seal into the case until it is 2 I6 AutomaticTransmission Extension
flush with the boss. Remove the tape. Housing
2. Install the transmission lever and/or inhibitor 3 Extension Housing adapter
switch. For 93LE only install the external cross 4 Support Bracket
shaft pin using tool 307-467 prior to installing the
transmission lever. 5 Bolt M10x25
3. Lower the vehicle. 6 Transmission Support
7 Lock Nut M10
8 Bolt M10x50
9 Cross Member
10 Bolt M8X46
11 Bolt M10x89
G73103 en 01/2003 2003.0 BA Falcon

97 LE (V8) 6. If the extension housing is to be removed mark

the driveshaft and pinion flange alignment and
remove the driveshaft.
NOTE: When disconnecting or removing the
driveshaft it is essential that the position of the
slip yoke relative to the output shaft and position
of the companion flange hardware be identified as
illustrated. Failure to return all parts to their
original position may induce driveline vibration.
7. Separate the park brake cable at the cable joiner.
8. Remove the speedometer transducer (non-ABS
vehicles only).
9. Loosen the extension housing bolts to drain the
fluid.
10. Remove the extension housing bolts and
withdraw the extension housing. Discard the
gasket.
Installation
1. Install a new gasket on the extension housing.
2. Install the extension housing.
3. Install the speedometer transducer (non-ABS
vehicles only).
4. Position the mass damper and insulator
assembly.
5. Install the insulator bolts then the mass damper
bolts.
6. Install the cross member.
7. Remove the transmission jack.
8. Install the drive shaft aligning the mating marks.
Item Description
9. Connect the park brake cable joiner.
1 Nut M8
2 V8 AutomaticTransmission Extension
Housing 11. Check the transmission fluid level.
3 Extension Housing adapter NOTE: All hardware must be correctly installed
4 Support Bracket
5 Bolt M10x25 Speedometer drive gear (Non-ABS
6 Transmission Support vehicles only)
7 Lock Nut M10
Removal
8 Bolt M10x50
1. Remove the extension housing.
9 Cross Member
2. The speedometer drive gear is retained to the
10 Bolt M8X46 output shaft by a spring clip. Depress the tang of
11 Bolt M10x89 the clip and slide the gear from the shaft.
Removal Installation
1. Raise the vehicle. 1. Position the retaining clip on the shaft with the
2. Support the transmission with a jack. flanged end towards the case.
3. Remove the transmission cross member. 2. Slide the gear over the clip. Ensure that the
retaining leg of the clip prevents the gear from
4. Remove the insulator from the extension housing. moving rearwards.
5. Remove the bolt/s securing the mass damper to 3. Install the extension housing with a new gasket.
the rear of the extension housing one bolt
securing the mass damper bracket on the side of 4. Check the fluid level.
the extension housing. Remove the damper.
G73106 en 01/2003 2003.0 BA Falcon

Extension housing seal 2. Place a drain pan under the transmission.

Remove the screws at the rear of the oil pan.
Removal Loosen the remaining screws and allow the fluid
1. Raise the vehicle. to drain.
1. Mark the driveshaft and pinion flange CAUTION: The fluid will be very hot if the
alignment and remove the drive shaft. transmission has just been operated.
2. Prise the seal from the housing. 3. Remove the remaining screws and lower the pan
Installation carefully, it will still contain a quantity of fluid.
1. Using the seal replacing tool, drive the seal until Discard this fluid and the oil pan seal.
the seal seats. 4. Unclip the oil filter assembly. Remove the filter.
2. Lubricate the seal and the driveshaft yoke with Installation
MIC75B grease and install the driveshaft aligning 1. Thoroughly clean the oil pan, filter assembly and
the marks on the shaft and pinion flange. the seal face of the transmission.
3. Lower the vehicle. 2. Check the condition of the ‘O’ ring seal on the oil
filter spigot and replace if necessary.
Extension housing bush
3. Position the filter assembly on the valve body and
Removal install the retaining clip.
1. Remove the extension housing. 4. Check the location of the oil pan magnet.
2. Prise the seal from the housing. 5. Place a new seal on the oil pan and install the
pan. Torque to 4.5 Nm.
3. Using the bush removing tool press the bush from
the housing. 6. Fill the transmission with approved fluid.
Installation 7. Lower the vehicle.
1. Place a new gasket on the extension housing and 8. Check for leaks.
install the housing.
Valve Body Assembly
2. Align the lubrication hole in the bush with the rib
along the upper inner surface of the housing. Removal
3. Using the bush replacing tool, drive the bush into 1. Raise the vehicle and remove the oil pan.
the housing until it is flush with the inner edge of 2. Remove the filter assembly.
the seal recess. Lubricate the bush.
3. Disconnect the solenoid wiring at the solenoids.
4. Drive the seal into the housing with the seal
replacing tool. 4. Remove the manual valve lever to manual valve
link.
5. Lubricate the seal and the driveshaft yoke with
MIC75B grease and install the driveshaft. 5. Remove the screws securing the valve body
assembly to the case and lower the valve body.
Oil Pan and Filter Installation
Removal 1. Ensure that the locating pin is correctly
positioned. Offer the valve body assembly to the
1. Raise the vehicle. case. Ensure the z-link is connected to the
manual valve and detent lever. Fit the long end of
the link to the manual valve first.
2. Install the screws. Torque the screws in the
specified sequence.
G73106 en 01/2003 2003.0 BA Falcon

Tightening Sequence Valve Body to Case
NOTE: All hardware must be correctly installed and Installation

torqued to specification. 1. Check the condition of the piston, push rod and
3. Check the alignment of the detent roller in the cover ‘O’ ring seals and replace if necessary.
manual lever detent quadrant. 2. Lubricate the ‘O’ rings with automatic
4. Connect the solenoid wiring. transmission fluid and install the servo piston in
the case. Ensure that Band struts are correctly
5. Lubricate the ‘O’ ring seal on the filter spigot and seated and located in push rod and anchor strut
carefully install the filter assembly on the valve
and that shim is correctly retained.
body. The spigot must not lean on one side while
being fitted. Install the retaining clip. 3. Install the retaining circlip.
6. Clean the oil pan and install a new seal on the 4. Adjust the band with correct shims.
pan. 5. Install valve body, filter and oil pan.
7. Install the oil pan. Torque to 4.5 Nm. 6. Lower the vehicle.
8. Fill the transmission with approved transmission 7. Check the fluid level, top up as necessary.
fluid. 8. Check for leaks.
10. Check for leaks. Rear Servo
Front Servo Removal
1. Raise the vehicle. Remove the oil pan, filter and
Removal valve body as previously described.
1. Raise the vehicle. 2. Remove the cover bolts and remove the assembly
2. Remove oil pan, filter and valve body as with the spring and rod.
previously described. 3. Remove the gasket.
3. Remove the servo cover retaining circlip.
4. Remove the servo piston by pushing carefully on
front servo pushrod.
G73112 en 01/2003 2003.0 BA Falcon

Installation 6. Remove the cover plate from the front of the

1. Lubricate the piston ‘O’ rings with A.T.F. and fit to converter housing and remove the converter to
the piston. Assemble the piston to the cover. flywheel bolts. Detach the inhibitor switch shield
Position the spring over the piston spigot and the (93LE only).
servo rod in the piston spigot. 7. Disconnect the inhibitor switch, speedometer
2. Assemble gasket to cover and assemble in case. transducer (where fitted) and solenoid wiring
NOTE: Do not use petroleum jelly on gasket. connectors from the side of the transmission.
Transmission - 93LE
3. Apply ‘Loctite 567’ sealant to the bolt threads.
Install the bolts and tighten.
4. Check that the band struts are correctly located.
Check band adjustment.
5. Install valve body, filter and oil pan as previously
described.
7. Check the fluid level and top up as necessary.
8. Run the engine and check for leaks at the cover
in Reverse and Manual 1.
Transmission
Removal
1. Disconnect the battery. Item Description
2. Raise the vehicle. If work is to be carried out on 1 Transmission wiring loom connector
the transmission or torque converter when
removed from the vehicle, drain the transmission 2 Inhibitor switch connector
fluid. Transmission Wiring and Shield - 97LE
3. Mark the driveshaft and pinion flange alignment
and remove the driveshaft. Install the extension
housing seal tool in the extension housing.
illustrated. Failure to return all parts to their
original position may induce driveline vibration.
For more information, refer to Section 205-01
4. Remove the catalytic converter assembly by
disconnecting it from thre axhaust manifold,
muffler inlet pipe and bracket.
5. Loosen the engine brace to cylinder block bolts.
Remove the brace to converter housing bolts Item Description
(97LE only).
1 Transmission wiring loom connector
2 Inhibitor switch connector
8. Remove the starter motor mounting bolts and
position the starter motor to one side.
9. Disconnect the fluid cooler lines. Plug the lines.
10. Separate the park brake cable joiner.
11. Support the transmission with a transmission jack.
Install the safety chain.
12. Remove the transmission crossmember.
13. Remove the mass damper and insulator from the
extension housing.
14. Lower the transmission jack until it is just
supporting the transmission.
G73112 en 01/2003 2003.0 BA Falcon

15. Remove the transmission control lever from the

transmission cross shaft.
16. Remove the converter housing to cylinder block
bolts.
17. Hold the converter firmly against the transmission,
move the transmission rearward and lower.
Secure the converter to the transmission and
remove the assembly from under the vehicle.
Installing Transmission - 93LE
Item Description
1 Transmission case
2 Lubricant ESA-MK-75B
3 Bolt M12x55
G73113 en 01/2003 2003.0 BA Falcon

Item Description
1 Transmission case
2 Bolt M10x50
3 Bolt M10x18
4 Cover flywheel
G73113 en 01/2003 2003.0 BA Falcon

Item Description 13. Connect the inhibitor switch, speedometer

transducer (if fitted) and solenoid wiring. Ensure
1 Transmission case
that the inhibitor switch 2 pin plug and breather
2 Bolt M12x55 tube are sealed. Attach the inhibitor switch shield.
3 Wiring retainer 14. Install the drive shaft. Match the alignment marks
Installation and secure the flange bolts.
1. With the converter properly installed on the
transmission, place it on the jack and install the
safety chain.
2. Raise the transmission into position. illustrated. Failure to return all parts to their
3. Install the transmission to engine attaching bolts. original position may induce driveline vibration.
4. Install the converter to flywheel bolts. Install the 15. Install the catalytic converter assembly.
converter housing cover and engine to body earth
16. Connect the park brake cable.
cable.
5. Install the starter motor.
18. Connect the battery.
6. Loosely connect the transmission cooler pipes.
19. Check the fluid level and top up with approved
7. Install the mass damper and rear mount on the
fluid as required (see Transmission Fluid Level
extension housing.
Check).
8. Detach the safety chain, raise the transmission
20. Check the operation of the transmission controls.
and install the transmission cross member.
21. Carry out the ’Throttle Learn’ procedure.
9. Remove the jack.
10. Tighten the cooler line unions.
11. Install the control lever on the transmission cross
shaft.
12. Check the gear shift cable adjustment (refer
section 307-05).
G73113 en 01/2003 2003.0 BA Falcon

22. If a new transmission has been installed the PCM

must be configured using an WDS tester and the
Service Card:
Enter SERVICE BAY FUNCTIONS
Select PCM
Select TRANSMISSION CONFIGURE (1)
This procedure ensures that the line pressure
is regulated to correspond with a green/new
transmission.
G73113 en 01/2003 2003.0 BA Falcon

DISASSEMBLY
Transmission 12. Remove the input shaft, forward clutch cylinder,

and the overdrive shaft as an assembly,
Special Tool(s) withdrawing them through the front of the case.
13. Remove the C3 clutch cylinder and sun gears.
Transmission bench cradle
14. Remove the front band struts. Remove the front
band.
15. Remove the two centre support retaining bolts
using a T50 Torx bit.
16. Remove the centre support retaining circlip.
Pump housing aligner
It is assumed that the transmission fluid has been

drained when the transmission was removed from the
vehicle and that the ‘special tools’ quoted are
available. The transmission is dismantled in a modular
fashion, and the details of disassembly for each
module is given under the appropriate subject.
1. Remove the converter and the converter housing.
2. Mount the transmission on the bench cradle No.
307-003. 17. Remove the centre support, 1-2 one way clutch,
3. Remove the oil pan and the oil pan seal. planetary gearset and output shaft as an
assembly.
4. Detach each end of the filter retaining clip from
the valve body and remove the filter. CAUTION: On no account hammer the
5. Detach the wires from each solenoid and lay the output shaft to remove the centre support as
wiring to one side. this will cause permanent damage to the
thrust bearing surfaces.
6. Remove the valve body securing screws and
remove the valve body from the case. 18. Remove the parking rod cam plate. (T40 Torx bit).
7. Remove the front servo cover circlip. Remove the 19. Remove the rear band struts and remove the
cover and piston. band.
NOTE: Plastic Servo block is retained by piston
return spring only.
Transmission Case
8. Remove the extension housing and the Special Tool(s)
speedometer drive gear (if fitted).
9. Remove the pump bolts using a multihex 8mm remover
spanner.
10. Remove the ‘O’ ring from the input shaft.
11. Using puller No. 307-003, remove the pump.
Cross pin remover installer
G73115 en 01/2003 2003.0 BA Falcon

Disassembly
1. Remove the external cross shaft pin using tool
307-467 (93LE only). Remove the inhibitor switch
from the case. Remove the cross shaft seals with
special tool 307-365.
2. Remove the circlips from the cross-shaft. Pull the
shaft to release the drivepin from the selector
quadrant.
3. Using tool 307-467 press the cross shaft pin from
the cross-shaft and withdraw the shaft from the
case. Retrieve the spring and pin.
Removing and Installing the Cross Shaft Pin
4. Remove the manual valve lever and the park rod.

5. Depress the tangs on the wiring loom plug and
detach it from the connector in the case. Detach
the No. 7 solenoid wire from the front of the case.
6. Remove the wiring connector retainer and
withdraw the connector from the case. Remove
the loom assembly.
7. Remove the parking pawl pivot and the pawl and
spring from the case.
8. Remove the rear servo lever and shaft.
9. Remove the rear servo cover and piston
assembly.
10. Remove the front servo release exhaust valve.
11. Remove both band adjustment shims.
12. Inspect the output shaft bushing in the case and
replace if necessary.
13. Inspect cooler line fittings and replace as
necessary.
14. Inspect the case for damage.
15. Do not remove the park rod lever unless
absolutely necessary.
NOTE: To Remove: Tap the outer end of the shaft
until it moves to break the grip in the case. Using a
wide shallow tapered drift as a wedge, drive the pin
out from the inside of the case and remove the lever
and spring.
G73115 en 01/2003 2003.0 BA Falcon

Forward Clutch Cylinder

Special Tool(s)
Clutch compression kit.
Disassembly
1. Place the assembly in a horizontal position. 11. Mount the clutch cylinder on tool 307-369 with
2. Remove the thrust bearing and adjustment shims C2/C4 end uppermost and compress the piston
from the input shaft. return spring. Remove the spring retaining circlip.
Release the tool and remove the circlip, keeper
3. Remove the circlip from the front of the clutch and spring.
cylinder and remove the input shaft.
4. Remove the overdrive shaft and the C1 clutch hub CAUTION: When removing the spring
assembly from the clutch cylinder. compressor, make sure that the spring keeper
5. Remove the C1 clutch plates from the cylinder. has not been trapped in the circlip groove and
that all spring pressure has been released
6. Remove the circlip retaining the C3 clutch hub in before removing the tool.
the rear of the clutch cylinder and remove the
hub.
7. Remove the C2/C4 clutch hub assembly and
remove the thrust bearing from the C4 hub.
8. Remove the C2 clutch plates.
9. Invert the clutch cylinder and remove the C4
clutch sleeve, clutch plates and the two wave
washers. The 3-4 one way clutch is located
between the C2 and C4 clutch hubs and the hubs
may be separated by rotating one hub clockwise
and withdrawing it from the other.
10. Remove the thrust block from the C4 clutch
cylinder hub.
G73116 en 01/2003 2003.0 BA Falcon

Compressing the Clutch Return Spring C3 Clutch Cylinder

Special Tool(s)
Clutch compression kit.
Disassembly
1. Remove the forward sun gear and thrust bearing
from the C3 clutch cylinder.
2. Remove the nylon thrust bearing, bearing support,

needle thrust bearing and thrust block from the
12. Invert the clutch cylinder on the compressor tool clutch cylinder hub.
and remove the C1 clutch piston return spring in a 3. Mount the clutch assembly on tool 307-369 and
similar manner. compress the piston return spring. Remove the
13. To remove the clutch pistons from the clutch circlip and release the spring.
cylinder, apply air pressure to the apply ports in
CAUTION: Make sure that the spring
the bore of the cylinder.
keeper has not been caught in the circlip
groove. Ensure all spring pressure has been
released before removing tool.
4. Remove the tool, circlip, keeper and spring.

Remove the reverse sun gear ‘O’ ring.
5. Remove the clutch plate retaining circlip and
remove the clutch plates.
G73116 en 01/2003 2003.0 BA Falcon

6. To remove the clutch piston from the clutch 3. Remove the 4 Torx head screws from the cover
cylinder, apply air pressure to the port between plate (Torx bit No. 30).
the iron sealing rings on the bearing journals of 4. Lift the cover plate from the cover. Remove the
the cylinder. ball check valves and spring from the pump cover.
7. Remove the reverse sun gear from the cylinder. 5. The retaining pins for the 3 valves are loose in the
cover, remove the pins. This may be done by
Planet Carrier & Centre Support pushing the sealing plugs in slightly and allowing
the pins to fall out or by withdrawing the pins with
Disassembly a magnet. Remove the 3 sealing plugs.
6. Remove the 3 valves.
7. Remove the ‘O’ ring seal from the periphery of the
pump cover.
8. Remove the pump gears from the pump body.
9. Remove the ‘O’ ring seal from the pump body.
10. Remove the lip seal from the front of the pump
body.
NOTE: Do not remove the seal unless
replacement is required.
Valve Body
Disassembly
1. Separate the planet carrier and centre support 1. Remove the detent spring and retainer plate using
from the output shaft. Remove the thrust bearings a T40 Torx bit.
from the output shaft and the planet carrier.
2. Slide the manual valve out of the lower valve
2. Separate the centre support from the planet body.
carrier by rotating it anti-clockwise.
3. Take note of the angular relationship of the
3. Lift the one way clutch from the planet carrier. solenoid terminals to the valve body. Remove the
4. Remove the circlip retaining the one way clutch solenoid and valve assembly as follows:
outer race in the planet carrier and remove the No. 1 solenoid.
race.
No. 2 solenoid.
5. Remove the one way clutch retainer and o-ring
from the planet carrier. No. 3 solenoid.
No. 4 solenoid.
Pump No. 5 solenoid.
Disassembly No. 6 solenoid.
NOTE: The following valves are housed in the pump 4. Place the valve body assembly on the bench with
cover: the upper body uppermost. Remove the 24
clamping screws with a No. 30 Torx bit. Separate
No. 7 solenoid. the upper and lower valve bodies by lifting the
Converter clutch control valve. upper body and the separator plate together. Turn
the upper body over the place on the bench with
Converter clutch regulator valve.
the separator plate uppermost.
Primary regulator valve.
5. Lift the separator plate and gaskets from the
1. Remove the wiring loom retainer plate and upper valve body, remove the 3 nylon (white) and
remove the No. 7 solenoid with a T30 Torx bit. 3 PIA (olive) check balls exposed in the valve
2. Remove the 5 washer head bolts from the cover body. Remove the keeper plate from the reverse
plate using a multipoint 8 mm socket. Separate lockout valve, spring and plug will drop out when
the pump assembly from the pump cover the upper valve body is tipped on its end.
assembly. 6. Remove the 1 filter and the one large nylon check
NOTE: The pump assembly should be supported ball from the lower valve body.
as the bolts are removed. If the pump assembly 7. Remove the keeper plates and pins from the 1-2,
does not come away freely from the pump cover 2-3, 3- 4, bar and car valves. The plates are loose
do not strike the converter support tube to free the in the valve body and will drop out when the valve
pump assembly. body is turned over. Pins can be removed with a
magnet.
G73120 en 01/2003 2003.0 BA Falcon

8. Remove the 1-2, 2-3 and 3-4 shift valves.

9. Depress the 4-3 sequence valve plug and remove
the keeper plate. Remove the plug, valve and
spring.
10. Depress the damper valve. Remove the keeper
pin and remove the valve and spring.
11. Drive out the roll pin and remove the spring and
ball check valve adjacent to the BAR valve.
NOTE: AII hardware must be correctly installed
G73120 en 01/2003 2003.0 BA Falcon

ASSEMBLY
Transmission 4. Install the rear servo lever and pivot pin. The lever
must pivot freely on its pin.
Special Tool(s)
Manual selector shaft shift seal
remover
Selector shaft pin remover and

installer
Transmission bench cradle 5. Assemble the park rod lever complete with return
spring and pivot pin. Apply a small amount of
sealer to the outer end of the pivot pin. No sealant
allowed between pin and lever. The lever must
pivot freely on its pin and the spring must return
the park rod lever.
1. Turn the transmission case upside down on the

bench and mount it to the transmission cradle
307-003.
2. Install all fittings, plugs and the breather. Apply
sealant where applicable. Ensure that the
breather is clear. Check that the tube fitting in the
rear of the case is filled and clear of obstruction.
3. Assemble the BIR valve and spring and secure
with the circlip. Ensure the circlip is completely
seated in its groove.
6. Install the parking pawl with its spring and install

the pivot pin. The pawl must pivot freely on its pin.
7. Connect the park rod to lever. Ensure the spring

and cam collar is firmly installed on the rod.
Check that the cam collar slides freely on the rod.
G73121 en 01/2003 2003.0 BA Falcon

8. Start the cross shaft into the case from the cable
side of the case, inhibitor switch end first, and
install the antirattle spring on the shaft. Position
the manual valve detent lever, aligning it with the
cross-shaft bore in the case. Push the shaft
through the detent lever until it starts in the detent
lever side of the case. Install the detent lever
drive pin in the shaft using tool 307-467 with the
adaptor over the pin. Press the pin into the shaft
until the tool bottoms. Remove the tool. Fit the
spring retaining circlip.
Manual Valve Detent Lever
Manual Valve Detent Lever
G73121 en 01/2003 2003.0 BA Falcon

9. Install new cross shaft seals using tool 307-366.

10. Install the inhibitor switch on the case.
11. Thoroughly check the internal wiring loom for
condition and continuity. Install a new external
cross shaft pin using tool 307-467. Press the pin
into the shaft until the tool bottoms.
12. Thoroughly check the internal wiring loom,
position the loom and locate the S7 solenoid
terminal in the pump mounting flange at the front
of the case. The S7 solenoid wire is routed under
the park rod and cross shaft in the case.
10 Pin connector and installation
13. Install the ten pin connector in the case engaging

the tangs into the notches in the case. It is
important that both tangs fully engage. This can
be checked visually on the outside of the case.
G73121 en 01/2003 2003.0 BA Falcon

Output Shaft & Gear Assembly

93LE (Non-ABS shown)
Assembly
1. Check that the output shaft bush is not worn or
damaged. Replace if necessary.
2. Check for damage to parking pawl teeth on ring
gear. Replace if necessary.
3. Check that the sealing ring grooves have not
been damaged.
4. Lubricate the sealing ring with automatic
transmission fluid.
5. Assemble the sealing rings to the output shaft
with the scarf cut uppermost.
6. If previously dismantled, assemble the ring gear
to the output shaft and secure with circlip. Ensure
that the circlip is firmly seated in its groove.
7. Fit the thrust bearing assembly No. 10 on the
output shaft using petroleum jelly.
8. Install the output shaft assembly in the case
carefully to prevent damage to the sealing rings.
Lubricate the case bush with petroleum jelly.
9. Install the speedo drive gear (non-ABS models
only).
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Thrust Bearing Location
G73124 en 01/2003 2003.0 BA Falcon

Rear Band Planet Carrier and Centre Support

Assembly Assembly
1. Check the band for any cracks or damage along Planet Carrier Assembly and Centre Support
the lining and metal backing. (93LE Shown)
2. Soak a new band in automatic transmission fluid
for a minimum of five minutes prior to assembly.
3. Install reaction anchor strut into maincase without
shims.
4. Install the rear band carefully into the
transmission case and ensure that it is properly
fitted in the case.
5. Position the apply strut on the rear band.
6. Engage the apply strut in the servo lever.
7. Band adjustment is to be left backed off to allow
easy installation of the planet carrier assembly
into transmission.
8. Install the cam plate and tighten screws to
specification. 1. Check the carrier and planet assembly for any
NOTE: AII hardware must be correctly installed damage or irregularity and ensure that all pinions
and torqued to specification. rotate freely and that pinion and float is within 0.1
to 0.5 mm.
2. Install the o-ring into the planet carrier o-ring
groove.
Rear Servo
3. Install the one way clutch retainer to the planet
Assembly carrier with the inner edge pointing downwards.
Inspect the one way clutch race and the sprag
assembly for wear or damage. Replace if
necessary.
4. Install the outer race in the drum. Press the race
to the bottom of the drum and install the retaining
circlip, as illustrated. Ensure the circlip is firmly
5. Install the one way clutch into the outer race with
the lip edge uppermost, as illustrated. Lubricate
the sprags with automatic transmission fluid.
6. Check that the plugs are fitted to the centre
support and assemble the centre support into the
one way clutch, as illustrated. Ensure that the
support will rotate in an anti-clockwise direction
1. Check the servo piston ‘O’ ring and gasket for any only.
damage. 7. Lubricate the needle thrust bearing No. 9 with
2. Lubricate the servo piston ‘O’ rings with automatic petroleum jelly and fit it to the rear face of the
transmission fluid and fit the ‘O’ rings to the piston planet carrier.
grooves. 8. Install the planet assembly and the centre support
3. Assemble the piston to the cover. Ensure that ‘O’ into the case and align the centre support
ring compression is adequate but not excessive. mounting bolt holes. Install the centre support
bolts finger tight. Install the circlip retainer
4. Align the spring on the piston spigot. Position the ensuring that circlip is completely seated in the
rear servo rod in the spigot. groove of the case.
5. Assemble the gasket to the cover and fit the 9. Remove the centre support bolts and apply
assembly to the case. Loctite 222 or equivalent to the threads. Install the
NOTE: Do not use petroleum jelly on gasket. bolts and torque to specifications.
6. Apply Loctite 567 sealant to the bolts. Install the 10. Adjust the rear band to specifications.
bolts and tighten to specification. Fit the wiring
loom clip to hold the wiring vertical.
G73123 en 01/2003 2003.0 BA Falcon

Extension Housing Front Band

Assembly Assembly
Extension Housing
1. Install the reaction anchor strut to the case.

1. Check the condition of the extension housing 2. Check the band for any cracks or damage along
bush, replace if necessary. its lining and metal backing.
2. Install a new seal to the extension housing. 3. If fitting a new band, soak the band in automatic
3. Position a new gasket to the extension housing. transmission fluid for a minimum of 5 minutes
prior to assembly.
NOTE: Do not use petroleum jelly to hold gasket
in position. 4. Install the front band into the transmission case
and ensure that it is properly seated in place.
4. Install the extension housing and torque the bolts 5. Position the reaction strut in its retaining clip and
to specification.
engage it with the band and anchor strut. Position
the apply strut in its retaining clip and engage it
Front Servo with the band and the servo piston rod.
Assembly 6. Band adjustment is to be backed off to aid
installation of the clutch cylinder.
1. Lubricate the cover ‘O’ ring with automatic
transmission fluid and assemble to the cover.
C2/C4 Clutch
2. Lubricate the piston ‘O’ rings with automatic
transmission fluid and assemble to the piston. Special Tool(s)
3. Fit the piston push rod assembly into the front
servo cover ensuring that the ‘O’ ring Clutch compression kit
compression is adequate but not excessive.
4. Install the front servo assembly into the case.
Ensure that the cover ‘O’ ring compression is
adequate but not excessive.
5. Compress the servo cover and fit the servo cover
retaining circlip and ensure that it is completely Clutch measuring kit 307-370
G73130 en 01/2003 2003.0 BA Falcon

Assembly 12. Install the spring and spring retainer on the piston.
Using Tool 307-369 compress the spring until the
retaining circlip can be installed. Ensure that the
circlip is firmly seated in its groove and remove
the tool. The wire diameter of this spring is 5.26
mm.
13. Install the C2 wave washer in the cylinder with the
crest of one wave covering one of the bleed
orifices in the C2 piston.
14. Measure and record the thickness of the flange of
the C2 sleeve.
15. Install the C4 clutch plates and wave washer into
the C2 actuating sleeve, with the rounded edge of
the steel plates down, in the following sequence:
Steel plate
1. Check the C2 piston bleed orifices for obstruction. Friction disc
Check the feed orifices in the cylinder bore.
Steel plate
2. Lubricate the ‘O’ rings with automatic
transmission fluid. Fit the small ‘O’ ring on the Friction disc
inner groove and the large ‘O’ ring on the outer Steel plate
groove of the piston. ‘O’ rings must not be twisted. Friction disc
3. Check the C4 piston bleed orifices for obstruction. Steel plate (selective)
Check the feed orifices in the cylinder bore.
Wave washer
4. Lubricate the ‘O’ rings with automatic
NOTE: Hold the cylinder horizontal and install the
transmission fluid and fit the small ‘O’ rings to the
sleeve and clutch plate assembly into the cylinder with
inner groove and the large ‘O’ rings to the outer
the crest of one wave of the washer in line with one of
groove of the piston.
the holes in the outside of the cylinder until the sleeve
5. Position the clutch cylinder with the C2/C4 cavity contacts the C2 wave washer.
facing upwards.
16. Check the C4 clutch pack clearance using special
6. Fit the C4 piston into the C2 piston with the bleed
tool 307-370 as illustrated. Use selective plates to
orifices in alignment. Ensure that the C4 piston
achieve the correct specification. If new friction
outer ‘O’ ring compression is adequate but not
plates are being fitted, remove the clutch pack
excessive.
and soak the friction plates in ATF for a minimum
7. Install the C2/C4 piston assembly into the cylinder of 5 minutes prior to reassembly. Clutch pack
with the piston bleed orifices aligned with the clearance must be taken before the elements are
holes on the outside of the cylinder until the OD of soaked in ATF. Reassemble the sleeve and clutch
the C2 piston enters the inner diameter of the pack into the cylinder.
cylinder. Ensure the C2 piston outer ‘O’ ring
compression is adequate not excessive.
8. Assemble the piston return spring to the piston
and fit the spring retainer over the spring. The
wire diameter of this spring is 4.3 mm.
9. Using special tool 307-369 compress the spring
sufficiently to enable the installation of the
retaining circlip. Ensure that the circlip is firmly
seated in its groove and remove the tool.
10. Check the C1 piston check valves for correct
function and the cylinder feed orifices for
obstructions. Lubricate the ‘O’ rings with
petroleum jelly and fit to their respective grooves.
The ‘O’ rings must not be twisted in the grooves.
11. Position the cylinder with the C1 cavity upwards.
Install the piston into the cylinder until the OD of
the piston enters the inner diameter of the
cylinder.
G73130 en 01/2003 2003.0 BA Falcon

C4 Clutch Pack Clearance
G73130 en 01/2003 2003.0 BA Falcon

C2 Clutch Pack Clearance 22. Align and fit the C4 hub to the C2 clutch and
OWC assembly. Check the rotation of the C2 hub.
While holding the C4 hub, the C2 hub should
rotate in the clockwise direction and lockup in the
anti-clockwise direction when viewed from the C2
hub.
17. Fit the thrust plate over the inner hub.

18. Install the C2 clutch plates in the cylinder in the
following sequence.
Friction disc
Steel plate 23. Apply petroleum jelly to thrust bearing No. 5 and
Friction disc fit it to the C4 hub.
Steel plate 24. Remove the C2 clutch plates from the clutch
cylinder.
Friction disc
25. Engage the C2/C4 clutch hub assembly in the C4
Steel plate (selective) clutch plates.
Friction disc 26. Install the C2 clutch plates.
Steel plate (selective) 27. Install the C3 hub and secure it with the circlip.
Friction disc Ensure that the circlip is firmly seated in its
19. Check the clutch pack clearance using the weight groove.
only from tool 307-370 as illustrated. Use
selective plate to achieve the correct specification.
If new friction plates are being fitted, remove the
clutch pack and soak the friction plates in ATF for
a minimum of 5 minutes prior to reassembly.
Clutch pack clearance must be taken before the
elements are soaked in ATF.
20. Lubricate and fit the 3-4 OWC. Lubricate and fit
the C2 OWC and end caps to the C2 hub.
21. Align the tangs and fit the nylon thrust washer
onto the C4 hub as illustrated.
G73130 en 01/2003 2003.0 BA Falcon

C3 Clutch, Reverse Sun Gear & 5. Align the C3 piston in the cylinder until the OD of
the piston enters the inside diameter of the
Forward Sun Gear Assembly cylinder. Ensure that the piston ‘O’ ring
Special Tool(s) Assemble the spring and spring retainer on the
Clutch Compression Kit piston. Using tool 307-369 compress the spring
sufficiently to enable the installation of the
retaining circlip. Ensure that the circlip is firmly
seated in the groove and remove the tool.
Fit the C3 wave plate to the C3 piston face with
one crest of the wave plate directly over one of
the piston orifices. Assemble the clutch plates and
Clutch Measuring Kit discs into the cylinder in the following sequence:
1. Steel plate outer.
2. Friction disc inner.
Assembly 6. Friction disc inner.
C3 Clutch and Reverse Sun Gear 7. Steel plate outer.
Align and fit the pressure plate with the
counterbore facing away from the clutch
plates. Install the circlip.
6. Check the clutch clearance using special tool
307-370 in the following manner:
Forward sun gear and C3 clutch assembly
1. Check the orifices in the cylinder are clear. Check

the C3 cylinder bush outside diameter against the
centre support inside diameter. Coat the sealing
rings with automatic transmission fluid and fit into
the C3 cylinder grooves.
2. Check the reverse sun gear splines, grooves and
thrust face for condition. Coat the ‘O’ ring with
automatic transmission fluid and fit it to the groove 1. (weight only) Place the weight on the
and the reverse sun gear. pressure plate and measure the distance from
3. Install the reverse sun gear in the C3 cylinder. the end of the cylinder to the top of the
Ensure that the ‘O’ ring compression is adequate pressure plate. Record this figure.
but not excessive. 2. Remove the weight.
4. Coat the C3 piston ‘O’ rings with automatic 3. Lift the pressure plate up against the circlip
transmission fluid and fit the small ‘O’ ring to the and measure the distance from the end of the
inner ring and the large ‘O’ ring to the outer ring of cylinder to the top of the pressure plate.
the C3 piston. ‘O’ rings must not be twisted in Record this figure.
grooves. Check that the bleed orifices of the
piston are clear. 4. Subtract the second reading from the first
reading to obtain the clutch pack clearance.
5. If new friction plates are being fitted, remove
the clutch pack and soak the friction elements
G73131 en 01/2003 2003.0 BA Falcon

in automatic transmission fluid for a minimum

of five minutes prior to reassembly.
6. Clutch pack clearance must be taken before
the elements are soaked in automatic
transmission fluid.
7. Lubricate the needle thrust bearing assembly
No. 7 with petroleum jelly and fit the bearing
over the forward sun gear, thrust washer face
to gear.
8. Align and fit the C3 clutch assembly over the
forward sun gear.
9. Fit the thrust plate securely over the reverse
sun gear.
10. Lubricate the needle thrust bearing No. 6 with
petroleum jelly and fit it to the thrust plate.
Ensure the lugs on the OD of the bearing fit in
the thrust plate counterbore.
11. Align and fit the plastic thrust washer to the
thrust plate with petroleum jelly as illustrated.
Install the assembly over the foward sun gear
shaft against the No. 6 thrust bearing.
12. Place assembly to one side.
C3 Clutch Assembly Clearance
G73131 en 01/2003 2003.0 BA Falcon

C1 Clutch Overdrive Shaft & Input C1 Clutch Assembly Clearance

Shaft
Special Tool(s)
Clutch Measuring Kit
Assembly
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with
petroleum jelly and fit them to the overdrive shaft.
The sealing rings may be held in place with a
small amount of petroleum jelly.
3. Assemble the clutch plate and disc into the
cylinder in the following sequence:
7. Steel plate outer (selective).
9. Steel plate outer (selective). 5. Check the fit of the C1 clutch hub on the overdrive
10. Friction disc inner. shaft. If it is loose, the hub and shaft assembly
4. Check the clutch pack clearance using special must be replaced.
tool 307-370. Use selective plates to achieve the 6. Coat the small nylon thrust spacer with petroleum
correct specification. If new friction plates are jelly and install it into the cylinder hub.
being fitted, remove the clutch pack and soak the 7. Carefully fit the overdrive shaft into the C1
friction elements in automatic transmission fluid cylinder so as not to damage the sealing ring.
for a minimum of five minutes prior to assembly. 8. Fit the small bronze C1 hub thrust washer in
Clutch pack clearance must be taken before place with petroleum jelly.
elements are soaked in automatic transmission
fluid. 9. Check the input shaft for any defect. Fit the input
shaft into the cylinder and secure it with the
circlip. Ensure the circlip is completely seated in
the groove
10. Coat the front and rear sealing rings and the outer
‘O’ ring with petroleum jelly and fit the input shaft.
11. Assemble the C1/C2/C4 clutch assembly to the
C3 clutch and sun gear assembly.
12. Install thrust bearing No. 8 onto the overdrive
shaft with spigot into the forward sun gear.
13. Install this assembly in the transmission case.
G73133 en 01/2003 2003.0 BA Falcon

Clutch
C1, C4, C2 Clutch
C1, C4, C2, C3 Clutch
G73133 en 01/2003 2003.0 BA Falcon

Pump Cover & Converter Support

Special Tool(s)
Pump Aligner
Assembly
Pump Cover
G73134 en 01/2003 2003.0 BA Falcon

Pump, Cover and Converter Support
1. Check the pump body for any damage, scoring or 4. Lubricate the pump bush and the drive and driven
similar in the pump gear recess. Check the pump gears with automatic transmission fluid. Install the
bush for wear or damage. pump driven gear and the pump drive gear to the
2. Thoroughly clean the pump body gear recess, pump body.
pump body flange and the pump gears. Install the 5. Lubricate the pump body ‘O’ ring with automatic
gears in the pump body and check the pump end transmission fluid and fit to the pump body. Put
clearance using a depth micrometer or similar. the pump body to one side.
The end clearance should be 0.020 - 0.040 mm. 6. Ensure that the pump cover cavities, ports, holes
3. Remove the gears from the pump body and install etc. are clean and free of any obstruction.
the seal flush with the front face of the pump body 7. Lubricate all loose parts with automatic
if this was removed previously. transmission fluid prior to assembly.
G73134 en 01/2003 2003.0 BA Falcon

8. Assemble the Primary Regulator valve to the

pump cover. Ensure that the regulator valve slides
freely and that the regulator valve plug ‘O’ ring
Install the retaining pin.
Primary Regulator Valve
G73134 en 01/2003 2003.0 BA Falcon

9. Install the converter clutch regulator valve and 10. Install the converter clutch control valve, spring
plug. The compression of the plug ‘O’ ring must and plug. Plug ‘O’ ring compression must be
be adequate but not excessive. Install the adequate but not excessive. Install the retaining
retaining pin. pin.
Converter Clutch Regulator Valve Converter Clutch Control Valve
G73134 en 01/2003 2003.0 BA Falcon

Valve Retaining Plugs
Converter Relief Valve
11. Install the converter feed check ball and spring.
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Check Ball Location
12. Install the gasket on the pump cover with 15. Assemble the pump to the pump cover using
petroleum jelly. alignment tool 307-363. Tighten all bolts finger
13. Install the cover plate and the solenoid wiring tight ensuring that the pump is flush against the
retainer to the pump cover. Ensure that the pump cover. Check that the alignment tool can
periphery of the cover plate is flush with the still be rotated. Tighten the bolts and the screw to
periphery of the pump cover. Tighten screws to 14 Nm in the order shown. Check that the
specification. alignment tool can still be rotated. Tighten bolts to
27 Nm in the order shown. Check that the
14. Fit No. 7 solenoid and secure it with the retainer alignment tool can be rotated.
and screw. Check that wiring or connector does
not rub on the input shaft or the C1/C2 clutch
cylinder.
G73134 en 01/2003 2003.0 BA Falcon

Pump bolt tightening sequence
16. Install the pump to transmission case gasket on

the case with petroleum jelly. Install the pump and
cover assembly over the input shaft being careful
not to damage the sealing rings. Tighten the
pump cover to case bolts to specification.
Tightening sequence pump to case
17. Check the transmission end float. Set to

0.5-0.65mm. Attach a dial indicator to the front of
the transmission case with the stylus resting on
the end of the input shaft. Apply a force of
approximately 250 newtons or 25kgs to the input
shaft. Zero the dial indicator.
Place a small lever behind the forward clutch
cylinder and lever the cylinder forward. The
measurement recorded on the dial indicator is the
transmission end float or clearance between the
No. 4 bearing and the converter support tube.
If unshimmed end float is greater than
specification, shims are to be placed between the
No. 4 bearing and the input shaft bearing surface.
If end float is less than 0.5 or greater than
0.65mm then the transmission has been
assembled incorrectly or the parts are out of
specification.
18. Adjust the front band to specifications.
G73134 en 01/2003 2003.0 BA Falcon

Gear Train End Float Check
Valve Bodies 7. Install the 1-2 shift valve, plug and retaining plate.
Assembly 1-2 Shift Valve
1. Wash the upper and lower valve bodies
thoroughly with cleansing solvent and blow dry.
2. Check the valve body cavities, ports and holes for
impurities or obstructions.
3. Install the detent lever locating pin.
4. Thoroughly wash all loose components.
5. Check that all valves slide freely in their location.
6. Install the S5 damper spring, piston and retaining
pin.
S5 Solenoid and Damper
G73134 en 01/2003 2003.0 BA Falcon

8. Install the 3-4 shift valve and retaining plate. 11. Install the bar valve, springs, plunger and retainer
pin.
S1 Solenoid and 3-4 Shift Valve
Band Apply Regulator Valve and S4 Solenoid
9. Install the 2-3 shift valve and retaining pin.

12. Install the car valve, springs, plunger and retainer
S2 Solenoid and 2-3 Shift Valve pin.
Clutch Apply Regulator Valve and S3 Solenoid
10. Install the 4-3 sequence valve, spring, plug and

retaining plate.
13. Install the solenoid supply valve, spring and
4-3 Sequence Valve retainer plate.
CAUTION: This aluminium valve is easily
damaged.
Solenoid Supply Valve and S6 Solenoid
14. Install S6 plunger, spring and retaining pin.
G73135 en 01/2003 2003.0 BA Falcon

15. Position the third feed ball (large nylon) in the

valve body and install the S5 and S6 solenoid
filters.
16. Check the separator plate for burrs etc.
17. Check the upper and lower valve body gaskets.
18. Install the lower valve body gasket on the lower
valve body.
Lower valve body
19. Install the Reverse Lockout valve, spring, plug

and retaining plate. Position the 6 PIA (olive) ball
checks in the upper valve body.
CAUTION: On separating the valve body
all 6 ball checks need to be replaced with new
PIA (olive) balls, using worn or incorrect ball
material may lead to reduced transmission
durability or erratic gear shifts.
20. Fit the upper valve body gasket. Install the
separator plate over the upper valve body.
21. Holding the separator plate to the upper valve
body to prevent the check ball from falling out,
install the upper valve body on the lower valve
body.
Upper valve body with checkball locations
22. Install all screws finger tight then tighten the

screws to specification in the prescribed
sequence.
G73135 en 01/2003 2003.0 BA Falcon

Tightening Sequence Upper to Lower Valve Body
23. Install the No. 4 solenoid. Ensure the solenoid is

firmly secured by the retainer and that the screw
is tightened to specification.
24. Install the No. 3 solenoid. Ensure the solenoid is
firmly secured by the retainer and that the screw
is tightened to specification.
25. Install the S6 solenoid assembly.
26. Install the 2-3 shift valve solenoid S2.
27. Install the 3-4 shift valve solenoid S1.
28. Install the S5 solenoid. Ensure that the solenoid is
pushed firmly into the valve body by the clamping
plate.
29. Install manual feed ball and spring (on lower face
adjacent to the BAR valve) and secure with the
retaining pin.
30. Install the manual shift valve.
31. Install the detent spring assembly (spring, shims,
support plate and screw). Ensure the screw is
tightened to specification. Check the spring for
wear or damage.
32. Align the valve body assembly on the
transmission case and install the manual valve
lever to manual valve link. Fit the long end of the
link to the manual valve first. Install the securing
bolts and tighten to specification in the specified
sequence.
G73135 en 01/2003 2003.0 BA Falcon

Tightening Sequence Valve Body to Case
33. Check the alignment of the detent roller and the

manual lever quadrant.
34. Connect the solenoid wiring.
S1 - Red
S2 - Blue
S3 - Yellow
S4 - Orange
S5 - Green
S6 - Violet
35. Check that the cross-shaft torque is within
specification. To do this, rotate the cross shaft to
the "P" position. Rotate the output shaft until the
parking mechanism locks. Measure the torque
required to rotate the cross-shaft from P-R (with
the output shaft unloaded). This torque must be
2.5-3.5 Nm. Add or remove shims from under the
detent spring as necessary to ensure correct
torque.
G73135 en 01/2003 2003.0 BA Falcon

Oil Filter and Pan Assembly

Assembly
Oil Filter Installation
1. Lubricate the oil filter sealing ring with automatic 5. Assemble the gasket on the pan lip. The gasket
transmission fluid. must be free of any distortion when installed.
2. Carefully assemble the oil filter to the valve body.
The spigot must not lean on one side while being
fitted.
3. Secure the oil filter assembly with the retainer.

Engage the long leg of the retainer first.
4. Check that magnet is located in the dimple in the
corner of the oil pan.
G73136 en 01/2003 2003.0 BA Falcon

6. Fit the oil pan assembly to the transmission case

and tighten the securing bolts to specification. Do
not over torque.
Oil Pan Tightening Sequence
Torque Converter & Housing

Assembly
1. Fit the "O" ring seal to the input shaft.
2. Locate the torque converter housing on the
transmission main case. Install and tighten the
securing bolts.
3. Fit the torque converter by pushing it fully back
and turning the converter until it engages the
pump drive dogs.
4. The converter is correctly installed when the
torque converter pilot hub is 4mm for 93LE and
0.5mm for 97LE in from the front face of the
torque converter housing.
G73136 en 01/2003 2003.0 BA Falcon

307-05-1 Automatic Transmission External Controls 307-05-1
SECTION : 307-05 Automatic Transmission

External Controls
CONTENTS PAGE
Automatic Transmission External Controls ...........................................................................307-05-2
Sequential Sport Shift Selector ............................................................................................307-05-2
Automatic Transmission External Controls ...........................................................................307-05-3
GENERAL PROCEDURES
Selector Cable Adjustment ...................................................................................................307-05-4
Handle Assembly ..................................................................................................................307-05-5
Torsion Spring .......................................................................................................................307-05-5
Housing Sub Assembly .........................................................................................................307-05-5
Gear Indicator Globe .............................................................................................................307-05-6
Cap .......................................................................................................................................307-05-7
Loom PCB (Printed Circuit Board) .........................................................................................307-05-8
Guide Lever ..........................................................................................................................307-05-9
Gearshift Assembly .............................................................................................................307-05-10
Bucket (Metal Pressing) ......................................................................................................307-05-12
Base and Lever Assembly ..................................................................................................307-05-12
Spring Leaf Detent ..............................................................................................................307-05-13
Selector Lever Cable ..........................................................................................................307-05-15
01/2003 2003.0 BA Falcon

Automatic Transmission External The Selector can be shifted from Drive(D) to Neutral
(N) without depressing the Button on the Handle. The
Controls Button must be depressed to shift from (N) to (R) and
from (R) to (P) as well as (P) to (R).
Sequential Sport Shift Selector
The Button does not need to be depressed when
The Sequential Sport Shift (SSS) Selector system is a shifting from (R) to (D) or when using Sequential
cable operated mechanical and Electronic Selector Sport Shift.
system. Mechanically it works similarly to previous Remove center console gear shift surround and
model T/Bars when moving from the Park to Drive
center console wing trims (refer Section 501-12).
position.
However when the lever is in ‘D’ position it can be

moved into Performance/Sport position by pushing the
lever to the left. It now Electronically controls the
Transmission.
NOTE: This is the Recommended ‘Towing’ position

for the Selector as well the Sequential Sport or
Performance position for Manual operation of the
Sequential Sports Shift.
The transmission will shift ‘Automatically’ when the
selector is in D or ‘Performance/Sport’ until the
selector lever is moved either forward or rearward to
the +/- position. The Sequential Sport Shifter is now in
Manual Mode and sequential Manual shifting is now
required.
If the Selector is pulled rearward (+) the ‘SSS’ will be
activated and the Transmission will upshift to a higher
gear, if the selector is pushed forward (-) the
transmission will shift down to a lower gear provided
the vehicle speed is within the safe operating speed
for the transmission.
G77031 en 01/2003 2003.0 BA Falcon

Automatic Transmission External

Controls
Loom PCB

2&3 5V Power Supply through 5V
4.7kOhm resistor
1&3 Voltage Measure Position ‘D’ — 3.96V
Position ‘DPEPF’ — 2.88V
Position ‘+’ — 1.83V
Position ‘–’ — 0.78V
G77032 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Selector Cable Adjustment

1. Move Selector to "P" position.
2. Raise the vehicle and ensure the transmission
operating lever is also in "P" (this is the most
Rearward position).
3. Connect the Cable to the Transmission Cable
Mount by pushing rearwards until the side tabs of
the cable click into the lock position.
NOTE: The Cable Push Rod is snapped onto the Pin.

Finally the adjuster clip is pushed closed on the Cable
auto adjuster.
G77033 en 01/2003 2003.0 BA Falcon

Handle Assembly Torsion Spring

Removal
1. Remove Centre Console and other associated
components. For additional information, refer to
Section 501-12.
NOTE: Do not remove Gearshift assembly from
the vehicle.
2. Move Handle to "P" position.
3. Open the spring legs with pliers and disengage
from the nest.

NOTE: Do not remove console and other associated
components from the vehicle.
1. Move Handle to "D" position.
2. Remove screw.
3. Remove Handle.
4. Remove torsion spring. Fit new spring.

Installation
Housing Sub Assembly
Removal
Section 501-12.
the vehicle.
Item Description
2. Disconnect main loom from Plug then Plug from
1 Selector handle base (squeeze clips).
2 Screw 3. Repeat process for the top LH corner of the
4. Insert new Handle then secure with screw. shifter.
G77034 en 01/2003 2003.0 BA Falcon

4. Lift corner labeled "A" first using narrow nose 3. Move Cover slide hole to "D" position.
pliers placing them between the Housing 4. Slide Housing assembly onto Lever through
assembly and base. Cover slide hole.
5. Place Housing assembly into Bezel recesses then
push down until locked into the Base.
6. Clip Plug into Base.
7. Connect main loom.
Gear Indicator Globe

Removal
Section 501-12.
the vehicle.
5. Squeeze flexible legs with pliers and lift until 2. Remove the handle assembly. For additional
disengaging the base. information, refer to Handle Assembly in this
section.
3. Remove the housing assembly. For additional
information, refer to Housing Sub Assembly in this
section.
6. Lift Housing assembly until disconnected from

lever.
7. Turn Globe holder with pliers until holder can be
pulled out of lower Housing.
8. Remove Housing assembly. Item Description
Installation 1 Selector handle
1. Insert Globe holder inside lower housing then 2 Screw
rotate approx 45 deg. 3 Housing assembly
2. Move orange indicator into the "D" position.
G77034 en 01/2003 2003.0 BA Falcon

4. Pull out Globe from globe holder. 3. Remove the housing assembly. For additional
section.
5. Push new Globe into Globe holder.

Installation
1. To install, reverse the removal procedure. For
additional information, refer to Housing Sub
Assembly.
Cap
Removal
Section 501-12.
the vehicle.
2. Remove the handle assembly. For additional
information, refer to Handle Assembly in this
section.
Item Description
1 Selector handle
2 Screw
3 Housing assembly
4. Move Lever into Tip position.
5. Remove damaged Cap by lifting the face above

the clip, and slide out.
G77038 en 01/2003 2003.0 BA Falcon

6. Fit new Cap, pushing onto arm until clipped. 2. Remove the handle assembly. For additional
information, refer to Handle Assembly
Replacement in this section.
section.
Installation
Loom PCB (Printed Circuit Board)

Removal
Item Description
components. For additional information, refer to 1 Selector handle
Section 501-12. 2 Screw
NOTE: Do not remove Gearshift assembly from 3 Housing assembly
the vehicle.
G77038 en 01/2003 2003.0 BA Falcon

4. Cut off tab with sharp blade. Guide Lever

Removal
Section 501-12.
the vehicle.
2. Remove the handle assembly. For additional
information, refer to Handle Assembly
information, refer to Housing Sub Assembly
5. Remove faulty Loom PCB.

6. Place new Loom PCB.
7. Secure new Loom PCB with screw provided in the
kit.
Item Description
1 Selector handle
2 Screw
3 Housing assembly
Installation
G77039 en 01/2003 2003.0 BA Falcon

4. Move Lever into Tip position. 7. Open two clips and push out Guide lever.
5. Press and lift to unclip in the order shown below. Installation

Gearshift Assembly
Removal
1. Raise the vehicle and disconnect the transmission
shift cable from the lower selector lever.
I6
V8
6. Move Handle to "D" position.
G77039 en 01/2003 2003.0 BA Falcon

2. Disconnect the four nuts that attach the housing 3. Remove the centre console and other associated
to the floorpan. components. For addition information, refer to
section 501-12.
4. Place the selector lever in the ’P’ position.
6. Reconnect the four nuts that attach the housing to
the floorpan.

4. Remove the centre console and other associated
components. For addition information, refer to
section 501-12.
5. Detach the back light bulb/wiring and selector
cable. 7. Hold the transmission shift rod and engage Park
on the transmission by pushing the shift rod as far
forward as possible.
8. Install the shift rod on the lower selector lever.
I6
6. Remove the whole floor shift housing by lifting

vertically.
Installation
1. Install the whole floor shift housing by lifting
vertically.
V8
2. Attach the back light bulb/wiring and selector
cable.
G77041 en 01/2003 2003.0 BA Falcon

9. Tighten the lock nut to the required torque to 28 4. Remove metal Bucket
Nm.
Remove two washers.
10. Lower the vehicle and check transmission
Remove Gasket (new gasket to be used when
operation in each selector lever detent position.
assembling to original condition).
11. Check that the mode light functions correctly.
Remove metal Bucket (pressing).
Bucket (Metal Pressing) Replace with new.
Installation
Removal
Section 501-12.
2. Remove shifter assembly from vehicle. For
additional information, refer to Gearshift assembly
in this section.
3. View before and after replacement of damaged

Bucket.
Item Description
1 Star washer
2 Gasket
3 Metal bucket
Base and Lever Assembly

Section 501-12.
G77041 en 01/2003 2003.0 BA Falcon

2. Remove shifter assembly from vehicle. For 6. Disassemble and rebuild the bottom part of the
additional information, refer to Gearshift assembly assembly. Refer to Bucket Replacement in this
in this section. section.
3. View before and after replacement.
4. Disassemble and rebuild the top part of the Item Description

assembly. Refer to Housing Sub Assembly
Replacement in this section. 1 Selector handle
5. Replace faulty sub assembly. 2 Screw
3 Housing assembly
4 Lever assembly
5 Metal bucket
6 Gasket
7 Star washer
Spring Leaf Detent

Section 501-12.
G77044 en 01/2003 2003.0 BA Falcon

2. Remove shifter assembly from vehicle. For Reverse disassembly process when
additional information, refer to Gearshift assembly rebuilding to original condition.
in this section.
3. View before and after replacement of damaged

spring.
Item Description
4. Remove damaged spring. 1 Star Washer
Remove two washers. 2 Gasket
Remove gasket (new gasket to be used when 3 Metal Bucket
assembling to original condition). 4 Screw
Remove metal pressing. 5 Spring Leaf Detent
Undo and remove screw.
Remove damaged spring. Place new spring
on the Base and secure with the screw.
G77044 en 01/2003 2003.0 BA Falcon

Selector Lever Cable

Removal
1. Release locking tab from the Transmission Cable
Mount.
2. Disconnect the cable from the housing.
3. Use a screwdriver to release the cable push rod
from the cable arm.
Installation
1. To reassemble simply push the cable end fitting
back into the pin.
I6 Selector Cable
G77045 en 01/2003 2003.0 BA Falcon

V8 Selector Cable
G77045 en 01/2003 2003.0 BA Falcon

308-01-1 Clutch 308-01-1
SECTION : 308-01 Clutch

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................308-01-2
Clutch .....................................................................................................................................308-01-3
Introduction ..........................................................................................................................308-01-3
Clutch Function ....................................................................................................................308-01-3
Clutch .....................................................................................................................................308-01-6
Symptom Chart ....................................................................................................................308-01-6
GENERAL PROCEDURES
Pressure Plate Inspection ......................................................................................................308-01-8
Clutch Disc Inspection ...........................................................................................................308-01-8
Clutch Pressure Plate Adjustment (XR6 Turbo Variant) ........................................................308-01-8
Disc and Pressure Plate ........................................................................................................308-01-9
Flywheel — I6 (all variants including XR6 Turbo) ................................................................308-01-10
Flywheel — All V8 Vehicles (incl XR8 & GT) .......................................................................308-01-11
Pilot Bearing — All Vehicles ................................................................................................308-01-11
Flywheel Auto Flex-Plate (XR6 Turbo only) .........................................................................308-01-13
Ring Gear — All Vehicles except XR6 Turbo ......................................................................308-01-13
Ring Gear — XR6 Turbo only ..............................................................................................308-01-14
01/2003 2003.0 BA Falcon

308-01-2 Clutch 308-01-2
SPECIFICATIONS
Description Nm
CSC to clutch housing 9.5
CSC to pipe fitting nut 14
CSC Bleed screw 8
Clutch pressure plate to flywheel
I6 20
V8 48
Flex plate to flywheel disc (Turbo only) 60
Flywheel to crankshaft
I6 75
V8 80
Dowel insertion depth in flywheel
(Proud of friction face)
I6 8mm
XR6 Turbo 10.5mm
V8 11.5mm
NOTE: The V8 flywheel is designed so that the dowel
will bottom out at the correct insertion depth.
G86726 en 01/2003 2003.0 BA Falcon

308-01-3 Clutch 308-01-3
Clutch
Introduction
Three clutch variants are used across the manual BA
Falcon range. All manual I-6 vehicles, except XR6T
are fitted with a one-piece flywheel and 254mm
clutch. Manual XR6T vehicles are fitted with a
two-piece flywheel and a heavy-duty 267mm clutch.
All manual V8 vehicles are fitted with a one-piece
flywheel, 292mm pressure plate and 280mm clutch
disc to provide a high torque capacity.
Clutch Function
The primary function of the clutch system is to
connect and disconnect engine power to the
transmission upon driver command.
Clutch System Components — STD I6

1 Flywheel 4 Clutch pressure plate
2 Transmission input shaft pilot bearing 5 Clutch slave cylinder/clutch release hub
and bearing
3 Clutch disc
G86727 en 01/2003 2003.0 BA Falcon

308-01-4 Clutch 308-01-4
Clutch System Components —XR6 Turbo
Item Description
1 Flywheel (2 piece assembly)
2 Transmission input shaft pilot bearing
3 Clutch disc
4 Clutch pressure plate
5 Clutch slave cylinder/clutch release hub
and bearing
G86727 en 01/2003 2003.0 BA Falcon

308-01-5 Clutch 308-01-5
Clutch System Components — V8 Standard

(3 valve) & XR8 (4 Valve)
Item Description A pilot bearing supports the end of the input shaft.
The bearing does not require lubrication unless the
1 Flywheel clutch system is serviced.
2 Transmission input shaft pilot bearing
The clutch does not require pressure plate re-setting
3 Clutch disc after disasembly or disc renewal.
4 Clutch pressure plate NOTE: The clutch pressure plate should always be
5 Clutch slave cylinder/clutch release hub adjusted before installation.
and bearing
For Standard I6, XR6 & all V8:

The clutch is a single plate, dry friction clutch disc with
a self-adjusting, diaphragm-style spring clutch
pressure plate.
The clutch operating mechanism consists of a clutch
slave cylinder with an integral release bearing.
A pilot bearing supports the end of the input shaft.
The bearing does not require lubrication unless the
clutch system is serviced.
The clutch does not require pressure plate re-setting
after disasembly or disc renewal.
For XR6 Turbo:

The clutch is a single plate, dry friction clutch disc with
diaphragm-style spring clutch plate.
The clutch operating mechanism consists of a clutch
slave cylinder with an integral release bearing.
G86727 en 01/2003 2003.0 BA Falcon

308-01-6 Clutch 308-01-6
Clutch
Symptom Chart

Clutch does not disengage correctly Worn clutch disc. Replace worn or defective parts
Failed pressure plate. Replace pressure plate

Self Adjusting Clutch (SAC) over Remove SAC and reset
adjusted.
Air in hydraulic system Bleed hydraulic system

Damaged Concentric Slave Cylinder Repair or replace CSC. Refer to
(CSC). Section 308-02.
Clutch pedal hang-up or excessive CSC damaged. Repair or replace CSC. Refer to
clutch pedal effort Section 308-02.
Master cylinder damaged. Replace clutch master cylinder

Noisy clutch operation when engine CSC bearing failure Replace CSC. Refer to Section
running 308-02.
Clutch disc damaged Replace clutch disc
Noisy clutch operation with engine off Binding at pedal support bracket Lubricate with engine oil or replace
support bracket bushing
CSC damaged Replace CSC. Refer to Section

308-02.
Binding within pressure plate Lubricate pressure plate pins
Clutch slips or chatters Worn or contaminated clutch lining Replace defective part. (If grease or oil
Grease or oil on clutch facings from: is causing the clutch to slip, replace
Release bearing the disc, remove the grease or oil from
Engine the pressure plate and flywheel and
CSC reuse if it is not burned or scored.)
Pilot bearing Repair source of leakage.
Transmission
Weak or failed pressure plate Replace pressure plate
Loose pressure plate to flywheel bolts Torque bolts to spec
Loose engine mount bolts Torque bolts to spec
Damaged CSC Replace CSC. Refer to Section

308-02.
Failed master cylinder Replace clutch master cylinder
Intermittent squawk Flywheel housing misalignment Replace flywheel housing

Clutch noisy when disengaged (Engine Pilot bearing worn Replace pilot bearing
running)
CSC bearing worn Replace CSC. Refer to Section

308-02.
Clutch spin or drag Failed pressure plate Replace pressure plate
Grease on linings of clutch disc Replace clutch disc and degrease

pressure plate and flywheel
Flywheel housing out of alignment Align to specifications
SAC over adjusted Remove SAC and reset
Damaged clutch disc Fit clutch disc correctly, if damaged

replace
G86728 en 01/2003 2003.0 BA Falcon

308-01-7 Clutch 308-01-7

Binding of the disc on the input shaft Check splines for burrs, rusting and
splines damage. Clean up splines and
lubricate with the specified lubricant
Air in hydraulic system Bleed hydraulic system

Low fluid level in hydraulic clutch Bleed clutch system and fill clutch fluid
system reservoir
CSC damaged Replace CSC. Refer to Section

308-02.
Clutch master cylinder damaged Replace master cylinder

NOTE: CSC - Concentric Slave Sylinder
SAC - Self Adjusting Clutch (not XR6 Turbo)
G86728 en 01/2003 2003.0 BA Falcon

308-01-8 Clutch 308-01-8
GENERAL PROCEDURES
Pressure Plate Inspection 2. Adjust the clutch pressure plate.

1. Rotate the adjusting ring counter clokwise
1. Inspect the friction surface of the pressure plate
until the tension springs are compressed. In
for burn marks, scoring or ridges, and warpage.
compressed form the springs should not be
Generally, pressure plate resurfacing is not greater than 14 mm.
recommended. However, minor burn marks,
scores or ridges may be removed. 2. Hold adjusting ring while releasing the
pressure on the clutch diaphragm fingers.
2. During the resurfacing process, the flatness of the
pressure plate must be maintained. If the
pressure plate is badly heat checked, or deeply
scored, replace it.
3. Clean the pressure plate and flywheel to be sure
the surfaces are free from any oil film. Do not use
cleaners with petroleum base, and do not
immerse the pressure plate in solvent.
4. Prior to fitment, insure the self adjusting clutch
pressure plate is reset as outlined in this section.
Clutch Disc Inspection
1. Inspect the clutch disc facings for oil or grease.
Eliminate the source of any oil or grease before
replacing the disc. Excessive grease will
contaminate the disc facings. Too much lubricant
in the transmission vent will force the transmission
lubricant past the input shaft seal and into the disc
facings.
2. Inspect the clutch disc for worn or loose facings.
Check the disc for distortion and for loose rivets at
the hub. Check for broken springs and springs
that can be moved radially. Springs that can be
moved laterally are acceptable.
3. Replace the disc assembly if any of these defects
are present. Be especially careful when installing
a new disc to avoid dropping it or contaminating it
with oil or grease. Check that the disc will slide on
the input shaft prior to installation.
Clutch Pressure Plate Adjustment
(XR6 Turbo Variant)
NOTE: The clutch pressure plate should always be
adjusted before installation.
1. Compress the clutch diaphragm fingers.
1. Position the clutch pressure plate in a press.
2. Use a suitable adapter and press the clutch
diaphragm fingers until the adjusting ring
moves freely.
WARNING: Do not over-travel as damage will

occur and clamp load will be reduced.
G86729 en 01/2003 2003.0 BA Falcon

308-01-9 Clutch 308-01-9
Vehicle Item Specification QTY

Disc and Pressure Plate variant
The following illustrations show the removal and XR6T Screw - Grade 8.8 S36D 6
installation procedure for the standard I6 pressure M8x1.25x16 Surface finish
plate and clutch disc, alone. However the HEX FLG HD
accompanying removal and installation instructions All V8 Bolt - N808969-S100 6
are pertinent to standard I6, XR6T and V8 clutch M10x1.5x28.5
systems, which are alike. As such the following HEX FLG HD
instructions should be followed when assembling PILOT
and/or disassembling any of these clutch systems.
Removal
NOTE: All V8 and I6 clutch systems, except XR6T
clutch, utilise a self-adjusting pressure plate. In such 1. Remove the transmission. For additional
systems the friction surface of the pressure plate information, refer to Section 308-03.
ratchets progressively forward as the clutch disc 2. Remove the bolts, clutch pressure plate and the
becomes worn. As such the ratcheting mechanism in clutch disc.
the self-adjusting pressure plates must be reset
before reassembling the clutch system with a new CAUTION: If the clutch disc and pressure
clutch disc in place. The procedure for resetting these plate are to be reinstalled, bolts must be
pressure plates are in clutch pressure plate removed evenly or permanent damage to the
adjustment covered earlier in this section. diaphragm spring will occur resulting in
complete clutch release.
Special Tool(s) If the parts are to be reused, index-mark the
Aligner, Clutch Disc clutch pressure plate to the flywheel. Also
All I6: Tool 308-257 (E9276) or inspect the pressure plate and clutch disc as
Transmission Input Shaft (23T) outlined in this section.
All V8: Generic Tool or Input
Shaft (10T)
Installation
1. Lubricate the transmission input shaft pilot
bearing with grease.
Materials
Item Specification
High-Temperature 4x4 ESA-M1C198-A
Front Axle and Wheel
Bearing Grease
Threadlock and Sealer Locktite 243
Hardware - Pressure Plate-to Flywheel
variant
All I6 Bolt - E602550-S36D 6
(except M8x1.25x25.5
XR6T) HEX HD
G86733 en 01/2003 2003.0 BA Falcon

308-01-10 Clutch 308-01-10
2. Using the special tool, position the clutch disc on 5. Install the transmission.
the flywheel.
1. For additional information, refer to Section
308-03.
Flywheel — I6 (all variants including

XR6 Turbo)
Materials
Item Specification
Threadlock and Sealer Loctite 243 or equivelant
E0AZ-19554-AA Loctite
Hardware - Flywheel-to-crankshaft
variant
All I6 Bolt - V800322 6
3. Using the special tool, align the clutch disc and fit (except M10x1.25x25
the clutch pressure plate. Install the bolts and XR6T) HEX HD
tighten in a star pattern sequence. XR6T Screw - V800524 6
NOTE: If reusing the clutch pressure plate and M8x1.25x19
flywheel, align the marks made during removal. HEX FLG HD
4. Remove tool. All V8 Bolt - N808139-S100 8
M10x1x26.5
HEX HD
Removal
2. Remove the clutch disc and pressure plate. For
additional information, refer to Disc and Pressure
Plate in this section.
3. Remove four of the six bolts. Leaving two
opposing bolts in place, loosely.
CAUTION: Two bolts should be loosened
but left in to prevent the flywheel from falling.
4. Separate the flywheel from the crankshaft.

5. Remove the bolts remaining in the crankshaft.
G86733 en 01/2003 2003.0 BA Falcon

308-01-11 Clutch 308-01-11
Installation 4. Separate the flywheel from the crankshaft.

1. Position the flywheel onto the crankshaft and 5. Remove the bolts remaining in the crankshaft.
install the flywheel-to-crankshaft bolts.
Apply threadlock and sealer to bolt threads.
Installation
NOTE: Both the standard I6 & XR6 Turbo
flywheel and crankshaft are designed with a 1. Position the flywheel onto the crankshaft and
single offset bolthole to ensure correct install the flywheel-to-crankshaft bolts.
angular alignment between crankshaft and Apply the threadlock and sealer to bolt
flywheel. These holes must be aligned before threads.
installing the six flywheel-to-crankshaft bolts.
2. Install the disc and pressure plate. For additional

2. Install the disc and pressure plate. For additional information, refer to Disc and Pressure Plate in
information, refer to Disc and Pressure Plate in this section.
this section. 3. Install the transmission. For additional information,
3. Install the transmission. For additional information, refer to Section 308-03.
Pilot Bearing — All Vehicles
Flywheel — All V8 Vehicles (incl XR8 &
Special Tool(s)
GT)
Installer, Pilot Bearing
Removal 308-105 (T85T-7137-A)
2. Remove the clutch disc and pressure plate. For
additional information, refer to Disc and Pressure
Plate in this section.
3. Remove six of the eight bolts. Leaving two Removal
opposing bolts in place, loosely. 1. Using a standard bearing puller, remove the
CAUTION: Two bolts should be loosened transmission input shaft pilot bearing.
but left in to prevent the flywheel from falling.
G86738 en 01/2003 2003.0 BA Falcon

308-01-12 Clutch 308-01-12
2. Inspect the transmission input shaft pilot bearing

for:
misalignment and looseness in the flywheel.
needle rollers for scoring, worn or broken
needle rollers, inadequate grease or
discoloration.
seal leakage.
Installation
NOTE: The transmission input shaft pilot bearing
should only be installed with the seal facing the
transmission. The transmission input shaft pilot
bearing is pregreased and does not require additional
lubrication. A new transmission input shaft pilot
bearing must be installed whenever it is removed.
1. Using a soft-face hammer and the special tool,
install the transmission input shaft pilot bearing.
G86738 en 01/2003 2003.0 BA Falcon

308-01-13 Clutch 308-01-13
Flywheel Auto Flex-Plate (XR6 Turbo Ring Gear — All Vehicles except XR6
only) Turbo
Vehicle Item Specification QTY Disassembly
variant
XR6T Bolt - V810171S26D 4
M10x1.25x17
HEX HD
Disassembly
1. Remove the flywheel assembly. For additional
information, refer to Flywheel section.
2. Index mark the flywheel disc together with the
auto-flex plate.
3. Undo the four screws attaching the flywheel disc
to the auto flex-plate and separate the two
components.
Assembly 1. Using a brass drift and hammer, drive the flywheel

1. Position the flywheel disc on the auto flex plate ring gear off the flywheel.
and align the markings on the disc and flex plate.
CAUTION: Do not heat the flywheel ring
NOTE: Both the XR6 Turbo flywheel and
gear to remove.
crankshaft are designed with a single offset
bolthole to ensure correct angular alignment CAUTION: Tap the flywheel ring gear
between the crankshaft and flywheel. These holes evenly to prevent binding.
must be aligned before installing the six
flywheel-to-crankshaft bolts. Assembly
WARNING: This procedure should be
performed only by a correctly equipped and
experienced acetylene torch operator. To avoid
personal injury, use tongs or wear welding gloves
and safety goggles when handling the heated
flywheel ring gear.
1. Evenly heat the flywheel ring gear.
CAUTION: Do not heat the flywheel ring
gear beyond 278°C (500°F). Use heat
indicating crayons to prevent over heating.
CAUTION: Keep the torch moving to
prevent hot spots.
2. Install the flywheel disc-to-flex plate bolts.
G86740 en 01/2003 2003.0 BA Falcon

308-01-14 Clutch 308-01-14
2. Install the flywheel ring gear using a brass drift.

NOTE: The bevel on the flywheel ring gear must
face the rear of the flywheel.
Ring Gear — XR6 Turbo only
WARNING: The ring gear should not be

removed from the auto flex plate on XR6T flywheel
assembly. Replace as assembly is required.
G86740 en 01/2003 2003.0 BA Falcon

308-02-1 Clutch Controls 308-02-1
SECTION : 308-02 Clutch Controls

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................308-02-2
Clutch Controls .....................................................................................................................308-02-3
Clutch Controls .....................................................................................................................308-02-4
Inspection and Verification - Clutch .....................................................................................308-02-4
Function Test .......................................................................................................................308-02-4
Symptom Chart ....................................................................................................................308-02-4
Pinpoint Tests ......................................................................................................................308-02-6
GENERAL PROCEDURES
Clutch Bleeding .....................................................................................................................308-02-8
Clutch Pedal ..........................................................................................................................308-02-9
Clutch Master Cylinder ..........................................................................................................308-02-9
Slave Cylinder .....................................................................................................................308-02-10
Clutch Hydraulic Fluid Tubes ..............................................................................................308-02-10
Clutch Reservoir ..................................................................................................................308-02-11
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Clutch System
Clutch control Hydraulic
System adjustment Automatic
Clutch pedal type Suspended
Fluid
Brake Fluid (Ford) Mobil ESZ - M6C55A
Description Nm
Clutch Pivot Bolt 20
Master Cylinder retaining bolts 14
Adjuster Motor Retaining Bolts 5 ± 0.5
(adjustable pedal)
Clutch Pivot Bolt (M8) 16 ± 2
Clutch Assembly Bolt (M6) 6 ± 0.5
Reservoir Bracket Bolts 2-4
G56329 en 01/2003 2003.0 BA Falcon

Clutch Controls
Component Location
Item Description Acronyms and Abbreviations

1 Clutch pedal deactivation switch APM Accelerator Pedal Module
2 Clutch reservoir
PCM Power Train Module
3 Brake and clutch pedal support bracket
4 Clutch master cylinder Step Over Height Difference Between Brake and
5 Clutch slave cylinder/clutch release hub Accelerator Pedal
and bearing
MSC Memory Seat Controller
The clutch control system actuates the clutch system. PPS Pedal Position Sensor
When the clutch pedal is depressed it pushes the
clutch master cylinder plunger which transmits
hydraulic pressure to the clutch slave cylinder. The
clutch slave cylinder engages and compresses the
clutch pressure plate diaphragm spring, releasing the
pressure on the clutch disc which in turn disengages
the transmission from the engine.
The hydraulic clutch system adjusts automatically
to compensate for clutch disc wear.
The clutch pedal starter interlock switch is
attached to the clutch pedal. Depressing the
clutch pedal manually closes the switch and
allows engine cranking.
The clutch pedal deactivation switch deactivates
the speed control system when the pedal is
depressed.
G56330 en 01/2003 2003.0 BA Falcon

Clutch Controls Function Test

Inspection and Verification - Clutch Condition Possible Function Pin Point
Source Test Test
The transmission and the clutch transfer the engine PEDAL Pedal Slow or Manual B
torque to the wheels. When diagnosing the
FEEL does not Application
transmission. Both the transmission and the clutch
return Test of the
should be considered when diagnosing concerns. Clutch
Verify the customer concern by operating the Pedal to
system. confirm
Visually inspect for obvious signs of mechanical Binding / Manual C
damage. Raspy pedal Test
If an obvious cause for an observed or reported Worn Pedal Visual
concern is found, correct the cause ( if possible) Pad Inspection
Clutch Pedal Refer to
If the concern is not evident, verify the symptom "Sinks" sinks Clutch
and refer to the Symptom Chart to the Floor Diagnosis
Check these items before entering Diagnostics. in Section
206-06
Topic Specification
CRUISE Not Visual A
Brake Fluid Ensure that the Reservoir is Filled CONTROL Functioning Inspection
Reservoir to the Max Point. Use Ford CLUTCH
Approved Brake Fluid Mobil ESZ - Adjustment Visual
SWITCH Inspection
M6C55A .
Switch Visual A
CAUTION: Do not allow Disconnected Inspection
brake fluid to contact vehicle HARD TO Master Visual
paint work. ENGAGE Cylinder Inspection
Vehicle Test Ensure That Your Local State GEARS Leakage
Drive to Speed Limits are Not Exceeded Slave Visual Refer to
Confirm Fault Cylinder Inspection Clutch
Battery Voltage Must be Greater Than 12 Volts Leakage Diagnosis
Obstructions Check for Any Obstructions at the in section
Brake Pedal Area, Such as Floor 308-01
Mats and Wiring Harnesses HARD TO Clutch Plate Refer to
Visual Inspection Chart ENGAGE Worn Clutch
GEARS Diagnosis
Electrical (ctd) in section
Oil leaks 308-01
Visibly damaged or worm parts Pressure Refer to
Loose or missing nuts or bolts plate Issue Clutch
Diagnosis
in section
308-01
Air in System Refer to
Clutch
Diagnosis
in section
308-01
Symptom Chart
Symptom Chart - (MSC) Memory Seat Controller

Excessive effort needed to depress Clutch pedal binds at pivot INSTALL a new clutch pedal
clutch pedal or has a rough or raspy or
sticky feel
G56331 en 01/2003 2003.0 BA Falcon


Clutch Master Cylinder CHECK Clutch Master Cylinder and
REFER to the Clutch Master Cylinder
Section.
Return clutch pedal spring damaged or CHECK the clutch pedal and INSTALL
bad positioned a new clutch pedal if necessary.
Worn or damaged clutch pedal INSTALL a new clutch pedal.
Foreign object caught in clutch pedal CHECK the clutch pedal.
Brake pedal does not return freely Weak or broken clutch pedal return CHECK the clutch pedal and INSTALL
spring a new clutch pedal if necessary.
Foreign object caught in clutch pedal CHECK the clutch pedal.

No response from the cruise control Unconnected cruise switch CHECK the connection between the
when the clutch pedal is pressed cruise switch and the cruise control.
Faulty clutch pedal switch flag INSTALL a new clutch pedal.
Bad position of the cruise switch CHECK the cruise switch. REPLACE
or CHANGE cruise witch.
Nothing happening when the clutch Connection between the low pressure CHECK any leak, CHANGE low
pedal is pressed line and master cylinder pressure line if necessary.
Connection between the high pressure CHECK any leak, CHANGE high
line and master cylinder pressure line if necessary.
Fluid level CHECK the fluid level and REFILL if

necessary.
Master cylinder CHECK the master cylinder, CHANGE

it if necessary.
Discomfort on the clutch pedal Clutch pedal pad worm or loose CHECK clutch pedal pad and
CHANGE it if necessary.
Padal feel Clutch Pedal Not Returning Once Go to PinPoint Test A

Released
"Raspy" Feel
Pedal Binding at Pivot
Pedal Pad Worn
Obstruction at / Under Pedal
Gears "CRUNCH" when changing Clutch Master Cylinder Leaking / Go to Section 308-01.
gears Faulty
Gears hard to select
Clutch Slave Cylinder Leaking / Faulty Go to Section 308-01.

Insufficient Master / Slave Cylinder Go to PinPoint Test A
Rod Travel
Worn / Damaged Clutch Plate Go to Section 308-01.

Damaged / Worn Clutch Pressure Go to Section 308-01.
Plate
Manual Transmission Issue. Gears / Go to Section 308-03.
Synchromesh Rings or Lack of
Lubrication
Air in System Refer to Clutch Diagnosis in Section

308-01.
Cruise control not turning off when Cruise Control Switch Faulty / Plug Go to PinPoint Test A
clutch activated Disconnected
Stop Lamp Switch Faulty / Plug Go to PinPoint Test C in Section
Disconnected 206-06.
G56331 en 01/2003 2003.0 BA Falcon

Pinpoint Tests
PINPOINT TEST A : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH

A1 STOP LAMP CIRCUIT FUSE
Check the 15 Amp Fuse # 7 . Yes
No
Go to A2
A2 CLUTCH PEDAL SWITCH CONTINUITY

Remove the clutch pedal switch. Refer to Section 308-01. Yes
Go to A3
Carry out a continuity test. With the switch plunger Out = Continuity.
Push the switch plunger Inwards = Open circuit. No
Replace the clutch pedal switch. Refer to
Push the switch pin Inwards = continuity. Section 308-01.
Is the clutch pedal switch electrical function Okay?
A3 SWITCH EARTH CIRCUIT CONTINUITY

Disconnect the electrical connector C-111 at the clutch pedal switch Yes
and the PCM connector. PCM issue. Refer to Section 303-14.
Check the Blue/Yellow wire (92) from the switch connector C-111 to No
the PCM terminal B05 RBS. Check and repair wiring or terminal fault.
Was there continuity?
PINPOINT TEST B : PEDAL NOT RETURNING ONCE RELEASED
B1 HYDRAULIC SYSTEM
Check the fluid reservoir for clutch fluid. Yes
Fill the reservoir with fluid. Refer to the
Was the reservoir empty? specifications. Go to B2 to ensure that the
master cylinder is not leaking.
No
Go to B2
B2 HYDRAULIC HOSES
Carry out a visual inspection of the clutch hydraulic hoses and hose Yes
clamps to see evidence of a leakage point. Rectify cause of fluid leakage or replace the
offending hose.
Was a leak evident at the hoses, joints or clamps?
No
Go to B3
B3 MASTER CYLINDER
Carry out a visual inspection of the master cylinder push rod plunger Yes
to cylinder area for signs of fluid leakage between push rod plunger Replace the clutch master cylinder. Refer to
and the entry point to the master cylinder. Section 308-02.
Was a leak evident? No
Go to B4
G56331 en 01/2003 2003.0 BA Falcon


B4 RETURN SPRING
Carry out visual inspection of the Return spring at the pedal pivot for Yes
damage. Replace the complete Pedal box assembly.
Was the return spring damaged or broken?
No
Go to B5
B5 OBSTRUCTION
Check for an obstruction that could causing the pedal not to return Yes
such as floor carpet, wiring harness jammed at the upper pivot area, Rectify cause of obstruction.
etc.
No
Was an obstruction found? There appears to be no issue with clutch pedal
return.
PINPOINT TEST C : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH
C1 PIVOT POINT BINDING OR "RASPY"

Remove the 2 x Torx head bolts used to retain the clutch master Yes
cylinder to the pedal box. Replace the clutch pedal / mount assembly.
Gently turn the flexible inlet hose to the master cylinder so that the it
is parallelWith the master cylinder body. This hose repositioning is No
carried out to enable the hose to pass through the master cylinder to Clutch pivot pin okay. Refit the clutch master
mounting opening. cylinder.
Gently withdraw the master cylinder (including flexible hose) through Go to the clutch diagnosis section for slave
the opening. Allow to hang loose. cylinder and pressure plate diagnostics.
Manually push on the clutch pedal to evaluate if any binding at the
pivot pin or "raspy" effect is felt.
Did you notice any binding or "raspy" feel?
G56331 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Clutch Bleeding
1. Reconnect all lines and hoses and ensure routing
is correct. ie. Ensure there are no kinks or
siphons present in the soft lines (especially the
reservoir line). This is extremely important as the
system will be difficult or impossible to bleed if
siphons exist.
2. Fill the clutch reservoir to Full mark and keep
filled above 1/4 full at all times during bleed
procedure.
3. Pump the clutch pedal at a moderate pace
through its full travel ensuring the pedal returns
fully up against it’s stop. Note that the pedal may
need to be pulled back manually by hand to fully
return. Rapid pedal returns can be of assistance if
the clutch appears difficult to bleed.
4. Continue to pump the clutch pedal in bursts of 10
pumps with a rest for 5 seconds (with pedal fully
returned) in between.
5. After 30 seconds to a minute some pedal feel
should exist, continue the pumping/resting cycle
until the pedal has come up fully (up to approx 5
minutes). Some rapid pumping at the end of this
time may improve the bleed slightly but is not
necessarily required.
6. If there is some initial sponginess or play in the
first part of pedal travel at this stage continue with
a CSC bleed. This is normally only required if the
CSC has been drained or replaced. Elevate the
vehicle to gain access to the underside of the
transmission and bleed the CSC manually by
depressing the pedal fully and holding it down
whilst an assistant opens and then closes the
bleed port on the side of the clutch housing
(similar process to manually bleeding the brakes).
Repeat until pumped fluid is not aerated (usually
2-4 strokes). Note that approx 3 full strokes will
almost empty the reservoir. Ensure that fluid
remains in the reservoir at all times or the
procedure may need to be started again.
7. The Clutch system should now be fully bled.
Ensure that the reservoir is filled to Full mark and
test drive the vehicle to ensure that the clutch is
disengaging properly and not dragging. Note that
the system is self-bleeding and some slight
improvement will occur in pedal feel and take-up
point after the vehicle has sat for a few hours or
overnight after the above bleed procedure. This is
normal as any emulsified air will coalesce and
bleed out automatically during this time.
G56332 en 01/2003 2003.0 BA Falcon

Clutch Pedal 3. Remove the push on decoupler from the clutch

pedal pin.
Removal
1. Remove two M6 nuts and bolts, Clutch assembly
can now be removed.
NOTE: Ensure that inserts in pedal box remain in
place.
4. Pull the clutch master cylinder forward until the

line clip is accessible. Remove the clip and
disconnect the line.
2. Clutch Master Cylinder is now free of bracket but

still retained on pedal by push-on fix.
Installation
Clutch Master Cylinder

WARNING: Clutch fluid contains polyglycol
ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If brake
fluid contacts eyes, flush eyes with running water 5. Disconnect the clutch master cylinder rod from the
for 15 minutes. Get medical attention if irritation clutch pedal arm. Remove the clutch master
persists. If taken internally, drink water and cylinder from the vehicle.
induce vomiting. Get medical attention
immediately.
CAUTION: Clutch fluid is harmful to painted

or plastic surfaces. If the clutch fluid is spilled
onto a painted or plastic surface, wash it
immediately with water.
1. Partially drain the clutch reservoir.
Drain to just below the clutch reservoir nipple.
2. Remove the hose at the clutch reservoir.
6. Remove the reservoir line from the clutch master

cylinder.
G56334 en 01/2003 2003.0 BA Falcon

7. To install, reverse the removal procedure. 5. To install, reverse the removal procedure.
Install new hose clamps on the reservoir line. 1. Position the clutch slave cylinder to the
Refill the brake master cylinder with the transmission and install the bolts.
specified fluid. 2. Bleed the clutch hydraulic system. For
Bleed the clutch hydraulic system. For additional information, refer to procedure in
additional information, refer to procedure in this chapter.
this chapter.
Clutch Hydraulic Fluid Tubes
Slave Cylinder Removal and Installation
WARNING: Clutch fluid contains polyglycol
1. Remove the transmission. For additional ethers and polyglycols. Avoid contact with eyes.
information, refer to Section 308-03. Wash hands thoroughly after handling. If brake
NOTE: Inspect the clutch housing for traces of fluid contacts eyes, flush eyes with running water
fluid. If brake fluid is visible, install a new clutch for 15 minutes. Get medical attention if irritation
slave cylinder. persists. If taken internally, drink water and
2. Remove the clutch slave cylinder. induce vomiting. Get medical attention
immediately.
2. Remove the clutch slave cylinder. CAUTION: Clutch fluid is harmful to painted
or plastic surfaces. If the brake fluid is spilled
onto a painted or plastic surface, wash it
immediately with water.
1. Partially drain the clutch reservoir.
Drain to just below the clutch reservoir nipple.
2. Remove the hose at the clutch reservoir.
3. Disconnect the hydraulic line from the clip on the
instrument panel.
1. Using a 3/32-inch punch and hammer, drive
out the roll pin and discard it.
2. Disconnect the hydraulic line.
4. Disconnect the hydraulic line from the clutch
master cylinder.
3. Inspect the clutch slave cylinder for the following: 5. Disconnect the lower end of the hydraulic line
1. Worn or damaged boot. from the clutch slave cylinder.
2. Leaking fluid. 6. Disconnect the hydraulic line from the clip on the
3. Contract and return smoothly. transmission.
NOTE: Make sure the O-ring is in the outlet port
CAUTION: The clutch release hub and or on the tube connector.
bearing is prelubricated and should not be 7. To install, reverse the removal procedure.
cleaned with solvent. The clutch release hub and
bearing are replaced as an assembly. Do not 8. Bleed the clutch hydraulic system. For additional
disassemble for inspection or replacement. information, refer to procedure in this chapter.
4. Inspect the clutch release bearing as follows:
1. Rotate the outer race while applying pressure.
If the bearing rotation is rough, install a new
clutch slave cylinder.
2. Inspect for wear or damage.
If wear pattern is continuous (not
segmented) and the wear appears to be
deep in bearing face, install a new clutch
slave cylinder.
G56334 en 01/2003 2003.0 BA Falcon

Clutch Reservoir
1. Remove the two M6 nuts securing the reservoir to
the reservoir bracket.
2. Remove the cap, drain the reservoir of all fluid

and replace cap.
3. Undo clamp on reservoir line and remove
reservoir.
4. To install, reverse removal procedure.
G56336 en 01/2003 2003.0 BA Falcon

308-03a-1 Manual Transmission — I6 308-03a-1
SECTION : 308-03a Manual Transmission — I6

CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................308-03a-3
Manual Transmission ..........................................................................................................308-03a-4
Manual Transmission .........................................................................................................308-03a-4
Manual Transmission ..........................................................................................................308-03a-8
Inspection and Verification .................................................................................................308-03a-8
Symptom Chart ..................................................................................................................308-03a-8
GENERAL PROCEDURES
Transmission Cleaning .....................................................................................................308-03a-10
Transmission Inspection ...................................................................................................308-03a-10
Aluminium Transmission Case Service ............................................................................308-03a-10
Taper Roller Bearings Inspection .....................................................................................308-03a-11
Fluid Level Check .............................................................................................................308-03a-11
Drain and Refill Transmission ...........................................................................................308-03a-11
Rear Extension Housing Oil Seal ......................................................................................308-03a-12
Shift Lever and Boot Assembly .........................................................................................308-03a-13
Speedometer Transducer and Drive Gear ........................................................................308-03a-14
Concentric Slave Cylinder (CSC) .....................................................................................308-03a-14
Transmission Damper .......................................................................................................308-03a-14
Reversing Light Switch .....................................................................................................308-03a-15
Transmission Cross - Member ..........................................................................................308-03a-15
REMOVAL
Special Service Tools .......................................................................................................308-03a-17
Transmission .....................................................................................................................308-03a-17
INSTALLATION
Transmission .....................................................................................................................308-03a-18
DISASSEMBLY
Transmission .....................................................................................................................308-03a-19
General .............................................................................................................................308-03a-26
Input Shaft Bearing ...........................................................................................................308-03a-26
Input shaft — to — output shaft bearing cup ....................................................................308-03a-27
Output Shaft ......................................................................................................................308-03a-28
Countershaft Bearing — Front ..........................................................................................308-03a-35
01/2003 2003.0 BA Falcon

(Continued)
Synchronizers ...................................................................................................................308-03a-36
Shift Cover ........................................................................................................................308-03a-37
Bearing Retainer Seal — Front .........................................................................................308-03a-40
ASSEMBLY
Transmission .....................................................................................................................308-03a-41
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Gear Ratios CSC to Pipe Fitting 14
XR6 T I6 & XR6 CSC Bleed Screw 8
First 2.95:1 3.35:1 Case to Flywheel Housing (retainer M8 21
Second 1.94:1 1.92:1 bolts)
Third 1.34:1 1.29:1 Case to Flywheel Housing (M12) 75
Fourth 1.00:1 1.00:1
Fifth 0.73:1 0.72:1
Reverse 2.76:1 3.15:1
Specified Clearances
Component Specification (mm)
Preload output shaft 0.01-0.1
1st Gear 0.18-0.33
2nd Gear 0.23-0.66
3rd Gear 0.23-0.58
5th Gear 0.13-0.86
Cluster shaft 0.013-0.102
Lubricant
I6 & XR6 XR6 T
Capacity 2.2 litre
Specification ESR-M2C-163A CASTROL
(DEXRON II) SYNTRANS B
(Ford R1-36)
2.05 litre
Oil Additive LubrizoI 7906 N/A
(150 ml)
Shift Turret
Colour Type Vehicle
Black Standard throw All I6 except
XR6 T
Gold Short throw XR6 T
Tightening Torques
Description Nm
Lower Boot Retainer 2
Shift Lever Bolts 37
Reversing Light Switch 37
Insulator to Extension Housing 50
Insulator to Crossmember 50
Crossmember to Body 50
Muffler Inlet Pipe Flange 35
Filler Plug 35
Extension Housing to Case 50
Reverse Spring Anchor Bolt 35
Flywheel Housing to Engine 65
Shift Lever Pivot Pin to Case 45
Shift Cover 10
Shift Turret to Ext. Housing 27
CSC to Flywheel Housing 9
G34500 en 01/2003 2003.0 BA Falcon

Manual Transmission
Manual Transmission
Three variants of the BTR T5 (M57) transmission are
used on the 6-cylinder BA Falcon range. The ABS &
non ABS standard I6 transmission models use a carry
over gearset (except for input shaft) and a standard
throw shifter turret is used. On the ABS model, the
speedo gear/tranducer ass’y is no longer required
and the signal is via the ABS sensors. The XR6 Turbo
model features a heavy-duty gearset, a short throw
shifter turret and a high performance transmission
lubricant.
On all BA 6-cylinder models the flywheel/clutch
housing incorporates the input bearing retainer into
the housing casting. A Concentric Slave Cylinder
(CSC) is mounted and bolted to the flywheel housing
supports. On the shifter turret, the gear shift lever bolt
mounting arrangement has been revised for all
models.
The M57 is a 5-speed manual transmission with 5th
speed as an overdrive gear. The 1st through 4th
gears and reverse gear are meshed within the case.
The 5th speed gear and synchronizer are located on
the back of the case in the extension housing where
the reverse brake is installed. The floor mounted shift
lever operates a shift rail which extends from the
extension housing turret to the shift cover. The
1st/2nd and 3rd/4th shift forks are mounted in the
cover. The 5th speed synchronizer and reverse sliding
gear are shifted through an intermediate lever
mounted on a pivot pin.
G34501 en 01/2003 2003.0 BA Falcon


1 Plug, Fill/Drain 5 Boot
2 Screw 6 Vent Cap
3 Control Lever & Housing Assy. 7 Vent & O-Ring Assy.
G34501 en 01/2003 2003.0 BA Falcon


10 Harness, Plastic 56 Fork, Shift, 5th
11 Bolt 57 Insert
12 Gear – Driving 58 Rail Assy., Shift
13 Bushing – Extension Housing 59 Gear, 5th Speed Drive
14 Connector Lead 60 Ring, Snap
15 Transducer Assembly (for non ABS 61 Gear, Speedo (Non ABS vehicles only)
vehicles only) 62 Clip, Speedo Gear (Non ABS vehicles
16 O-Ring only)
17 Retaining Clip 63 Bolt
18 Bolt 64 Flywheel Housing (contains input shaft
19 Extension, Bushing & Plate Assy. bearing retainer)
20 Plate, Detent Guide 65 Seal, Oil
21 Plug, Cup 66 Shim
22 Lever, Bonded Offset 67 Bearing Assy., Input Shaft
23 Isolator cup 68 Shaft, Input
24 Ball 69 Cup
25 Spring 70 Taper Roller Bearing
26 Seal, Oil 71 Circlip
27 Funnel, Oiling 73 Gear, 5th Driving
28 Bolt 74 Bearing Assy., Main Shaft Rear
29 Bolt, Alignment 75 Gear, 1st Speed
30 Pin, Selector Arm 76 Sleeve Assy., Bearing
31 Shaft, Shifter 77 Bearing
32 Fork, Shift, 3-4 78 Sleeve
33 Fork, Shift, 1-2 79 Ring Assy., Blocking
34 Insert 80 Synchronizer Assy., 3rd-4th
35 Arm Assy., Selector 81 Spring, Synchronizer
36 Plate, Interlock 82 Sleeve, Synchronizer
37 Plate, Selector 83 Insert
38 O-Ring 84 Hub, Synchronizer
39 Plug 85 Gear, 3rd Speed
40 Cover, Case 86 Bearing
41 Ring, Retaining 87 Spacer
42 Pin, Pivot 88 Ring, Snap
43 Switch, Back-Up 89 Washer, Thrust
44 Bolt, Spring Anchor 90 Gear, 2nd Speed
45 Lever, Shift, 5-R 91 Bearing, 2nd Speed
46 Ring, Snap 92 Spacer
47 Spacer, Rev. Cone 93 Shaft Assy., Output
48 Cone, Reverse 94 Ring, Spiral Retaining
49 Ring, Blocking 95 Washer, Thrust
50 Synchronizer Assy., 5th 96 Cone, Inner
51 Spring, Synchronizer 97 Race, Outer Cone
52 Sleeve, Synchronizer 98 Ring, 1-2 Blocking
53 Insert 99 Spring
54 Hub, Synchronize 100 Gear, Reverse Sliding
55 Pin, Roll 101 Insert
G34501 en 01/2003 2003.0 BA Falcon

Item Description
102 Ball
103 Shaft and Hub Assy.
104 Spring
105 Fork, Pin & Roller Assy., Reverse
106 Bolt
107 Retainer, Rear
108 Shim
109 Pin, Roll
110 Shaft, Reverse Idler
111 Gear, Reverse Idler
112 O-Ring
113 Bearing Assy., Countershaft Rear
114 Bearing Assy., Countershaft Front
115 Gear, Countershaft
116 Case Assy., Transmission
117 Bush
118 Concentric Slave Cylinder & lines
119 Screw
120 Hose Clip
Reverse Brake
The reverse brake is applied through the 5th synchro
sleeve. This stops the rotation of the cluster gear
before the reverse idler is engaged eliminating gear
clash when the vehicle is stationary and reverse gear
is selected.
The spacer slides onto the cluster spline and rotates
with it. A snap ring holds the reverse brake
components in position. The tab on the reverse cone
locates into a recess in extension housing adjacent to
the lubrication funnel.
A shift interlock system, located in the cover prevents
engagement of more than one gear. The shift detent
is located in the extension housing turret and consists
of a detent plate, offset lever and spring loaded ball.
All gears except reverse are synchronized and helical
cut for smooth, crisp shifts and quiet operation.
Reverse is provided through a reverse idler gear
which slides along a shaft to engage spur gears on
the countershaft and output shaft. The case is
aluminium and all fasteners are metric.
G34501 en 01/2003 2003.0 BA Falcon

Gear rollover noise will disappear when the clutch is

Manual Transmission disengaged or when the transmission is engaged in
gear. In the event that a transmission bearing is
Inspection and Verification damaged, the noise is more pronounced while
NOTE: Gear rollover noise, inherent in manual engaged in gear under load or coast conditions than
transmissions, (caused by the constant mesh gears in NEUTRAL. When concerns of this nature are
turning at engine idle speed while the clutch is encountered, it will be necessary to road test the
engaged and the transmission is in NEUTRAL), and vehicle to determine if bearing noise exists. Under no
clutch release bearing noise are sometimes mistaken circumstances should any transmission rework be
for mainshaft bearing noise. Noise caused by a worn attempted to eliminate gear rollover noise, or clutch
or damaged clutch release bearing will be loudest release bearing noise.
when the clutch is held disengaged.
Symptom Chart

Transmission Noisy in Gear Lubricant level low or wrong type. Remove transmission. If noise is
howling during start-up, check pilot
bushing. Check for loose flywheel and
housing alignment. Service or replace
as required. Refer to Section 308-01.
Transmission to flywheel housing and Fill to bottom of filler plug hold with
flywheel housing to engine block bolts proper lubricant.
loose.
Pilot bushing worn or damaged. Tighten bolts to 61-88 N-m (45-65

lb-ft).
Improper transmission pilot Replace housing or input shaft bearing
engagement into flywheel housing. retainer as required. Refer to Section
308-01.
Worn or damaged internal Disassemble transmission. Inspect
components. Input, output and countershaft
bearings, gear and gear teeth for wear
and damage. Service or replace as
required.
Transmission Leaks Excessive amount of lubricant in Check level and type. Fill to bottom of
transmission–wrong type. filler plug hole.
Other component(s) leaking. Identify leaking fluid at engine, power

steering and/or transmission.
False report. Remove all traces of lubricant on

exposed transmission surfaces. Check
vent for free breathing. Operate
transmission and Inspect for new
leakage. Service as required.
Worn or damaged Internal Remove transmission. Inspect for
components. leaks at the input shaft bearing retainer
seal and gasket, shift rail expansion
plug top cover gasket. Inspect case for
sand holes. Service or replace as
required.
Inadequate thread sealant on threads. Apply sealant to bolt threads.
Transmission difficult to shift Improper clutch release. Refer to Section 308-01 for clutch
servicing procedures.
Internal shift mechanism binding. Remove transmission and free up shift

mechanism.
Synchronizer sleeve to hub fit. Remove and check for burrs or fit.
G34502 en 01/2003 2003.0 BA Falcon


Binding condition between input shaft Check alignment and service as
and crankshaft pilot bearing. required. Refer to Section 308-01.
Improper fluid. Drain and refill with specified fluid

(refer Specifications section).
Gears Clash When Shifting from One Engine idle speed too high. Adjust engine idle speed.
Forward Gear to Another
Improper clutch release. Ensure complete clutch release. Refer

to Section 308-01 for clutch servicing
procedures.
Binding condition between Remove transmission and replace pilot
transmission input shaft and crankshaft bushing. Refer to Section 308-01.
pilot bushing.
Worn or damaged shifter forks, Service or replace as required.
synchronizer assembly, or gear clutch
teeth.
Transmission Jumps Out of Gear Stiff or improperly installed boot. Verify Jump-out with boot removed.
Replace boot if necessary.
Interference between shift handle and Adjust console to eliminate
console. interference.
Transmission to engine mounting Tighten bolts to specification.
loose.
Flywheel housing to engine crankshaft Replace parts as required. Refer to
out of alignment. Section 308-01.
Improper engagement between Replace parts as required. Refer to
transmission pilot and flywheel Section 308-01.
housing.
Input shaft pilot bearing worn. Replace pilot bearing. Refer to Section
308-01.
Worn or damaged internal Check input and output shafts for
components. excessive end play, shift forks for
loose mounting on shift rails, worn
pads, shift rail detent system for wear
or damage, synchronizer sliding sleeve
and gear clutch teeth for wear or
damage. Service or replace as
required.
Transmission Will Not Shift Into One Floor shift, interference between shift Adjust console or cut out floorpan to
Gear – All Other Gears OK handle and console or floor cut out. eliminate interference.
Restricted travel of internal shifter Remove transmission. Inspect shift rail
components. and fork system, synchronizer system
and gear clutch teeth for restricted
travel. Service and replace as
required.
Transmission is Locked in One Gear. It Internal shifter components worn or Remove transmission. Inspect the
Cannot be Shifted Out of that Gear damaged. problem gear or gearshift rails and fork
and synchronizer for wear or damage.
Service or replace as required.
Selector arm finger broken. Remove transmission. Replace

selector arm assembly.
Bent shifter forks at pads and selector Service or replace as required.
slot.
Transmission Will Not Shift Into Worn or damaged internal Remove transmission. Check for
Reverse (All Others OK) components. damaged reverse geartrain, misaligned
reverse relay lever, shift rail and fork
system
G34502 en 01/2003 2003.0 BA Falcon

308-03a-10 Manual Transmission/Transaxle — I6 308-03a-10
GENERAL PROCEDURES
Transmission Cleaning 12. Inspect the synchronizer blocking rings for

widened index slots, rounded clutch teeth, and
1. Wash all parts except ball bearings, O-rings and smooth internal surfaces (must have machined
seals in a suitable cleaning solvent. Brush or grooves). With the synchronizer blocking ring on
scrape all foreign matter from the parts. Be careful the cone, the distance between the face of the
not to damage any parts with the scraper. synchronizer blocking ring and the clutch teeth on
the gear must not be less than 0.5mm (0.020
CAUTION: Do not clean, wash or soak inch).
transmission seals in cleaning solvents. Dry
all parts with compressed air. 13. Replace speedometer drive gear (where fitted) if
teeth are stripped or damaged. Make certain to
2. Rotate ball bearings in a cleaning solvent until all install correct size replacement gear.
lubricant is removed. Hold bearing assembly to
prevent it from rotating and dry it with compressed 14. Replace the output shaft if there is any evidence
air. of wear or if any of the splines are damaged.
3. Lubricate bearings with Multi-Purpose Grease and 15. Inspect bushing and seal in the extension
wrap them in a clean, lint-free cloth or paper until housing, and replace if worn or damaged. The
ready for use. bushing and/or seal should be replaced after the
extension housing has been installed on the
4. Clean the magnet in the bottom of the case with transmission.
kerosene or mineral spirits.
16. Replace the seal in the input shaft bearing
Transmission Inspection retainer.
1. Inspect transmission case for cracks, worn or 17. Replace seals on the cam and shafts.
damaged bearing bores, damaged threads, or any
other damage that could affect operation of the
transmission.
2. Inspect the front face of the case for small nicks
or burrs that could cause misalignment of the
transmission with the flywheel housing. Remove
all small nicks or burrs with a fine file.
3. Replace any cover that is bent or distorted. Make
sure that the vent hole in the cover is open.
4. Check the condition of the shift levers, forks, shift
rails, and the lever and shafts.
5. Inspect the bearings. Refer to Bearing Inspection.
6. Replace roller bearings that are broken, worn or
rough, and check their respective races.
7. Replace the countershaft (cluster) gear if the teeth
Aluminium Transmission Case Service
are chipped, broken or worn. Replace the NOTE: If an aluminum transmission case thread is
countershaft if it is bent, scored or worn. damaged, service kits may be purchased from local
8. Replace the reverse idler gear or sliding gear if jobbers. To service a damaged thread, the following
the teeth are chipped, worn or broken. Replace procedures should be carefully followed.
the idler gear shaft if bent, worn or scored. 1. Drill out the damaged threads, using the same
9. Replace the input shaft and gear if the splines are drill size as the thread OD. For example, use a
damaged or if the teeth are chipped, worn or 16mm drill for a M16x1.5 thread.
broken. If the roller bearing surface in the bore of 2. Select the proper special tap and tap the drilled
the gear is worn or rough, or if the cone surface is hole. The tap is marked for the size of the thread
damaged, replace the gear and the gear rollers. being serviced. Thus, the special tap marked
10. Replace all other gears that are chipped, broken M16x1.5 will not cut the same thread as a
or worn. standard M16x1.5 tap. It does cut a thread large
11. Check the synchronizer sleeves for free enough to accommodate the insert, and after the
movement on their hubs. Make sure that the insert is installed the original thread size
alignment marks (if present) are properly indexed. (M16x1.5) is restored.
G34503 en 01/2003 2003.0 BA Falcon

3. Select the proper coil inserting tool. These tools 3. Clean the plug, inspect the gasket condition and
are marked with the thread size being serviced. replace where necessary.
Place the insert on the tool and adjust the sleeve 4. Install the plug.
to the length of the insert being used. Press the
insert against the face of the tapped hole. Turn Drain and Refill Transmission
the tool clockwise and wind the insert into the
hole until the insert is one-half turn below the 1. Clean the area around the drain and filler plugs.
face. 2. Remove the drain and filler plugs.
4. Working through the insert, bend the insert tang 3. Clean the drain and filler plugs. (Apply pipe
straight up and down until it breaks off at the sealant with Teflon to the plug threads.)
notch. 4. Install the drain plug.
5. Improperly installed inserts can be removed with 5. With the vehicle on a level surface fill the
the extractor tool. Place the extractor tool in the transmission to the bottom of the filler plug hole
insert so that the blade rests against the top coil with the specified transmission oil.
one-fourth to one-half turn away from the end of
6. Install the filler plug.
the coil. Tap the tool sharply with a hammer so
that the blade cuts into the insert. Exert downward
pressure on the tool and turn it counterclockwise
until the insert is removed.
These tools are marked with the thread size being
serviced. Place the insert on the tool and adjust
the sleeve to the length of the insert being used.
Press the insert against the face of the tapped
hole. Turn the tool clockwise and wind the insert
into the hole until the insert is onehalf turn below
the face.
Taper Roller Bearings Inspection

NOTE: It is recommended to replace all bearings
during a major overhaul of the gearbox. The cost of
removing and disassembling transmissions is too high
to run the risk of bearing damage after they have
been put back together.
1. If it is desired to reuse bearings, the cone
assembly must not be removed from the
component. The bearings should be inspected for
the following damage:
Discolouration of surfaces by heat.
Excessive pitting and bruising caused by
foreign material.
Etching or corrosion.
Spalls from fatigue of metal.
Scoring of roller ends due to inadequate
lubrication.
Damaged bearing cage.
Gauges or nicks on bearing surfaces.
NOTE: The bearing should be replaced as a unit. Do
not replace cup or cone assembly only.
Fluid Level Check

1. Clean around the filler plug and remove the plug.
2. If lubricant does not flow from the filler hole, fill the
case with the specified lubricant until it is level
with the bottom of the filler hole with vehicle in a
level position.
G34510 en 01/2003 2003.0 BA Falcon

Removal
Rear Extension Housing Oil Seal
1. Remove driveshaft. Refer to Section 205-01.
Special Tool(s) WARNING: Failure to match marks when
Impact slide hammer re-assembling the driveshaft may induce
100-001 driveline vibration.
NOTE: Before dis-assembly, mark the matching
points on slip yoke and transmission output shaft.
Mark the mating points on bolt, yoke flange,
companion flange, nut and balance nut (if fitted).
Re-assemble with matching points matched ± 1
spline, and all mating hardware in original hole.
Seal remover
307-365 NOTE: Do not hang the driveshaft from the
transmission extension housing as this may
damage the extension housing oil seal and/or
bush.
2. Remove oil seal from extension housing with
impact slide hammer and seal remover.
Extension housing seal replacer
308-260 (E9321)
Installation 4. Remove any contaminants from the driveshaft slip

1. Lubricate extension housing oil seal bore by yoke’s working surface before re-installingit into
wiping with approved lubricant. the transmission extension housing.
2. Using seal replacer, push oil seal into extension NOTE: During installation of the driveshaft into
housing flush of housing rear face. transmission, plunge the slip yoke the minimum
distance into the extension housing to avoid slip
3. Lubricate oil seal lips with approved fluid. yoke radius damaging oil seal.
G34511 en 01/2003 2003.0 BA Falcon

3. Working through the console aperture remove the

one bolt and one nut securing the shift lever to the
transmission and remove the lever.
WARNING: Failure to match marks when

re-assembling the driveshaft may induce driveline
vibration.
NOTE: Before dis-assembly, mark the matching
points on slip yoke and transmission output shaft.
Mark the mating points on bolt, yoke flange,
Shift Lever and Boot Assembly

Removal
1. Unscrew the gearshift knob from the gear lever.
2. Gently prise the boot retaining panel from the
console and lift the boot and retainer from the
lever. For more information refer to Manual
Transmission Ecternal Control 308-06.
Item Description
1 Lever Knob
2 Lever Locator
3 Bolt
4 Nut
5 Transmission Stalk Sleeve
6 Plate
7 Bolt Locator (with bolt stud)
8 Nut
9 Shift Lever
10 Boot Assembly
Installation
1. Position the shift lever on the left hand side of the
transmission lever, install and torque the bolts to
specification.
2. Push yellow foam block down firmly over lever join
to its home position. Make sure the "L" printed on
foam block faces passenger side.
3. Locate the boot and retainer over the shift lever
and press the retainer lugs into the console.
G34512 en 01/2003 2003.0 BA Falcon

4. Apply loctite to threads. Screw the knob onto the 2. Detach the fluid hose from the mounting clips and
shift lever until it starts to tighten, continue extricate it from the flywheel housing.
tightening until the graphics on the knob are
correctly aligned.
Speedometer Transducer and Drive

Gear
Removal
NOTE: Only vehicles not fitted with ABS utilise a
transmission driven speedometer transducer, hence
the following removal/installation procedures are
pertinent only to such vehicles.
2. Disconnect the wiring plug.
3. Remove the transducer.
3. Using a T30 Torx® driver remove the two CSC
4. Pry off the retaining clip and remove the gear. mounting bolts that attach the CSC to the flywheel
5. Remove the ’O’ ring seal. housing.
1. Install the ’O’ ring. 1. Place the CSC in the position shown and install
2. Install the gear and the retaining clip. the two CSC mounting bolts. Torque to
3. Lubricate the seal and gear with transmission oil. specification.
4. Install the transducer into the housing and 2. Route the CSC hydraulic hose in the orientation
connect the wiring. shown and tighten the CSC-to-hydraulic hose
fitting. Torque to specification.
5. Lower the vehicle. NOTE: Ensure the hydraulic hose is mounted in
Concentric Slave Cylinder (CSC) the clips located on and in the flywheel housing.
Removal Transmission Damper

NOTE: Before the CSC can be removed the Removal
transmission must be removed from the vehicle and
1. Undo the nuts on the three transmission damper
the clutch bled according to the procedure setout in
Section 308-01. mounting bolts.
2. Remove the transmission damper mounting bolts.
1. Undo and disconnect the CSC fluid hose from the
CSC using a suitable 10-mm spanner. 3. Detach the damper and mounting bracket from
the transmission extension housing.
Installation
1. Position the transmission damper and bracket
such that the holes in the bracket line up with the
holes in the extension housing.
2. Insert the three transmission damper mounting
bolts through the aligned holes in the damper
bracket and extension housing.
3. Thread the damper mounting nuts onto the bolts.
Torque to specification.
NOTE: The damper mounting nuts are of the
Nyloc® variety and should be replaced each time
the transmission damper is removed.
Item Description
1 Hose Clip
2 CSC-to-Hose fitting
3 Bleed Screw
G34512 en 01/2003 2003.0 BA Falcon

Reversing Light Switch 5. Detach the transmission-to-isolator mounting plate

from the transmission, remove the nuts from the
Removal two mounting bolts numbered (3).
1. Disconnect the wiring plug and remove the switch
from the left hand side of the case with a 22 mm
socket.
Installation
1. Clean the threads of the switch and apply pipe
sealant with Teflon to the threads.
2. Install the switch and torque to specification.
Transmission Cross - Member

Removal
1. Raise the vehicle on a hoist and support the
transmission on a trolley jack.
2. Remove the four cross-member to chassis
mounting bolts.
3. Unscrew the isolator-to-cross member mounting Item Description
nut (numbered (6)) from the bolt numbered (2) in 1 Isolator-to-Cross Member Bracket
the figure below, together with the two bolts
numbered (5). 2 Bolt - (M10x89) Wafer HD
4. Remove and disassemble the cross 3 Bolt - (M8x46)x2 Wafer HD
member-to-isolator assembly. 4 Insulator Element
5 Nut - (M10x1.25)
6 Bolt - (M10x1.5x25)x2
7 Screw - (M10x50)x4 (Trilobial)
8 Transmission Cross Member
9 Transmission-to-Isolator Mounting Plate
10 Nut - (M8x1.25)
Installation
1. Position the transmission-to-isolator mounting
plate in the orientation shown and attach it to the
transmission by installing the two mounting bolts
numbered (3) and mating nuts (numbered (10)).
Torque nuts to specification.
NOTE: Ensure that the isolator to cross-member
bolt (numbered (2)) is installed in the mounting
plate before affixing it to the transmission.
G34530 en 01/2003 2003.0 BA Falcon

2. Assemble the cross member isolator assembly

and attach it to the transmission isolator mounting
plate.
3. Install the two screws numbered (5) and attach
the nut numbered (6). Torque all screws and nuts
to specification.
4. Using a transmission jack, ensure that the
transmission cross member is aligned with the
mounting points on the underside of the chassis.
5. Install the two cross-member-to-chassis mounting
screws (numbered (7)). Torque screws to
specification.
G34530 en 01/2003 2003.0 BA Falcon

REMOVAL
Special Service Tools WARNING: Failure to match marks when

re assembling the driveshaft may induce
Tool Number Description driveline vibration.
T40 Torx Bit (Countershaft) NOTE: Before disassembly, mark the matching
E1673U15A Puller Adaptor (Use with points on the slip yoke and transmission output
E1673P or E1673MT) shaft. Mark the mating points on the CV flange,
T50 Torx Bit (Pivot Pin) companion flange, nut and balance nut (if fitted).
E9319 Snap Ring
Expander/Installer
E9320 Input Shaft Seal Installer 8. Bleed the concentric slave cylinder (CSC)
Kit according to the procedure set out in section
308-01. Disconnect the CSC hydraulic clutch line
E9318 Countershaft Bearing
from the firewall.
Cup
Remover/Installer WARNING: Failure to support CSC
E7518B Bearing Installation Tool connector during tightening or loosening of
(Countershaft) bleed screw may result in damage to CSC.
Attachment for E7511-A 9. Remove the starter motor bolts and remove the
Handle motor.
E9322 Dial Indicator Mounting 10. Support the engine and transmission assembly
Rod with a transmission jack.
E1673P or E1673MT Puller (Use with 11. Remove the bolts securing the transmission
E1673U15A) cross-member to the body.
E7511A Countershaft Bearing 12. Lower the transmission jack until the rear of the
Installer (Handle) engine rests against the bulkhead.
E9321 Extension Housing 13. Disconnect the reversing light switch and, where
T30 Torx Bit (CSC) necessary, the speedometer transducer.
14. The engine must be tilted down at the
Transmission transmission and before removing the flywheel
housing-to-engine bolts. Raise the vehicle’s
Removal bonnet before tilting the engine or else the bonnet
1. Unclip the console cover to access the gear may be damaged. The engine can be tilted by
shifter prior to removing the gearshift boot, either:
insulating foam and lever. 1. jacking up the front end or
2. From inside the vehicle, remove the gearshift 2. using a harness to pull down the rear of the
boot, insulating foam and lever. motor.
3. Raise the vehicle on a hoist. 15. Remove the flywheel housing-to-engine bolts.
4. The exhaust should be removed from the outlet
manifold and unbolted from the vehicle. WARNING: Do not seperate transmission
5. Detach the exhaust from the hanger bracket on from vehicle engine by removing the 4
the transmission damper. transmission case bolts.
6. After removing the exhaust, drain the clutch
reservoir of all fluid into a container. This is to
stop any change of the fluid dripping on to the
exhaust when it is re-installed into the vehicle.
7. Mark the driveshaft so that it may be installed in
the same relative position.
Disconnect the shaft at the centre bearing mount,
by detaching the centre bearing bracket from the
centre bearing carrier (cross member) and detach
the rear CV joint from the diff pinion companion
flange, by undoing the bolts. Slide the driveshaft
backwards, until the slip yoke slides off the output
shaft. Install a dust cover or extension housing
seal replacer into the extension housing to
prevent lubricant leakage.
G34518 en 01/2003 2003.0 BA Falcon

REMOVAL (Continued)
16. Move the transmission rearward until the input

shaft clears the pressure plate housing, then
lower the jack and remove the transmission.
NOTE: Removal of transmission from vehicle is
easier if the front of the engine is jacked up
carefully to tilt the transmission down at the rear.
Item Description
1 Bolt (M8) x2
2 Bolt (M10x50) x4
3 Screw (M10x50) x4 (Trilobial)
G34518 en 01/2003 2003.0 BA Falcon

INSTALLATION
Transmission the markings on the CV joint and companion

flange mate up.
Installation Finally, bolt the centre-bearing bracket to the
1. Place the transmission on a transmission jack. centre-bearing cross member. Torque all bolts to
specification. Ensure any shims are re-used in
NOTE: The CSC, CSC hydraulic line,
original location.
transmission damper and transmission cross
member must be attached to the transmission 13. Attach the exhaust to the mounting bracket on the
before installation can proceed. transmission damper, via the rubber isolator.
14. Connect the exhaust to the outlet manifold. The
2. The engine must be tilted down before the
exhaust should not be fitted prior to the CSC
transmission can be moved into position. Raise
being reconnected and bled otherwise brake fluid
the vehicle’s bonnet before tilting the engine. The
will drip down onto the catalyst converter.
engine can be tilted by either:
1. jacking up the front end or
16. From inside the vehicle, install the gearshift lever,
2. using a harness to pull down the rear of the
insulator foam and boot.
motor.
3. Using a jack, raise the transmission and move it
forward until the flywheel housing locates on the
engine guide pins, ensuring that the spline on the
input shaft slides through the hub on the clutch
disc and the end of the shaft locates in the spigot
(pilot) bearing in the crankshaft.
NOTE: Installation of transmission into the vehicle
is easier if the front of the engine is jacked up
carefully to tilt the transmission down at the rear.
4. Install the flywheel housing to engine bolts.
Torque all bolts to specification.
5. Connect the wiring to the reversing light switch
and, where necessary, the speedometer
transducer.
6. Install the starter motor and mounting bolts.
Torque to specification.
7. Raise the transmission using the jack until the
transmission cross member rests against the
chassis.
8. Install the bolts securing the transmission cross
member to the chassis. Torque to specification.
9. Remove the transmission jack.
10. Attach the CSC hydraulic clutch line to the firewall
and charge the clutch system with fluid according
to the procedure set out in Section 308-01.
11. Remove any contaminants from the driveshaft slip
yoke’s working surface before re-installing it into
the transmission extension housing.
NOTE: During installation of the driveshaft into
transmission, plunge the slip yoke the minimum
distance into the extension housing to avoid slip
yoke radius damaging oil seal.
12. Install the driveshaft. Ensure that the markings on
the transmission output shaft and slip yoke line
up, before sliding the slip yoke over the
output shaft and that the centre bearing bracket
mates up with the centre bearing cross member.
Once the driveshaft is connected to the
transmission, bolt the rear CV joint to the
differential pinion companion flange, ensuring that
G34529 en 01/2003 2003.0 BA Falcon

DISASSEMBLY
Transmission 4. Using a 12-mm double-hex head socket remove

the four main case-to-flywheel housing bolts and
Disassembly detach the transmission from the flywheel
1. Mount the transmission (with flywheel housing housing.
attached) in a bench-mounted holding fixture or
equivalent.
2. Using a 3/8-inch drive ratchet and extension,
remove the drain plug located on the right hand
side of the transmission case.
3. Remove the CSC unit as Removal of Concentric

Slave Cylinder in Chapter Section 308-01.
Remove the four integral flywheel housing-to-main
case bolts located between the CSC mounting
bosses.
WARNING: Using an 11mm spanner,
restrain the steel female fitting in the CSC
whilst undoing the mating tube fitting to avoid
damaging the CSC
NOTE: The input shaft bearing carrier is integral
within the flywheel housing. Removal will result in
partial disassembly of the transmission main case.
5. Remount the transmission in the holding fixture.
6. Using a 13mm socket, position shift lever in
NEUTRAL position and remove turret cover
retaining bolts.
G34519 en 01/2003 2003.0 BA Falcon

7. Using a suitable pry bar, break turret 9. Using a 15mm socket, remove the eight extension
cover-to-extension housing seal by prying housing retaining bolts.
carefully between housing and cover. Remove
turret cover.
CAUTION: Do not attempt to remove the
bonded offset lever while the extension
housing is bolted in place. A lug, located at
the bottom of the bonded offset lever, meshes
with the detent plate preventing enough
rearward movement of the bonded offset lever
to allow removal.
10. Using a suitable pry bar, break extension

housing-to-case seal by prying carefully between
housing and case.
8. Using a suitable pin punch and hammer, remove

roll pin retaining bonded offset lever to shifter
shaft.
11. Remove extension housing and bonded offset

lever as an assembly by sliding rearward away
from case.
G34519 en 01/2003 2003.0 BA Falcon

12. Remove offset lever, roll pin, detent spring and 15. To remove shift cover, lift it slightly and slide to
detent ball from extension housing detent plate. filler plug side of transmission. When shift
mechanism clears groove in fifth/reverse shift
lever, continue lifting cover.
13. Using a 10mm socket, remove shift cover

retaining bolts.
16. Support fifth/reverse shift rail assembly with a
block of wood and drive out roll pin from fifth gear
shift fork with a suitable pin punch.
14. Using a suitable pry bar, break cover-to-case seal

by prying carefully between cover and case.
17. Using snap ring pliers, remove fifth gear

synchronizer snap ring retainer, splined washer,
reverse cone and synchronizer blocking ring from
rear of countershaft.
G34519 en 01/2003 2003.0 BA Falcon

18. Remove fifth gear, synchronizer and shift fork as 22. Rotate fifth/reverse shift rail clockwise to
an assembly. disengage ball stud from fifth/reverse shift lever.
Pull fifth/reverse shift rail rearward slightly and
rotate shift rail counter clockwise to align ball stud
with slot in case and remove shift rail.
19. Using long needlenose pliers, remove C-clip

retaining fifth/reverse shift lever to lever pivot pin.
23. Press downward on speedometer gear retaining

clip and slide gear off output shaft. Remove
retaining clip.
20. Remove fifth/reverse shift lever pivot pin with Torx

® bit driver. Do not remove the fifth/reverse shift
lever at this point.
21. Using a 22mm wrench, remove the backup lamp
switch. 24. Rotate input shaft until flat on 4th gear clutching
teeth aligns with countershaft. With input shaft
properly aligned, remove it from case.
G34519 en 01/2003 2003.0 BA Falcon

25. Remove fourth gear synchronizer blocking ring 28. Remove fifth/reverse shift lever, reverse shift fork
from the third/fourth synchronizer. and reverse positioning spring from case by
NOTE: If the race sticks, it is probably misaligned grasping lever and lifting straight up as an
in the case bore. To free the race, work the shaft assembly. If case replacement is necessary,
back and forth in the case. remove reverse positioning spring anchor pin by
removing the Tizz bushing from the anchor bolt
head and then removing the anchor bolt.
26. Remove output shaft bearing race from rear of

case. To partially remove bearing race, pull
rearward on output shaft until first gear stops 29. Using a suitable pin punch and hammer, remove
against case. roll pin from reverse idler shaft.
27. Tilt output shaft assembly upward and lift out of 30. Remove reverse idler shaft by sliding it out of
case. back of case. Remove reverse idler gear and
NOTE: Observe location of shift lever, shift fork overtravel rubber stop from case.
and inhibitor spring prior to removal. Also observe
the rotation action of the reverse positioning
spring during removal. This will be helpful during
assembly.
G34519 en 01/2003 2003.0 BA Falcon

31. Using a hammer and Locknut Staking Tool flatten 34. Remove rear countershaft bearing race from
tabs on countershaft retainer at all four corners. countershaft.
NOTE: If the race sticks, it is probably misaligned
in the case bore. To free the race, work the shaft
back and forth in case.
32. Using a T40 Torx® driver, remove four bolts from

countershaft retainer.
35. Install Front Hub Remover/Replacer and Bearing

Pulling Attachment or equivalent to the
countershaft with the jaws behind the countershaft
bearing, and remove bearing.
33. Remove countershaft retainer and shim(s).
36. Move countershaft rearward through bearing bore.

Tilt assembly upward and remove from case.
G34519 en 01/2003 2003.0 BA Falcon

Disassembly
General
1. Using a press and Pinion Bearing Cone Remover
NOTE: The following transmission subassembly or equivalent, remove input shaft bearing.
procedures should be performed only when
necessary. After carefully inspecting each
subassembly, disassemble only those requiring
component replacement or further inspection.
Input Shaft Bearing

Special Tool(s)
Differential Side Bearing
Replacer
205-412
Pinion Bearing Cone Replacer

205-408-01
G34520 en 01/2003 2003.0 BA Falcon

Assembly Special Tool(s)

1. Using a press and a capped length of pipe, install Bearing Cone Replacer
input shaft bearing. 205-412
Disassembly
1. Using Bearing Cup Puller and Slide Hammer or
equivalent, remove bearing cup.
Input shaft — to — output shaft

bearing cup
Special Tool(s)
Bearing Cup Puller
205-408
Slide Hammer D80L

205-102
G34522 en 01/2003 2003.0 BA Falcon

Assembly Special Tool(s)

1. Using Bearing Cone Replacer, press bearing cup Bearing Pulley Attachment
in input shaft pocket. 205-408-01
CAUTION: Make sure bearing cup is fully
seated.
Disassembly
1. Using Bearing Pulling Attachment or equivalent,
press off input shaft-to-output shaft taper roller
bearing.
Output Shaft
Special Tool(s)
205-411
2. Remove snap ring.
Spiral Snap Ring Replacer

308-259
G34522 en 01/2003 2003.0 BA Falcon

3. Using a press and Pinion Bearing Cone Remover 5. Remove fifth gear snap ring.
or equivalent, remove 3rd/4th synchronizer, 3rd
speed blocking ring, and 3rd gear as an
assembly.
6. Using a press and Pinion Bearing Cone Remover

or equivalent, remove fifth gear.
4. Remove needle bearing assembly and spacer

from output shaft.
G34523 en 01/2003 2003.0 BA Falcon

7. Remove output shaft rear bearing. 10. Remove ball using a pencil magnet.
NOTE: There is a snug fit between the sleeve and
the output shaft.
11. Remove three-piece first gear synchronizer

blocking ring assembly from output shaft.
8. Remove first gear.
12. Remove second gear snap ring and thrust

washer.
9. Remove needle bearing assembly and sleeve.
G34523 en 01/2003 2003.0 BA Falcon

13. Remove second gear from output shaft. 16. Remove spiral snap ring and thrust washer from
output shaft.
14. Remove second gear needle bearing assembly

and spacer. 17. Remove three-piece second gear synchronizer
blocking ring assembly.
Remove 1st/2nd synchronizer from output shaft.
15. Disengage spiral snap ring from slot in output

shaft using a small screwdriver.
Assembly
1. Install 1st/2nd synchronizer assembly, and
three-piece 2nd gear synchronizer blocking ring
assembly onto output shaft.
NOTE: Align slots in synchronizer blocking ring
with tabs in 1st/2nd synchronizer.
For synchronizer assembly, refer to Synchronizer
Disassembly and Assembly.
G34523 en 01/2003 2003.0 BA Falcon

2. Install thrust washer onto output shaft. Install 5. Install second gear thrust washer and snap ring
spiral snap ring using Spiral Snap Ring Replacer. using snap ring pliers.
3. Install second gear needle bearing and spacer. 6. Install three-piece first gear synchronizer blocking
ring assembly onto output shaft.
NOTE: Align slot in first gear synchronizer
blocking ring with tab on 1st/2nd synchronizer.
4. Install second gear onto output shaft.

NOTE: Align slots in second gear with tabs on
synchronizer blocking ring assembly.
7. Drop ball into output shaft.
NOTE: Use pencil magnet if necessary.
G34523 en 01/2003 2003.0 BA Falcon

8. While aligning notch in sleeve with ball, slide 11. Lubricate fifth gear splines with petroleum jelly
sleeve onto output shaft. Install needle bearing and position on output shaft. Using a press and a
assembly over sleeve. capped length of pipe, 31.75mm ID x 356mm (1 1
/4 inch ID x 14 inch) press fifth gear onto output
shaft.
9. Install first gear onto output shaft.

NOTE: Align slots in first gear with tabs on first
gear synchronizer blocking ring assembly.
10. Install rear output shaft bearing onto output shaft. 12. Using snap ring pliers, install fifth gear snap ring.
The bearing taper must face the rear of the shaft.
CAUTION: Ensure the output shaft and gear

splines are carefully aligned. If splines are
improperly aligned, damage could occur when the
gear is pressed onto the output shaft.
G34523 en 01/2003 2003.0 BA Falcon

13. Install spacer and split needle bearing assembly 15. Install snap ring.
onto output shaft.
16. Press on input shaft-to-output shaft taper roller

14. Using a press and a 1 1 /2 inch deep well socket, bearing.
install 3rd/4th synchronizer, third gear
synchronizer blocking ring and third gear as an CAUTION: Make sure bearing is fully
assembly. seated against snap ring.
NOTE: Before pressing components together,
ensure the synchronizer hub faces the short end
of the output shaft. Hold third gear against the
synchronizer to maintain synchronizer blocking
ring alignment. Ensure that 3rd speed gear is fully
seated against the thrust washer after assembly.
G34523 en 01/2003 2003.0 BA Falcon

1. Using a press and Remover Tube and Mainshaft

Countershaft Bearing — Front Front Bearing Replacers and Countershaft Front
Bearing Replacer (assembled to support case),
Special Tool(s) remove bearing race with O-ring from case.
205-411 CAUTION: Failure to properly support the
case will result in permanent distortion of
case during bearing race removal.
Remover Tube
308-262
Countershaft Front Bearing

Replacer
308-262
Disassembly
NOTE: Remove the front countershaft bearing race
only if it is worn or damaged. If the bearing race is
removed, Sealer or equivalent must be used during
installation.
Assembly
1. Install O-ring onto bearing race. Coat bearing race
outside diameter with Sealer or equivalent and
position bearing race to case.
G34524 en 01/2003 2003.0 BA Falcon

2. Using Pinion Bearing Cone Replacer and

Remover/Replacer Tube, support transmission
case on press. Press bearing race until flush with
case.
NOTE: The first/second gear synchronizer is available

only as an assembly with the output shaft. The
synchronizer hub is pressed onto the output shaft with
an interference fit; therefore, no attempt should be
made to separate the hub from the shaft. The
Synchronizers retaining springs, inserts, detent ball and spring are
available for service. If the hub or sleeve is worn, the
Disassembly output shaft and synchronizer must be replaced as an
NOTE: The following procedures apply to all assembly.
synchronizer assemblies. The gear synchronizers are
slightly different in design. Notation is made where
procedural differences occur.
1. Before disassembling the synchronizer, scribe
alignment marks on the sleeve and hub for
assembly reference.
2. Using a screwdriver, remove the two synchronizer
retaining springs. Remove the inserts.
Assembly
NOTE: When assembling a synchronizer sleeve and
hub, match the alignment marks made during
disassembly. The sleeve and hub have an extremely
close fit and must be held square during assembly to
prevent jamming. Do not force the sleeve onto the
hub.
1. Assemble the inserts and synchronizer retaining
springs onto the sleeve and hub. The retaining
springs engage the same insert but rotate in
opposite directions.
2. On fifth gear synchronizer only, install the
Reverse Blocking Ring into the synchronizer.
G34524 en 01/2003 2003.0 BA Falcon

3. Assemble retaining springs, inserts and sleeve 2. Rotate shifter shaft counterclockwise. When the
onto hub. Refer to illustration in Step 1 for selector arm disengages from the selector arm
positioning of the retaining springs and inserts. plate, pull shifter shaft rearward. The selector arm
roll pin will now be accessible.
Remove selector arm roll pin using a 5mm
(3/16-inch) diameter pin punch and remove the
shifter shaft.
Shift Cover
Disassembly
1. Mark shift forks for assembly reference. Position
selector arm plates and selector arm in the
NEUTRAL position. The gearshift selector arm
plates should now be centered over the control
selector arm.
G34526 en 01/2003 2003.0 BA Falcon

3. Pull shifter shaft out of cover using a twisting Assembly

motion.
1. Install a new O-ring seal.
2. If disassembled, assemble the shift forks, selector

arm plates and nylon inserts.
WARNING: Do not assemble the 3-4 shift
fork black nylon inserts or the selector arm
plate onto 1-2 shift fork.
NOTE: The narrow side of the C-shaped selector
interlock plate has to be positioned in the shift
cover slot. The control selector arm roll pin hole
has to be toward the rear of the cover.
4. Remove shift forks, roll pin and shift interlock from

shift cover.
G34526 en 01/2003 2003.0 BA Falcon

3. Install control selector arm and selector interlock

plate as an assembly.
CAUTION: Ensure the roll pin is installed

slightly below the selector arm surface. Failure to
4. Position shift forks in cover. Lubricate shifter shaft
countersink the roll pin may result in interference
with petroleum jelly. Slide shaft through shift cover
between the pin and the interlock plate during
and shift components until it stops against the
shifts.
front of the cover.
NOTE: The 1-2 shift fork is the larger fork. The
shift fork offset is to face the rear of the cover.
The 3-4 gear shift selector arm plate is to be
positioned under the 1-2 gearshift selector arm
plate.
NOTE: If on disassembly, the shifter shaft is
burred or nicked, remove to prevent damage to
the bush coating.
G34526 en 01/2003 2003.0 BA Falcon

5. Align the hole in shifter shaft and the control 2. Install end play shim and bearing race.
selector arm to install the roll pin using a 5mm NOTE: If seal is being replaced as a part of a
(3/16-inch) pin punch. transmission overhaul, do not install the end play
shim.
Bearing Retainer Seal — Front

Disassembly
1. Detach flywheel from transmission main case and
remove the end play shim.
2. Using a screwdriver, carefully pry seal from
flywheel housing.
Assembly
1. Using Differential Side Bearing Replacer install
new seal.
G34526 en 01/2003 2003.0 BA Falcon

ASSEMBLY
3. Using a press and Cluster Gear Bearing installer

Transmission and Remover Tube install countershaft rear
Assembly bearing to countershaft.
1. Using a press, install front countershaft bearing
onto countershaft using Pinion Bearing Cone
Replacer.
4. Install rear countershaft bearing race onto

countershaft.
2. Position countershaft in case.

CAUTION: Failure to properly support the
countershaft can result in permanent
distortion of the case during bearing
installation.
NOTE: Support the countershaft using two pieces
of 7mm (1/4 inch) bar stock.
5. Install countershaft bearing retainer to

transmission housing with four 13mm bolts.
NOTE: This should be done initially without any
shims installed. Tighten bolts to 15-27 Nm (11-20
lb-ft).
G34528 en 01/2003 2003.0 BA Falcon

6. Measure end play using Dial Indicator with 9. If removed, apply Pipe Sealant with Teflon ® to
Bracketry. Remove retainer and install necessary reverse positioning spring anchor pin threads.
shim(s) between countershaft retainer and rear Install anchor pin and tighten to 8-15 Nm (6-11
countershaft bearing race. Verify end play is lb-ft). Install Tizz bushing over anchor pin head by
within 0.013-0.102mm. After installing tapping lightly into position with hammer.
countershaft retainer and shims, bend tabs on 10. Align fifth/reverse shift lever, reverse shift fork and
retainer over the four attaching bolts. reverse positioning spring as shown.
7. Position reverse idler gear in case with shift lever 11. Lower assembly into case and install looped end
groove facing rear of case. Install reverse idler of reverse positioning spring onto anchor pin.
shaft and rubber overtravel stop.
Install shaft from rear of case and position
overtravel stop between gear and shaft support.
12. Position reverse idler gear into the NEUTRAL

position and align reverse shift fork onto reverse
idler gear. Once aligned, push downward on shift
8. Using a 5mm (3/16-inch) pin punch, install fork until fully engaged into reverse idler gear.
reverse idler shaft roll pin. NOTE: Observe reverse positioning spring
rotation. Reverse positioning spring should rotate
counter clockwise into its installed position.
G34528 en 01/2003 2003.0 BA Falcon

13. Install output shaft assembly. 16. Install fifth/reverse shift rail into transmission case
by aligning ball stud with slot in case and aligning
shift rail with reverse shift fork. Once ball stud
enters case, rotate shift rail clockwise and push in
shift rail until ball aligns with fifth/reverse shift
lever. Rotate shift rail counterclockwise until ball
stud fully engages shift lever.
14. Align notches in synchronizer blocking ring with

inserts in 3-4 synchronizer and install
synchronizer blocking ring.
17. Install fifth gear, synchronizer and shift fork as an

assembly.
15. Install output shaft rear bearing race. If necessary,

tap bearing race into position using a plastic
tipped hammer.
18. Install fifth gear synchronizer blocking ring,

Reverse Cone, spacer and snap ring.
NOTE: Ensure tabs on spacer engage splines of
countershaft and the tab on the reverse cone is at
the 12 o’clock position to assist when installing
the extension housing.
G34528 en 01/2003 2003.0 BA Falcon

NOTE: Ensure lubrication funnel engages into end of 21. Install speedometer gear.
countershaft gear. Before installing the pivot pin, NOTE: The tab on the retainer clip engages a
ensure the shift rail ball stud is fully engaged with the hole in the output shaft.
shift lever.
19. Apply Pipe Sealant with Teflon ® to the pivot pin
threads and install the fifth/reverse shift lever pivot
pin.
Tighten pivot pin to 34-47 Nm (25-35 lb-ft) using a
T50 Torx ® driver. Apply Pipe Sealant with Teflon
® to the reverse light switch and install using a
22mm socket. Tighten to 27-47 Nm (20-35 lb-ft).
CAUTION: Do not apply silicone sealer to top

of transmission case surface under any
circumstances, as sealant could fall into
transmission and affect operation.
22. Apply 3.2mm (1/8-inch) bead of Silicone Sealer
RTV Silastic 1080 or equivalent to shift cover
assembly.
Position cover to filler plug side of transmission
and lower into position until shift forks engage
synchronizers. Continue lowering cover and move
into position to engage fifth/reverse shift lever.
NOTE: Ensure all synchronizers are in the
NEUTRAL position and that the shift forks in the
cover are in the NEUTRAL position.
23. Install shift cover retaining bolts. Tighten cover
retaining bolts to 8-11 Nm.
20. Using needlenose pliers, install C-clip on shift

lever pivot pin.
G34528 en 01/2003 2003.0 BA Falcon

24. Apply a 3.2mm (1/8-inch) bead of Silicon Sealer 27. Press downward on bonded offset lever to
RTV Silastic 1080 or equivalent on the extension compress detent spring and push lever and
housing mating surface. Apply Silicone Sealer housing into position. Ensure the reverse cone tag
RTV Silastic 1080 or equivalent to the lubrication is engaged in the recess in the housing.
funnel and install funnel into countershaft gear.
28. Install extension housing retaining bolts. Tighten

25. Coat detent spring with petroleum jelly and install to 47- 61 Nm (30-45 lb-ft).
in offset lever. Lubricate detent plate and install
detent ball in neutral position on plate. Position
bonded offset lever in extension housing with
spring over detent ball.
26. Slide lever and extension housing into position as

an assembly.
G34528 en 01/2003 2003.0 BA Falcon

29. Using a suitable pin punch, align the hole in 33. Tighten retaining bolts to 15-27 Nm (11-20 lb-ft).
shifter shaft with hole in bonded offset lever and
install roll pin.
34. Remount the transmission (with flywheel housing)

in the holding fixture and check output shaft
geartrain end play as follows:
Rotate transmission to the vertical position
with extension housing facing up.
Mount Dial Indicator with Bracketry on the
extension housing with the indicator stylus
contacting the output shaft.
Rotate the input and output shafts. Zero the
dial indicator.
NOTE: Output shaft geartrain end play must
be checked and adjusted at this point.
30. Install input shaft. Align flat on sychronizer teeth

with countershaft before installing input shaft.
NOTE: Ensure 3-4 synchronizer blocking ring is
still in proper position.
31. Install bearing race in the bearing retainer located

in the back of the flywheel housing.
NOTE: Do not install end play shims at this point.
32. Temporarily, attach the flywheel housing to the
transmission main case.
G34528 en 01/2003 2003.0 BA Falcon

Using a wood block, push upward on the 37. Reattach the flywheel housing (with shims and
input shaft and note the dial indicator reading. bearing race located in the integral bearing
NOTE: A shim must be installed that is the retainer) and hand tighten the four main
thickness of the dial indicator reading. This case-to-flywheel housing bolts. Tighten the four
will provide zero end play. integral flywheel housing-to-main case retaining
A pre-load of 0.01-0.1mm must be applied. bolts to specification.
38. Torque the four integral flywheel housing-to-main

case retaining bolts to specification. Check
CAUTION: Thickest shim must be installed end play.
closest to the front bearing cup.
35. Detach the transmission from the holding fixture
and remove the flywheel housing. Remove
bearing race from flywheel housing and install the
necessary shim(s).
39. Apply a 3.2mm (1/8-inch) bead of Silicone Sealer

RTV Silastic 1080 or equivalent on the turret
cover.
36. Apply a 3.2mm (1/8 inch) bead of Silicon Sealer

RTV Silastic 1080 or equivalent to the edge of the
integral bearing retainer and around the retainer
bolt holes in the back of the flywheel housing.
G34528 en 01/2003 2003.0 BA Falcon

40. Position turret cover on the extension housing and

tighten the retaining bolts to 24-30 Nm.
41. Install and tighten drain plug to 27-40 Nm.
G34528 en 01/2003 2003.0 BA Falcon

308-03b-1 Manual Transmission — TR3650 308-03b-1
SECTION : 308-03b Manual Transmission —

TR3650
CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................308-03b-2
Manual Transmission ..........................................................................................................308-03b-3
Transmission Identification ...............................................................................................308-03b-7
Manual Transmission ..........................................................................................................308-03b-8
GENERAL PROCEDURES
Bearings — Inspection ........................................................................................................308-03b-9
IN-VEHICLE REPAIRS
Seal ...................................................................................................................................308-03b-11
Gearshift Lever and Boot ..................................................................................................308-03b-11
Gearshift Boot and retainer Assembly ..............................................................................308-03b-12
REMOVAL
Transmission .....................................................................................................................308-03b-13
DISASSEMBLY
Transmission .....................................................................................................................308-03b-15
Input Shaft and Bearing ....................................................................................................308-03b-24
Output Shaft ......................................................................................................................308-03b-25
Countershaft Bearing ........................................................................................................308-03b-36
Synchronizers ...................................................................................................................308-03b-37
Gearshift Rail Bushing ......................................................................................................308-03b-37
Gearshift Rail and Fork .....................................................................................................308-03b-38
ASSEMBLY
Transmission .....................................................................................................................308-03b-39
INSTALLATION
Transmission .....................................................................................................................308-03b-51
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Driveshaft flange to pinion flange bolt 112
Inspection Standards and Tolerances
Synchronizer blocking 0.5 mm
ring to conical face
runout
Assembly Standards
Input shaft end play 0.023 mm –
0.051 mm
Countershaft cluster gear 0.0 mm –
end play 0.076 mm
Output shaft end play 0.025 mm –
0.051 mm
Lubricant/Adhesive/Cleaner Specifications
Premium Long-Life ESA-M1C75-B
Grease
XG-1-C, K or T
Threadlock and Sealer WSK-M2G351-A5
E0AZ-19554-AA
Black Silicone Rubber ESB-M4G92-A
D6AZ-19562-BA
Pipe Sealant with ESR-M18P7-A
Teflon®
D8AZ-19554-A
Stnthetict MERCON® MOBIL 1 SYNTHETIC
(ATF) Transmission Fluid ATF (Dextron III ATF
E6AZ-19582-B Alternative)
Lubricant Refill Capacities
Stnthetict MERCON® 3.8L (8.0 pt)
(ATF) Transmission Fluid
E6AZ-19582-B
Description Nm
Gearshift lever to extension housing 25-40
bolt
Gear shift lever to gear shift stub shaft 37
bolt
OSS to case bolt 10
Reverse idler gear bolt 20-35
Fifth/reverse lockout bolt 20-35
Clutch housing to transmission main 25-40
case bolt
Extension housing to transmission 25-40
main case bolt
Drain plug 20-35
Reversing lamp switch 20-35
Fill plug 20-35
Transmission to engine bolt 75
Engine plate to transmission bolt 27
Crossmember to frame bolt 41
Crossmember to transmission support 58
bolt
G34230 en 01/2003 2003.0 BA Falcon

Manual Transmission
The TR3650 five-speed manual transmission features
the following:
The fifth speed gear functions as an overdrive
gear.
The forward gears are synchronized and helical
cut.
The reverse gear operates through a
constant-mesh, fully synchronized system.
The shift interlock system prevents the
engagement of more than one gear.
The countershaft is serviced as an assembly.
An aluminum main case, extension housing and
bell housing.
G34231 en 01/2003 2003.0 BA Falcon

Transmission Internal Components — Disassembled View
G34231 en 01/2003 2003.0 BA Falcon


1 Input shaft seal 38 Reverse gear synchronizer hub (part of
2 Shim 7124)
3 Input shaft front bearing and cup 39 Reverse gear synchronizer insert (part of
7124)
4 Input shaft
40 Reverse gear synchronizer sleeve (part of
5 Input shaft pocket bearing
7124)
6 Input shaft thrust bearing 41 Retaining ring
7 Input shaft thrust washer
42 Reverse needle bearing
8 Retaining ring
43 Reverse driven gear
9 Third/fourth gear synchronizer assembly 44 Reverse gear bushing
10 Third/fourth gear synchronizer blocking
45 Selector gate
ring
46 Mainshaft rear bearing and cup
11 Third/fourth gear synchronizer spring (part
of 7124) 47 Mainshaft fifth gear
12 Third/fourth gear synchronizer insert (part 48 Retaining ring
of 7124) 49 Output shaft speed (OSS) sensor
13 Third/fourth gear synchronizer hub (part of 50 Retaining ring
7124) 51 Shim
14 Third/fourth gear synchronizer sleeve (part 52 Countershaft front bearing and cup
of 7124)
53 Countershaft
15 Third gear
54 Countershaft rear bearing and cup
16 Third gear needle bearing
55 Thrust bearing
17 Third gear bushing
56 Countershaft fifth gear
18 Check ball
57 Countershaft fifth gear needle bearing
19 Thrust washer
58 Countershaft fifth gear bearing spacer
20 Second gear needle bearing
59 Retaining ring
21 Second gear
60 Fifth gear synchronizer assembly
22 First/second gear synchronizer inner cone
61 Fifth gear synchronizer blocking ring
23 First/second gear synchronizer outer cone
62 Fifth gear synchronizer spring (part of
24 Output shaft 7124)
25 Retaining ring 63 Fifth gear synchronizer hub (part of 7124)
26 First/second gear synchronizer assembly 64 Fifth gear synchronizer insert (part of
27 First/second gear synchronizer blocking 7124)
ring 65 Fifth gear synchronizer sleeve (part of
28 First/second gear synchronizer spring (part 7124)
of 7124) 66 Fifth gear clutch cone
29 First/second gear synchronizer hub (part of 67 Retaining ring
7124)
68 Reverse idler gear support
30 First/second gear synchronizer insert (part
69 Reverse idler gear shaft
of 7124)
31 First/second gear synchronizer sleeve 70 Reverse idler gear
(part of 7124) 71 Reverse idler gear needle bearing
32 First gear needle bearing 72 Reverse idler gear bearing spacer
33 First gear
34 Reverse clutch cone
35 Reverse gear synchronizer assembly
36 Reverse gear synchronizer blocking ring
37 Reverse gear synchronizer spring (part of
7124)
G34231 en 01/2003 2003.0 BA Falcon

Transmission Case and Shift Components — Disassembled View
G34231 en 01/2003 2003.0 BA Falcon

Item Description Transmission Identification

1 First/second shift rail
2 First/second shift fork
3 Shift fork inserts
4 First/second shift finger
5 Third/fourth shift rail
6 Third/fourth shift fork
8 Third/fourth shift finger
9 Fifth/reverse shift rail
10 Reverse gear shift fork
11 Fifth gear shift fork
Item Description
13 Shift arm bearing
1 Transmission assembly number
14 Spacer
2 Build date code–month
15 Shift arm selector inhibitor
3 Build date code–day
16 Main shift rail
4 Build date code–year
17 Gearshift offset lever
5 Shift number
18 Spacer
6 Serial number
19 Bearing
7 Service repair code
20 Gearshift lever
8 Identification number located on left lower
21 Gearshift plate and spring side of transmission case
22 Shipping seal
23 Output shaft seal
24 Extension housing bushing
25 Extension housing
26 Vent
27 Fifth/reverse gear lockout
28 Magnet
29 Shift interlock plate
30 Transmission main case
31 Interlock pins
32 Drain plug
33 Reverse lamp switch
34 Detent plug
35 Detent spring
36 Detent
37 Clutch housing
38 Ball stud
39 Bearing
Transmission Identification
The transmission identification tag is located under
the lower bolt that retains the extension housing to the
main case.
G34231 en 01/2003 2003.0 BA Falcon

Manual Transmission
G34232 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Bearings — Inspection 4. Inspect bearing for cracked inner race.

NOTE: If any of the following conditions exist, install a
new bearing.
1. Inspect the bearing for a bent cage.
5. Inspect the bearing and raceway for etching.

If etching is present, inspect the seals.
2. Inspect bearings for galling (metal smears on

roller ends).
Galling is caused by overheating, poor
lubrication or an overload situation.
If galling is found, install a new bearing and
inspect the seals.
6. Inspect the bearing for heat discoloration (dark

blue).
If heat discoloration is evident, check the
bearing and race for loss of temper. Draw a
file across the component. If the file cuts the
metal, there is a loss of temper.
3. Inspect the bearing for brinelling (surface

indentations in the raceway).
G34233 en 01/2003 2003.0 BA Falcon

7. Inspect the bearing for fatigue spalling (metal

flaking).
G34233 en 01/2003 2003.0 BA Falcon

IN-VEHICLE REPAIR
Installation
Seal
1. Using the special tool, install the extension
Special Tool(s) housing fluid seal.
Installer, Transmission
Extension Housing Oil Seal
308-227 (T94P-7657-A)
Slide Hammer
100-001 (T50T-100-A)
Remover, Bushing
307-001 (TOOL-1175-AC) or
Equivalent
Removal
1. With the vehicle in NEUTRAL, raise and support
the vehicle. For additional information, refer to
Section 100-02.
2. Remove the driveshaft. For additional information,
2. Install the driveshaft. For additional information,
CAUTION: Index-mark the driveshaft refer to Section 205-01.
flange and pinion flange, and the driveshaft
slip yoke and transmission output shaft. CAUTION: Align the index marks.
3. Using the special tools, remove the extension 3. Check the transmission fluid level, add fluid if
housing fluid seal. necessary.
Gearshift Lever and Boot

1. Place the Gearshift lever in the Neutral position
gate.
3. Gently prise the retainer lugs of the RH top side
finisher panel from the console. For additional
4. Repeat for the LH top side finisher panel.
5. Gently prise the retainer lugs of the consoles top
prindle surround panel from the console. Lift
vertically away from the gearshift lever. For
G34235 en 01/2003 2003.0 BA Falcon

6. Remove the upper bolt and lower nut securing the 5. Remove the centre console. For additional
shift lever to the transmission and remove the information, refer to Section 501-12.
lever. 6. Remove the gearshift lever boot and retainer
assembly by lifting vertically away from the
transmission stub lever.
7. Inspect the Gearshift lever assembly for wear or

damage. To install, reverse the removal
procedure with attention to the following 7. Clean and inspect the boots for wear or damage.
instructions. To install, reverse the removal procedure.
8. Position the shift lever on the left hand side of the NOTE: All hardware must be correctly installed
transmission lever, install and torque the nut & and torqued to specification.
bolt to specification.
9. Apply locktite to the thread on the shift lever.
Screw the knob onto the shift lever until it starts to
tighten, continue tightening until the graphics on
the knob are correctly aligned.
Gearshift Boot and Retainer Assembly

information, refer to Section 100-02 for hoisting
the vehicle.
2. Remove the four nuts securing the gearshift lever
boot and retainer assembly to the floorpan.

4. Remove the gearshift lever as Gearshift Lever
removal and installation section.
G34235 en 01/2003 2003.0 BA Falcon

REMOVAL
Transmission 7. Disconnect the reversing lamp switch electrical

connector. Disconnect the wiring harness from the
Removal transmission.
1. Remove gearshift lever and boot as described
earlier in this section.
2. With the vehicle in NEUTRAL, raise and support
Section 100-02.
3. Remove the dual converter H-pipe. For additional
4. Mark the driveshaft so that it may be installed in
the same relative position.
Disconnect the shaft at the centre bearing mount,
by detaching the centre bearing bracket from the
centre bearing carrier (cross member) and detach
the rear CV joint from the diff pinion companion
flange, by undoing the bolts. Slide the driveshaft
backwards, until the slip yoke slides off the output 8. Remove the starter motor. For additional
shaft. Install a dust cover or extension housing information, refer to Section 303-06.
seal replacer into the extension housing to 9. Remove the bolts.
prevent lubricant leakage.
WARNING: Failure to match marks when
re assembling the driveshaft may induce
driveline vibration.
NOTE: Before disassembly, mark the matching
points on the slip yoke and transmission output
shaft. Mark the mating points on the CV flange,
10. Remove the starter solenoid nuts and position the

wires aside.
5. Bleed the concentric clave cylinder (CSC)

according to the procedure set out in section
308-01.
6. Disconnect the CSC hydraulic clutch line from
wall.
11. Remove the starter motor.
12. Disconnect the wiring harness from the
transmission.
13. If transmission disassembly is necessary, drain
the transmission fluid.
G34237 en 01/2003 2003.0 BA Falcon

REMOVAL (Continued)
14. Position a transmission jack and support the 17. Remove the bolts.
transmission.
18. Lower the transmission and remove the five bolts.

15. Remove the bolts and the transmission
crossmember.
19. Move the transmission rearward until the input

shaft clears the pressure plate housing, then
16. Lower the transmission jack until the rear of the lower the jack and remove the transmission.
engine rests again the bulk head.
NOTE: The engine must be tilted down at the WARNING: Do not seperate transmission
transmission and before removing the flywheel from vehicle engine by removing the 4
housing-to-engine bolts. Raise the vehicle’s transmission case bolts.
bonnet before tilting the engine or else the bonnet NOTE: Removal of transmission from vehicle is
may be damaged. The engine can be tilted by easier if the front of the engine is jacked up
either: carefully to tilt the transmission down at the rear.
1. jacking up the front end or
2. using a harness to pull down the rear of the
motor.
G34237 en 01/2003 2003.0 BA Falcon

DISASSEMBLY
Transmission 3. Attach the transmission to the special tool.
Special Tool(s)
Remover, Mainshaft Bearing
308-058 (T77J-7025-H)
Screw, Bearing Removal tube

308-092 (T84T-7025-B)
Holding Fixture, Transmission

307-003 (T57L-500-B)
Remover, Bushing
307-001 (TOOL-1175-AC)
4. Remove the case plug, then rotate the

transmission to a horizontal position.
NOTE: Position a drain pan under the
Remover/Installer, Bearing transmission.
Tube
308-024 (T75L-7025-B) 5. Using the special tools, remove the extension
housing fluid seal.
Disassembly
NOTE: During disassembly, if any roll pins, retaining
rings or bearings are removed, install new
components. Install bearings and bearing cups as a
set.
1. Remove the clutch release hub and bearing and
the clutch release lever. For additional
2. Clean the transmission exterior with solvent and
dry with compressed air. During disassembly,
clean all components with solvent and dry with
compressed air.
WARNING: Make sure protective eye wear
is in place.
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6. Remove the bolts and the gearshift lever. 9. Using a 3.9 mm punch and a hammer, drive the
NOTE: Rotate the transmission to a vertical split pin downward.
position.
NOTE: Position the gearshift lever in NEUTRAL.
10. Remove the 12 bolts.
7. Inspect the gearshift offset lever insert and O-ring

for wear or damage. Install a new insert as
necessary.
11. Using a flat-blade screwdriver, separate the

extension housing, then remove the gearshift
offset lever from the transmission case.
Remove and discard the split pin from the
gearshift offset lever during removal.
8. Remove the bolts and the shift spring and plate.
NOTE: If necessary, remove the spring and plate
for disassembly.
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12. Remove the fifth/reverse gear lockout bolt. 15. Remove the OSS sensor tone wheel retaining ring
if present.
13. Remove the fifth/reverse gear lockout.

16. Using the special tools, remove the OSS sensor
tone wheel if present.
14. Remove the shipping seal.
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17. Remove the OSS sensor tone wheel check ball. 20. Remove the fifth gear shift fork, synchronizer
assembly, synchronizer cone and the fifth gear as
an assembly.
18. Remove and discard the fifth gear synchronizer

retaining ring.
21. Remove the fifth gear clutch cone.
19. Using a 3.9 mm punch and a hammer, remove

and discard the pin from the fifth gear shift fork. 22. Remove the fifth gear synchronizer blocking ring.
Inspect the blocking ring for wear or damage.
Install new blocking rings as necessary.
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23. Remove the fifth gear synchronizer sleeve from 26. Remove the check ball.
the synchronizer hub.
27. Using a 3.9 mm punch and a hammer, drive out

24. Remove the synchronizer inserts and the springs. the split pin, then remove the third/fourth shift
finger. Discard the split pin.
25. Remove the needle bearings and the thrust

washer. 28. Using a 3.9 mm punch and a hammer, drive out
The fifth gear needle bearing is three the split pin, then remove the first/second shift
separate pieces: bearing, spacer, bearing. finger. Discard the split pin.
Inspect the needle bearing for wear or
damage. Install new bearings as necessary.
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29. Remove the main shift rail and the plastic spacer. 32. Remove the three detent plugs, springs and the
detents.
30. Remove the bolts and the shift interlock plate.

CAUTION: Do not remove all the bolts while
in the horizontal position.
Rotate the transmission to a horizontal
position. Remove 12 bolts, leaving two
opposing bolts in. Rotate the transmission to
a vertical position, then remove the remaining
two bolts.
31. Using a magnet, remove the interlock pins.

One lock pin in the center rail, two between
the rails.
34. Carefully pry the clutch housing from the

transmission main case.
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35. Remove the transmission main case from the 37. Remove the mainshaft and shift assembly.
clutch housing.
38. Remove the input shaft. For input shaft

36. Lift the mainshaft 13 mm upward, tilt the disassembly, refer to Input Shaft and Bearing in
countershaft outward and remove the this section.
countershaft.
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39. Remove the shift rails and shift forks from the 43. Remove the reverse idler gear bearing.
main shaft. For gearshift rail and fork The reverse idler gear is three separate
disassembly, refer to Gearshift Rail and Fork in pieces: bearing, spacer, bearing.
this section.
Inspect the bearing for wear or damage.
Install new bearings as necessary.
40. Remove the reverse idler shaft bolt. Remove and

discard the seal.
44. Disassemble the clutch housing.
1. Remove the countershaft bearing cup and
shim.
2. Remove the input shaft bearing cup and shim.
3. Remove the input shaft seal.
Carefully pry out from the inside of the
case.
41. Remove the reverse idler gear assembly.

42. Remove the reverse idler gear from the shaft.
Inspect the gear for wear or damage. Install a
new gear as necessary.
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45. Remove the rear countershaft bearing.
46. Remove the rear countershaft bearing cup and

the rear output shaft bearing cup.
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Input Shaft and Bearing

Special Tool(s)
Remover, Driver Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent
Installer, Drive Pinion Bearing

Cone
205-011 (T57L-4621-B)
Remover/Installer, Bearing
Tube
Disassembly
1. Disassemble the input shaft.
1. Remove the third/fourth synchronizer blocking
ring. Item Description
2. Remove the input shaft thrust washer. 1 Synchronizer blocking ring
3. Remove the input shaft thrust bearing. 2 Thrust washer
4. Remove the input shaft pocket bearing. 3 Thrust bearing
Inspect all components for wear or damage. 4 Thrust washer
Install new components as necessary. 5 Pocket bearing
2. Using the special tool and a press, remove the
input shaft front bearing assembly. Discard the
bearing.
3. Inspect the input shaft and bearings for wear or

damage. Install new components as necessary.
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4. Using the special tools and a press, install the

new input shaft front bearing. CAUTION: Hand tighten the special tool to
prevent gear damage.
CAUTION: Support the output shaft while

using the press to prevent damage to the shaft or
gears.
2. Using the special tool, press fifth gear, the spacer,
the output shaft bearing and reverse gear from
the output shaft.
Discard the output shaft bearing.
5. Install the input shaft pocket bearing, the washer,

input shaft bearing and the third/fourth
synchronizer blocking ring.
Lubricate the bearing and bearing race with
petroleum jelly.
Output Shaft
Special Tool(s)
3. Remove reverse gear needle bearing.
Remover, Drive Pinion Bearing
Cone Inspect the needle bearing for wear or
205-D002 (D79L-4621-A) or damage. Install a new needle bearing as
equivalent necessary.

Cone
205-011 (T57L-4621-B)
Disassembly
1. Remove the retaining ring above fifth gear.
G34240 en 01/2003 2003.0 BA Falcon

4. Remove the check ball and the blocking ring. 6. Remove the first gear needle bearing.
Inspect the blocking ring for wear or damage. Inspect the needle bearing for wear or
Install new blocking rings as necessary. damage. Install a new needle bearing as
necessary.
7. Remove the first gear synchronizer inner cone,

the first gear synchronizer outer cone and the first
gear synchronizer blocking ring.
Inspect all components for wear or damage.
Install new components as necessary.
5. Using the special tools, press the bearing spacer,

the reverse gear synchronizer cone and first gear
from the output shaft.
NOTE: Install the special tool with the flat side
facing first gear.
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8. Remove and discard the retaining ring. 11. Remove the third gear.
NOTE: Reposition the output shaft on the press Inspect the gear for wear or damage. Install a
with the input shaft end facing upward. new gear as necessary.
9. Remove the third/fourth synchronizer hub. 12. Remove the third gear needle bearing.
damage. Install a new needle bearing as
necessary.
10. Remove the third/fourth blocking ring.
NOTE: Install the special tool behind second gear

with the flat side of the tool facing second gear.
13. Using the special tool, remove the spacer, second
gear thrust washer and second gear.
Inspect the gear for wear or damage. Install a
new gear as necessary.
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14. Remove the check ball and second gear needle Assembly
bearing.
1. Carry out the following before reassembling:
Inspect the gears for broken or cracked teeth.
damage. Install a new needle bearing as
necessary. Check for unusual wear patterns.
Inspect the thrust washers for face wear,
cracks, scoring and for signs of heat damage.
Inspect the bearings, bearing cups and the
synchronizers for wear or damage.
Inspect the output shaft for scoring or worn or
damaged splines. Install new components as
necessary.
2. Lubricate all components with the recommended
transmission fluid when reassembling.
NOTE: Position the output shaft with the output end
facing upward.
NOTE: Install the synchronizer assembly with the
deeper center flange of the synchronizer hub facing
toward the rear of the output shaft.
15. Remove the second gear synchronizer inner
cone, second gear synchronizer outer cone and 3. Install the first/second synchronizer assembly on
the second gear synchronizer blocking ring. the output shaft, then install a new retaining ring.
Inspect all components for wear or damage. It may be necessary to press the hub into
Install new components as necessary. position on the shaft.
16. Remove the snap ring, then using the special tool,
press off the first/second gear synchronizer.
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4. Install the first gear synchronizer blocking ring. 7. Install the first gear needle bearing.
Align the blocking ring tabs with the Apply petroleum jelly to the bearing.
synchronizer assembly.
8. Install first gear.

5. Install the outer first gear synchronizer cone. Rotate the gear to align the gear slots with the
inner cone tabs.
6. Install the inner first gear synchronizer cone.

Rotate the inner cone till it is seated.
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9. Install the reverse synchronizer cone. 11. Using the special tools, install the reverse gear
bearing spacer.
10. Install the reverse gear blocking ring.
12. Install reverse gear needle bearing.

Apply petroleum jelly to the bearing.
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13. Install reverse gear. 15. Install the thrust washer. Be sure to align the slot
Rotate the gear to align the gear slots with the in the washer with the check ball.
inner cone tabs.
16. Install a new rear output shaft bearing, then fifth

gear. Using the special tool, press both the
bearing and gear into place.
14. Install the check ball.

17. Reposition the output shaft with the input end
Use petroleum jelly to hold the check ball in facing upward.
place.
18. Install the second gear synchronizer blocking ring.
Rotate the blocking ring until seated.
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19. Install the second gear synchronizer outer cone 21. Install second gear.
and the second gear synchronizer inner cone. Rotate the gear to align the gear slots with the
inner cone tabs.
20. Install the second gear bearing.

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22. Install the check ball. 23. Install the thrust washer. Be sure to align the slot
in the washer with the check ball.
Use petroleum jelly to hold the check ball in
place.
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24. Press the bearing spacer onto the output shaft. 25. Install the third gear bearing.
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26. Install third gear. 27. Install the third gear synchronizer blocking ring.
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28. Install the third/fourth gear synchronizer body. Countershaft Bearing

Install the synchronizer body with the raised
center facing downward. Special Tool(s)
Rotate the blocking ring until seated. Remover, Drive Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent

Cone
205-011 (T57L-4621-B)
Disassembly
1. Cut the outer cage, then remove the outer cage
and rollers.
29. Install a new retaining ring.
2. Using the special tool and a press, remove the

inner bearing.
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3. Using the special tools, install the new Gearshift Rail Bushing
countershaft bearing.
Special Tool(s)
Universal Puller Set
303-DS005 (D80L-100-A) or
equivalent
Installer, Shift Rail Bushing

308-244 (T96P-7025-F)
Synchronizers
Disassembly Slide Hammer
NOTE: This procedure applies to all synchronizer 100-001 (T50T-100-A)
assemblies.
1. Scribe an alignment mark on the sliding sleeve
and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the
synchronizer struts and the springs.
Disassembly
1. Using the special tools, remove the gearshift rail
bearing from the transmission case. Discard the
bearing.
3. Install the synchronizer struts and the springs.

4. Install the sliding sleeve.
CAUTION: Match the alignment marks
made during disassembly. The sleeve and the
hub have an extremely close fit. Hold the
sleeve and hub square to prevent jamming. Do
not force the sleeve onto the hub.
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2. Using the special tool, install the main shift rail 3. Position the gearshift fork on the shift rail. Align
bearing. the split pin hole and install a new split pin.
CAUTION: Support the shift rail to
prevent damage to the parts.
Gearshift Rail and Fork

Disassembly 4. Install the gear shift fork inserts.
1. Using a 5/32-inch drift and a hammer, remove
and discard the split pin. Slide the shift fork from
the shift rail.
2. Remove the gearshift fork inserts.
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ASSEMBLY
NOTE: If a new rear output shaft bearing was

Transmission installed or a new rear countershaft bearing is being
used, install new bearing cups.
Special Tool(s)
3. Install the rear countershaft bearing cup and the
Dial Indicator Gauge with rear output shaft bearing cup.
Holding Fixture
100-002 (TOOL-4201-C) or Lubricate the bearing cups and the shift rail
equivalent bearing with petroleum jelly.
Holding Fixture, Transmission

307-003 (T57L-500-B)
Remover/Installer, Bearing
Tube
308-024 (T75L-7025-B)
4. Install the rear countershaft bearing.
Replacer/Adapter
308-239 (T96P-7025-A)
Installer, Transmission
Extension Housing Oil Seal
5. Install the reverse idler gear bearings and spacer

on the shaft.
1. Lubricate all components with transmission fluid

during assembly.
2. Attach the clutch housing to the special tool.
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6. Install the reverse idler gear on the shaft. 9. Install the front input shaft bearing cup and the
front countershaft bearing cup. Do not install the
shims at this time.
Install the transmission main case.
7. Install the reverse idler gear into the case.
10. Install the input shaft.
8. Install a new seal on the reverse idler bolt, then

install the bolt in the transmission case.
11. Install the shift rails and shift forks on the

mainshaft.
NOTE: If a new front input shaft bearing or front

countershaft bearing was installed, install new bearing
cups.
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12. Install the mainshaft onto the clutch housing. 14. Install the case with two opposing bolts.
The notches on the shift rail should be
pointing upward.
Align the shift rails in the bores.
15. Using a dial indicator gauge, measure the input

shaft end play by applying an upward load on the
output shaft. Record the measurement.
NOTE: Rotate the transmission so that the input
shaft is pointing upward.
NOTE: Rotate the input shaft to seat the bearings.
13. Install the countershaft.

Lift the mainshaft upward, tilt the countershaft
and install.
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16. Rotate the transmission so that the input shaft is 18. Remove the two bolts and lift the transmission
pointing downward. main case off.
17. Using the special tools, measure the countershaft

gear end play by pulling upward on the
countershaft. Record the measurement.
NOTE: Rotate the countershaft to seat the
bearings.
19. Remove the countershaft.
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20. Remove the mainshaft. 22. Remove the front input shaft bearing cup and the
front countershaft bearing cup.
23. Using the special tools, install the new input shaft
seal.
21. Remove the input shaft.

24. Using the recorded end play measurements,
select and install the appropriate shims to achieve
the correct end play.
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25. Install the front input shaft bearing cup and the 27. Install the mainshaft.
front countershaft bearing cup.
26. Install the input shaft.
28. Install the countershaft.
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29. Clean the mating surfaces of the transmission 31. Install the lock plate.
main case and the clutch housing. Apply a bead
of silicone rubber to the sealing surface on the
clutch housing then install the transmission main
case. Tighten the bolts in a star pattern.
32. Install the detents and the detent springs.
30. Install the lock pins.
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33. Install the detent plugs. 36. Install the synchronizer springs and inserts.
34. Install the check ball. 37. Install the sliding sleeve on the synchronizer hub.
Use petroleum jelly to hold the check ball in Align the pockets in the blocking ring with the
place. struts in the synchronizer.
The sliding sleeve is not reversible. Install the
sleeve with the bevel edge away from the
gear.
35. Install the thrust washer and the three-piece fifth

gear needle bearing.
38. Install fifth gear blocking ring.
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39. Install the fifth gear synchronizer cone. 42. Install a new snap ring.
40. Install the fifth gear shift fork, the synchronizer 43. Install the third/fourth shift finger, then install a
assembly, the synchronizer cone and fifth gear as new split pin.
an assembly.
Install the split pin until it is flush with the shift
finger.
41. Install a new split pin.

Install the pin until it is flush with the fork. 44. Install the control rail and the plastic spacer, then
install the first/second shift finger. Install a new
split pin.
Install the split pin until it is flush with the shift
finger.
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45. Install the OSS sensor tone wheel check ball. 48. Install the fifth/reverse gear lockout.
Use petroleum jelly to hold the check ball in
place.
49. Install the bolt.
46. Place the OSS sensor tone wheel on the output

shaft, aligning the slot in the OSS wheel with the
check ball. Using the special tool, install the OSS
sensor tone wheel.
50. Clean the mating surfaces of the transmission

main case and the extension housing. Apply a
bead of silicone rubber to the sealing surface of
the transmission case.
47. Install a new OSS sensor tone wheel retaining

ring.
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51. Install the extension housing and at the same time 55. Using the special tool, install a new extension
install the gear shift off-set lever. housing seal.
Lubricate the seal with transmission fluid.
52. Install the shift spring and bracket.
53. Install a new split pin in the gear shift off-set lever. 56. Install the shipping seal.
The split pin should be flush in the gear shift
off-set lever.
54. Seat the extension housing and tighten the bolts
to specification.
Fill the gear shift off-set lever with petroleum
jelly.
57. Rotate the transmission to a horizontal position.

58. Clean the mating surfaces of the shift cover
opening surface and the shift cover. Apply a bead
of silicone rubber to the shift cover opening
surface.
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59. Install the gear shift lever.
60. Install the clutch release hub and bearing and the
clutch release lever. For additional information,
NOTE: Before installing the transmission, the ball
stud, the clutch release lever and the input shaft
guide tube must be cleaned and lubricated.
61. Fill the transmission with transmission fluid to the
specified level.
Transmission capacity is 3.8 liters (8.0 pints).
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INSTALLATION
Transmission
NOTE: Before installing the transmission, the ball
stud, clutch release lever and the input shaft must be
cleaned and lubricated. Use Motorcraft Premium
Long-Life Grease XG-1-C or XG-1-K or equivalent
meeting Ford specification ESA-M1C75-B.
Installation
1. To install, reverse the removal procedure. For
additional information, refer to Transmission in
this section.
Check, and as necessary, fill the transmission
with transmission fluid. The total fill capacity is
3.8L (8.0 pt).
2. Apply sealant to the fill plug threads and install
the fill plug.
Use pipe sealant with Teflon®.
G34246 en 01/2003 2003.0 BA Falcon

308-06-1 Manual Transmission External Controls 308-06-1
SECTION : 308-06 Manual Transmission External

Controls
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................308-06-2
External Controls ..................................................................................................................308-06-3
Symptom Chart ....................................................................................................................308-06-3
Pinpoint Tests ......................................................................................................................308-06-3
Gearshift Lever .....................................................................................................................308-06-5
Gearshift Boot and Retainer Assembly .................................................................................308-06-5
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Gearshift lever retaining nut 8.9 - 12.1
Gearshift lever retaining bolt 29.5 -40.3
Gearshift lever boot and retainer 8.9 - 12.1
assembly retainer nut
G73254 en 01/2003 2003.0 BA Falcon

External Controls 3. If an obvious cause for an observed or reported

Inspection and Verification before proceeding to the next step.
4. If the concern is not visually evident, verify the
1. Verify the customer concern. symptom and refer to the Symptom Chart.
damage.
Symptom Chart

External controls operate with Gearshift lever damaged. Go to PinPoint Test A.
excessive freeplay.
Transmissions gearshift selector lever Go to PinPoint Test B.
damaged.
External controls do not operate freely. Gearshift lever fouled. Go to PinPoint Test A.
Transmissions gearshift selector lever Go to PinPoint Test B.
damaged
External controls causes excessive Gearshift boot and retainer assembly Go to PinPoint Test A.
cabin noise/odor. damaged.
Pinpoint Tests
PINPOINT TEST A : ABNORMAL EFFORTS OR NOISE/ODOR
A1 CHECK THE GEARSHIFT LEVER

Detach the gearshift lever from the transmission gearshift selector Yes
lever. Install a new gearshift lever. Refer to Gearshift
Lever in this section
Is the gearshift levers isolation rubber damaged?
No
Go to B1
A2 CHECK FOULING OF THE GEARSHIFT LEVER

Remove the gearshift lever knob/boot and insulation pad. Yes
Remove obstruction.
Is the gearshift levers fouled through its shift gate?
No
Go to B2
A3 CHECK GEARSHIFT LEVER LEAKS CABIN NOISE

Remove the gearshift lever boot and retainer assembly. Yes
Install a new gearshift lever boot and retainer
Is the gearshift levers boot damaged? assembly.
No
Check boot and retainer assemblies correctly
installed and hardware torqued to specification.
G73255 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : ABNORMAL TRANSMISSION GEARSHIFT SELECTION
B1 CHECK THE TRANSMISSIONS GEARSHIFT SELECTOR

LEVER
Detach the gearshift lever from the transmission gearshift selector Yes
lever. Install a new gearshift selector lever. Refer to
Manual Transmission Section.
Is the gearshift selector lever damaged?
No
Check for obstruction.
B2 CHECK THE TRANSMISSIONS GEARSHIFT SELECTOR

LEVER SHIFT GATE
Remove the gearshift lever knob/boot and insulation pad. Yes
Service the Transmission as internal shift
Is the gearshift gate difficult to select or binds? mechanism damaged. Refer to Manual
Transmission Section 308-00.
No
Check for obstruction.
G73255 en 01/2003 2003.0 BA Falcon

Gearshift Lever 2. Remove the four nuts securing the gearshift lever
boot and retainer assembly to the floorpan.
1. Place the Gearshift lever in the Neutral position
gate.
3. Gently prise the retainer lugs of the RH top side
finisher panel from the console. For additional
4. Repeat for the LH top side finisher panel.
5. Gently prise the retainer lugs of the consoles top
prindle surround panel from the console. Lift
vertically away from the gearshift lever. For
6. Remove the upper bolt and lower nut securing the
shift lever to the transmission and remove the 3. Lower the vehicle.
lever.
4. Remove the gearshift lever as Gearshift Lever
removal and installation section.
5. Remove the centre console. For additional
6. Remove the gearshift lever boot and retainer
assembly by lifting vertically away from the
transmission stub lever.
7. Inspect the Gearshift lever assembly for wear or

damage. To install, reverse the removal
procedure with attention to the following
instructions.
8. Position the shift lever on the left hand side of the
transmission lever, install and torque the nut &
bolt to specification.
7. Clean and inspect the boots for wear or damage.
9. Screw the knob onto the shift lever until it starts to
To install, reverse the removal procedure.
tighten, continue tightening until the graphics on
the knob are correctly aligned. NOTE: All hardware must be correctly installed
Gearshift Boot and Retainer Assembly

information, refer to Section 100-02 for hoisting
the vehicle.
G73256 en 01/2003 2003.0 BA Falcon

309-00-1 Exhaust System 309-00-1
SECTION : 309-00 Exhaust System

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................309-00-2
Exhaust System ....................................................................................................................309-00-3
Exhaust System ....................................................................................................................309-00-4
Pinpoint Tests ......................................................................................................................309-00-4
GENERAL PROCEDURES
Exhaust System Alignment ...................................................................................................309-00-5
All Rear Muffler Assemblies ..................................................................................................309-00-6
All Intermediate Muffler Assemblies .....................................................................................309-00-6
6 Cylinder Catalyst Assembly ...............................................................................................309-00-6
8 Cylinder Catalyst Assemblies (LHS & RHS) ......................................................................309-00-6
8 Cylinder Y — Pipe Assemblies ..........................................................................................309-00-7
System Diagrams ..................................................................................................................309-00-7
01/2003 2003.0 BA Falcon

SPECIFICATIONS
6 Cylinder Torque Specifications

Description Nm
Catalyst assembly inlet pipe to 25 Nm
manifold nuts.
Catalyst assembly outlet pipe to 35 Nm
intermediate muffler assembly inlet
pipe bolts.
Intermediate muffler outlet pipe to rear 35 Nm
muffler inlet pipe nuts.
8 Cylinder Torque Specifications
Description Nm
Catalyst assembly inlet pipes to 25 Nm
manifold nuts (LHS & RHS).
Catalyst assembly outlet pipes to 35 Nm
Y-pipe assembly inlet pipe nuts.
Y-pipe assembly outlet pipe to 35 Nm
intermediate muffler assembly inlet
pipe bolts.
Intermediate muffler outlet pipe to rear 35 Nm
muffler inlet pipe nuts.
HEGO sensor to catalyst assembly 47.5 Nm
inlet pipe (LHS only).
XR8 Y-pipe band clamp 17 (22Max)
G86726 en 01/2003 2003.0 BA Falcon

Exhaust System The TWC is designed to provide a long life. No

maintenance is necessary for the TWC. Avoid the
The exhaust system provides an exit for exhaust following conditions:
gases and reduces engine noise by passing exhaust Driving with a misfiring engine
gases through the three way catalytic converter Continuously running the engine with a misfiring
(TWC), an intermediate muffler forward of the rear
spark plug.
axle and a rear muffler. Rubber exhaust hanger
insulators attach the exhaust system to the hanger Parking or stopping the vehicle over combustible
brackets. material such as dry grass. The material can be
ignited by the high temperatures of the TWC and
CAUTION: Under no circumstances should the muffler.
non "Original Equipment" exhausts be fitted.
Heat Shields
Three Way Catalytic Converter (TWC) Exhaust system heat shields attached to the
The three way catalytic converter (TWC) plays a underbody protect the vehicle from exhaust system
major role in the emission control system. The TWC heat and should be inspected at regular intervals to
operates as a gas reactor. Its catalytic function is to ensure they are not dented or out of position. If a
speed the heat-producing chemical reaction of shield is damaged or shows evidence of deterioration,
components in the exhaust gases in order to reduce it should be replaced. The shields for the intermediate
air pollutants. muffler, over-axle pipe, and rear muffler are installed
separately.
Precautions
WARNING: The normal operating temperature

of the exhaust system is very high. Never work
around or attempt to repair any part of the
exhaust system until it has cooled. Use special
care when working around the TWC. The TWC
heats to a high temperature after only a short
period of engine operation. Failure to follow these
WARNING: Exhaust gases contain carbon

monoxide which can be harmful to health and are
potentially lethal. Exhaust system leaks should be
repaired immediately. Never operate the engine in
enclosed areas. Failure to follow these
CAUTION: Do not use leaded fuel in a vehicle

equipped with a TWC.
CAUTION: In a vehicle that is continually

misfueled, the lead in the fuel will be deposited in
the TWC and completely blanket the catalyst.
Lead reacts with platinum to ’’poison’’ the
catalyst. Continuous use of leaded fuel can
destroy the catalyst and render the TWC useless.
CAUTION: The addition of lead to the TWC

can also solidify the catalyst, causing excessive
back pressure in the exhaust system and possibly
causing engine damage.
CAUTION: Extremely high temperatures of

1,100°C (2,012°F) or above due to misfiring or an
over-rich fuel/air mixture will cause the ceramic
base to sinter or burn, destroying the TWC.
G56311 en 01/2003 2003.0 BA Falcon

Exhaust System
This section covers general exhaust system
diagnosis, tests, adjustment and repair procedures.
For exhaust system component removal,
disassembly, assembly, installation, clearances,
torque requirements, and bracket locations refer to
the illustrations in Removal and installation section.
Inspect the inlet pipe, outlet pipe, and muffler for
cracked joints, broken welds and corrosion damage
(holes) that would result in a leaking exhaust system.
Inspect the clamps, brackets and insulators for cracks
and stripped or badly corroded bolt threads.
Pinpoint Tests
Engine performance
An exhaust system performance complaint, such as
excessive back pressure is usually noticeable by its
effect on engine performance. For diagnosis of
exhaust system problems that affect engine
performances, refer to section Section 303-00,
Section 303-01A, Section 303-01B, Section
303-01C(engine diagnosis and testing).
Leaks
External leaks in the exhaust system are often
accompanied by noises or exhaust gas emitted from
under the vehicle. A visual inspection of the exhaust
system usually will show the location of the leak. Look
for holes, ruptured joints and corroded areas in the
muffler, inlet pipe and outlet pipe. Examine joints and
connections for deposits that would be caused by
exhaust gas leakage.
Noise/Vibration
A misaligned exhaust system is usually indicated by
vibration, grounding, rattling, or binding of the
components. Often the associated noise is hard to
distinguish from other chassis noises. Use a rubber
mallet to lightly tap on exhaust components and heat
shields to identify noise and vibration areas. It is
important that exhaust clearances and setting
procedures as shown in illustrations in Removal and
installation section be adhered to whenever repairs
involving the exhaust system are carried out. Inspect
exhaust system welds, insulators and insulator
brackets for cracks or breaks. Shake the exhaust
system to identify any exhaust-to-body/chassis
contact. Ensure that the insulators are in a neutral
position when the exhaust system is hot, before
replacing components in an endeavor to correct a
noise, vibration or harshness problem.
G56312 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Exhaust System Alignment

NOTE: The exhaust system must be free of leaks,
binds, grounding and excessive vibration.
Exhaust system vibration, grounding or binds are
usually caused by: loose, broken insulators or
brackets or improperly connected pipes. Any of the
aforementioned conditions may cause changes to
clearances of the exhaust system components. If any
of these conditions exist, the exhaust system
components must be checked, adjusted or replaced to
make certain the specified clearances (refer to the
illustrations in Removal and installation section) are
maintained.
Perform the following procedures to adjust the
exhaust system components:
1. Loosen the securing hardware, and the pipe
support brackets.
2. Progressively align the exhaust system, using the
relative lateral position of the hanger brackets
(exhaust/body mounted) and rubber isolators as a
guide.
NOTE: Exhaust hangers are designed to be
under a small amount of tension when the
exhaust system is cold. This allows for thermal
expansion of the system during normal operation.
3. Tighten all attachments.
NOTE: Tighten the exhaust manifold nuts evenly
and alternately.
4. Start the engine and check the exhaust system for
leaks.
NOTE: Mufflers, inlet pipes and outlet pipes,
gaskets, brackets, and insulators should be
replaced if they are defective or become badly
corroded. Do not attempt to repair these parts.
G56313 en 01/2003 2003.0 BA Falcon

All Rear Muffler Assemblies 6 Cylinder Catalyst Assembly

1. Remove nuts connecting catalyst assembly to
WARNING: Care must be taken so as to avoid
manifold.
damage to exhaust system & fuel tank heat
shields. If shields are damaged or substantially NOTE: Manifold studs and mating exhaust nuts
distorted they should be replaced, and the fuel are one time use parts only and must be
tank inspected for damage. replaced.
1. Remove the nuts connecting the intermediate 2. Remove bolts connecting intermediate muffler to
muffler assembly to the rear muffler assembly. catalyst assembly. Discard the gasket.
Discard the gasket. NOTE: The bolts connecting the intermediate
2. Disconnect rear muffler assembly from the muffler to the catalyst assembly are of a
hangers at the front and rear of the muffler and self-threading type that have been used to tap
remove by pushing muffler rearward and gently thread directly into the catalyst assembly outlet
moving ’over-axle pipe’ through cavity above IRS pipe flange. Conventional class 10.0 bolts with
(sedan only). similar geometry can be used in place of these
self-threading bolts.
procedure. 3. Disconnect the catalyst assembly from the hanger
NOTE: Install new gaskets at each point. on the outlet pipe and remove.
NOTE: Assembly is the reverse of the removal 4. Installation is the reverse of the removal
procedure. To ease reattachment of rubber procedure.
isolators to hanger brackets, a mild detergent NOTE: Care must be taken when attaching a
solution can be applied to the bracket. catalyst assembly to a manifold such that it is
correctly aligned. To achieve this, firstly do up the
NOTE: Care must be taken when attaching a
nuts by hand as far as possible (using a socket
catalyst assembly to a manifold such that it is
with extension), and then torque the nuts up in
correctly aligned. To achieve this, firstly do up the
steps alternating between the two until the
nuts by hand as far as possible (using a socket
nominal torque is achieved.
steps alternating between the two until the
nominal torque is achieved. 8 Cylinder Catalyst Assemblies (LHS &
NOTE: Upon conclusion of assembly, system
RHS)
should be checked for leaks and correct Removal and Installation
alignment, refer Sections on Diagnosis and
1. Remove nuts connecting catalyst assembly to
Testing and General Procedures.
manifold. Both sides will require the removal of an
additional nut retaining a heat shield.
All Intermediate Muffler Assemblies NOTE: Manifold studs and mating exhaust nuts
Removal and Installation are one time use parts only and must be
replaced.
1. Remove bolts connecting intermediate muffler to
catalyst assembly (6 cylinder) or Y-pipe assembly 2. Remove nuts connecting Y-pipe to catalyst
(8 cylinder). Discard the gasket. assembly. Discard the gasket(s).
NOTE: The bolts connecting the intermediate 3. Disconnect catalyst assembly from the hanger on
muffler to the catalyst/Y-pipe assemblies are of a the outlet pipe and remove.
self-threading type that have been used to tap 4. Installation is the reverse of the removal
thread directly into the catalyst assembly outlet procedure.
pipe flange (6 cylinder) or directly into weld nuts
on the Y-pipe outlet flange (8 cylinder). NOTE: Care must be taken when attaching a
Conventional class 10.0 bolts with similar catalyst assembly to a manifold such that it is
geometry can be used in place of these correctly aligned. To achieve this, firstly do up the
self-threading bolts. nuts by hand as far as possible (using a socket
2. Remove the nuts connecting the intermediate steps alternating between the two until the
muffler assembly to the rear muffler assembly. nominal torque is achieved.
Discard the gasket.
3. Disconnect intermediate muffler assembly from
the hanger on the outlet pipe and remove.
procedure.
G56318 en 01/2003 2003.0 BA Falcon

8 Cylinder Y — Pipe Assemblies

1. Remove nuts connecting Y-pipe to catalyst
assembly. Discard the gasket(s), and nuts.
2. Remove bolts connecting intermediate muffler to
Y-pipe assembly. Discard the gasket.
NOTE: The bolts connecting the intermediate
muffler to the catalyst assembly are of a
self-threading type that have been used to tap
thread directly into weld nuts on the Y-pipe
assembly outlet flange. Conventional class 10.0
bolts with similar geometry can be used in place
of these self-threading bolts.
3. Remove the Y-pipe assembly.
procedure.
System Diagrams
Sedan - 6 cylinder (ULP)

1 M10 Nut assembly 6 Rubber exhaust hanger insulators
2 Three-way catalytic converter 7 Nut assembly
3 Intermediate muffler assembly
4 Nut Assembly
5 Rear muffler assembly
G56320 en 01/2003 2003.0 BA Falcon

Sedan - 8 cylinder (ULP)
Item Description
1 M10 Nut assembly
2 Three-way catalytic converter
3 Two-way adapter
5 Nut Assembly
7 Rubber exhaust hanger insulators
8 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

Sedan - 6 cylinder (SFLPG)
Item Description
1 M10 Nut assembly
4 Nut assembly
7 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-10 Exhaust System 309-00-10
Wagon - 6 cylinder (ULP & SFLPG)
Item Description
1 M10 Nut assembly
6 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-11 Exhaust System 309-00-11
Ute - 6 cylinder (ULP)
Item Description
1 M10 Nut assembly
6 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-12 Exhaust System 309-00-12
Ute - 6 cylinder (SFLPG)
Item Description
1 M10 Nut assembly
4 Nut Assembly
7 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-13 Exhaust System 309-00-13
Ute - 8 cylinder (ULP)
Item Description
1 M10 Nut assembly
2 Two-way adapter
7 Nut Assembly
8 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-14 Exhaust System 309-00-14
XR6 (ULP)
Item Description
1 M10 Nut assembly
4 Nut Assembly
7 Nut assembly
G56320 en 01/2003 2003.0 BA Falcon

309-00-15 Exhaust System 309-00-15
XR6 Turbo (ULP)
Item Description
1 M10 Nut assembly
4 Nut Assembly
7 Bolts x 3
G56320 en 01/2003 2003.0 BA Falcon

309-00-16 Exhaust System 309-00-16
Ute – XR6 Turbo (ULP)
Item Description
1 Three way catalytic converter
2 Front muffler assembly
3 Nut assembly
6 Bolts x 3
G56320 en 01/2003 2003.0 BA Falcon

309-00-17 Exhaust System 309-00-17
XR8 (ULP)
Item Description
1 M10 Nut assembly
3 XR8 Y Pipe Assembly
5 Nut assembly
7 Nut Assembly
8 Nut assembly
9 XR8 Y Pipe Band Clamp
G56320 en 01/2003 2003.0 BA Falcon

310-00-1 Fuel System 310-00-1
SECTION : 310-00 Fuel System

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................310-00-2
Fuel System ..........................................................................................................................310-00-3
Electrical Fuel Pump .............................................................................................................310-00-4
Evaporative Emission Control System ..................................................................................310-00-4
Fuel Filters ............................................................................................................................310-00-5
Fuel system shut off switch ..................................................................................................310-00-5
Fuel pressure regulator ........................................................................................................310-00-6
Fuel System ..........................................................................................................................310-00-7
Symptom Chart ....................................................................................................................310-00-7
Pinpoint Tests ......................................................................................................................310-00-7
GENERAL PROCEDURES
Pump Operation Check ..........................................................................................................310-00-9
Pressure Test .........................................................................................................................310-00-9
Fuel Flow (Volume) Test ........................................................................................................310-00-9
Draining Fuel ........................................................................................................................310-00-10
Purge Control Valve Testing ................................................................................................310-00-10
Fuel Tank (Sedan) ...............................................................................................................310-00-11
Fuel Tank (Wagon) ..............................................................................................................310-00-11
Fuel Tank (Ute) ....................................................................................................................310-00-11
In — Line Filter .....................................................................................................................310-00-12
Fuel Supply and Fuel Return Lines .....................................................................................310-00-12
Vapour Lines ........................................................................................................................310-00-14
Carbon Canister ...................................................................................................................310-00-14
Fuel Module - Fuel Pump ....................................................................................................310-00-15
Sender Assembly .................................................................................................................310-00-16
Fuel Shut Off Switch ............................................................................................................310-00-17
01/2003 2003.0 BA Falcon

310-00-2 Fuel System 310-00-2
SPECIFICATIONS

Description Specification LPG Idle Solenoid to Converter 16
Fuel Tank Capacities — Total LPG Converter to Mounting Bracket 7
Sedan 68 Litres LPG Tank to Floor Mounting Bolts 50
Wagon 69 Litres (Sedan)
Ute 78 Litres LPG Tank to Floor Mounting Studs 50
(Wagon)
Single Fuel LPG
LPG Service Valve to Tank 5
LPG Fuel Tank Manufactured by APA
Industries LPG AFL to Tank 5
Capacity: LPG Pressure Relief Valve 60
Sedan 93L (usable) LPG Gauge (AXIOM) 5
Wagon 116L (usable)
Ute 92L (usable)
LPG Fuel Sender 0-176 ohms
LPG Pressure Relief Relief Pressure: 2.55
Valve MPa
LPG Service Line Bundy-Tube - Performed
8mm
Diameter (with flexible
pressure)
hose at tank end on
sedan)
LPG Converter and Filter VIALLE - FS Type
Lock Off Assembly (Special)
LPG Mixer Assembly Tickford - LPG Fuel
PCM
For detailed electrical specifications of the fuel
injection system, refer to Diagnosis and Testing, in
Section 303-14.
Fuel Pump (6 & 8 Cylinder)
Delivery (minimum) 277 cc in 10 seconds @
270 kPa,
12 Volts
Pressure at:
engine idle 225 kPa, 250 kPa I6HO
engine stationary 270 kPa, Base I6
270 kPa, Base V8
400 kPa, Turbo I6
Maximum pressure drop 10% in 10 seconds
on engine shut down
Fuel pump resistance at < 10 ohms
loom connector:
Description Nm
Pressure Regulator Tube Nut 27
Fuel Tank Retaining Shield – Sedan 35
Fuel Tank Retaining Strap – 28
Wagon/Ute
Sender Unit/Pump Screws – All 1.9 – 2.5
LPG Flared Connections 37
LPG Converter Bracket to Spring Upper: 35
Tower Lower: 15
G345270 en 01/2003 2003.0 BA Falcon

310-00-3 Fuel System 310-00-3
Fuel System pump assembly is mounted in the top of the tank. The
tank is secured to the underbody by two steel straps.
Nylon tubing with a wear resistant outer sheath form
the fuel lines. The vapour line is a nylon tube. These
lines connect the tank to the main underbody lines.
The carbon canister is mounted on the tank.
A nylon tube connects it to the central spigot of the
pump top. Another nylon line joins the canister outlet
to the main body lines. The canister has a corrugated
nylon breather hose which is clipped into a cross
member to reduce ingestion of water or dust into the
canister.
Ute
Sedan
The fuel tank on sedan models is a two piece
moulding with a separate steel filler neck (joined by
rubber hose).
The tank is located beneath the floor of the left hand
side rear passenger.
The top of the filler neck is located in the left hand
rear quarter panel. The filler neck is fixed to the side
rail with a specially coated bolt that ensures electrical
grounding to eliminate electrostatic charge.
The fuel pump assembly is mounted in the tank and is
accessible beneath a plastic plug under the rear Item Description
cushion on the LHS of the vehicle. The fuel level 1 Pressure/Return Lines
sender arm assy. is mounted remotely from the pump 2 Tank
on the internal baffle inside the tank. It is serviceable
and is electrically connected via the fuel pump wiring 3 Rear Wiring Assembly
connector. The fuel tank on ute models is a one piece moulding
Nylon tubing form the fuel lines. The vapour vent line with an integral filler neck. It is located beneath the
is a large diameter corrugated nylon tube and is ute load floor, between the rear of the cabin and
attached to the Fuel Limit Vent Valve (FLVV) on the forward of the axle.
top of the tank. It vents directly into the canister. The filler neck is located in the left hand rear quarter
A nylon purge line then connects the canister back to panel. The tank is electrically grounded via the metal
the main underbody lines. The canister has a end of the filler neck to the body via a grounding wire
corrugated nylon breather hose which is clipped into a in the pump loom.
cross member to reduce ingestion of water or dust The fuel gauge sender unit and fuel pump assembly is
into the canister. mounted in the top of the tank. The tank is secured to
The tank is secured to the underbody by a large the underbody by two straps.
galvanized steel stamping which also acts as a shield. Nylon tubing with a wear resistant outer sheath form
The carbon canister is mounted on the body adjacent the fuel lines. The vapour line is a nylon tube. These
to the tank on the other side of the exhaust pipe and lines connect the tank to the main underbody lines.
above the IRS.
The carbon canister is mounted on the tank. A nylon
Wagon tube connects it to the central spigot of the pump top.
Another nylon line joins the canister outlet to the main
The fuel tank on wagon models is a one piece body lines. The canister has a corrugated nylon
moulding with an integral filler neck. It is located breather hose which is clipped into a cross member to
beneath the wagon load floor, rearward of the axle. reduce ingestion of water or dust into the canister.
The top of the filler neck is located in the left hand
rear quarter panel. The tank is electrically grounded All models
via the metal end of the filler neck to the body via a Steel tubing, 8.0 mm O/D for fuel delivery and return
grounding wire. The fuel gauge sender unit and fuel and 6.3 mm O/D for vapour, forms the main
underbody lines. The tubes are coated with zinc PVF
G345271 en 01/2003 2003.0 BA Falcon

310-00-4 Fuel System 310-00-4
for corrosion protection. (The main body harness also the system after the engine is shut down. The
contains one or two 4.9 mm brake lines) Elastomer pressure retention helps to prevent hot starting
lined nitrile rubber hoses connect the engine fuel rail problems.
to the main underbody lines. System pressure is controlled by a pressure regulator
The wagon also includes a washer line to connect the valve mounted on the fuel rail.
washer bottle to the windscreen nozzle. All Falcon models have the electric pump mounted in
A fuel filter is installed in the delivery line and a Modular Reservoir Assembly (MRA). The MRA has
attached to the LHS side rail roughly in line with the B an integral reservoir in which the fuel pump rests to
pillar. The filter consists of a paper filtering element in ensure that the pump pickup is submerged in fuel at
a stainless steel casing. The filter is a sealed unit and all times during extreme vehicle manoeuvres and
is replaced as an assembly when required. attitudes when the fuel level in the tank is low.
The fuel system supplies the fuel injectors with filtered The reservoir is spring loaded to maintain the pump
fuel at a controlled pressure. The Powertrain Control and sender is always in contact with the bottom of the
Module (PCM) controls the fuel pump and the on/off fuel tank (for improved low fuel usage and fuel gauge
duration (pulse width) and timing of the fuel injectors. accuracy). A filtering element is located in the fuel
pump reservoir to prevent contaminants which could
Fuel Injection PCM damage internal components of the pump. The
The electronic fuel injection system supplies the electrical system has a fuel pump control relay which
correct amount of fuel to the engine as required for is controlled by the engine management PCM.
the operating conditions. When the ignition switch is ’OFF’ the contacts of the
PCM and fuel pump relays are open. When the
Each cylinder has an individual fuel injector controlled ignition switch is first turned to the ON position, the
sequentially to inject the fuel at the optimum point in PCM power relay is energized, closing its contacts.
the engine cycle. The Powertrain Control Module
(PCM) adjusts the fuel injection pulse width, delivering With the ignition switch ’ON’ and prior to moving it to
a precise quantity of fuel into the intake port above ’START’ fuel pump operation will be audible.
the inlet valve. The fuel pump is powered via the contacts of the fuel
Fuel is injected into the cylinders in the same pump relay. If the ignition switch is not turned to the
sequence as the ignition firing order. As the fuel is START position, the PCM will open the ground circuit
injected into a closed port, the period that each after approximately one second. Opening the ground
charge remains in the port is even for all cylinders, circuit de-energizes the fuel pump relay which, in turn,
ensuring optimum mixture throughout the engine. de-energizes the fuel pump.
This circuitry provides for pre-pressurization of the
Fuel System Components fuel system. When the ignition switch is turned to the
The fuel system consists of the following components. START position, the PCM operates the fuel pump
relay to provide fuel for starting the engine while
Fuel Tank cranking. After the engine starts and the ignition
Fuel Pump switch is returned to the ON position, power to the
Fuel Supply and Return Lines fuel pump is again supplied through the fuel pump
relay.
Fuel Filter
The PCM senses engine speed and shuts off the fuel
Fuel Rail pump by opening the ground circuit to the fuel pump
Fuel Injector relay when the engine stops or is below 120 rpm.
Fuel Pressure Regulator
Fuel Shut off Switch
Evaporative Emission Control System
A large percentage of overall emissions can consist of
Electrical Fuel Pump petrol vapours that might escape from the fuel tank.
The fuel supply system incorporates an electric fuel These evaporative losses occur not only when the
pump mounted inside the fuel tank. vehicle is operating but also when the vehicle is
parked. In fact most vapours are lost when the vehicle
Both the normal 6 cylinder and 8 cylinder vehicles use is parked.
a single stage turbine type pump with a minimum
output, at 13 volts, of 110 litres per hour at 270 kPa. These losses have been eliminated by providing a
sealed fuel tank system. With such a system, fuel
Some Tickford vehicles and high performance vapours are trapped and directed to the engine for
vehicles may have fuel pumps with higher flow rates burning in the normal combustion process.
and a higher pressure regulator on the engine fuel
rail. The system consists of the following components
The pump has a check valve inside the outlet port. fuel tank
The function of this valve is to maintain pressure in vapour lines
G345271 en 01/2003 2003.0 BA Falcon

310-00-5 Fuel System 310-00-5
carbon canister control valve when engine operating conditions are

canister purge control valve favourable.
fuel tank filler cap When the purge valve is open, manifold vacuum is
applied to the canister. Fresh air is drawn through the
These components form the Fuel Expansion and canister from the corrugated nylon tube on the
Vapour Collection System and the Vapour Vent and
atmospheric port. As the fresh air is drawn through
Storage System.
the carbon bed it releases the vapour from the
Fuel Expansion and Vapour Collection granules and carries it into the engine to be
consumed in the combustion process.
All fuel tanks are is designed to leave a volume void
or space above the fuel when the tank is filled to Filler Cap
capacity: The filler cap incorporates a two way
Sedan 68 litres pressure/vacuum relief valve. The cap functions as a
Wagon 69 litres check valve under normal operating conditions. It
allows air to enter the tank as fuel is used while
Ute 78 lites preventing vapours to escape to the atmosphere. IT
Filled to capacity is generally when the fuel bowser IS VERY IMPORTANT THAT THE CORRECT CAP
nozzle shuts off. This space allows for the expansion IS USED.
of the fuel and the collection of vapours.
The cap opening pressure have been varied since the
Trickle filling the tank beyond rated capacity will EA Falcon in 1988 to improve vapour management.
damage the emission system. To prevent this, DO To indicate the difference the colour of the cap was
NOT fill past the first bowser shut off click. changed.
Vapour Vent and Storage Black...... 2.5 kPa 1988 to 1998
Sedan: In addition to the fuel vapours generated in Grey....... 4.5 kPa 1998 to 2002
the tank the vapour generated during refueling are Green..... 11 kPa 2002
vented through the Fuel Limit Vent Valve (FLVV) and
the Roll Over Valve (ROV) to the carbon canister CAUTION: It is very important that the correct
where they are stored prior to being consumed in the cap is used.
engine.
Pressure in the tank will force vapour into the canister
Fuel Filters
The FLVV and the ROV prevents the canister from To prevent the fuel injectors becoming clogged or
receiving liquid fuel in the event of a vehicle roll over contaminated with foreign material, the fuel system
accident. contains four levels of filtering:
The FLVV controls the rated liquid capacity of the Fuel Pump: A filter screen is mounted on the
tank. intake side of the fuel pump. The filter is part of
Wagon & Ute: The fuel vapours generated in the tank the assembly and cannot be replaced separately.
are vented through the vapour line to the carbon Fuel Filter Assembly: The fuel filter assembly is
canister where they are stored prior to being located in the fuel supply line between the fuel
consumed in the engine. pump and the fuel rail. The fuel filter assembly
Pressure in the tank will force vapour into the canister must be periodically replaced according to the
via the central spigot on the pump unit. The upper maintenance schedule.
filler neck is vented via a nylon line back to the tank. Fuel Pressure Regulator: A filter is located on
A rollover valve is installed in the central spigot. The the inlet side of the fuel pressure regulator. The
valve prevents the canister from receiving liquid fuel in filter is part of the assembly and cannot be
the event of a vehicle roll over accident. replaced separately.
Fuel Injectors: A mesh screen on the inlet side of
Carbon Canister the fuel injector prevents foreign debris and
The canister contains a quantity of activated carbon materials from entering the fuel injector
granules for storage of fuel vapours and filters to mechanism. The filter is part of the assembly and
prevent ingress of particulate matter into the engine. It cannot be replaced separately.
is mounted on or near the tank.
Fuel system shut off switch
Pressure and vacuum in the fuel tank forces vapours
through the vapour line into the canister where it is All Barra models are fitted with a switch that cuts off
adsorbed by the carbon granules. Purging of the fuel supply to the engine in the event of an accident.
vapours from the canister is controlled by a signal Sudden vibrations such as collisions when parking
from the PCM that varies the duty cycle (frequency of may also activate this switch.
opening and closing) of the solenoid type purge
G345274 en 01/2003 2003.0 BA Falcon

310-00-6 Fuel System 310-00-6
Fuel pressure regulator

The fuel pressure regulator works with the fuel pump
to maintain a steady pressure relationship between
the fuel line side of the injectors and the intake
manifold. The regulator is a spring loaded diaphragm.
The spring keeps the appropriate amount of pressure
in the fuel system. When there is a high vacuum in
the intake manifold, such as at high rpm, the pressure
in the fuel system must be reduced. When there is
low pressure in the intake manifold, such as at low
speed or full throttle operation, the pressure in the fuel
line must be increased. In order to maintain desired
fuel pressure, excess fuel is returned to the tank by a
separate line from the pressure regulator.
G345274 en 01/2003 2003.0 BA Falcon

310-00-7 Fuel System 310-00-7
Fuel System Ensure that there is fuel in the tank.

NOTE: If Diagnostic Trouble Code P0230 is displayed
Inspection and Verification during the PCM Self Test the fuel pump relay
actuating circuit is faulty. This fault must be rectified
WARNING: Fuel supply lines will remain before carrying any further fuel delivery tests.
pressurized for long periods of time after engine To carry out pressure and volume tests it is first
or pump shut down. Use care to prevent personal necessary to install a remote control switch in the
injury or combustion of fuel when disconnecting power line to the pump. Detach the loom connector
fuel lines. from the base of the fuel pump relay. Connect the
switch across terminals 57 (BK) and 787 (BK/Y) of the
CAUTION: Do not run the fuel pump in a dry loom connector.
condition, to do so will damage internal
components of the pump.
Symptom Chart
NOTE: Please note the following assumptions:
Battery voltage has been checked and verified as 12V
Starter motor is cranking
DTC 0232 on PCM not flagged

Able to crank (ie starter motor working) Fuel Pump Go to Pinpoint test A
but engine does not catch Fuel shut off switch
Fuel relay in PDB
Wiring, circuitry
Ignition coils, spark plugs
Pinpoint Tests
PINPOINT TEST A : ABLE TO CRANK (IE. STARTER MOTOR WORKING) BUT ENGINE DOES NOT
CATCH
A1 CHECK IF FUEL SHUT OFF SWITCH IS "ACTIVATED"

(O/C BETWEEN FUEL PUMP AND POWER FROM PDB)
Turn key to ACC or ON. Yes
Go to A2
Is fuel shut off switch activation light on cluster illuminated?
No
Press fuel shut off switch button, then retry
starting vehicle. Fuel shut off switch is accessed
via scuff plate in front passenger foot well.
A2 LISTEN FOR FUEL PUMP OPERATION

Turn key to ON and for fuel pump. Fuel pump should make buzzing or Yes
clicking noise when operational. Check ignition coils and spark plugs
NB: two people are required for this test: 1 person to turn key, 1
person to listen to fuel pump under car.
No
Go to A3
Is fuel pump operational?
A3 CHECK FUEL FUSE IN PDB

Check if fuel fuse in PDB is blown. Yes
Replace fuel fuse with a new fuse, then retry
Is fuel fuse in PDB blown? starting vehicle.
No
Go to A4
G345275 en 01/2003 2003.0 BA Falcon

310-00-8 Fuel System 310-00-8

A4 CHECK VOLTAGE SUPPLY TERMINAL OF FUEL RELAY
SOCKET IN PDB
Remove fuel relay from PDB Yes
Check wiring between fuel fuse and fuel relay
Measure voltage of fuel relay socket terminal (on PDB) circuit 1059 to socket terminal (on PDB) circuit 1059.
grond
Is 12V measured on terminal? No
Go to A5
A5 CHECK PDB RELAY

Turn key to OFF position. Yes
Replace Fuel relay and retest for correct
Place finger on fuel pump relay in PDB
operation.
Turn key to ON and feel for activation "click" from fuel relay.
No
NB: two people are required for this test: 1 person to turn key, 1 Go to A6
person to place finger on fuel relay.
Is fuel relay activating?
A6 CHECK VOLTAGE ACROSS FUEL PUMP

Check voltage across fuel pump. Refer to Section 310-00 for Yes
instructions to access fuel pump Problem with fuel pump. Replace fuel pump
Is voltage across fuel pump 12V? No
Go to A7
A7 CHECK IF FUEL SHUT OFF SWITCH IS CONNECTED TO

HARNESS
Remove scuff plate in front passenger foot well. Yes
Connect fuel shut off switch to harness, then
Is fuel shut off switch connected to harness? retry starting vehicle.
No
Go to A8
A8 CHECK CONTINUITY OF FUEL SHUT OFF SWITCH

Disconnect fuel shut off switch. Yes
Fuel shut off switch is faulty. Replace fuel shut
Check continuity of fuel shut off switch off switch and retry starting vehicle.
Does fuel shut off switch function as expected?
No
Go to A9
A9 CHECK VOLTAGES SUPPLIED TO FUEL SHUT OFF

SWITCH
Measure voltage of circuit 787A at Fuel shut off switch terminal on Yes
harness. There is a wiring break between fuel relay
socket terminal (on PDB) and connector of fuel
Is 12V measured? shut off switch (on harness). Repair harness and
retest for correct operation.
No
There is a wiring break between the connector
of fuel shut off switch (on harness) and fuel
pump connector (on harness). Repair harness
and retest for correct operation.
G345275 en 01/2003 2003.0 BA Falcon

310-00-9 Fuel System 310-00-9
GENERAL PROCEDURES
Pump Operation Check 2. Start the engine if possible and note the fuel
pressure at idle.
1. Detach the fuel delivery line (the line coming from If the engine cannot be started install a remote
the filter) from the fuel rail. Place the end of the control switch at the relay.
delivery line in a container. Operate the switch and note pressure.
2. Switch ignition on. The pump should deliver fuel Specification:
for one second. Switch ignition off. 270 kPa Base I6
3. If the pump does not run, detach the wiring 300 kPa Base V8
connector from the pump end of the loom. On
400 kPa Turbo I6
sedan this connector is located beneath the
plastic cover which is under the rear seat cushion. 3. If the pressure reading is low slowly close off the
On wagon the connector is accessible via a fuel delivery test line between the gauge and the
rubber grommet in the floor of the luggage space. fuel rail while operating the pump. Pressure
On utes the connector may be accessible under should increase to at least 400 kPa.
the vehicle via the extended wiring loom. If pressure does not increase a faulty fuel pump is
indicated.
4. Connect a voltmeter across the loom terminals.
Switch on the ignition while observing the meter. Fuel Flow (Volume) Test
The meter should read battery voltage for
approximately one second then drop to zero.
Failure to do this indicates a fault in the power WARNING: Engine must be switched off
supply circuit. during this test.
5. Check the pump for continuity. Connect an 1. Disconnect the fuel return line from the steel line
ohmmeter across the terminals of the pump lead. (lower dash panel) and place the end of the
(Specifications - less than 10 ohms.) flexible hose into a graduated container.
NOTE: Do not attempt to detach the fuel pump 2. Operate the remote control switch for 10 seconds.
lead from the pump bracket. 3. Remove the measuring container and check
contents against specification:277 cc.
Pressure Test NOTE: Fuel volume must be at nominal regulated
pressure. See specifications listed in Pressure
1. ’T’ The fuel pressure gauge (refer Special Tools
Test of General Procedures in this chapter.
section) into the fuel delivery line.
Fuel System Pressure Retention
1. Operate the remote control switch for 10 seconds
and note fuel pressure.
Maximum pressure drop permissible is 10% in 10
seconds. A pressure drop in excess of this figure
indicates a leak in the pressure system.
2. Check by closing off the pressure line just before
the gauge.
No pressure drop - leak in pressure line to
pump or in non-return valve of pump.
Pressure continues to drop - leak in injectors,
pressure regulator or fuel rail connections.
To determine source of pressure leak close
off the fuel return line.
Item Description
No pressure drop - replace pressure
1 Fuel Pressure Gauge regulator.
2 Quick Connect Fitting Pressure continues to drop - check fuel rail
3 Pressure Line connections and test injectors.
3. Remove the pressure gauge and reconnect fuel
lines.
4. Check for fuel leaks.
5. Remove the remote control switch and install the
loom plug in the base of the relay.
G345278 en 01/2003 2003.0 BA Falcon

310-00-10 Fuel System 310-00-10
Draining Fuel
If the fuel pump is operational then it should be used if
it is necessary to drain fuel from the tank. Disconnect
fuel return line at main underbody lines and attach a
transparent drain tube. Run engine to facilitate
expedient fuel removal. Air bubbles in fuel stream will
indicate low fuel level.
CAUTION: Care should be taken to ensure

fuel pump is not run dry.
1. In situations where the fuel pump is not
functioning then:
Use a nylon 5 mm OD tube carefully inserted
down the filler neck, past the tank check valve
to the bottom of the tank to siphon the fuel.
Sedan
1. With the vehicle on a level surface and the fuel
tank no more than 1/2 full it is not necessary to
remove any fuel from the tank.
Purge Control Valve Testing
1. Detach the solenoid valve.
2. Apply 250 mm Hg vacuum to one port of the
valve.
3. Apply 12V across the solenoid terminals. Vacuum
should collapse immediately. If this does not
happen, renew the valve.
G345278 en 01/2003 2003.0 BA Falcon

310-00-11 Fuel System 310-00-11
Fuel Tank (Sedan) Installation

1. Raise tank into straps and latch bolt/nut assy. into
Removal body mounting brackets.
1. Drain the fuel from the fuel tank into a suitable 2. Connect the pump sender electrical loom to the
container. pump top connector.
2. Disconnect vapour and fuel lines at main 3. Replace tank attaching bolts at filler neck and
underbody lines (QFC’s). torque to 15Nm.
Quick Fit Connectors (QFC) is normally removed 4. Replace floor mounted air flow through vent.
by pushing the QFC further on (approx 1mm),
squeezing the knurled pads together and then 5. Reconnect earth lead located on filler neck.
pulling QFC off. 6. Torque fixing bolts at fuel tank straps to 25 - 30
3. Disconnect balance line. Nm.
4. Disconnect vent and purge lines at canister 7. Reconnect balance line.
(QFC). 8. Reconnect vapour and fuel lines at main
5. Disconnect fuel filler hose and clamp. underbody lines (QFCs).
6. Disconnect electrical connector on top of pump. Fuel Tank (Ute)
7. Remove IRS module Refer to Section 204-02a.
8. Remove Tank shield bolts and nuts. Removal
1. Drain the fuel from the fuel tank into a suitable
9. Lower tank carefully to ground.
container.
NOTE: Do not allow the tank to hang from the fuel
lines, wiring or filler neck during removal. 2. Raise vehicle.
3. Remove driveshaft.
Installation
4. Disconnect parkbrake cable at the adjuster.
1. Position the tank and shield under the vehicle and
loosly attach with bolts and nuts. 5. Remove rear calipers.
2. Align tank and shield via holes in shield and 6. Remove the U bolts and spring plate on both LH
dimples in tank. and RH sides and slide rear axle back towards
rear of vehicle as far as possible.
3. Tighten bolts and nuts to specification.
7. Disconnect two fuel Quick Fit Connectors and the
4. Connect the wiring plug. fuel vapor line connector at the end of the body
5. Reconnect balance line. mounted fuel and brake harness assy.
6. Connect vapour and fuel lines to the main body 8. Disconnect balance line.
lines. 9. Disconnect wiring for fuel sender/pump from
7. Connect rubber hose on filler neck to tank. upper cross-member.
8. Connect vent and purge lines to canister. 10. Remove 13 mm bolts that retain the fuel tank
9. Fill the tank, start the engine, and check all straps.
connections for leaks.
10. Reinstall IRS.
Fuel Tank (Wagon)

Removal
1. Drain the fuel from the fuel tank into a suitable
container.
2. Disconnect vapour and fuel lines at main
underbody lines (QFC’s).
3. Disconnect balance line.
4. Remove floor mounted air flow through vent.
5. Remove tank attaching bolts at filler neck.
6. Disconnect earth lead located on filler neck.
Item Description
7. Loosen fixing bolts at fuel tank straps.
1 Chassis
8. Support tank and lower sufficiently to allow the
pump sender electrical loom to be disconnected. 2 Fuel Tank Assembly Strap
9. Lower tank and remove from vehicle. 3 Bolt
G345283 en 01/2003 2003.0 BA Falcon

310-00-12 Fuel System 310-00-12
11. Carefully maneuver tank out of position and lower 6. Tighten the retaining strap nuts.
to the ground.
Item Description
Item Description 1 Neck Collar
1 Fuel Tank Assembly 2 Tank
12. Remove pump, Refer to Pump Removal and 3 Nut M8x20 Corflex
Installation in this section. 7. Fill the tank with fuel and check for leaks and fuel
Installation gauge.
1. Loosely hang the tank in the vehicle by the tank
straps. In — Line Filter
2. To ensure correct position of the tank when the Removal
tank straps are fully tightened it is recommended 1. Raise the vehicle on a hoist.
that some liquid soap or detergent be smeared on
the tank strap rubber insulators. 2. Remove fuel filter line retaining nipples.
3. Reconnect the fuel pump wiring at the cross 3. Loosen filter retaining clamp and slide filter
member. rearward to remove from the vehicle.
4. Reconnect balance line. Installation
5. Reconnect the fuel line quick connect fittings to 1. Install the filter in the retaining clamp with the
the main fuel and brake harness on the body. The arrow on the can in the direction of fuel flow.
return fuel line has a piece of silver tape adjacent 2. Fit and tighten fuel line retaining nipples to 32
to the quick fit connector. Nm.
3. Run engine and check for fuel leaks.
4. Lower vehicle.
Fuel Supply and Fuel Return Lines

Removal
1. With the vehicle on a level surface and the fuel
level below the bottom of the filler neck it is not
necessary to remove any fuel from the tank.
Item Description
1 Pressure/Return Lines
2 Tank
3 Rear Wiring Assembly
G345283 en 01/2003 2003.0 BA Falcon

310-00-13 Fuel System 310-00-13
2. Disconnect the line at each end and remove the

line from the holding clips along the underbody.
Item Description
1 Fuel Tube Assembly
Item Description 2 Vapour Fuel Hose
1 Fuel tube return 3 Fuel Tube Assembly
2 Fuel vapour hose 4 Fuel Line Support Bracket
3 Fuel tank to vapour hose 5 Rivet
4 Rear brake lines
5 Fuel tube return
Item Description
Item Description 2 Ventilation to Storage Canister Rear Tube
1 Fuel Tube Assembly 3 Front Upper to Engine Tube
2 Blind Rivet 4.8 x 13.8 4 Return Fuel Line Assembly
G345288 en 01/2003 2003.0 BA Falcon

310-00-14 Fuel System 310-00-14

1 Rivet 1 Fuel Tubing Shield
2 Fuel Tube Assembly 2 Screw
3 Vapour Line
4 Delivery Line
5 Return Line
Item Description
1 Fuel Tank Filler Pipe Assembly
2 Bolt M6x25
Item Description 3 Cobra Clamp
1 Fuel Tank Assembly 4 Pipe End
2 Fuel Lines Installation
3 Bracket 1. Position the lines in the underbody clips and
tighten the clips. Fill the tank, start the engine,
and check for leaks.
Vapour Lines
The vapour lines can be replaced similarly to the fuel
lines.
Carbon Canister
The carbon canister is good for the life of the vehicle;
however the canister must be replaced if punctured,
subjected to crushing, corrosion or contamination by
any liquid such as oil, fuel or water.
G345288 en 01/2003 2003.0 BA Falcon

310-00-15 Fuel System 310-00-15
5. Disconnect the fuel module assembly electrical

harness.
6. Remove the three fuel lines using AU601 from the
fuel module assembly.
Item Description
1 Tube
2 Return Fuel Tube
7. Unscrew all six fuel module bolts using a Philips
3 RR BrakeTube Assembly screwdriver.
Fuel Module - Fuel Pump

Special Tool(s)
Quick connect removal special
service tool
AU601
Removal
1. Record radio presets and disconnect the negative
terminal of the battery. 8. Remove fuel module retainer and fuel module
2. Relieve fuel system pressure. Refer to the Fuel assembly from the fuel tank.
Pressure Relief in the General Procedure section 9. Disconnect (Blue/Black) sender electrical
of this chapter. connector from the fuel module.
3. Drain fuel tank. Refer to Draining Fuel in the NOTE: After removing the fuel module assembly,
General Procedure section of this chapter. cover the fuel tank to prevent any contamination
4. Remove the rear seat cushion. of fuel.
Installation
1. Replace original gasket from top of fuel tank with
a new gasket.
CAUTION: Fuel module gasket must
always be replaced with a new gasket before
installing a new fuel module assembly.
2. Reconnect (Blue/Black) sender electrical
connector to new fuel module assembly.
3. Reinstall fuel module assembly to the fuel tank.
G345291 en 01/2003 2003.0 BA Falcon

310-00-16 Fuel System 310-00-16
4. Screw fuel module retainer onto fuel module Sender Assembly

assembly and fuel tank with bolts, tightening to
2.2±0.3Nm. Removal
1. Remove the Fuel Module, Refer to Fuel pump
Removal and Installation in this section.
CAUTION: Do not allow any portion of the
float arm to bend. Be sure the 90º bend near
the pivot of the float arm is intact. A deformed
float arm will result in an inoperative sending
unit.
2. Remove the sender assembly from the bracket by
moving it to forward and to the side.
5. Connect the three fuel lines to the fuel module

assembly.
6. Connect the electrical harness to the fuel module
assembly.
3. Rotate the sender assembly and manovour out.
7. Replace the rear seat cushion.
8. Refill the fuel tank.

9. Reconnect the battery and reset the radio presets
and the clock.
G345291 en 01/2003 2003.0 BA Falcon

310-00-17 Fuel System 310-00-17
Installation
1. Reverse the removal process.
Fuel Shut Off Switch

Removal
1. Remove left front scuff plate. Please see Section
501-05 for scuff plate installation and removal
instructions.
2. Unscrew Fuel shut off switch.
Installation
1. Reverse the removal process.
G345293 en 01/2003 2003.0 BA Falcon

310-02-1 Acceleration Control 310-02-1
SECTION : 310-02 Acceleration Control

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................310-02-2
Acceleration Control ..............................................................................................................310-02-3
Acceleration Control ..............................................................................................................310-02-4
Symptom Chart ....................................................................................................................310-02-4
Pinpoint Tests ......................................................................................................................310-02-8
Accelerator Pedal and APM unit — Adjustable Pedals ......................................................310-02-11
Accelerator Pedal and APM unit — Fixed Pedals ..............................................................310-02-12
Adjustable Pedal Indexing ..................................................................................................310-02-14
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Carrier Plate Bolts (fixed accelerator 6 ± 0.5
pedal only)
Adjustment Motor Retaining Bolts 5 ± 0.5
(adjustable pedal)
Accelerator Gearbox Torx Head 2.5 ± 0.5
Screws (adjustable pedal only)
APM Mounting Bolts 6 ± 0.5
G73252 en 01/2003 2003.0 BA Falcon

Acceleration Control
Acronyms and Abbreviations
APM Accelerator Pedal Module
PCM Powertrain Control Module
Step Over Height Difference Between Brake and
Accelerator Pedal
MSC Memory Seat Controller
PPS Pedal Position Sensor
G73253 en 01/2003 2003.0 BA Falcon

Acceleration Control Mechanical Electrical

Accelerator Pedal Fuse(s)
Inspection and Verification Accelerator pedal pad Relay(s)
1. Verify the customer concern. Adjustment Wiring harness
mechanism Electrical connector(s)
Fuel injection pump
or electrical damage.
Accelerator pedal
position sensor
APM
MSC
PCM
4. If the cause is not visually evident, verify the
symptom and refer to Symptom Chart.
Symptom Chart
Symptom Chart

Excessive Effort Required Too Pedal Binds Go to PinPoint Test A
Depress Accelerator Pedal
Foreign Object Effecting the APM Go to PinPoint Test A
Worn or Damaged APM Go to PinPoint Test A
APM Return Spring Damaged Go to PinPoint Test B

Engine Idle Speed Higher Than Incorrect Signal from APM Go to PinPoint Test B
Specification
PCM Issue Refer to PCM Diagnosis Section.

Accelerator Pedal Does Not Return APM Return Spring Damaged Go to PinPoint Test B
Freely
Foreign Object Caught in the APM Go to PinPoint Test A

No Engine Response when APM Electrical Connection Go to PinPoint Test D
Accelerator Pedal Pushed
PCM Issue REFER to Section 303-14.
APM Faulty Go to PinPoint Test D
Unable to Adjust the Accelerator Pedal APM Electrical Connection Go to PinPoint Test D
Faulty Potentiometer (memory only) Go to PinPoint Test D

Memory settings Incorrect (memory Go to PinPoint Test D
only)
Adjustment Cable Go to PinPoint Test C

Accelerator and Brake Pedal "step Adjustment Issue Go to PinPoint Test C
over" (height difference) Incorrect
Symptom Chart -(For adjustable pedal box only)

Unable to adjust the accelerator pedal Unconnected Adjustment motor CHECK the connection between the
motor and the MSC
Disengaged adjustment gear box in RECONNECT adjustment gear box
the carrier plate
G73255 en 01/2003 2003.0 BA Falcon


Faulty Potentiometer (Memory Pedal REPLACE potentiometer
Box Only)
Incorrect memory settings (Memory RESET memory
Pedal Box Only)
Step over between brake pedal and Incorrect-adjustment Refer to Assembly and Disassembly of
accelerator pedal Accelerator Pedal Indexing.
NOTE: Do not run to stall on the accelerator
transmission. Unit is designed to stall through brake
transmission.

CONNECTOR C - 395 PEDAL BOX HARNESS
NOTE: Depending on the vehicle level some of the terminals listed below will be blank. High series connector
shown. Values given are with connector C-395 connected, ignition on and back probing the terminals.

1 10AB (Green/Red) 12 - 14 Volts
Brake and Cruise switch (High)
2 1489 (Red) Using adjustment switch - Centre =0 Volts,
Pedal adjusting motor - A Upwards = 12-14 Volts. Downwards = 0.1 Volt
3 1490 (White) Using adjustment switch - Centre =0 Volts,
Pedal adjusting motor - B Upwards = 0.1 Volt. Downwards = 12-14 Volts
4 57 H (Black) Clutch switch N/A
5 511 (Blue/Green) 12-14 Volts (Brake pedal pushed - 0 Volts)
Cruise control deactivation switch -
signal
10Y (Green/Red) 0 Volts (Brake pedal pushed - 12-14 Volts)
Brake switch - signal
1491 (White) N/A
Pedal position sensor - B
1491A (Blue/Yellow) N/A
Pedal position sensor - A
BLANK
92 (Blue/Yellow) N/A
Clutch switch - signal
G73255 en 01/2003 2003.0 BA Falcon

CONNECTOR C - 379 PEDAL ADJUSTMENT MOTOR

NOTE: Ignition to be "ON" for Voltage Tests.

1 1489 (R), 1494 (L) Voltage less than 2 Volts
2 1490 (W), 1495 (R) Voltage less than 2 Volts
CONNECTOR C - 317 HARNESS TO APM

NOTE: Voltage values with the connector C-317 disconnected. Ignition On.

1 EMPTY
2 3011 (B-O) 0 VOLTS
GROUND
3 3835 (Y-W) 0 VOLTS
PPS1 OUT
4 3837 (GR-Y) 0 VOLTS
GROUND
5 3015 (W-R) 0 VOLTS
PPS3 OUT
6 3010 (BR) 5 VOLTS
VREF (+)
7 3836 (Y-L) 5 VOLTS
VREF (+)
8 3012 (W) 0 VOLTS
PPS2 OUT
G73255 en 01/2003 2003.0 BA Falcon

APM CONNECTOR TERMINALS

NOTE: To remove this connector from the APM, pull the Red plastic tab upwards, then use a small flat blade
screw driver between the Red tab and connector body to push a retainer inwards. Remove connector gently
away from the APM Turn the Ignition Off.
DO NOT move throttle pedal while measuring continuity.
APM Resistance Reading from Pin to Pin

Pin Number(s) Circuit Closed Throttle Wide Open Throttle
Designation/Description
1-2 Terminal 1 and 2 1.9 kΩ 1.2 kΩ
1-3 Terminal 1 and 3 6.2 Ω 6.2 Ω
G73255 en 01/2003 2003.0 BA Falcon

Pinpoint Tests
PINPOINT TEST A : PEDAL "FEEL"
CAUTION: Tests to be carried out with the Engine not running.
A1 OBSTRUCTION AT APM
Inspect the APM for any obstructions such as carpet or a poorly fitted Yes
floor mat. Remove the obstruction and recheck. If problem
still exists, Go to PinPoint Test A2.
NOTE: A Pedal end stop is built into the APM. It should be clear of
the carpet at all times. No
Replace the APM. Refer to Removal and
Did you find an obstruction? Installation instructions in this chapter.
A2 EXCESSIVE EFFORT REQUIRED

Very slowly apply the Pedal all the way to Full throttle. Yes
Did the Pedal movement appear Rough or Sticking? Installation instructions in this chapter.
No
Go to A3
A3 EXCESSIVE FORCE EVALUATION

Yes
Is Excessive force (greater than 4 kg) required to operate the Replace the APM. Refer to Removal and
Accelerator pedal? Installation instructions in this chapter.
No
Go to A5
A4 PEDAL RETURN TOO SLOW

Check if the Accelerator pedal is too slow in returning to the Idle Yes
position. Replace the APM. Refer to Removal and
Installation instructions in this chapter.
Did the pedal return to idle but too slowly (greater than 0.5
Seconds)? No
Go to A5
A5 LIGHT PEDAL FEEL

Check to verify if the Accelerator pedal feel is too light. Yes
NOTE: Do not compare other vehicle model as the pedal efforts are Installation instructions in this chapter.
different from model to model
No
Is the force to initiate movement of the Accelerator pedal less APM Operating correctly.
than1 kg force?
G73255 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : IDLE SPEED ISSUE

NOTE: Step 2, Engine running, Automatic transmission vehicle in Park, Manual transmission vehicle in
Neutral and Handbrake engaged.

B1 ENGINE SPEED TOO HIGH
Check for an obstruction that could be holding the Accelerator pedal Yes
open. Remove obstruction and recheck. If problem
remains, Go to B2.
Did you find an obstruction?
No
Go to B2
B2 PEDAL RETURN TO IDLE

Hold the Accelerator pedal down until the Engine speed is 2000 RPM Yes
(vehicle tachometer). APM idle speed return okay.
Release the Accelerator pedal and check the vehicles Tachometer for No
the specified idle speed. Carry out Check of the APM. Go to PinPoint
Did the Engine RPM return to the specified speed at idle? Test D.
PINPOINT TEST C : ADJUSTABLE ACCELERATOR PEDALS ONLY
C1 NO ACCELERATOR RESPONSE - PART 1

Check to see if the electric wiring connector C-379 is connected to the Yes
pedal adjust motor. Go to C2
Is C-379 connected? No
Reconnect the connector and retest.
C2 NO ACCELERATOR RESPONSE - PART 2

Check to see if the electric wiring connector C-395 is connected. Yes
Go to C3
Is C-395 connected?
No
Reconnect the connector and retest.
C3 ADUSTMENT CABLE
Check the adjustment cable for jamming, crushed, twisted or caught Yes
condition. Remove the adjustment cable (Refer to Section
308-01). Grasp the inner cable to see if it turns
Did any of the above occur? freely, if not replace the cable.
No
Go to C4(memory only-see note) or Go to C5
(non memory)
C4 STEP OVER HEIGHT CHECK PART 1

pedal. Go to section 206-06 pinpoint test E.
Is the measured height distance more than 40mm? No
Go to C5
G73255 en 01/2003 2003.0 BA Falcon


C5 STEP OVER HEIGHT CHECK PART 2
this chapter.
Is the measured height distance less than 30mm?
No
Step Over height okay, no further work required.
PINPOINT TEST D : ELECTRICAL CHECK

D1 WIRING TO APM
Carry out an inspection of the electrical connector C-317 between the Yes
vehicle wiring harness and the APM. Go to D2
Were the electrical connectors correctly, joined? No
Re-attach electrical connectors and confirm that
the fault no longer exists.
D2 APM CONTINUITY CHECK

Disconnect the vehicle harness electrical connector from the APM. Yes
Go to D3
Using a Multimeter check the continuity of the APM terminals as
outlined. Refer to resistance APM connector reference for terminal No
layout. Replace the APM. Refer to Removal and
Were the readings to specification? Installation instructions in this chapter.
D3 VEHICLE CONNECTOR TO APM

Disconnect connector C-317. Yes
APM circuit okay.
Ignition ON.
Carry out electrical checks by back probing the terminals housed in No
connector C-317. Carry out testing of the faulty terminal / circuit.
Consult the wiring diagrams.
Were the terminal input / outputs correct?
G73255 en 01/2003 2003.0 BA Falcon

Accelerator Pedal and APM unit — 4. Remove accelerator pedal assembly by first
rotating and then pulling to side as shown.
Adjustable Pedals
CAUTION: When removing accelerator
Removal pedal assembly keep accelerator adjustment
CAUTION: The adjustable pedal system must gearbox and accelerator mechanism aligned at
be indexed whenever the brake pedal assembly or all times.
the accelerator pedal assembly is serviced.
1. Remove pedal box from car. To remove pedal box
see section Section 206-06.
2. Remove accelerator gearbox screws.
5. Remove bolts / nuts to separate Carrier plate from

APM unit.
3. Remove pivot pin using flat head screwdriver.
Installation
1. Loosely reinstall the bolts / nuts to the Carrier
Plate and APM unit.
G73256 en 01/2003 2003.0 BA Falcon

2. Install the pivot pin to align the Carrier Plate and 6. Install the pivot pin.
APM unit.
7. Install the accelerator gearbox screws to the

3. Tighten the bolts / nuts to the Carrier Plate and specified torque.
APM unit to the specified torque.
8. Install the pedal box to the car. Refer to pedal box

4. Remove the pivot pin. installation in Section 206-06.
5. Install the accelerator pedal assembly by sliding
to the side and then rotating into position as CAUTION: The adjustable pedal system
shown. must be indexed whenever the brake pedal
assembly or the accelerator pedal assembly is
CAUTION: When installing the accelerator serviced.
pedal assembly keep accelerator adjustment
gearbox and accelerator mechanism aligned at Accelerator Pedal and APM unit —
all times. Fixed Pedals
Removal
1. Remove pedal box from car. To remove pedal box
see Section 206-06.
G73256 en 01/2003 2003.0 BA Falcon

2. Remove nut and bolt holding accelerator pedal 5. Remove bolts / nuts to separate the Carrier Plate
assembly to pedal box. from the APM unit.
3. Remove pivot pin using flat head screwdriver. Installation

1. Loosely reinstall the bolts / nuts to the Carrier
Plate and APM unit.
4. Remove accelerator pedal assembly.
2. Install the pivot pin to align the Carrier Plate and

APM unit.
G73257 en 01/2003 2003.0 BA Falcon

3. Tighten the bolts / nuts to the Carrier Plate and 7. Install the accelerator pedal assembly to the pedal
APM unit to the specified torque. box screw to the specified torque.
4. Remove the pivot pin. 8. Install the pedal box to the car. Refer to pedal box
5. Install the accelerator pedal assembly by sliding installation in Section 206-06.
to the side and then rotating into position as
CAUTION: The adjustable pedal system
shown.
must be indexed whenever the brake pedal
CAUTION: When installing the accelerator assembly or the accelerator pedal assembly is
pedal assembly keep accelerator adjustment serviced.
gearbox and accelerator mechanism aligned at
all times. Adjustable Pedal Indexing
CAUTION: The adjustable pedal system must
be indexed whenever the brake pedal assembly or
the accelerator pedal assembly is serviced.
CAUTION: If the fuse box is removed the

battery must be disconnected first.
NOTE: Access to the drive cable is made easier by
removing the fuse box.
1. Adjust pedals to approx mid position and
disconnect the adjustment cable.
6. Install the pivot pin.
G73257 en 01/2003 2003.0 BA Falcon

2. Operate the switch until the accelerator pedal 5. Detach the drive cable from the brake pedal
reached its upper limit of travel. assembly.
3. Connect the drive cable to the brake pedal 6. Operate the switch until the accelerator pedal is
assembly. adjusted to its lower limit of travel.
4. Operate the switch until the brake pedal is in the 7. Adjust the accelerator pedal back 2- 3 mm.
stall position at the lower limit of travel.
G73258 en 01/2003 2003.0 BA Falcon

8. Reconnect the drive cable to the brake pedal

assembly.
9. Check the the brake and accelerator pedals are

correctly set. Step over height should be between
30 and 40 mm.
G73258 en 01/2003 2003.0 BA Falcon

412-00-1 Climate Control System — General Information 412-00-1
SECTION : 412-00 Climate Control System —

General Information
CONTENTS PAGE
Climate Control System — General Information ...................................................................412-00-2
Climate Control System .......................................................................................................412-00-2
Climate Control System — General Information ...................................................................412-00-4
Acronyms and Abbreviations ..............................................................................................412-00-4
01/2003 2003.0 BA Falcon

Climate Control System — General Manual over-ride of automatic control mode is able to
be selected at any time.
Information
The air conditioning system includes a software
Climate Control System strategy to protect the compressor and to notify the
dealer of a degradation in air conditioning
The 2002 model year Falcon is fitted with an all new performance caused by low refrigerant charge or A/C
heater/ventilation/air conditioning (HVAC) system. system blockage.
Features of the new system are:
All electric control of the HVAC system with
Control Components
manual selections available on the manual The HVAC unit incorporates a HIM (HVAC Integrated
climate control (MCC) and manual/automatic Module) that controls all aspects of the units
selections available on the Automatic Climate operation.
Control (ACC). The HIM is connected to the CAN (Controller Area
Intelligent microprocessor control of the unit is Network) serial data bus through which flow all sensor
built into all systems. and command inputs required to operate the climate
Filtering of all air passing through system with a control system.
standard mesh filter and the option of a finer Operator commands are input into the ICC. The ICC
pollen filter. then passes the command input through the CAN to
Light weight high performance heat exchangers. the HIM. The HIM takes the information and performs
the required actions, and outputs the appropriate
Dual zone temperature control is standard on
some models. information for the ICC display screen. The HIM also
monitors some vehicle operating data for optimisation
The heater housing only differs from the heater/air of Climate Control System performance.
conditioning system in that no evaporator is fitted.
Heating/Ventilation/Air Distribution
The new unit features heating to the rear occupants
through the console if the Floor mode is selected by
the front occupants. However, if the front occupants
select face mode, the rear occupants will only receive
non-heated air through the console.
Unlike previous units where airflow to the rear is only
available in face mode, airflow to the rear is
maintained in all modes except full demist.
The blower fan speed is now able to be more finely
selected. On the Manual Climate Control, the blower
fan speed dial can select 14 operable speeds. On the
Automatic Climate Control, in AUTO mode the fan
speed is continuously variable to maintain the
optimum comfort setting while with manual override,
there are 10 operable speeds available.
Air Conditioning
A single zone manual (SZMCC) and a dual zone
automatic conditioning system (DZACC) are available.
All systems are provided with intelligent
microprocessor control.
Climate Control System operation selections are
available via the buttons and dials on the Interior
Command Centre (ICC) and selections are displayed
on the ICC display screen.
In the case of automatic climate control, the system
automatically adjusts the operation mode of the
system to provide a set comfort under all operating
conditions.
Dual zone allows different comfort settings for driver
and passenger.
G23651 en 01/2003 2003.0 BA Falcon

Feature AU Falcon Barra

Mode Actuation Vacuum Electric - Integrated HIM module
Air Mix Actuation Low Series Cable Electric - Integrated HIM module
Air Mix Actuation High Series Electric Electric - Integrated HIM module +
DZ actuator
Control logic Low Series Fixed logic in Interface Module Intelligent software control
incorporated into HIM
Control logic High Series Intelligent software control in Intelligent software control
Interface Module incorporated into HIM
Water Tap Yes Not required
Air Filter No Filter mesh standard, Pollen filter
optional
Blower fan control 4 Speed conventional Resistor 14 detent fan speed control
integrated in HIM
Dual Zone No Yes
ACC compatible Semi Yes
Rear Foot Heating None Via console outlet
A/C performance monitor No Yes - software strategy to detect
A/C performance degradation.
A/C compressor protection Yes Yes - more substantial than AU
HVAC Interface AU Falcon Barra

Mount Points 2 - Cowl 3 - Cowl
2 - Dash 1 - Dash
2 - Floor Bracket
Sound Insulator Two piece Insulator one fitted with Integrated Assy with HVAC -Fixing
HVAC - Fixed with fir tree clips posts on case, locating guide ribs
Cut away around pass throughs around all pass throughs
and mount points Spacer rings on all mount points
Drain Solid drain on passenger side with Solid drain on centreline with
laminated foam seal. laminated foam seal
G23651 en 01/2003 2003.0 BA Falcon

Climate Control System — General

Information
Acronyms and Abbreviations
NOTE: The following acronyms will be used
throughout this section.
A/C Air Conditioning

ACC Automatic Climate Control
ACPT Air Conditioning Pressure Transducer
BEM Body Electronics Module
CAN Controller Area Network
DTC Diagnostic Trouble Code
DZ Dual Zone
ECU Electronic Control Unit
EEC Electronic Engine Control (part of
PCM)
EVT Evaporator Vent Temperature
HIM HVAC Integrated Module
HTR Heater
HVAC Heating, Ventilation & Air Conditioning
ICC Interior Command Centre
MAX Maximum
MCC Manual Climate Control
MIN Minimum
MSG Message
N/A Not Applicable
PCM Powertrain Control Module
PID Parameter Identifier
RPM Revolutions Per Minute
SZ Single Zone
G23652 en 01/2003 2003.0 BA Falcon

412-02-1 Heating and Ventilation 412-02-1
SECTION : 412-02 Heating and Ventilation

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................412-02-2
Heating and Ventilation .........................................................................................................412-02-3
Air Conditioning ....................................................................................................................412-02-4
Dual Zone Automatic Climate Control System ....................................................................412-02-4
Distribution Modes ...............................................................................................................412-02-6
Air Filtering ...........................................................................................................................412-02-8
HVAC Ducting ......................................................................................................................412-02-8
Heating and Ventilation .......................................................................................................412-02-10
Symptom Chart ..................................................................................................................412-02-10
PID Chart ...........................................................................................................................412-02-12
DTC Chart ..........................................................................................................................412-02-13
Pinpoint Tests ....................................................................................................................412-02-13
Blower Fan Assembly .........................................................................................................412-02-20
HVAC Assembly .................................................................................................................412-02-20
HVAC Case Scroll ...............................................................................................................412-02-21
Heater Core Assembly ........................................................................................................412-02-22
Case Assy — Recirc Door Complete ..................................................................................412-02-22
HIM Assy .............................................................................................................................412-02-24
Actuator — Electric Airmix (ACC only) ...............................................................................412-02-26
Shaft — Airmix Door DZ/SZ ................................................................................................412-02-27
Dual Zone Sub Harness .....................................................................................................412-02-28
Filter and Cover Assembly — Mesh (Standard Fitment) ....................................................412-02-28
Filter — Particle (Optional Fitment) ....................................................................................412-02-29
Vent Outlet Register — Outboard Register ........................................................................412-02-29
Vent Outlet Register — Centre Register .............................................................................412-02-30
Vent Outlet Register — Floor Console Register .................................................................412-02-30
Floor Console Duct .............................................................................................................412-02-31
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Lubricants
HVAC Lever Cam Dow Corning Molykote
Grease PG 54 Silicon Grease
Engine Coolant Do not top up the cooling
system with tap water.
Use only Ford Specified
Coolant at a Ratio of 30 -
50 %
A/C System O-Ring PAG ND-Oil 8
Lubrication
A/C System O-Rings Refrigerant O-Ring,
green HNBR, Evaporator
Outlet (large) - part no.
BA19S710A
Evaporator Inlet (small) -
part no. BA19S710B
Description Nm
HVAC Mounting Upper Bolts (4) 6-8
HVAC Mounting Lower Nuts (2) 9 - 12
Evaporator Tube to A/C Tube 12.7 - 17.3
Clamping Bolt
HVAC Case Hi / Lo Plastic Self 1.1 - 1.5
Tapping Screws
Heater Tube Clamp Retaining Screw 1.1 - 1.5
Evaporator Plastic End Plate 1.1 - 1.5
HIM to HVAC Self Tapping Screws 1.1 - 1.5
Blower Motor to HVAC Self Tapping 1.1 - 1.5
Screws
G34250 en 01/2003 2003.0 BA Falcon

Heating and Ventilation Manual Climate Control System
Instrument Panel
Item Description
1 Air Conditioning Button
The airflow volume and direction can be regulated
with the controls on the instrument panel and by 2 Air Distribution Buttons
adjusting the instrument panel. 3 Air Distribution Buttons
4 Air Distribution Buttons
Instrument panel and rear console adjustable
vents 5 Fan Speed Dial
The airflow can be turned on or off with the rotary 6 Recirculated Mode
controls at the side of the vents. Vents should be 7 Rear Window Demist
either fully open (top detent position) or fully closed 8 Air Distribution Buttons
(bottom detent position). 9 Air Distribution Buttons
10 Temperature Control Dial
Blower fan speed selector

The rotary blower fan speed selector is used to adjust
the blower fan speed. At the lowest setting the fan is
off, unless A/C is selected. Outside air will still enter
the cabin if fresh air is selected, even with the blower
off.
The direction of the airflow can be adjusted

horizontally and vertically within the swivelling range
of the air vanes and vents.
NOTE: The blower fan will only operate with the

ignition in the ON position.
Temperature Control
The temperature of the air maybe adjusted using the
temperature control dial. Turn the dial clockwise to
increase heating. Turn the dial anti-clockwise to
G34251 en 01/2003 2003.0 BA Falcon

decrease heating. Turning the dial fully anti-clockwise

will toggle "A/C MAX" mode, which provides maximum Dual Zone Automatic Climate Control
occupant cooling, by switching on the air conditioning System
and selecting recirculated air inlet and face level air
outlet. When turning the dial clockwise after selecting
A/C MAX, fresh air will automatically be selected while
the other A/C MAX modes will remain unchanged.
NOTE: The heater maintains warmth only when the
engine is operating. Full heating is only available
when the engine is at normal operating temperature
Item Description
1 Temperature Control LHS
2 Windscreen Demist
3 Air Distribution Mode Button
4 Rear Window Demist
5 Temperature Control RHS
Air conditioning 6 Air Conditioning Button
Press the A/C button to select the air conditioner 7 On/Off Auto Mode Button
on/off. 8 Fan Speed Dial
NOTE: If the blower fan is off and A/C is turned on 9 Recirculated Mode
the fan will automatically come on to the lowest The dual zone automatic climate control system
speed. A/C MAX mode is selected by turning the automatically controls heating, cooling and fan speed
temperature control dial fully anti-clockwise to the A/C to maintain the desired level selected between 18 ºC
MAX position. A/C MAX automatically switches on the and 30 ºC when operated in the ’AUTO’ mode. The
air conditioner, selects the Recirculated Air inlet mode selected comfort setting (eg. 22ºC) is automatically
and Face Level air outlet mode. These modes can be maintained when ’AUTO’ mode is selected. Driver
manually overridden. and front passenger have independent comfort
settings. 22 ºC is the recommended comfort setting
for most users.
A microcomputer and sensors monitor cabin, outside
air, air conditioner evaporator and engine
temperatures as well as the strength of direct
sunshine on the interior of the vehicle. Instrument
panel face level vents should be adjusted to direct
airflow to suit personal comfort.
Automatic Operation
After starting the engine, if ’Off’ is displayed in the
control panel display window, press the ’AUTO’
button to turn the system on. Adjust the comfort level
to the desired temperature using the ’Temperature
The A/C MAX graphic will continue to be displayed control’ buttons. After starting the engine, if ’AUTO’
while the temperature control dial is set to A/C MAX appears in the display window, the system will
and the Recirculated Air inlet mode is retained. automatically adjust to that comfort level without any
further assistance.
NOTE: The air conditioner will only operate with the
engine running.
NOTE: To maximise cooling efficiency, select A/C
MAX and select a high fan speed setting
G34251 en 01/2003 2003.0 BA Falcon

different setting until the driver’s setting is no longer

’LOW’ or ’HIGH’. When the driver changes the
setting from ’LOW’ or ’HIGH’, both passenger and
driver settings are controlled together by the driver
until the passenger adjusts their temperature setting.
When the vehicle is started, the passenger and driver
settings are set at the previously set driver’s setting. If
the driver then adjusts the temperature setting, both
passenger and driver settings are controlled together
by the driver until the passenger adjusts their
temperature setting. The passenger setting can be
re-linked to the driver setting at any time by holding
down the auto button for more than 2 seconds.
NOTE: The heater maintains warmth only when the
’Auto’ mode automatically controls air source, air engine is operating. Full heating is only available
distribution, fan speed, air conditioning and when the engine is at normal operating temperature.
temperature. From time to time you may notice the air
distribution mode and fan speed changing. This is the Blower fan speed selector
system’s normal mode of operation whereby it selects The blower fan speed selector is used to adjust the
the mode of air distribution and fan speed most blower fan speed. To turn the fan off completely,
appropriate to maintain the selected comfort setting. press the "OFF" button.
When starting the vehicle on a cold day with a cold
engine, air discharge is delayed until the engine NOTE: The blower fan will only operate with the
begins to reach operating temperature. ignition in the ON position.
Simultaneously, the blower fan speed will increase to
assist warm air circulation throughout the cabin. As
the interior air warms to the preselected comfort
setting, the fan speed will then decrease.
The OFF button will turn the automatic climate control
system off but will allow fresh air to enter the cabin
through the instrument panel vents. Fan speed and air
distribution may be controlled in the off mode.
Semi-Automatic operation
If desired, you may override the automatic control
system and operate some features manually (such as
fan speed and air distribution). Manually selecting
such features when in ’Auto’ mode will change the
system to ’Semi-auto’. Full automatic control can be
resumed at any time by pressing the ’Auto’ button. Outside Air Temperature
Dual zone temperature control A sensor under the passenger-side exterior mirror
monitors outside temperature. This is displayed in the
Dual zone temperature control allows the driver and
message display window. Correct operation of the
front passenger to set independent air temperatures
sensor relies on air moving across the sensor.
according to personal preference.
Therefore, at low vehicle speed, or operating the
NOTE: This does not allow independent distribution vehicle for a short period of time, the display may
modes or fan speed, only temperature. differ slightly from the true outside air temperature.
The rear console vent outputs correspond to all Windscreen demist
Climate Control outputs as set by the driver and front
passenger. In the event that fast demisting of glass is required,
The temperature may be set within the range of 18ºC press the demist button. Air is directed to the
to 30ºC, in 0.5ºC increments. If a temperature below windscreen and side window vents to demist glass.
18ºC is selected, then ’LOW’ is displayed. If a The air conditioner and blower fan will operate, the
temperature above 30ºC is selected, then ’HIGH’ is fresh air mode will be selected and heating (if
displayed. available) will be used. When the glass is demisted,
press the AUTO button to return to automatic climate
If the driver selects either ’LOW’ or ’HIGH’, the control.
passenger setting is also changed to ’LOW’ or
’HIGH’ and the passenger is unable to choose a
G34251 en 01/2003 2003.0 BA Falcon

Heated rear Window Demister Air Conditioning

With the ignition ON, press the switch to turn the Press the ’A/C’ button to toggle the air conditioner
demister on. The graphic on the Interior Command on/off. Note: if the fan is off and A/C is turned on the
Centre screen will appear. To turn off, press the fan will automatically come on to the lowest speed.
switch again, otherwise the demister will automatically NOTE: If the system is OFF and the A/C is turned ON
turn itself off after approximately 15 minutes. the system will return to ’AUTO’ operation.
To switch off, press the switch again, otherwise the

NOTE: If the system is OFF and the A/C is turned ON
demister will automatically turn itself off after
approximately 15 minutes. the system will return to ’AUTO’ operation.
NOTE: The air conditioner will only operate with the
Distribution mode selector engine running.
May be used to direct the air to particular groups of
NOTE: To maximise cooling efficiency, select AUTO
outlet vents. Press the button repeatedly up or down operation.
until the desired setting is shown in the display
window. Information on distribution modes can be Distribution Modes
found later in this section.
Distribution modes can only be selected with the
ignition on.
Face level
Air is directed to the adjustable instrument panel vents
and the centre console vents (for rear seat
passengers). The vents may be adjusted for direction
and flow or may be individually closed if desired.
G34251 en 01/2003 2003.0 BA Falcon

Face level/footwell Windscreen demist/footwell

Air is directed to the adjustable instrument panel Air is directed to the windscreen and side window
vents, centre console vents (for rear seat passengers) vents to aid in glass demisting Air is also directed to
and front footwell vents. If heating is selected, heated the front footwell vents. and centre console vents (for
air is directed to the front footwell vents and partially rear seat passengers).
heated air is directed to the face level vents.
The warmer the setting, the warmer the air to face If
full cooling is selected, cool air is delivered to face
and footwell vents.
Footwell
Air is directed to the front footwell vents, centre
console vents (for rear seat passengers) and a small
amount is also directed to the windscreen and side
Windscreen demist window vents to reduce glass misting or fogging.
When windscreen demist mode is selected, the A/C
and fresh air modes are automatically selected for
glass demisting. Also, the blower fan will automatically
start at the lowest fan speed if the fan was not already
running. For maximum demisting, highest heating and
highest fan setting should also be used.
NOTE: A/C and fresh air mode can be manually
overridden but demist efficiency will be reduced.
G34251 en 01/2003 2003.0 BA Falcon

Fresh/Recirculated air selector finer pollen filter is also available, as an accessory

item, from your Ford dealer.
Fresh or recirculated air is controlled by pressing the NOTE: Extended operation of the climate control
recirculated mode button. Pressing the button will system in a recirculated air mode may lead to a
alternate between fresh and recirculated air modes. A reduction in air quality in the cabin. The air in the
graphic indicating the selected mode will appear on cabin should be periodically refreshed by selecting
the display. fresh air settings.
In normal circumstances, the fresh air mode should
be selected to maintain the quality of air inside the To clean the standard mesh filter, blow through mesh
vehicle and to prevent the build-up of stale air or with compressed air and wash with luke warm water.
odours, and to reduce windscreen misting. For the optional pollen filter (where fitted), the filter
To prevent the ingress of dust, odours or fumes, cannot be washed. When serviced, the pollen filter
select the recirculated air mode. The recirculated air should be replaced. If the filter is blown through with
mode can also be used to allow the air conditioner to compressed air, rather than replaced, the air quality
more effectively cool the vehicle’s cabin. Do not use and airflow quantity may be degraded.
the recirculated air mode if vehicle occupants are HVAC Ducting
smoking as tobacco odours may remain.
The fresh air intake to the HVAC unit enters the
plenum chamber through the cowl grilles underneath
the windscreen wipers. The recirculated air intake to
the HVAC unit is inside the cabin behind the glove
box and directly below the LH plenum chamber. The
HVAC fresh air entry is attached to the plenum
chamber with a foam seal. Outlet air from the HVAC
unit can exit into the instrument panel duct, to the
floor vent outlets or to the floor console duct. The
HVAC unit is attached to the floor console duct with a
foam seal.
Between the HVAC unit and the firewall at the
locations where the heater and evaporator tubes pass
through, foam pads are fitted around the tubes to seal
the firewall openings.
Air Filtering
The air selector system is fitted with a fine mesh
particle filter to exclude leaf debris, dust and dirt. A
G34251 en 01/2003 2003.0 BA Falcon

HVAC Air Distribution Outlets
Item Description HIM HVAC Integrated Module

1 Fresh air intake HTR Heater
2 HVAC air outlet to front screen demist HVAC Heating, Ventilation & Air Conditioning
3 HVAC air outlets to face vents ICC Interior Command Centre
4 Floor and console ducts MAX Maximum
5 Recirculated air intake MCC Manual Climate Control
The instrument panel duct directs outlet air to the MIN Minimum
demist/screen, face centre and face side LH/RH vent MSG Message
outlet registers. The instrument panel duct is an N/A Not Applicable
integral part of the instrument panel and is not a
separately serviceable item. If the duct is faulty, the
complete instrument panel must be replaced. RPM Revolutions Per Minute
The floor console duct is removed from the vehicle as EATC Electronic Air Temperature Control
part of the floor console assembly. The duct can then EEC Electronic Engine Control
be separated from the console. Refer to Removal & PCM Powertrain Control Module
Installation procedure later in this section.
BEM Body Electronics Module
Acronyms and Abbreviations ACPT Air Conditioning Pressure Transducer
The following acronyms will be used throughout this SZ Single Zone
section. DZ Dual Zone
A/C Air Conditioning
ACC Automatic Climate Control
CAN Controller Area Network
DTC Diagnostic Trouble Code
G34251 en 01/2003 2003.0 BA Falcon

Heating and Ventilation

Check these items before entering Diagnostics.
Topic Specification
Vehicle Battery Voltage Greater than 12 Volts
Engine to be running In all Tests
Record all DTC’S present Before Clearing
Ensure that a false DTC has not been set because of Customer may have to be questioned on the vehicle
prior work on the vehicle. history if a DTC root cause component cannot be
Example: If the LHF door (ACC vehicle) was found.
removed at a body shop, Ambient temperature
sensor DTC will be set.
When referring to a Temperature / Resistance table. Place an accurate electronic Thermometer near to
the Sensor in question.
When using pressure gauges Ensure that they are correctly calibrated and that the
needles rest on Zero with no Refrigerant in the lines
and the gauge valves open.
Vacuum pump must pull down to -100 kPa (30 in/hg) Change the Vacuum pump oil approximately every
15 evacuations, to improve pull down time.
Symptom Chart

No airflow in selected mode ICC Go to Section 413-08.
Evaporator Core Ice-Up Go to Section 412-03, Pinpoint test D.
Intake Air Filter Restriction Go to PinPoint Test I.
Mode (HIM) Go to PinPoint Test D, E, F, G, H, J.
Low Battery Charge Refer to Section 412-04, Go to

PinPoint Test H.
CAN Message Failure Refer to Section 412-04, Go to

PinPoint Test M.
Plenum Area Restriction Go to PinPoint Test A.
Blower Motor Go to section 412-04, Pinpoint test L.
Insufficient airflow in selected mode Plenum Area Restriction Go to PinPoint Test A.

Instrument panel/console duct Go to PinPoint Test B.
restriction
Evaporator Core Ice-Up Go to section 412-03, Pinpoint test D.
Intake Air Filter Restriction Go to PinPoint Test I.
Low Blower Voltage Go to section 412-04, Pinpoint test H.
Fresh / Recirc Door Jammed Go to PinPoint Test D.
Sun Load Sensor Refer to section 417-01.
Airflow direction incorrect Mode (HIM) Go to PinPoint Test D, E, F, G, H, J.
Linkage Disconnect Go to PinPoint Test D, E, F, G, H, J.
G34252 en 01/2003 2003.0 BA Falcon


ICC Go to Section 413-08.
Blower motor not operating on Can Message Refer to Section 412-04, Go to
selected speed PinPoint Test M.
Blower Input Function Refer to Section 412-04, Go to

PinPoint Test L.
A/C not cold ICC Refer to Section 413-08.
Driver side Actuator Motor Go to PinPoint Test H.
Passenger side Actuator Motor Go to PinPoint Test G.
Low Refrigerant Charge Refer to Section 412-03.
A/C Compressor Not Engaging Refer to Section 412-03, Go to

PinPoint Test A & B.
Evaporator Temperature Sensor Refer to Section 412-04, Go to

PinPoint Test B.
Ambient Air Sensor Refer to Section 412-04, Go to

PinPoint Test A.
Cabin Temperature Sensor Refer to Section 412-04, Go to

PinPoint Test P.
Blower Motor Refer to Section 412-04, Go to

PinPoint Test L.
Passenger side temperature Hotter Go to PinPoint Test K.
than Drivers side
Sun Load Sensor Refer to section 417-01.
Heating ineffective Passenger side Actuator Motor Go to PinPoint Test G
Driver side Actuator Motor Go to PinPoint Test H.

Heater Core Issue/Engine cooling Go to PinPoint Test C.
issue
Ambient Air Sensor Refer to Section 412-04, Go to

PinPoint Test A.
Cabin Temperature Sensor Refer to Section 412-04, Go to

PinPoint Test P
ICC Refer to Section 413-08.
Leaking Heater Core Go to PinPoint Test C.

Blocked Heater Core/Engine Cooling Go To section 303-03.
system
Smell from HVAC through vents Leaking Evaporator Core Go to section 412-03, Pinpoint test E.
Intake Air Filter Contaminated Go to PinPoint Test I.
Vehicle Carpet Wet Visual inspection to verify if the HVAC

drain hose is blocked or misaligned
with the hole in Transmission tunnel.
Noise Blower Motor Go to section 412-04, Pinpoint test L.
G34252 en 01/2003 2003.0 BA Falcon


Orifice Tube Refer to Section 412-03.
Low Refrigerant Charge Refer to Section 412-03.

Heater Core "Gurgle" Sound/Engine Refer to section 303-03.
Cooling system bleed issue
ICC Display Ambient temperature display Go to section 412-04 Pinpoint test A.

inaccurate
Display character fault Refer to section 413-08.
Display illumination fault Refer to section 413-08.
PID Chart Acronym Description HIM Configuration

The following table lists all PID’s utilised by the WDS ACC MCC HTR
service tool to access specific functions within the RIGHTOT Driver’s Display YES N/A N/A
HIM. Set Temperature
Acronym Description HIM Configuration MC_VREF Vehicle Battery YES YES YES
Voltage
ACC MCC HTR
HIM_STAT ECU Diagnostic YES YES YES
CCNT Number of YES YES YES Operating State
Continuous Trouble
CONPROV Configuration and YES YES YES
Codes Set
Programming
NTCSDT Number of Trouble YES YES YES Version
Codes Set due to
CANDSV CAN Diagnostic YES YES YES
Diagnostic Test
Specification
A_CT Evaporator YES YES N/A Version
Temperature
RECIRDS Recirculation Door YES YES YES
ETSFD External YES N/A N/A Actual Position
Temperature
Sensor Filtered RECIRDTP Recirculation Door YES YES YES
Target Position
Data
CCACTM Climate Control YES YES YES
EXT_TEMP External YES N/A N/A
Temperature From Actuator Modes
Sensor (unfiltered) MOD_ID Module YES YES YES
Configuration
PBDAP Passenger Blend YES YES YES
Door Actual Check
Position CCMODE Climate Control N/A YES N/A
Mode
PBDTP Passenger Blend YES YES YES
Door Target BEM_MSG GEM - Body YES YES YES
Position Electronics Module
CAN Message
BLENDDR Driver Blend Door YES N/A N/A
Position Receive Status
CDU_MSG ACM - Interior YES YES YES
BLENTP Driver Blend Door YES N/A N/A
Control Center
Target Position
Module CAN
BLOWVOL HVAC Blower YES YES YES Message Receive
Voltage Status
BLOWAP Blower Motor YES YES YES PCM_MSG PCM - Powertrain YES YES YES
Speed - Actual Control Module
Position CAN Message
BLOWTP Blower Motor YES YES YES Receive Status
Speed - Target ACCS AC Compressor YES YES N/A
Position Cycling Request
LEFTOT Passenger’s YES N/A N/A CAL_VER EEprom Calibration YES YES YES
Display Set Version
Temperature
G34252 en 01/2003 2003.0 BA Falcon

Acronym Description
HIM Configuration
ACC MCC HTR
CAL_VRAM Calibration Version YES YES YES
Currently Loaded
in RAM.
DTC Chart
Refer to DTC chart in Section 412-04.
Pinpoint Tests
PINPOINT TEST A : PLENUM CHAMBER AIR RESTRICTION (ACC / MCC / HTR)
CAUTION: Take all the standard safety procedures when dealing with A/C system refrigerant,
including Eye protection and Gloves.
NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING

A1 VISUAL INSPECTION - ABOVE COWL GRILLES
Inspect the cowl panel grilles (LH and RH) below the windscreen Yes
wiper arms for evidence of airflow obstruction. Remove the airflow obstruction, and blow out
any debris using compressed air.
Was there debris, dust or insects on the top of the cowl grille
obstructing intake air to the cabin? No
Go to A2
A2 VISUAL INSPECTION - BELOW COWL GRILLES

Remove the cowl panel grilles (LH and RH). Refer to section 501-02. Yes
Remove the airflow obstruction, and blow out
Inspect the plenum inlet chamber below the cowl grilles for evidence any debris using compressed air.
of airflow obstruction.
Was there debris, dust or insects in the plenum inlet chamber No
obstructing intake air to the cabin? Plenum chamber air intake was not restricted.
PINPOINT TEST B : INSTRUMENT PANEL/ CONSOLE DUCT RESTRICTION (ACC/MC/HTR)
including Eye protection and Gloves. Refer to Section 412-03 for the complete Safety Precautions.
NOTE: The instrument panel duct (incorporating demist/screen, face centre and face side ducts) is an
integral part of the instrument panel, and is not a separately serviceable item. If the duct is faulty, the
complete instrument panel must be replaced (Refer to section 501-12).

B1 VISUAL INSPECTION - VENT OUTLETS
Inspect the demist vent outlets for evidence of airflow obstruction, Yes
including a dash mat or other item which may cover the vent outlet. Remove the airflow obstruction.
Is there evidence of airflow obstruction at any demist vent No
outlets? Go to B2
G34252 en 01/2003 2003.0 BA Falcon


B2 Airflow TEST - VENT OUTLETS
Run the engine and switch on the ACC with blower fan operating at Yes
maximum speed. Instrument panel duct is not restricted.
Whilst selecting the air outlet modes using the ICC button, check for No
air delivery at all vent outlets (demist/screen, face front, face side Go to E & F
LH/RH, floor LH/RH and rear console).
Is airflow supplied to each vent outlet?
PINPOINT TEST C : HEATER CORE LEAKING CAUSING “SMELL” (ACC / MCC / HTR)
CAUTION: If the Heater Core is to be removed, ensure that the Heater core tubes are "capped" to
avoid any Coolant spillage onto the vehicle interior.
NOTE: NOTE: REFER to SECTION 412-02 SYMPTOM CHART BEFORE PROCEEDING
C1 COOLING SYSTEM PRESSURE

Conduct engine cooling system pressure test. Refer to section 303-03 Yes
for test procedure. No Cooling system leakage evident.
Does the cooling system hold pressure? No
Go to C2
C2 VISUAL INSPECTION
Start Engine, select Full heat and Highest Blower Fan speed at the Yes
ICC. Replace the Heater core. Refer to removal and
installation instructions in this section.
Run Engine for a minimum of 10 Minutes.
From under the vehicle inspect the A/C drain tube for evidence No
of Engine coolant. Is there evidence at the drain tube of Coolant? The Heater core is not the cause of the Coolant
leakage or Smell.
PINPOINT TEST D : ACTUATOR — RECIRCULATE DOOR (ACC / MCC / HTR)
CAUTION: If carrying out a "feel" test for door movement, care should be taken to avoid injury to
your Hand from moving parts such as blower motor, levers, etc.
G34252 en 01/2003 2003.0 BA Falcon


D1 VISUAL INSPECTION - RECIRC DOOR LEVER TO HIM
CAM
Remove the Glove Box. Refer to Section 501-12. Yes
Go to D2
Remove Air Intake Filter.
Carry out a visual inspection to see if the Recirc door cam is No
connected to the HIM BLACK lever pin, Using a flat blade screwdriver, gently move /
prise the HIM lever pin into the recirc door cam.
Is the lever connected?
D2 VISUAL INSPECTION - RECIRC DOOR OPERATION

Check for full door movement to Fresh and Recirc while pushing the Yes
ICC Button with visual inspection or by inserting your hand through System OK
the Air Intake Filter opening. Clear DTC
Perform HVAC On - Demand Self Test refer to
Is the Fresh / Recirc Door moving fully from fresh to recirc? section 412-04
No
Go to section 412-04 Pinpoint test C.
PINPOINT TEST E : ACTUATOR SCREEN/FACE DOOR (ACC / MCC / HTR)
E1 VISUAL INSPECTION - SCREEN / FACE DOOR

OPERATION
Check for full door movement to Screen and Face while pushing the Yes
ICC Button. Check for air delivery from Face and Screen modes System OK
alternatively with blower operating at full speed. Clear DTC
Perform HVAC On-Demand Self Test. Refer to
Are the Screen and Face modes selectable? Section 412-04.
No
Go to E2
E2 VISUAL INSPECTION - HIM LEVER TO HVAC CAM

Go to Section 412-04 , Section D.
Using a mirror and a torch view the lever area between the HIM and
the HVAC to see if the HIM BLUE and GREEN lever pins are slotted No
into the HVAC lever cams. Remove the instrument panel. Refer to Section
Were the HIM lever pins slotted into the HVAC lever cams? 501-12.
Remove and Install the HIM ensuring that HIM
levers and HVAC cams are connected. Refer to
removal and installation instructions in this
section.
PINPOINT TEST F : ACTUATOR — FLOOR/CONSOLE (ACC / MCC / HTR)
G34252 en 01/2003 2003.0 BA Falcon


F1 VISUAL INSPECTION - FLOOR / CONSOLE DOOR
OPERATION
Check for door movement to Floor while pushing the ICC Button. Yes
Check for air delivery from floor with blower operating at full speed. System OK
Clear DTC
NOTE: It is usual for airflow from rear console while Floor / Heating Perform HVAC On-Demand Self Test. Refer to
is selected. Section 412-04.
Is the Floor mode selectable? No
Go to F2
F2 VISUAL INSPECTION - HIM LEVER TO HVAC CAM

Refer to Section 412-04, Go to PinPoint Test F.
the HVAC to see if the HIM YELLOW lever pin is slotted into the No
HVAC cam. Remove the instrument panel. Refer to Section
Was the HIM lever pin slotted into the HVAC cam? 501-12.
Remove and Install the HIM ensuring that HIM
levers and HVAC cams are connected. Refer to
removal and installation instructions in this
chapter.
PINPOINT TEST G : ACTUATOR — PASSENGER AIR TEMPERATURE MIX (ACC / MCC /HTR)
NOTE: This actuator is utilized to control air temperature to both passenger and driver by the single zone (SZ)
manual climate control system. It is used to control only the passenger side air temperature for dual zone (DZ)
automatic climate control system. H (High) and L (Low) settings are not possible via the passenger
temperature rocker switch on ACC system.
G1 VISUAL INSPECTION - PASSENGER AIR MIX DOOR

OPERATION
Check for full door movement to full Hot and full Cold while operating Yes
the ICC button. (For MCC, set dial control to Hot then Cold. For ACC, System OK
select H then L by drivers temperature setting rocker switch.) Clear DTC
Does the passenger air mix door move to full Hot and full Cold Section 412-04.
positions?
No
Go to G2
G2 VISUAL INSPECTION - HIM TO TEMP DOOR SHAFT

Go to Section 412-04, pinpoint test E.
the HVAC to see if the HIM is connected to the temperature door No
shaft. Remove the instrument panel. Refer to Section
Was the HIM connected to the temperature door shaft? 501-12.
Remove and Install the HIM ensuring that
temperature door shaft coupling is connected to
the HIM. Refer to removal and installation
instructions in this chapter.
G34252 en 01/2003 2003.0 BA Falcon

PINPOINT TEST H : ACTUATOR — DRIVER AIR TEMPERATURE MIX (ACC)
NOTE: This actuator is utilized to control air temperature to the driver side only for dual zone (DZ) automatic
climate control system.
H1 VISUAL INSPECTION - DRIVER AIR MIX DOOR

OPERATION
Check for full door movement to full Cold and full Hot while operating Yes
the ICC button. (Select C then H by the Drivers temperature setting System OK
rocker switch.) Clear DTC
Feel the face outlet temperature change temperature from Cold to Hot
Section 412-04.
using your hand.
Does the driver temperature change from Cold to Hot? No
Go to H2
H2 VISUAL INSPECTION - DRIVERS SIDE ACTUATOR TO

SHAFT
From under the Drivers side, view the Driver’s actuator shaft in Yes
between the airmix actuator and the HVAC, for movement while Go to H3
changing the temperature from Hot to Cold using the ICC button.
No
Did the shaft turn when Hot to Cold selected? Refer to Section 412-04, Go to PinPoint Test G.
H3 VISUAL INSPECTION - DRIVERS SIDE SHAFT

MOVEMENT
Set the ICC to face mode. Yes
Broken shaft, replace the HVAC Door Module.
Remove the ICC. Refer to Section 413-08. Refer to removal and installation instructions in
Insert your hand through the ICC opening and try turning the this chapter.
temperature door shaft.
No
Does the shaft turn? Refer to Section 412-04, Go to PinPoint Test G.
PINPOINT TEST I : INTAKE AIR FILTER RESTRICTION (ACC / MCC / HTR)
CAUTION: Do not use "Hot" water to clean the standard mesh Filter. Do not use any water to
clean the optional pollen filter.
G34252 en 01/2003 2003.0 BA Falcon


I1 AIR INTAKE INSPECTION
Standard mesh filter - using Compressed air,
Remove the Intake Air Filter, refer to section 412-01. "blow" any contamination from the mesh Filter.
Was there Debris, Dust or Insects obstructing airflow through the Rinse the mesh Filter under Luke warm water.
Intake Air Filter? Optional Pollen Filter. If heavily contaminated -
Replace Filter. If mildly contaminated, use
compressed air to "blow" out any contamination.
NOTE: Cleaning rather than replacing the
optional pollen filter may degrade the air quality
and airflow quantity.
No
Air Intake Filter not the cause of the airflow
restriction.
PINPOINT TEST J : HIM LEVER TO FLOOR/CONSOLE DOOR ROD INSPECTION (ACC / MCC / HTR)
CAUTION: Do not alter the mode position, with your hand on the rod otherwise your hand could
become jammed and cause skin damage.
J1 VEHICLE SETUP
Remove the Glove box. Refer to Section 501-12. Yes
Ensure that the plastic rod retainer clip is in
Start Engine. place at the Floor door lever end. Then refer to
At the ICC select Face Mode. chapter Section 412-04, Go to PinPoint Test F.
Locate and follow the Rod with your hand from the HIM all the way to No
the Floor door lever. Reconnect rod into the Floor door lever and
Is the rod connected to the Floor door lever? secure with the retaining clip.
G34252 en 01/2003 2003.0 BA Falcon

PINPOINT TEST K : PASSENGER SIDE TEMPERATURE WARMER THAN THE DRIVERS SIDE (ACC /
MCC)
including Eye protection and Gloves.
NOTE: If the A/C suction (low side) pressure is lower than specification because of a low refrigerant charge,
the refrigerant "super heat" increases and cooling in the evaporator may be irregular, causing the passenger
side temperature to "feel’ warmer.

K1 VERIFICATION - VEHICLE SET-UP
Start Engine. Yes
Go to K2
Run vehicle at operating temperature.
Set ICC to full Cold (Low, L) Passenger / Driver side (ACC) or Full No
Cold (MCC). HVAC System Temperature "split" is to
specification. System Okay.
Select Fresh air intake mode.
Put bonnet up.
Ensure A/C compressor is engaged (Refer 412-03).
ACC - Select manual override - Face mode.
MCC - Select Face mode.
Select the highest blower fan speed.
Insert a thermometer into the Face vent, drivers side. Allow the
temperature reading to stabilise (stay at one constant temperature)
Take a reading.
Quickly insert the thermometer into the passenger side Face vent and
allow to stabilise. Take a reading.
Is the difference in temperature between the Passenger side and
Drivers side greater than 10 Degrees?
K2 REFRIGERANT PRESSURE LOW

Connect A/C Manifold Gauge set (High & low side pressure gauges) Yes
as per section 412-03. Conduct A/C System Performance test for low Perform HVAC On - Demand Self Test refer to
A/C pressures as per section 412-03. section 412-04. Go to PinPoint Test B.
Were the A/C system pressure readings to specification? No
Refer to section 412-03. Conduct an A/C
System Leak test for possible refrigerant
leakage. Discharge, repair as required, evacuate
and recharge the A/C system.
G34252 en 01/2003 2003.0 BA Falcon

Blower Fan Assembly HVAC Assembly

Removal Removal
1. Disconnect electrical connector. 1. Recover refrigerant from the A/C system. Refer to
2. Undo three screws. Section 412-03.
3. Lower the Blower Fan assembly and remove. 2. Drain engine coolant. Refer to Section 303-03.
3. Disconnect A/C tubes, Refer to Section 412-03.
CAUTION: Evaporator O-rings and tube
ends should be capped to prevent damage
and contamination.
4. Disconnect Heater hoses.
CAUTION: Cap the heater tube ends to
prevent coolant spillage onto the vehicle
interior.
5. Remove Instrument Panel, Refer to Section
501-12.
6. Disconnect blower harness.
7. Disconnect HIM main harness (power)
Item Description 8. Disconnect HIM main harness (control).
1 Electrical Connector
2 3 Screws
Installation
1. Refit components in reverse order.
CAUTION: Ensure correct alignment of
cooling air guide.
Item Description
1 HIM Main power harness
2 Evaporator sensor elec connector
3 HIM Main control harness
9. Undo the four nuts and two bolts used to retain
the HVAC Assembly mountings to the firewall.
G34254 en 01/2003 2003.0 BA Falcon

10. Carefully work the firewall insulation off and over Installation
each speed nut with a screw driver.
NOTE: A small amount of firewall insulation
around the mounting points may be damaged at HVAC Case Scroll
removal stage, but this is not deemed to be a
problem. Removal
11. Carefully remove the HVAC assembly from the 1. Undo one Screw (HIM).
passenger side of the vehicle.
NOTE: On removal of the HVAC, if a large
section of firewall insulation is damaged, repair
before re-installing the HVAC Assembly.
G34259a en 01/2003 2003.0 BA Falcon

2. Undo one Screw (Heater Tubes). 2. Remove two screws used to retain the tube shield
to HVAC.
3. Undo five Screws (Case-Scroll).

3. Remove shield-heater tubes.
4. Remove Case Scroll.

4. Slide out the Heater Core.
CAUTION: Care should be taken when
withdrawing heater core to prevent bending of
pipes (High stress may result at joint between
tank and pipe if end of pipes used as
"handles")
Installation
1. Refit all previously removed components in
reverse order.
CAUTION: When inserting heater core
ensure that core "bottoms out" before fitting
shield heater tube. Also ensure that foam seal
is not distorted or damaged so as to affect
Installation integrity of air seal between case and core.
Case Assy — Recirc Door Complete
CAUTION: Ensure correct alignment
Removal
between tongue and groove of mating parts.
1. Remove the HVAC Assembly.
Heater Core Assembly
Removal
1. Remove HVAC Assembly, as outlined in the
Removal and Installation procedure in this
section.
G34259a en 01/2003 2003.0 BA Falcon

2. Remove Seal-A/C Tubes. 6. Undo five Screws retaining the recirc door
housing to the HVAC Assembly.
3. Remove one Screw from the A/C tube retaining

plate. 7. Push in HIM Recirc Lever.
CAUTION: Beware not to disengage slider
block from HIM recirc lever and ensure part is
greased when reassembled (see specifications
in this chapter).
Item Description
1 Screw
2 AC tube retaining plate
4. Remove Plate-A/C Tubes. 8. Remove Case-Recirc.
5. Remove Mesh Filter and Cover Assembly or
Particle Filter as outlined in this section.
Installation
CAUTION: Ensure correct alignment
between tongue and groove of mating parts.
G34260 en 01/2003 2003.0 BA Falcon

HIM Assy 5. Disengage Rod from the Floor Door lever.

NOTE: Retain the rod and clip for reuse.
Removal
501-12.
2. Disconnect HIM electrical connectors.
6. Disengage and withdraw Airmix Coupler.

NOTE: Use a flat screw driver and carefully prise
airmix coupler off passenger airmix shaft.
Item Description
3. Disconnect HIM electrical connectors.
Harness driver side actuator (ACC only)
7. Push in HIM Recirc Lever.

CAUTION: Excessive force will damage
airmix shaft flange.
CAUTION: If airmix shaft accidentally is
withdrawn from case follow procedure in
Shaft-Airmix Door DZ/SZ, Steps 1-5.
4. Remove the three Screws used to retain the HIM

to HVAC.
G34260 en 01/2003 2003.0 BA Falcon

8. Rotate and remove HIM. 3. If scroll fitted, align heatsink into scroll opening.
NOTE: Ensure alignment of airmix shaft with HIM
coupling and alignment of tab with centre case.
4. Align airmix coupler (1 to 2, 4 to 3).

CAUTION: Top mounting peg must be
Installation located.
1. Fit rod floor door to HIM in reverse order to
removal procedure.
5. Align face and demist cams with HIM levers.
2. Depress airmix coupling into installation position.

NOTE: At this stage the HVAC cam levers should
be greased before installing HIM. Refer
specifications in this chapter,
6. Rotate HIM and engage airmix hub into heater

case (tilt HIM onto heater).
G34260 en 01/2003 2003.0 BA Falcon

7. Insert 3 screws (2 screws if SCROLL Assembly is Actuator — Electric Airmix (ACC only)
not yet fitted).
Removal
1. Set driver side temp to full cold, face mode.
NOTE: If setting the drivers temp is not possible.
The HIM would have to be removed.
501-12.
8. Check that the airmix shaft is correctly fitted into

airmix door (refer installation procedure for
Shaft-Airmix Door DZ/SZ in this section).
9. Rotate airmix door to align keyway with airmix
coupling to fully engage airmix shaft.
3. Disconnect Dual Zone Sub Harness at the

actuator.
4. Undo three screws retaining the actuator to
HVAC.
10. Reconnect electrical connectors.
Item Description
G34260 en 01/2003 2003.0 BA Falcon

5. Using flat screw driver between the airmix shaft 2. Gain access to airmix shaft via face outlet
flange and actuator carefully prise off the actuator. opening.
CAUTION: Excessive force will damage
airmix shaft flange.
3. Rotate airmix door to position shown in picture.
Installation
CAUTION: If airmix shaft is accidentally
withdrawn from case the procedure outlined in
Shaft-Airmix Door DZ/SZ steps 1 - 5 need to be
followed prior to installation of actuator.
1. Align keyway and refit actuator in reverse order.
NOTE: Shown with HIM removed.

4. Insert airmix shaft ensuring keyway is correctly
aligned.
Shaft — Airmix Door DZ/SZ

NOTE: The Shaft-Airmix door is not a serviced item.
1. Remove the instrument panel (refer to section
501-12). Remove the HIM (refer to this section).
Open the face door.
G34257 en 01/2003 2003.0 BA Falcon

5. Maintain force on airmix shaft end and ensure 4. Unclip Harness and remove.
airmix door is depressed fully as shown in sketch
thus correctly aligning airmix door to shaft.
Installation
Dual Zone Sub Harness
Filter and Cover Assembly — Mesh
Removal (Standard Fitment)
1. Refer to HVAC Assembly removal procedure in
this section and follow steps 1 - 12 inclusive. Removal
2. Disconnect harness connector from 1. Refer to glove compartment removal procedure,
Actuator-Electric Airmix. Section 501-12 to gain access to Filter.
2. Slide Mesh Filter and Cover assembly to open
position (LH side).
3. Disconnect harness connector from HIM.
3. Pull out Filter-assembly.
Installation
G34257 en 01/2003 2003.0 BA Falcon

Filter — Particle (Optional Fitment) Vent Outlet Register — Outboard

Removal
Register
1. Refer glove compartment removal procedure, Removal and Installation
Section 501-12 to gain access to Filter. 1. Peel off door seal over area covering end cap of
2. Slide Cover and Seal Assembly to open (LH side). instrument panel.
2. Remove end cap.
3. Remove Cover & Seal Assembly.

3. Remove trim spear from instrument panel. Care
must be taken with trim removal or inboard
retainer clip will be broken.
4. Pull out Particle Filter.
4. Remove three screws/self tappers from registers.

Ease register on inboard top edge to dislodge clip
and remove register.
Installation
5. Assemble in reverse order.
G73255 en 01/2003 2003.0 BA Falcon

Vent Outlet Register — Centre Installation

Register 1. Position Air Register.
Removal
1. Remove Interior Command Centre and Remote
Key Receiver taking all precautions described in
section 413-08.
2. Remove wire harness from Air Register.
2. Tighten 3 X M5 screws to 1.5 Nm, top centre

screw first.
3. Remove 3 X M5 screws from Air Register.
3. Reposition wire harness to Air Register.
4. Remove Air Register.
4. Install the Remote Key Receiver and the ICC.

Vent Outlet Register — Floor Console

Register
1. Close flaps on register.
G73255 en 01/2003 2003.0 BA Falcon

2. Pry register out of lower retainer clips first, then 4. Invert console and ease rear section away from
top clips. main body.
3. Remove register. 5. Remove eight retaining screws locating duct to

4. On assembly of register, enter lower clips first and console.
roll register into place.
Floor Console Duct
The floor console duct is removed from the vehicle as
part of the floor console assembly. The duct can then
be separated form the console.
1. Remove floor console and duct assembly (Refer
to section 501-12).
2. Remove vent outlet floor console register (Refer
to procedure in this section).
3. Lift console lid and remove two rearmost screws.
6. Carefully spread console at front to allow duct

clearance over locating lugs. Spread rear of
console at rear and lift out duct.
7. To install, reverse the steps 1-6.
G73262 en 01/2003 2003.0 BA Falcon

412-03-1 Air Conditioning 412-03-1
SECTION : 412-03 Air Conditioning

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................412-03-3
Air Conditioning Safety Precautions ......................................................................................412-03-4
Climate Control System .......................................................................................................412-03-5
A/C Compressor and Clutch Assembly ................................................................................412-03-6
A/C Compressor Pressure Relief Valve ...............................................................................412-03-6
A/C Condenser Core ............................................................................................................412-03-6
Refrigerant Lines ..................................................................................................................412-03-7
A/C Evaporator Core ............................................................................................................412-03-7
A/C Orifice Tube Assembly ..................................................................................................412-03-8
Refrigerant Dye ....................................................................................................................412-03-8
Suction Accumulator ............................................................................................................412-03-8
A/C Cycling Switch (evaporator thermistor) .........................................................................412-03-8
A/C Pressure Cut-Off Switch (Pressure Transducer) ..........................................................412-03-9
Quick Joint Connection ........................................................................................................412-03-9
Air Conditioning Joint Design .............................................................................................412-03-10
Charge Port Valves ............................................................................................................412-03-11
Engine Cooling Fans (Condenser Fans) ...........................................................................412-03-11
Air Conditioning ....................................................................................................................412-03-12
A/C Functional Inspection Chart ........................................................................................412-03-12
A/C Fault Symptom Chart ..................................................................................................412-03-12
Air Conditioning System Performance Test .......................................................................412-03-18
A/C System Leak Test .......................................................................................................412-03-22
A/C System Noise Test ......................................................................................................412-03-23
Module Configuration .........................................................................................................412-03-24
WDS Parameter Identifier (PID) chart ................................................................................412-03-24
WDS Diagnostic Trouble Code (DTC) chart ......................................................................412-03-25
A/C disable strategy chart ..................................................................................................412-03-27
Air Conditioning & HVAC Relay and Fuses .......................................................................412-03-31
Pinpoint Tests ....................................................................................................................412-03-31
GENERAL PROCEDURES
Manifold Gauge Set Connection ..........................................................................................412-03-39
Electronic Leak Detection ....................................................................................................412-03-40
Fluorescent Dye Leak Detection ..........................................................................................412-03-40
A/C System Discharging and Recovery ...............................................................................412-03-42
A/C System Evacuation and Charging ................................................................................412-03-42
Refrigerant Oil Replacement Quantity .................................................................................412-03-43
Replenishment of Refrigerant Oil .........................................................................................412-03-44
A/C System Flushing ...........................................................................................................412-03-44
01/2003 2003.0 BA Falcon

(Continued)

A/C Hose/Tube Pad Fitting ..................................................................................................412-03-45
O-Ring Removal and Lubrication .........................................................................................412-03-46
Air Conditioning (A/C) Compressor — I6 Engine .................................................................412-03-46
Air Conditioning (A/C) Compressor — V8 Engine ...............................................................412-03-47
Compressor Clutch, Compressor Pressure Relief Valve and Compressor Shaft Seal .......412-03-48
Air Conditioning (A/C) Compressor Bracket ........................................................................412-03-48
Evaporator Core ...................................................................................................................412-03-49
Orifice Tube Assembly .........................................................................................................412-03-50
Quick Joint Clamp ................................................................................................................412-03-52
Suction Accumulator ............................................................................................................412-03-54
Pressure Cut-off Switch (Pressure Transducer) ..................................................................412-03-55
Condenser Assembly ...........................................................................................................412-03-56
Condenser Inlet Hose Assembly (Discharge Hose) ............................................................412-03-57
Compressor Inlet Hose Assembly (I6 & V8 — Suction Hose) and Accumulator Outlet Tube
Assembly (V8 — Suction Tube) ...........................................................................................412-03-57
Condenser to Evaporator tube assembly (A/C liquid line) ...................................................412-03-58
Evaporator clamp (E-Clamp) ...............................................................................................412-03-59
Air Conditioning Cycling Switch (evaporator thermistor) .....................................................412-03-59
Engine Cooling Fans (Condenser Fans) .............................................................................412-03-60
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Suction accumulator & A/C liquid line - 15
A/C compressor 10S17C evaporator E-clamp bolt
Displacement 188 cc Suction tube (V8) clamp - side rail 6
screw
Cylinder bore 32.0 mm (1.26 in)
Suction hose/tube clamp - spring tower 35
Cylinder stroke 23.38 mm (0.92 in)
nut
Rotation Clockwise A/C condenser core - A/C liquid line & 10
Magnetic clutch discharge hose bolts
Air gap between pulley 0.35 mm - 0.60 mm A/C condenser core bracket - radiator 7
and hub (0.014 in 0.024 in) bolts
A/C cycling switch (evaporator thermistor) Discharge hose clamp - radiator 8
Manual Climate Control support bolt
Air outlet vent 6.00°C max Discharge hose clamp (V8) - cross 8
temperature cycling Switching temperatures member bolt
differential will increase as the O-Ring Specifications
blower fan speed
reduces. Description Part No
Automatic Climate Control Refrigerant O-Ring, green/blue BA19S710B
evaporator inlet (small)
Air outlet vent 6.00°C max
temperature cycling Switching temperatures Refrigerant O-Ring, green/blue BA19S710A
differential will increase as evaporator outlet (large)
temperature selection Refrigerant O-Ring, black discharge V890158S
becomes hotter. hose/tube (small)
A/C pressure relief valve Refrigerant O-Ring, black suction V890157S
Open 3,430 - 4,100kPa (497 - hose/tube (large)
595psi)
A/C pressure cut-off switch (pressure
transducer)
low pressure cut-out 200kPa
high pressure cut-out 3,170kPa
Lubricants
PAG Compressor Oil 200cc (supplied in comp)
ND-Oil 8 (250 cc can -
AY19L000A)
Refrigerant R-134a 650 ± 50g
( YN-19)
Description Nm
A/C compressor bolt (black colour) 23
upper front mount
A/C compressor bolts (gold colour) 23
A/C compressor bracket bolts - I6 48
A/C compressor bracket bolts - V8 28
A/C liquid line - front LH apron body 10
clamp bolt
A/C liquid line - rear LH body saddle 8
clamp nut
A/C liquid line - nut joint 23
A/C compressor - suction & discharge 10
hose bolts
Suction accumulator bracket nuts 8
G86726 en 01/2003 2003.0 BA Falcon

Air Conditioning Safety Precautions Refrigerant oil will absorb moisture from the
atmosphere if left uncapped. Do not open an
oil container until ready to use, and install the
cap immediately after using. Store the oil in a
WARNING: To avoid accidental deployment clean, moisture-free container.
and possible injury, the air bag system backup Air conditioning O-rings are made from a
power supply must be depleted before repairing material compatible with refrigerant and
any climate control components. To deplete the refrigerant oil. Always use the correct
backup power supply, disconnect the battery replacement air conditioning O-ring, or A/C
positive cable and wait one minute. Failure to system leakage may occur.
If an A/C O-ring is not supplied with A/C hose
injury.
assembly, coat the refrigerant O-ring with oil
Use only R-134a refigerant before assembling.
When installing a refrigerant line, avoid sharp
WARNING: R-134a is classified as a safe bends. Position the line away from the
refrigerant, but misuse can make it dangerous. exhaust or any sharp edges that can chafe the
The following precautions must be observed. line.
Failure to follow these instructions may result in
personal injury. Tighten threaded fittings only to
specifications. The aluminum fittings used in
Always wear safety goggles when repairing an the refrigerant system will not tolerate
air conditioning system. overtightening.
Avoid contact with liquid refrigerant R-134a. When disconnecting a fitting, use a wrench on
R-134a vaporizes at approximately -25°C both halves of the fitting to prevent twisting of
(-13°F) under atmospheric pressure and it will the refrigerant lines or tubes.
freeze skin tissue.
Do not open a refrigerant system or uncap a
Never allow refrigerant R-134a gas to escape new component unless it is as close as
in quantity in an occupied space. R-134a is possible to room temperature. This will
non-toxic, but it will displace the oxygen prevent condensation from forming inside a
needed to support life. component that is cooler than the surrounding
Allow the engine to cool sufficiently prior to air.
carrying out maintenance or serious burns
and injury can occur. CAUTION: To avoid contamination of the A/C
system:
CAUTION: To avoid damaging the vehicle or Keep service tools and the work area clean.
A/C components, the following precautions must
be observed: Never open or loosen a connection before
discharging the system.
Do not add R-12 refrigerant to an A/C system
that requires the use of R-134a refrigerant. When loosening a connection, if any residual
These two types of refrigerant must never be pressure is evident, allow it to leak out before
mixed. Doing so can damage the A/C system. opening the fitting.
A number of manufacturers are producing Before charging, evacuate a system that has
refrigerant products that are described as been opened to install a new component or a
direct substitutes for refrigerant R-134a. The system that has discharged through leakage.
use of any unauthorized substitute refrigerant Seal open fittings with a cap or plug
can severely damage the A/C components. If immediately after disconnecting a component
repair is necessary, use only new or recycled from the system.
refrigerant R-134a. Clean the outside of the fittings thoroughly
Do not remove the sealing caps from a new before disconnecting a component from the
component until ready to install. system.
G73302 en 01/2003 2003.0 BA Falcon

Climate Control System

Clutch Cycling Orifice Tube Refrigerant System Components (“The refrigerant cycle”)

1 Evaporator thermistor 8 Low pressure low temperature liquid
refrigerant
2 Suction Accumulator assembly
9 Low pressure low temperature refrigerant
3 A/C Orifice Tube
vapour
4 A/C Charge Port (high pressure side)
10 Condenser core
5 A/C Pressure Tranducer 11 Compressor + Clutch assembly
6 High pressure high temperature refrigerant
12 Compressor bracket
vapour
13 A/C charge port (low pressure side)
7 High pressure moderate temperature liquid
refrigerant 14 Evaporator Core
G73302 en 01/2003 2003.0 BA Falcon

The A/C refrigerant system is a clutch cycling orifice The 10S17C A/C compressor has the following
tube type. The system consists of the following characteristics:
components: a 10-cylinder swashplate design
A/C compressor/clutch assembly displacement of 188cc
A/C condenser core A two-piece lip-type seal is used to seal the shaft
A/C evaporator core opening in the assembly.
A/C charge port valve (high pressure side) Five double-acting pistons operate within the
A/C charge port valve (low pressure side) cylinder assembly. The pistons are actuated by a
swashplate that changes the rotating action of the
connecting refrigerant lines
shaft to a reciprocating force.
suction accumulator Reed-type discharge valves are located between
The refrigerant system operation is controlled by the the cylinder assembly and the head at each end
following: of the A/C compressor.
A/C evaporator core orifice The A/C compressor uses PAG Compressor Oil
A/C cycling switch (evaporator thermistor) ND-Oil8 or equivalent (meeting Ford specification
A/C compressor pressure relief valve WSH-M1C231-B). This oil contains special
additives necessary for the A/C compressor.
A/C pressure cut-off switch (pressure transducer)
The magnetic A/C clutch has the following
The refrigerant system incorporates an A/C characteristics:
compressor controlled by an A/C cycling switch.
It drives the compressor shaft.
The A/C cycling switch senses A/C evaporator core
temperature to control A/C compressor operation. When battery positive voltage (B+) is applied to
the A/C clutch field coil, the clutch disc and hub
An A/C compressor pressure relief valve is installed in assembly is drawn toward the A/C clutch pulley.
the A/C discharge hose assembly to protect the
refrigerant system against excessively high refrigerant The magnetic force locks the clutch disc and hub
pressures. assembly and the A/C clutch pulley together as
one unit, causing the compressor shaft to rotate.
An A/C evaporator core orifice is installed in the
condenser to evaporator line (A/C liquid line) to meter When B+ is removed from the A/C clutch field
the liquid refrigerant into the A/C evaporator core. coil, springs in the clutch disc and hub assembly
move the clutch disc away from the A/C clutch
A/C Compressor and Clutch Assembly pulley.
A/C Compressor Pressure Relief Valve
An A/C compressor pressure relief valve is
incorporated in the compressor A/C body to:
relieve unusually high refrigerant system
discharge pressure buildups of (3.43MPa [497
psi] and above).
prevent damage to the A/C compressor and other
system components.
avoid total refrigerant loss by closing after the
excessive pressure has been relieved.
A/C Condenser Core
The A/C condenser core has the following
NOTE: Internal A/C compressor & compressor clutch characteristics:
components are not repaired separately. Install a new It is an aluminum fin-and-tube design heat
A/C compressor only as an assembly. exchanger located in front of the vehicle radiator.
NOTE: Installation of a new suction accumulator is It cools compressed refrigerant gas by allowing air
required when repairing the air conditioning system to pass over the fins and tubes to extract heat and
when there is physical evidence of system by condensing gas to liquid refrigerant as it is
contamination from a failed A/C compressor, damage cooled.
to the suction accumulator, evidence of the A/C
system being open to the atmosphere/leaking or
evidence of moisture absorption.
G73302 en 01/2003 2003.0 BA Falcon

Refrigerant Lines A/C Evaporator Core

NOTE: Installation of a new suction accumulator is
required when repairing the air conditioning system
when there is physical evidence of system
contamination from a failed A/C compressor, damage
The condenser to evaporator line (A/C liquid line)
contains high pressure liquid refrigerant upstream of
the A/C evaporator core orifice. This orifice tube can
be serviced by disconnecting liquid line from the body
and undoing the nut joining both halves of the liquid
line. The liquid line incorporates a high pressure
charge port valve which is only used in the vehicle
assembly plant.
The A/C HVAC assembly contains the A/C evaporator
The condenser inlet hose (discharge hose) contains core. The A/C evaporator core is the plate/fin type
high temperature high pressure refrigerant vapour. with a unique refrigerant flow path.
This discharge hose incorporates an A/C pressure
A mixture of refrigerant and oil enters the evaporator
cut-off switch (pressure transducer) which disables
core through the A/C evaporator core inlet tube and is
the compressor in the event of excessively high or low
routed so it flows through the core tubes and
system pressures, and selects low or high condenser
channels from driver to passenger side of the core.
fan speeds.
The compressor inlet hose (suction hose) contains
low temperature low pressure refrigerant vapour. In
the V8 vehicle, the suction hose is attached to a
suction tube via a quick-connect clamp. For all
models, the suction hose/tube is attached to the
suction accumulator via a quick-connect clamp. The
suction hose incorporates a low pressure charge port
valve which is used for all A/C system servicing.
The BA Falcon 6-cylinder petrol/LPG compressor inlet
hoses (suction hoses) from Feb 2004 have been
standardised (BA-19997-D) and this is different to the
early level of BA Falcon petrol/LPG suction hoses
(BA-19997-A and BA-19997-C), both in the hose
material and routing.
All hose/tube assemblies contain refrigerant O-rings The Refrigerant Flow path follows the flow shown.
which are retained in a recessed groove. These
O-rings seal against leakage using radial compression
once the joint is fully assembled and further tightening
of the fitting bolt or tube nut will not improve the
sealing performance. These O-rings are black in
colour and made of a special material compatible with
refrigerant and refrigerant oil. Use only black genuine
Ford refrigerant O-rings for replacement.
On the evaporator inlet and outlet tube joints,
green/blue refrigerant O-rings are fitted. Again, these
O-rings are made of a special material compatible
with refrigerant and refrigerant oil, and are different
dimensions to the black refrigerant O-rings. Use only
green/blue genuine Ford refrigerant O-rings for
replacement in these locations.
G73302 en 01/2003 2003.0 BA Falcon

A/C Orifice Tube Assembly The BA Falcon suction accumulator from December
2003 (BA-19C808-B, post December 2003) has a
different mounting to the earlier version of BA Falcon
accumulator (BA-19C808-A, pre December 2003).
Both the later level accumulator bracket and the
welded body apron brackets have been revised, and
the later level accumulator bracket cannot be fitted to
the earlier level body bracket.
The suction accumulator is mounted via the A/C
accumulator bracket onto the LH body apron. The
inlet tube of the suction accumulator is connected to
the A/C evaporator outlet tube. The outlet tube of the
accumulator is connected to the A/C suction
hose/tube assembly.
After entering the inlet of the suction accumulator,
heavier oil-laden refrigerant contacts an internally
mounted dome (which serves as an umbrella) and
NOTE: Install a new A/C orifice tube assembly
drips down onto the bottom of the canister.
whenever a new A/C compressor is installed.
A small diameter oil bleed hole, in the bottom of
NOTE: The red orifice tube can not be interchanged the vapour return tube, allows the accumulated
with different colour orifice tubes from previous heavier liquid refrigerant and oil mixture to
models. re-enter the compressor suction line at a
The A/C orifice tube has the following characteristics: controlled rate.
located at the nut joint in the A/C liquid line As the heavier mixture passes through the small
(condenser to evaporator line). diameter liquid bleed hole, it has a second chance
to vapourise and recirculate through the A/C
color-coded red. compressor without causing compressor damage
an orifice diameter of ~1.5 - 1.6mm (~0.060in). due to liquid slugging.
changes the high-pressure liquid refrigerant into a A fine mesh screened filter fits tightly around the
low-pressure liquid. bottom of the vapour return tube to filter out
filter screens are located on the inlet and outlet refrigerant system contaminant particles.
ends of the orifice body A desiccant bag is mounted inside the canister to
the inlet filter screen acts as a strainer for the absorb any moisture which may be in the
liquid refrigerant flowing through the A/C refrigerant system.
evaporator core orifice.
A/C Cycling Switch (evaporator
O-ring seals on the A/C evaporator core orifice thermistor)
prevent the high-pressure liquid refrigerant from
bypassing the A/C evaporator core orifice. The evaporator sensor is located on the driver’s side
Adjustment or repair cannot be made to the A/C of the evaporator core towards the lower face of the
orifice tube assembly. If damaged or blocked, a core. The tip of the thermistor contains a sensor which
new A/C orifice tube assembly must be installed. is connected via a harness to the HIM (HVAC
Integrated Module). The sensor is located in an
Refrigerant Dye optimized position on the core face and controls
compressor “ON”/“OFF” set point as air off
R-134a fluorescent tracer dye has been added to the
temperature changes.
A/C system of this vehicle, supplied in the
accumulator. The refrigerant dye has a limited life of The HIM Module changes the set point depending on
~500 hours of air conditioning operation. blower fan speed and thus prevents core ice up.
Varying the fan speed also varies the set point for
Leak checking can be performed with an ultra-violet
cycling the compressor clutch. It is not necessary to
lamp and viewed through ultra-violet glasses.
remove the evaporator core when replacing the
Suction Accumulator thermistor.
The position of the thermistor in relation to the
evaporator air off airflow is critical for efficient
operation of the refrigeration system. It is therefore
vital that the correct removal and replacement
procedure is followed as incorrect positioning of the
thermistor sensor will adversely effect efficiency, and
could also result in core ice up.
G73302 en 01/2003 2003.0 BA Falcon

A/C Pressure Cut-Off Switch (Pressure been a 2 minute delay since engagement +
Transducer) evaporator thermistor registers less than 10ºC +
there are no engine/transmission cooling
requirements for high speed fan.)
The condenser fan is also engaged automatically
if there are engine/transmission cooling
requirements, even if the A/C switch is off.
In both low and high speeds, both condenser fans
operate together.
Quick Joint Connection
The A/C pressure transducer is used to interrupt A/C

compressor operation in the event of high or low
system discharge pressures.
The A/C pressure cut-off switch is mounted on the
high pressure discharge hose assembly.
CAUTION: It is necessary to discharge the

refrigerant system to remove the A/C pressure
cut-off switch.
If the compressor discharge pressure drops below Item Description
200kPa, the pressure transducer sends a signal 1 Male fitting
to the EEC which disengages the A/C 2 O-ring, suction
compression. 3 Female fitting
If the compressor discharge pressure rises to 4 Quick joint clamp
approximately 3,170kPa, the pressure transducer
sends a signal to the EEC which disengages the The quick joint connection is a refrigerant line
A/C compressor. coupling held together with a plastic clamp. The
plastic clamp has locking tabs that grip the tube shape
When the pressure drops to approximately and hold tubes together.
2,570kPa, the pressure transducer signal via the
EEC allows the A/C compressor to re-engage. The o-ring seals are black in colour and made of
a special material compatible with refrigerant &
The pressure transducer is also used for condenser refrigerant oil. Use only black refrigerant O-Rings
fan control. in this location.
When the A/C switch is engaged below a set A special service tool is required to remove the
vehicle speed, the condenser fan is engaged quick joint connector. Its insertion is important to
automatically if the compressor discharge proper removal of the quick joint.
pressure is high.
Male fitting (suction hose) must be fully inserted
When the compressor discharge pressure into female fitting.
reaches approximately 2,100kPa, the pressure
transducer signal via the EEC engages the Lubricate o-rings with refrigerant oil to make
high-speed fan control. smooth insertion.
When the pressure drops to approximately 1800
kPa, the pressure transducer signal via the EEC
engages the low speed fan control. (If there has
G73302 en 01/2003 2003.0 BA Falcon


1 Female fitting 1 Clamp interlocking tabs
2 Male fitting 2 Stopper lever
3 O-Ring seals 3 Quick joint clamp removal tool
Quick joint clamp wraps around the tube 4 Clamp guide
connection.
Air Conditioning Joint Design
Interlocking tabs on clamp hold clamp in place.
Quick joint clamp clicks shut. In the A/C system, there are 3 types of joints:
radial seal pad fitting or nut joint
Compression seal 45° taper joint
Radial seal quick connect joint
For all radial seal joints, the O-ring is retained in a
recessed groove. The O-ring seals against leakage
using radial compression once the joint is fully
assembled, and further tightening of the fitting bolt or
tube nut will not improve the sealing performance. Full
insertion of the tube joint is critical to prevent O-ring
damage. All retained O-rings are black refrigerant
O-rings made from a special material compatible with
refrigerant and refrigerant oil. All quick-connect joints
use two black retained refrigerant O-rings for sealing.
At the evaporator inlet and outlet tube joints,
If gap exists, clamp cannot be closed. green/blue refrigerant O-rings are used in a 45° taper
compression seal. Again, these O-rings are made of a
Clamp can rotate freely on tube joint until A/C
special material compatible with refrigerant and
system is charged with refrigerant.
refrigerant oil, and are different dimensions to the
Alignment of clamp guide to quick joint clamp black refrigerant O-rings. In addition, the evaporator
removal tool is required for clamp removal. tube green/blue refrigerant O-rings are different
dimensions from previous models.
Prior to making any hose/tube connections, lubricate
the O-ring with compressor oil to avoid refrigerant
leakage.
Fine fibre and dust can affect seal performance.
When disassembling joints, keep O-rings capped to
prevent O-ring damage, contamination and moisture
ingression.
G73302 en 01/2003 2003.0 BA Falcon

The fitting is an integral part of the refrigeration line or

component.
Special couplings are required for both the
high-side and low-side charge ports.
The Schraeder-type valve core can be replaced if
the seal leaks.
Always install the appropriate A/C charging valve
cap on the charge port valves after repairing the
refrigerant system.
The high pressure charge port cap located on the
liquid line charge port is smaller than the low
pressure charge port cap located on the suction
hose/tube.
Engine Cooling Fans (Condenser Fans)
The vehicle is fitted with dual electric cooling fans
mounted in a fan shroud directly behind the radiator
assembly.
These fans are used for both engine cooling and air
conditioning condenser cooling. The fans are
controlled by three relays via the Powertrain Control
Module, and when required, operate at low speed
(1400 rpm) or high speed (2300 rpm) depending on
the engine and A/C cooling demands.
Refer to Wiring section and Engine Cooling section
303-03 for further details.
CAUTION: When the ignition is ON, the fans

Charge Port Valves may start without warning.
The high-pressure charge port valve is located on the CAUTION: During service operations ensure
A/C liquid line (condenser to evaporator line). that the fan is not rotated in a direction opposing
The low-pressure charge port valve is located on the normal operation (designated by an arrow on the
suction hose or tube assembly. fan blade), or this may damage the motor. For
more information refer to section 303-03.
Item Description
1 A/C charging valve cap (low pressure)
2 A/C suction hose/tube
3 Charge port valve
4 O-ring seal
5 A/C liquid line
6 A/C charging valve cap (high pressure)
G73302 en 01/2003 2003.0 BA Falcon

Air Conditioning
In order to correctly diagnose the root cause of the
fault, it is advisable that the technician follow the
following Air Conditioning System Fault Test process.
System fault System test A System test B System test C System test D
A/C Cooling A/C System A/C Fault Symptom A/C System Performance test or WDS tester or
fault Functional Chart, then A/C system leak test or Pinpoint tests
Inspection test, A/C system noise test, then
then
A/C Functional Inspection Chart
A/C component Result for Inspection Pass System Fault for Inspection Fail
A/C system Good cooling performance from Refer to A/C Fault Symptom Chart
system
A/C compressor Engages with A/C on (comp clutch Wiring fault, refer pinpoint test A
centre turns) ICC fault, refer 413-08.
A/C cooling fault, refer A/C Fault
Symptom Chart.
Compressor drive belt Does not slip or whip when A/C is Accessory drive fault, refer 303-05
engaged
A/C discharge hose Hot to touch with A/C on A/C cooling fault, conduct A/C
Performance test
A/C suction hose Cold to touch with A/C on A/C cooling fault, conduct A/C
Performance test
A/C liquid line - before orifice tube Hot to touch with A/C on A/C cooling fault, conduct A/C
Performance test
A/C liquid line - after orifice tube Cool to touch with A/C on A/C cooling fault, conduct A/C
Performance test
Condenser fan Air flow across condenser A/C cooling fault, conduct A/C
Performance test
Wiring fault, refer pinpoint test F
Suction accumulator Cold to touch with A/C on A/C cooling fault, conduct A/C
Performance test
System blower fan speed & Air flow and cooling as Blower fault, refer 412-04
temperature selection selectedOperates at all fan speeds Air distribution fault, refer 412-02
A/C cooling fault, refer A/C Fault
Symptom Chart
A/C Fault Symptom Chart
Symptom Possible Cause Possible Root Confirmation Test Possible Fix

Area Cause
No A/C cooling If Comp clutch If Comp clutch
engages… engages…
Refrigerant fault Low A/C system Conduct A/C Recharge A/C
charge Performance test system to
specification
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
A/C system Conduct A/C Replace blocked
refrigerant blockage Performance test component
Poor compressor Inefficient A/C Cooling fault, Replace
performance compressor refer 412-03 Compressor
pumping assembly
Loose comp drive Visual Inspection Tighten drive belt
belt Refer 303-05
Slipping comp. Visual inspection Replace
clutch Compressor
assembly
If Comp clutch is If Comp clutch is
not engaging… not engaging…
Electrical fault Fuse or Wiring fault, refer to Repair circuit
disconnected wire Pinpoint test A
Comp clutch field Refer to Pinpoint Replace
coil open circuit test A for clutch Compressor
assembly
WAC relay open Refer to Pinpoint Replace relay
circuit test B for Relay
ICC display or ICC fault, refer Refer to 413-08
control fault 413-08
HIM / CAN / BEM / Pinpoint test for Refer 412-04,
EEC / PCM fault each Part Refer to 413-08 or 303-14
412-04, 413-08 or
303-14
Blower fan not Pinpoint test for Refer 412-04
operating Blower fan, 412-04
Insufficient battery Refer to section Refer 412-04
voltage 412-04
Compressor or Comp clutch Visual inspection for
Replace
clutch fault slipping clutch slip Compressor
assembly
Excessive clutch air Visual inspection for Replace
gap clutch engagement Compressor
assembly
Compressor seized Hand turn Replace
compressor Compressor
assembly
Refrigerant fault Low A/C system Conduct A/C Recharge A/C
charge Performance test system to
specification
Insufficient A/C Refrigerant fault Low A/C system Conduct A/C Recharge A/C
cooling charge due to Performance test system to
improper initial and Leak test specification
charge
Air in A/C system Conduct A/C Recharge A/C
due to poor Performance test system to
evacuation specification
Contaminant in A/C Conduct A/C Recharge A/C
system due to poor Performance test system to
quality refrigerant specification
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
Excessive A/C Conduct A/C Recharge A/C
system charge Performance test system to
specification
Excessive Check repair Drain compressor,
refrigerant oil history, conduct A/C Replace
Performance test Accumulator,
Recharge refrigerant
oil to specifications
Refrigerant flow Orifice tube Inspect orifice tube Replace orifice tube
fault blocked/restricted
Orifice tube Inspect orifice tube Replace orifice tube
bypassed, missing
or damaged O-ring
Incorrect orifice tube Inspect orifice tube Replace orifice tube
A/C hose/tube flow Inspect for hose & Replace faulty part
restriction tubing restrictions,
kinks, delamination
Air flow heat pick-up Air duct heat pick-up Air distribution fault, Refer to 412-02
fault fault after refer to 412-02
evaporator
Air inlet heat pick-up Air distribution fault, Refer to 412-02
fault before refer to 412-02
evaporator
Air mix door position Air distribution fault, Refer to 412-02
fault refer to 412-02
Air mix door leak Air distribution fault, Refer to 412-02
refer to 412-02
Fresh/recirc door Air distribution fault, Refer to 412-02
position fault refer to 412-02
Fresh/recirc door Air distribution fault, Refer to 412-02
leak refer to 412-02
Poor evaporator Restricted air flow Inspect Evaporator Replace Evaporator
performance through evaporator core, Refer to this
(clogged or chapter
damaged fins)
Restricted air flow to Air Distribution fault, Refer to 412-02
evaporator (filter or refer 412-02
duct)
Blower fan not Blower fault, refer to Refer to 412-04
operating correctly 412-04, Pinpoint
test L
Evaporator Conduct Pinpoint Replace Evaporator
refrigerant flow test 412-03-D
blocked/restricted
Poor compressor Inefficient Conduct A/C Replace
performance compressor Performance test Compressor
pumping assembly
Slipping comp drive Visual Inspection of Tighten Belt
belt Belt
Slipping comp. Visual Inspection of Replace
clutch clutch operation Compressor
assembly
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
Insufficient Assess oil amount Add oil as specified
refrigerant oil in system, using A/C or replace
quantity causing Noise test compressor if
comp seizure damaged
Insufficient Assess oil return, Replace
refrigerant oil using A/C Noise test Accumulator
transfer from and replacement of
blocked accumulator accumulator
oil pick-up
Poor condenser Condenser Conduct A/C Replace condenser
performance refrigerant flow performance test
blocked/restricted
Restricted air flow to Assess air flow Remove restriction
condenser across condenser
and compare
against equivalent
vehicle
Restricted air flow Assess air flow Clean / Repair fin
through condenser through condenser damage or replace
(clogged or and inspect fins condenser
damaged fins)
Engine overheating Engine cooling fault, Refer to 303-03
refer to 303-03
Radiator Engine cooling fault, Refer to 303-03
overheating refer to 303-03
Hot air re-circulating Prevent hot air Prevent
through condenser re-circulating and re-circulation with
compare A/C correct air deflector
performance before and seals
and after
modification
Cooling fan fault Incorrect cooling fan Test fan operation Repair fault, replace
operation for refer to Pinpoint test part
condenser pressure F
conditions
One or both cooling Test fan operation Replace cooling
fans refer to Pinpoint test fans
open-circuited/not F
operating
Incorrect operation Excessive A/C high Incorrect cooling fan Engine Cooling Refer to 303-03
of A/C cooling pressure operation for fault, refer to 303-03
compressor cut-out condenser pressure
conditions
Excessive A/C Conduct A/C Recharge A/C
system charge performance test system to
specification
Condenser Conduct A/C Replace condenser
refrigerant flow performance test
blocked/restricted
Orifice tube Check for Replace orifice tube
blocked/restricted temperature
difference before
and after orifice tube
location
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
Uneven cooling Low A/C system Go to section Recharge A/C
Passenger vent charge 412-02, Pin point system to
outlet air warmer test K, conduct A/C specification
than driver vent system performance
outlet air test & A/C leak test
A/C compressor Evaporator Inspect thermistor Reassemble
cycles too frequently thermistor location refer to this thermister
incorrectly located chapter
A/C compressor Restricted air flow Inspect evaporator Clean evaporator or
excessive cycle on through evaporator surface replace
time
Restricted air flow to Air Distribution fault Improve air flow to
Evaporator refer to this chapter evaporator
Air/Moisture in A/C Conduct A/C Recharge A/C
system Performance test system to
specification
A/C system Conduct A/C Replace blocked
refrigerant blockage Performance test part and Recharge
A/C system to
specification
A/C will not switch HIM / can / EEC / Electrical fault, refer Refer to 412-04,
off- electrical fault BEM / PCM fault to 412-04, 413-08 or 413-08 or 303-14
303-14
ICC display or ICC fault, refer to Refer to 413-08
control fault 413-08
Comp. clutch relay Pinpoint test B Replace relay
Evaporator Pinpoint test 412-04 Repair fault, replace
thermistor short part
circuit/calibration
fault
Evaporator Inspect thermistor Reassemble
thermistor location refer to this thermister
incorrectly located chapter
Abnormal Noise A/C will not switch Insufficient clutch air Visual inspection of Replace
off- comp clutch gap Air gap Compressor
fault assembly
Noisy with A/C not Drive belt Visual inspection of Replace belt
operating loose/worn Belt
Comp. clutch Conduct A/C noise Replace
bearing fault test, Hand turn Compressor
clutch rotor assembly
Noisy with A/C off, Blower motor fault Blower fault, refer to
blower fan on 412-02
Blower fan out of Blower fault, refer to
balance 412-02
Noisy with A/C Worn/damaged Conduct A/C noise Replace
operating compressor test Compressor
assembly
Comp. clutch Visual Inspection of Replace
engagement or magnetic clutch Compressor
disengagement fault assembly
Slipping drive belt Visual Inspection for Tighten drive belt
belt
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
A/C component Conduct A/C noise Isolate noise source
resonance/rattling test and detect
noise source
Comp. discharge Conduct A/C noise Isolate noise
pulsation noise test condition
transfer to body
Excessive Conduct A/C Recharge A/C
compressor noise Performance test to system to
due to overcharged judge overcharged specifications
system
Refrigerant flow Conduct A/C Recharge A/C
hiss/gurgle due to Performance test to system to
overcharged system judge overcharged specification,
Refrigerant flow Conduct A/C noise Isolate/replace A/C
hiss/gurgle due to test and detect liquid line
A/C liquid line noise noise source
transmission
Refrigerant flow Conduct A/C noise Replace orifice tube
hiss/gurgle due to test and/or liquid line
faulty orifice tube
Control component Intermittent A/C Intermittent power to Compressor wiring Repair circuit
fault operation clutch fault, refer to
Pinpoint test A
Pressure transducer Open-circuit Go to Pinpoint test Repair fault, replace
fault C part
Short circuit Go to Pinpoint test Repair fault, replace
C part
Calibration fault Go to Pinpoint test Replace sensor
C
Cabin temperature Open-circuit Go to section Repair fault, replace
sensor fault 412-04 part
Short circuit Go to section Repair fault, replace
412-04 part
Calibration fault Go to section Replace sensor
412-04
Ambient Open-circuit Go to section Repair fault, replace
temperature sensor 412-04 part
fault
412-04 part
412-04
Sun Load sensor Open-circuit Go to section Repair fault, replace
fault 417-01 part
417-01 part
417-01
Evaporator Open Circuit Go to Pinpoint test Repair fault, replace
Thermistor fault G part
G73303 en 01/2003 2003.0 BA Falcon


Area Cause
Calibration fault Go to Pinpoint test Replace sensor
G
ICC display screen Not working, Refer to 413-08 Refer 413-08
or button fault Incorrect operation
For additional information, refer to Section 412-00. 3. Insert a thermometer (or temperature measuring
device) into one of the Centre Face Level
Air Conditioning System Performance Registers. Monitor the Register air outlet
Test temperature and record only when it is stable. (ie:
NOTE: This test is used to ascertain the maximum When the temperature has stopped falling). Allow
a minimum of 5 minutes for the Register air
cooling capability of the air conditioning system.
temperature to stabilise before taking readings.
Vehicle preparation: 4. Monitor the pressure gauge readings and record
stabilised pressures.
NOTE: Check the following items before carrying out
NOTE: Pressure modulations even when the
the test - adjust as necessary.
system has stabilised is normal.
1. No heat pickup when the A/C controls are in the
5. If the system cycles, record the maximum and
full cold position.
minimum vent temperatures, maximum discharge
2. The engine cooling fans for correct operation and pressure, minimum suction pressure and
providing adequate condender airflow. approximate clutch on and off time in seconds.
3. Condenser and Radiator core fin condition NOTE: Cycling should only occur at lower
(obstruction by insect, grass, screens etc.). ambient temperatures. (Refer to Recommended
4. Full Recirculation air mode is achieved. Compressor Cycle Times overpage.)
5. Compressor drive belt tension. 6. Record the Ambient air temperature of the day
6. Face level air outlet mode achieved. away from direct sunload using the air
temperature measuring device.
7. Temperature door is achieving full cold position.
8. Correct operation of Automatic Climate Control 7. For the air register vent temperatures, if the
system was cycling, calculate the average of the
system (Perform diagnosis self-test).
maximum and minimum temperatures. Use the
9. Engine coolant level in radiator supply tank. AVERAGE register temperature for comparison
Test Conditions: against the normal values on the graph. If the
system was not cycling, compare the measured
1. Engine Idling at operating temperature with the vent temperature against the normal values on
transmission in Park with the handbrake applied. the graph.
2. Vehicle doors closed with all windows fully 8. Next, compare these temperature and pressure
opened and bonnet raised. readings with Normal values between the upper
3. An R134 Manifold Gauge set connected to the and lower limits shown in the graphs below. Using
high and low side service port connections. this information and the Diagnostics table, the
4. The vehicle positioned in the shade at least 1.5 likely cause of capacity loss can be diagnosed.
For more information on A/C system diagnosis,
metres from any wall.
refer to the A/C fault symptom chart in this
5. Air conditioning operating on recirc, face, full cold, section.
(max.) high blower fan for 5 minutes until A/C
system temperatures stable. CAUTION: Never top-up with R134a. If low
R134a charge is suspected remove the
Test Procedure: remaining charge and re-fill with the
1. Run with the engine idling and A/C set as per test recommended R134a quantity.
conditions for 5 minutes until the A/C system
temperatures are stable.
NOTE: To achieve these settings on automatic
climate control vehicles, select manual over-rides.
2. Confirm that the Compressor is engaged.
G73303 en 01/2003 2003.0 BA Falcon

Normal centre register Average Air Temperature
NOTE: RECOMMENDED COMPRESSOR CYCLE

TIMES:
In ambient temperatures below about 25°C, the
A/C compressor cycle time will vary.
For reference:
The compressor should cycle ON for 5
MINIMUM to 30 seconds.
The compressor should cycle OFF for 2 — 12
MAXIMUM seconds.
G73303 en 01/2003 2003.0 BA Falcon

Normal High side Pressure
G73303 en 01/2003 2003.0 BA Falcon

Normal Low side Pressure
Air Conditioning System Performance Test Diagnostics
Vent temp Disch press Suct press Clutch on time Fault Likely cause
High High High Long to Low condenser air Blocked condenser or
continuous flow. radiator core.
One or both cooling
fans not working.
Non approved parts
blocking air flow.
Hot air Only one cooling fan
recirculating operating.
through the Radiator heat shields
condenser. missing.
High High Normal to high Long to Air in the system. Poor evacuation.
continuous
High Normal to high Normal to low Long to Low refrigerant to Blocked or wrong size
continuous the evaporator. orifice.
High Normal to high Normal Long to Low refrigerant Leaking joint, pipe, or
continuous charge. component.
Normal to Normal to low Normal Long to Partial blockage Contamination in
high continuous of the evaporator refrigerant circuit.
refrigerant circuit. Damaged, crimped or
dented evaporator
tubes.
G73303 en 01/2003 2003.0 BA Falcon

Vent temp Disch press Suct press Clutch on time Fault Likely cause
High Normal Normal Long to Heat pick up in air Fresh/recirc door not
continuous inlet system. fully in recirc or
leaking.
Hot engine
compartment air
drawn into the inlet.
Excessive oil in Failure to flush before
system. changing compressor.
High Normal Normal Normal Heat pick up in Temp control not
the air delivery achieving full.
system. (after the
evaporator core)
High Low Normal Long to Condenser Damaged or crimped
continuous refrigerant flow condenser tube.
low. Contaminants blocking
refrigerant circuit.
High Low High Long to Poor compressor Worn or damaged
continuous performance. compressor.
Compressor drive belt
or clutch slipping.
Restricted suction Delaminated, crimped
line. or block suction line.
Normal to Normal to low High Long to Insufficient Wrong orifice tube
high continuous restriction at fitted.
orifice. Damaged or missing
orifice tube ‘O’ ring.
Normal High Normal to high Normal Refrigerant over Topping up instead of
charge. full evac and charge.
Normal Normal to low Normal to low short Low evaporator Partially blocked
airflow. evaporator fins.
Restriction in recirc
duct.
Low Normal to low Normal to low continuous Clutch not Evaporator air off
disengaging. thermistor faulty or not
clipped into the correct
core location
A/C System Leak Test R-134a fluorescent tracer dye has been added to the
A/C system of this vehicle, supplied in the
Two options are available for detection of joint leaks. accumulator. The refrigerant dye has a limited life of
~500 hours of air conditioning operation.
1. Refrigerant R-134a Leakage detection
Leak checking can be performed with an ultra-violet
NOTE: For more information, refer to Electronic leak lamp and viewed through U.V. glasses.
detection in this section. A/C system pressure must be above 551kPa (80psi)
Refrigerant leakage can be determined by a leak for this operation, and the A/C system must have run
detector. Be sure to remove all oil from the test area for ~15 minutes prior to leak testing, to allow the dye
before using the leak detector, because the oil may to mix thoroughly.
contain refrigerant which would give erroneous Scan all components, fittings and lines with Rotunda
readings. ultra-violet 164-R0721 or equivalent.
Check for leakage at the compressor shaft seal, and Leaks can be pin-pointed by bright yellow-green glow
at all system fittings and lines as detailed in Joint of the tracer dye.
Locations in this Section.
After the leak is repaired, the traces of dye can be
2. Alternative Leak detection (leak tracer dye) removed from previously leaking areas by using any
general purpose oil solvent.
NOTE: For more information, refer to Fluorescent Dye
leak detection in this section.
G73303 en 01/2003 2003.0 BA Falcon

A/C System Noise Test

All compressor driven air conditioning systems will emit noise. Careful system tuning has been undertaken to
suppress most noise emissions. However, with improvements to cabin quietness, customer complaints for
noise, vibration and harshness may need to be addressed. The following chart and proceeding explanations
help with these issues.
Action Conditions
Inquire about customer complaint What kind of noise (tone/loudness).
When noise occurs (first time etc.).
Where is it heard from
What conditions it occurs in
Validate the customer claim Reproduce conditions that noise occurs in
Detail what, when, where noise occurs
Check air conditioning system Check system layout.
Check gas pressures
Check belt tension and alignment
Make judgement on type of noise Use attached notes to judge noise
Detail what and where noise occurs
Find noise source and transmission path
Isolate source to verify
Make repair and judge affect Remove source (replace, unbolt) if faulty component
Mask noise source if possible
Mask transmission path (insulate)
Explain your findings to customer Detail your activities
If required, request owner to document when noise complaint occurs
to help investigation
Test Procedure
NOTE: This test is used to identify customer complaints.
Vehicle Conditions
Ensure the system is not over charged with refrigerant by conducting an A/C System Performance Test.
Inspect to confirm that system is assembled correctly. That is, compressor is fastened to bracket, drive
belt is tight, condenser is rubber mounted, A/C pipework is not touching body, retaining clamps are in
correct positions, etc.
1. Reproduce the customer complaint noise. (complaint needs to be clearly identified).
2. Gauge if noise is abnormal (it is important to understand the characteristics of the vehicle in its normal
state, to judge what is abnormal). Seek additional advice if necessary.
3. Detail what and how noise occurs.
4. Find the noise source and verify it’s transmission path by isolating suspect part from the vehicle. That is,
float condenser or A/C piping in space to cut the transmission path, etc. If the noise disappears, this
validates the noise source or transmission path.
5. Identify the best method to remove the source. If not possible, mask the source output or isolate the
transmission path.
6. Explain you investigations to the owner, as they are attuned to a noise, and it may be difficult for them to
accept that the total removal of the noise may not be possible. With noise issues, improvement can often
be made but complete removal cannot always be achieved (eg. if the noise complaint is a characteristic of
the actual car or a normal A/C system operating characteristic) . Detailing your findings will make your
explanation easier.
G73303 en 01/2003 2003.0 BA Falcon

A/C Noise Symptom Chart

Internal wear of compressor - Lack of lubricating oil. In a system with Check rattling noise from compressor,
Mechanical ‘rattling’ noise occurs with a gas leak, the oil has escaped with using a screwdriver to hear
compressor engagement the refrigerant. compressor internals. Replace
Lack of lubricating oil has caused wear compressor and also fix the system
to the compressor internal surfaces. leak to prevent recurrence. Likewise, if
you detect a leak in the system,
estimate and add refrigerant oil to A/C
system to ensure future compressor
reliability.
Resonant noise with accessory - With Cause is due to drive accessory Check the drive accessories. If
A/C on, a ‘cooing’ or ‘woo’ noise can resonating at specific engine speed. accessory can be isolated (press down
be heard inside the car. Vibration of The vibrations are transmitted to the with a screwdriver) the noise level will
steering wheel can also occur. vehicle body causing the noise. be lowered. Repair method can be to
Because resonant noise is similar to stop vibrations of the assembly or
compressor pulsation noise, you must modify transmission route to the
distinguish by different checking vehicle body.
method.
Compressor discharge pulsation noise Cause is pressure fluctuation of To check:
- With A/C on, a rumbling noise is refrigerant discharged from – Remove the discharge hose
heard inside the vehicle. Vibration of compressor vibrating the high pressure mounting clamp and recheck.
steering can also occur. The noise piping, and abnormal noise occurs by – Float the condenser without
level rises if the outside temperature is resonating with the car. attachments and recheck.
high. To repair:
– Put rubber bush between pipe
clamps.
– If not fixed, decrease refrigerant to
minimum specified level.
Module Configuration For module configurations that effect the air
conditioning refrigerant system, refer to:
Special Tool(s) EEC/PCM..........303-14
WDS Diagnostic System (WDS) HIM..................412-04
ICC..................413-08
BEM.................419-10
WDS Parameter Identifier (PID) chart
Special Tool(s)
The air conditioning refrigerant system does not itself WDS Workshop Diagnostic
contain any programmable modules, but the operation System
of the climate control system and the output of some
A/C Sensors rely on a number of programmable
modules. These modules are accessed via the WDS
service tool, and the modules may require
re-configuring as part of the repair procedure. The
WDS is used to select appropriate data for the
vehicle, and each module configuration must be The following chart lists all PID’s used by the WDS
relevant for the specific Climate Control system (eg. service tool to access data relevant to the system.
MCC, ACC, single zone, dual zone, etc.) and for the Acronym Description
circumstance where the module has been modified or from ECC/PCM
replaced. If this procedure is not followed, the module
may not function correctly and may set a number of ACPRES A/C Pressure (PSI)
Diagnostic Trouble Codes. (1 PSI = 6.89kPa)
HFC High Speed Fan On (Engine
Cooling Fan)
LFC Low Speed Fan On (Engine
Cooling Fan)
RPM Engine Speed (RPM)
G73303 en 01/2003 2003.0 BA Falcon

Acronym Description Acronym Description

VS Vehicle Speed (MPH) OFF OFF (ACC)
CHT Cylinder Head Temperature ACC_POS ACC Position
from HIM TMPKNOBP Temperature Selector Status
ACCS A/C Compressor Cycling BLWR_FAN Blower Fan Speed
Request AC_SEL_SW Air Conditioning Switch Status
A_CT Evaporator Temperature RECIRC Recirculation Status
ETSFD External Temperature Sensor MODE_SW Mode Switch
Filtered Data (Ambient
from BEM
Temperature)
EXT_TEMP External Temperature From AC_SUNSEN A/C Sunload Sensor Status
Sensor (unfiltered) (Ambient INT_TEMP Interior Temperature Sensor
Temperature) from Instrument Cluster
BLOWVOL HVAC Blower Voltage VEH_SPD Vehicle Speed
BLOWAP Blower Motor Speed - Actual VBATT_VAL System Battery Voltage Value
Position
BLOWTP Blower Motor Speed - Target WDS Diagnostic Trouble Code (DTC)
Position chart
LEFTOT Passenger’s Display Set
Temperature Special Tool(s)
RIGHTOT Driver’s Display Set WDS Workshop Diagnostic
Temperature System
MC_VREF Vehicle Battery Voltage
RECIRDS Recirculation Door Actual
Position
RECIRCDTP Recirculation Door Target
Position
The following chart lists all DTC’s relevant to the A/C
CCMODE Climate Control Mode system that may be set due to operation failures. The
from ICC codes may be set due to either intermittent or
AUTO AUTO (ACC) permanent failures.
WDS Display Fault Description Possible Cause

from EEC/PCM
P0532 A/C Refrigerant Pressure Sensor A Checked at key on, engine off and
Circuit Low Input continuously when A/C on
Pressure sensor out of calibration,
open-circuit
P0533 A/C Refrigerant Pressure Sensor A Checked at key on, engine off and
Circuit High Input continuously when A/C on
Pressure sensor out of calibration,
short-circuit
P1463 A/C Pressure Sensor insufficient Slipping compressor clutch
pressure change Poor compressor performance
Low A/C refrigerant charge
P1474 Fan Control primary circuit Low Speed Engine Cooling Fan circuit
fault
Cooling fan fault
P1479 High Fan Control primary circuit High Speed Engine Cooling Fan
circuit fault
cooling fan fault
P0534 A/C Refrigerant Charge Loss Checked continuously when A/C on:
Low A/C refrigerant charge or A/C
System blockage
G73303 en 01/2003 2003.0 BA Falcon

WDS Display Fault Description Possible Cause

P1465 A/C relay circuit WAC Relay fault
relay wiring circuit fault
P1270 Engine RPM or Vehicle Speed limiter Refer to A/C disable strategy list in this
reached section.
P1285 Cylinder Head over-temperature Engine overheating fault
P1299 condition, protection active Refer to A/C disable strategy list in this
section.
U1900/P1796 CAN communication bus fault HIM/CAN/BEM/circuit to EEC/PCM fault
from HIM
B2014 Climate Control A/C Post-Evaporator Sensor leads disconnected from HIM
Sensor open circuit sensor failure
HIM failure
B1947 Climate Control A/C Post-Evaporator Sensor leads shorted together
Sensor short to ground sensor failure
HIM failure
B2513 Blower (Fan) circuit failure HVAC air flow restriction
HIM failure
B2006 Blower Motor Switch out of range Invalid data code sent by vehicle
sub-system
B2005 Climate Control Temperature Switch out Invalid data code sent by vehicle
of range sub-system
B1255 Air temperature external sensor circuit Sensor lead disconnected from module
open Sensor failure
Internal module failure (HIM)
B1257 Air temperature external sensor circuit Sensor leads shorted together
short to ground Sensor leads shorted to vehicle body
Sensor failure
Internal module failure (HIM)
U2196 Invalid ‘Engine RPM’ data Invalid data code sent by vehicle
sub-system
U2197 Invalid ‘Vehicle Speed’ data Invalid data code sent by vehicle
sub-system
U2199 Invalid ‘Engine Coolant Temperature’ Invalid data code sent by vehicle
data sub-system
B2007 (Driver/Passenger) Solar radiation Sun load sensor faulty, out of calbration
B2890 Sensor out of range
from ICC
B1318 Battery voltage low Low system voltage detected.
Battery or alternator fault.
B2923 Climate control button stuck Climate control button jammed
U2201 Ambient temperature data invalid HIM did not have valid ambient
temperature data output
from BEM
B1250 Air temperature internal (cabin) sensor Cabin temperature sensor failure
circuit failure
B1251 Air temperature internal (cabin) sensor Cabin temperature sensor wiring fault,
circuit open open circuit
B1253 Air temperature internal (cabin) sensor Cabin temperature sensor wiring fault,
circuit short to ground short-circuit
B1259 Solar radiation sensor circuit open Sun load sensor wiring fault, open circuit
B1261 Solar radiation sensor circuit short to Sun load sensor wiring fault, short-circuit
ground
G73303 en 01/2003 2003.0 BA Falcon

A/C disable strategy chart

The following chart lists the conditions under which the A/C System is disabled to prevent compressor
operation, either temporarily or permanently. The A/C System may be disabled temporarily to pretect the
compressor until conditions are suitable for operation, on permanently until a fault is rectified.
DTC Code A/C is Disabled under the following conditions

N/A - (temporary A/C A/C is disabled when the A/C pressure transducer (ACPT) exceeds the
disengagement only) maximum allowed pressure, and is re-engaged when the ACPT output drops
back down to an acceptable pressure (eg. may occur in extremely high ambient,
high vehicle speed conditions)
N/A - (temporary A/C A/C is disabled when the A/C pressure transducer (ACPT) drops below the
disengagement only) minimum allowed pressure, and is re-engaged when the ACPT output rises up
to an acceptable pressure (eg. may occur in extremely low ambient
temperatures)
P0532,P0533 A/C is disabled when the ACPT output is out of range (circuit or calibration fault)
P1463 A/C is disabled when the ACPT pressure rise after A/C clutch engagement is
less than the minimum allowed and is re-engaged when the engine speed drops
back down to a lower rpm. ( This may indicate clutch slip, low A/C charge or
faulty compressor)
P0534 A/C is disabled when the A/C performance is not acceptable for given ambient
temperature and vehicle operating conditions
P0534 A/C is disabled when the A/C gas charge level is too low during A/C operation
P0534 A/C is disabled when the A/C gas charge level drops during A/C operation
N/A - (temporary A/C A/C is disabled when the engine speed is greater than the maximum allowed for
disengagement only) a given vehicle speed, and continues to be disabled when the engine speed is
greater than the maximum allowed for A/C re-engagement
P1270 A/C is disabled when the engine speed is more than the maximum allowed for
A/C operation (close to red-line rpm), and continues to be disabled when the
engine speed is greater than the maximum allowed for A/C re-engagement
N/A - (temporary A/C A/C is disabled when the engine speed is less than the minimum allowed for
disengagement only) A/C operation (below idle rpm)
U1900 A/C is disabled when the HIM CAN link is missing
N/A - (temporary A/C A/C is disabled at the first A/C engagement after a new or reflashed PCM, if the
disengagement only) A/C is engaged at too high an engine speed
P1299 A/C is disabled just before the engine cylinder head temperature exceeds a
maximum allowable temperature and the cylinder head protection is activated
G73303 en 01/2003 2003.0 BA Falcon

Simplified Air Conditioning Electrical Circuit
NOTE: For more information, refer to complete Air

Conditioning Control Circuit in Wiring section.
C-121 (A/C Compressor)

1 Circuit 347A B-Y 12V when A/C on
Power
2 Circuit 57A B Earth (less then 5 Ohms to chassis ground)
Ground
G73303 en 01/2003 2003.0 BA Falcon

C-127 (A/C Clutch Diode)

1 Circuit 57S B Earth (less then 5 Ohms to chassis ground)
Ground
2 Circuit 347B B-Y 12V when A/C on
Power
C-122(A/C Pressure Transducer)

1 Circuit 359C GR Earth (less then 5 Ohms to chassis ground)
2 Circuit 440 BR Feedback Voltage 0V to 5.0V
3 Circuit 351E BR-W Reference Voltage 5.0V±0.25V
G73303 en 01/2003 2003.0 BA Falcon

C163 (Power Distribution Board) - WAC Relay

1 Circuit 347B B-Y 12V supplied when Relay engaged
Power
2 Circuit 175A B-Y 12V supplied with IG ON condition
3 Circuit 321 GR-W Earth from ECC for A/C operation
4 Circuit 361C R 12V supplied with A/C Relay engaged
G73303 en 01/2003 2003.0 BA Falcon

C-376 Evaporator Thermister

NOTE: View from wire entry side (rear).

1 Sensor ground Voltage (V) between HIM terminal connection D
pin 1 and C376 pin 13
0V (ground)
2 Sensor supply Voltage (V) between HIM terminal connection D
NOTE: With ignition ON and sensor
disconnected, refer to sensor voltage from
sensor output table, Pinpoint test G.
Air Conditioning & HVAC Relay and
Fuses
The air conditioning compressor cut-out relay (WAC relay, R3-black) is located in the Engine Compartment
Fuse Box.
The A/C compressor clutch is protected with a 30 amp fuse (F11-pink, combined with the engine fuse) located
in the Engine Compartment Fuse Box.
The A/C condenser fans (engine cooling fans) are controlled with three relays (R8, R9, R10-all white) located
in the Engine Compartment Fuse Box. Each fan circuit is protected with a 40 amp fuse (F5, F6-both green)
also located in this fuse box.
The three relay coils are protected by a single 15A fuse (F2-blue) located in the instrument panel fuse box.
The HIM electrical circuits are protected with two fuses, one 15 amp (F4-blue) and one 10 amp, (F27-red),
both located in the Instrument Panel Fuse Box.
The HVAC blower fan circuit is protected with a 40 amp fuse (F7-green) located in the Engine Compartment
Fuse Box.
Pinpoint Tests
Special Tool(s)
Electrical Multimeter
G73303 en 01/2003 2003.0 BA Falcon

PINPOINT TEST A : COMPRESSOR OPERATION
A1 CHECK COMPRESSOR OPERATION

Turn blower motor to high speed Yes
Operation is normal.
Turn A/C switch on.
Set controls to maximum cooling. No
Go to A2.
Inspect magnetic clutch operation.
Does rotor and hub engage and drive the compressor?
A2 CHECK THE A/C COMPRESSOR CIRCUIT 347 (B-Y) FOR

POWER
Measure the voltage between the A/C compressor clutch C-121, Yes
circuit 347A, harness side and ground. Go to A3.
Is the voltage greater than 10 volts? No
Go to A4.
A3 CHECK THE A/C COMPRESSOR CIRCUIT 57 (B) FOR

OPEN CIRCUIT
Measure the resistance between the A/C compressor clutch, circuit Yes
57A (B) harness side and ground. INSTALL a new compressor. Refer to Section
412-03.
Is the resistance less than 5 ohms?
No
REPAIR the circuit. TEST the system for normal
operation.
A4 CHECK CIRCUIT 347 (B-Y) FOR POWER

Measure the voltage between the A/C clutch relay circuit 347, harness Yes
side and ground. Repair circuit, Test for normal operation from
relay to compressor.
No
Go to A5.
A5 CHECK THE A/C CLUTCH RELAY CIRCUIT 175 (B-Y)

FOR POWER
Measure the voltage between A/C clutch relay C163, circuit 175A Yes
(B-Y), harness side and ground. Go to B1. Check relay operation.
Go to A6.
A6 CHECK THE 30A FUSE C163 CIRCUIT 50 (R) FOR

POWER
Measure the voltage between fuse pin and ground. Yes
Repair the circuit from the fuse to relay.
Is the voltage greater than 10 volts? Test the system for normal operation.
No
Inspect battery and wiring circuit. Repair the
circuit, test the system for normal operation.
G73303 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : WAC RELAY OPERATION

NOTE: Also refer to PCM section 303-14, Air Conditioner Inputs.
B1 CHECK RELAY OPERATION

Turn blower motor to high speed Yes
Relay operation is normal.
Turn A/C switch on at normal idle condition.
Does WAC relay engage. No
Go to B2.
B2 CHECK RELAY OPERATION

Set circuit as follows: Yes
Power (12V) to pin 361 (Pin No.4) on relay Relay operation is normal. Go to B3
Earth (0V) to pin 321 (Pin No.3) on relay No
Relay should close to give continuity between circuits 175 (Pin No.2) Replace relay.
and 347 (Pin No.1).
Is the resistance less than 5 Ohms across terminals 1 & 2 ?
B3 CHECK RELAY FOR POWER CIRCUIT 361C

Operate the A/C system at maximum cooling. Yes
Go to B4
Check voltage between ground and 361C (R) wire on wiring harness.
Is voltage greater than 10 Volts? No
Repair circuit from EEC to relay and test for
normal operation. Go to B6.
B4 CHECK EEC OUTPUT 321 GRW

Check for resistance between ground and 321 GRW on wiring Yes
harness. EEC output is normal. Go to B5.
Is resistance less than 5 Ohms? No
Check A/C disable strategy chart. Confirm
correct EEC operation. Repair circuit and test for
normal operation.
B5 CHECK WIRING CIRCUIT 347 TO CLUTCH

Check for resistance between circuit 347 at wiring harness and 347 at Yes
compressor. Circuit 347 is normal. Go to B6.
Is resistance less than 5 Ohms? No
Repair circuit and test for normal operation.
B6 CHECK WIRING CIRCUIT 175A FOR POWER

Check voltage between ground and 175A Yes
Is voltage greater than 10 Volts?
No
Repair circuit. Test for normal operation.
G73303 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : PRESSURE TRANSDUCER OPERATION

NOTE: Also refer to PCM section 303-14, Air Conditioner Inputs.
C1 CHECK THE PRESSURE SWITCH REFERENCE

VOLTAGE
Check voltage between ground and circuit 351 BR-W on wiring Yes
harness. Go to C2.
Is reference voltage correct to spec: V=5±0.25V? No
C2 CHECK EARTH AT SWITCH

Check resistance between ground and circuit 359 on wiring harness. Yes
Go to C3.
Is switch earth present?
No
C3 CHECK SWITCH OUTPUT SIGNAL

Apply 5 V to circuit 351 at switch. Yes
Switch operation is normal.
Apply earth to circuit 359 at switch.
Ensure A/C refrigerant pressure is within 200kPa and 3170 kPa. No
REPLACE switch.
Check voltage between ground and circuit 440 at switch.
Is voltage within range 0.0 V to 5.25 V ?
PINPOINT TEST D : EVAPORATOR CORE ICE UP
CAUTION: Follow all Climate Control system safety precautions when dealing with A/C system
refrigerant.
D1 COMPRESSOR CYCLING
NOTE: Test can not be conducted in high ambient temperatures, as the Yes
compressor may not cycle off, if the ambient temperature is high. Go to D2.
Turn blower motor to high speed. No

Go to PinPoint Test G to check evaporator
Switch A/C ON. thermistor.
Set to recirculated air.
Set controls to maximum cooling.
Ensure all vehicle doors and windows are closed.
Does the Compressor Cycle OFF and ON?
D2 PRESSURE GAUGE EVALUATION

Is the suction pressure constantly at or below approx 150 kPa Yes
with the A/C On and Engine speed held at approx 2.000 RPM ? Conduct A/C Performance test to diagnose the
cause of the Low suction pressure. Refer to
Section 412-03.
No
Go to D3.
G73303 en 01/2003 2003.0 BA Falcon


D3 SUCTION TUBE INSPECTION
Does the Evaporator outlet tube at the Accumulator Frost or Yes
Ice-up, with the A/C ON, Blower fan speed 1 (low) and the Engine Check Orifice Tube and recharge A/C system for
speed held at 2000 RPM for 3 - 5 Minutes? correct gas charge. Refer to Section 412-03.
No
Special Tool(s)
Evaporator leak test tool
PINPOINT TEST E : EVAPORATOR CORE REFRIGERANT LEAKAGE
CAUTION: Follow all Climate Control system safety precautions when dealing with A/C system
refrigerant.
NOTE: An Evaporator Core Refrigerant leakage will also cause “Smell”. This is due to the PAG Refrigerant
Oil being released with the Refrigerant.
NOTE: Removal of the Evaporator core should not be undertaken unless all other potential leak sources has
been eliminated.
Prior to removing Evaporator core from the vehicle conduct Fluorescent Dye Leak test and or Electronic Leak
detection (Refer to pg. 412-03-40).
E1 VACUUM HOLDING TEST

To attach the Evaporator leak test tool, you must first remove the Yes
evaporator core. Refer to procedure in this chapter. Go to E2.
Attach the Evaporator leak test tool to the Evaporator tubes. No
Replace the Evaporator core. Refer to this
NOTE: Fit new Ford green o’rings onto the Evaporator pipes before section.
installing special tool.
Connect the Low side charging station coupling to the special tool
charge port.
Evacuate the evaporator core until 30 in/hg is reached. Turn off the
Low side gauge tap. Allow the vacuum reading to stabilise for 30
minutes minimum.
NOTE: The pressure may rise initially as the refrigerant absorbed in

the oil will boil off, and then the vacuum reading will stabilise.
Does the vacuum reading on the Low side gauge hold steady for
a minimum of 15 minutes ?
G73303 en 01/2003 2003.0 BA Falcon


E2 PRESSURE HOLDING TEST
With the special tool still attached to the evaporator inlet / outlet tubes, Yes
charge the evaporator with refrigerant through the Low side special The Evaporator core is not the root cause of
tool charge port. Refrigerant leakage. Carry out full and accurate
leak testing of the remaining A/C system
Charge with approx. 100 grams of refrigerant. Turn the Low side components using an Ultra Violet lamp or a
pressure gauge tap off. Allow the pressure reading to stabilise. Refrigerant Leak detector. Refer to this section
Does the evaporator pressure reading on the Low side pressure (Flurorescent Dye Leak Detection or Electronic
gauge hold steady for a minimum of 15 minutes? Leak Detection).
No
Replace the evaporator core. Refer to Section
412-03.
PINPOINT TEST F : CONDENSER FAN OPERATION/PERFORMANCE

NOTE: Also refer to PCM section 303-14, Electro Drive Fans.
F1 CHECK FOR AIRFLOW OBSTRUCTION

Visually inspect A/C condenser core and radiator core for obstructions Yes
such as leaves or bugs. Remove obstruction and clean A/C condenser
core and radiator
Is there any obstruction ? Retest system.
No
Go to F2.
F2 FAN SELF-TEST
The cooling fan motors and circuits are tested during a PCM key On Yes
Engine Off Self-Test, using the WDS (Refer to section Section Refer to DTC chart in Section 412-03 and
303-14). Faults detected by the PCM will be recorded as DTC’s. Section 303-14.
Repair circuit, replace faulty parts, test for
NOTE: Prior to executing the self-test, any other DTC’s which have normal operation.
been set should be recorded and cleared.
No
The condenser fans are not at fault.
Fan Relay 1 Relay 2 Relay 3 Fan 1 Fan 2
Speed
OFF OFF OFF OFF OFF OFF
LO ON OFF OFF LOW LOW
HI ON ON ON HIGH HIGH
Did the self-test set any DTC’s ?
G73303 en 01/2003 2003.0 BA Falcon

PINPOINT TEST G : A/C CYCLING SWITCH (EVAPORATOR THERMISTOR)
G1 SYSTEM ON DEMAND SELF TEST

Start and run engine until normal operating temperature is reached. Yes
Go to G2 if code B2014 is set.
Ensure vehicle battery voltage is within normal operating range Go to G3 if code B1947 is set.
(12~14volts) before proceeding with test.
Using WDS scan tool, record all DTC’s set in the HIM memory. No
System is OK.
Using WDS scan tool, clear all DTC’s set in the HIM memory.
Using WDS scan tool, perform HVAC On Demand Self Test (refer
section 412-04).
Are any DTC codes set?
G2 SENSOR WIRING INSPECTION

Disconnect the 2 way Evaporator sensor connector D from the HIM Yes
and inspect terminals on the sensor lead assembly for damage or Replace Evaporator sensor
corrosion.
No
Do the terminals appear damaged? Go to G3.
G3 SENSOR INSPECTION - RESISTANCE

CHARACTERISTIC
Turn off the Air Conditioner, select face outlet, full cold (not A/C Max), Yes
(’C’ or ’Low’ for ACC) and operate HVAC blower at full speed to Go to G4.
stabilise the Evaporator sensor temperature.
No
Disconnect the 2 way Evaporator sensor connector D from the HIM. Replace Evaporator sensor.
Carefully insert the test probes of a resistance meter in to the REAR
of the Evaporator sensor connector (wire side). Inserting probes in to
front of terminals will damage the sensor assembly and cause
intermittent A/C operation. Compare the sensor resistance value
overpage with a temperature thermometer located in the face outlet.
Is the resistance reading within specification (+/- 5 degC) as per
sensor output table?
G4 MODULE FUNCTION CHECK - EVAPORATOR SENSOR

TEMPERATURE READING
Reconnect the sensor 2 way connector D to the HIM. Yes
System OK.
Connect WDS Scan Tool.
Read the A_CT value (Evaporator sensor temperature) from the HIM. No
Go to G5.
Does the value closely match the temperature thermometer
located in the face outlet (+/- 5 degC) as per sensor output table
overpage?
G5 MODULE FUNCTION CHECK - EVAPORATOR SENSOR

SUPPLY VOLTAGE
Check the Evaporator sensor supply voltage with a voltmeter. Yes
Go to G6
With the Evaporator sensor 2 way connector D inserted in to the HIM,
attach the positive probe to pin 2 (LHS) and the negative probe to pin No
1 (RHS) of the rear of the Evaporator sensor connector. Refer to Replace HIM
Evaporative sensor connector diagram for correct pin designations.
Using sensor output table, compare the voltage reading against a
temperature probe located in the face outlet with the HVAC Blower
fan operating at high speed.
Does the voltage value closely match the temperature
thermometer located in the face outlet (+/- 5 degC)?
G73303 en 01/2003 2003.0 BA Falcon


G6 MODULE OUTPUT CHECK - EVAPORATOR SENSOR
SUPPLY VOLTAGE
Remove evaporator sensor plug from HIM. Yes
System OK.
Using a voltmeter, attach the probes to the HIM output terminals for Clear DTC.
the evaporator sensor.
Ensure ignition key is ON. No
Replace HIM.
Is the voltage reading within 4.5-5.5 Volts?
Evaporator Thermister (Temperature Sensor)

Output
Temperature Sensor Sensor Voltage
Degrees Resistance (Volts)
(Celsius) (Ohms)
-30 25.37k 4.16
-25 18.90k 3.94
-20 14.19k 3.68
-15 10.73k 3.39
-10 8.17k 3.08
-5 6.27k 2.76
0 4.85k 2.44
5 3.78k 2.13
10 2.97k 1.84
15 2.35k 1.56
20 1.87k 1.34
25 1.50k 1.14
30 1.21k 0.96
35 0.98k 0.81
40 0.75k 0.68
45 0.66k 0.57
50 0.55k 0.48
55 0.45k 0.41
NOTE: Use this table as a guide only. Minor
variations between actual readings are acceptable.
G73303 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Manifold Gauge Set Connection 3. Remove the A/C charging valve cap from the
high-pressure service charge port located on the
Special Tool(s) liquid line.
R-134a Manifold Gauge Set
or equivalent
1. Turn both valves on the R-134a Manifold Gauge

Set all the way to the left to close the
low-pressure and high-pressure hoses to the
centre manifold and centre hose.
4. Connect the R-134a manifold gauge set

low-pressure hose with the R-134a low side quick
disconnect to the low-pressure service charge
port.
2. Remove the A/C charging valve cap from the

low-pressure service charge port located on the
suction hose assembly.
5. Connect the R-134a manifold gauge set

high-pressure hose with the R-134a high side
quick disconnect to the high-pressure service
charge port.
G73326 en 01/2003 2003.0 BA Falcon

5. If a leak is found, recover the refrigerant and

Electronic Leak Detection repair the system. For additional information refer
Special Tool(s) to A/C system discharging and recovery in this
section.
Refrigerant Leak Detector
or equivalent Fluorescent Dye Leak Detection
Special Tool(s)
120 Watt UV Spot Lamp
or equivalent
or equivalent
CAUTION: Good ventilation is necessary in
the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated
with refrigerant gas, the leak detector will indicate
this gas all the time. Odours from other chemicals
such as antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the same NOTE: Ford Motor Company vehicles are produced
problem. A fan, even in a well-ventilated area, is with R-134a Leak Tracer Dye incorporated into the
very helpful in removing small traces of A/C system. The location of leaks can be pinpointed
contamination from the air that might affect the by the bright yellow-green glow of the tracer dye.
leak detector. Since more than one leak can exist, always inspect
1. Be sure to remove all oil from the test area before each component.
using the leak detector, because the oil may If accumulator is replaced, it is supplied with new dye,
contain refrigerant which would give erroneous which has a limited life of ~500 hours of Air
readings. conditioning operation.
2. Remove the Interior Command Centre (ICC). 1. Run the A/C system for ~15 minutes prior to leak
Refer to section 413-08. testing, to allow the dye to mix thouroughly.
3. Detect for leaks inside the HVAC Case assembly 2. Ensure that the A/C system pressure is between
by inserting the leak detector probe down the vent 413 - 551kPa (60 - 80psi) at 24°C (75°F) with the
opening in the top of the HVAC case. engine off.
4. Check for leakage at the compressor shaft seal, 3. Check for leaks using a 120-watt UV spot lamp,
and at all system fittings and lines as per Joint and viewed through U.V. glasses.
Locations in this section.
Leak test the refrigerant system using the 4. Observe for die trace at the drain tube of the
refrigerant leak detector. Follow instructions HVAC above the transmission.
included with leak detector for handling and 5. Scan all components, fittings and lines of the A/C
operation techniques. system, as per joint locations listed in Electronic
NOTE: System pressure should be between 413 - Leak Detection in this section.
551kPa (60 - 80psi) at 24°C (75°F) with the 6. Remove the ICC (Refer to section 413-08) and
engine off. observe die trace inside the HVAC case
assembly.
7. After the leak is repaired, remove any traces of
leak dye with a general purpose oil solvent.
G73326 en 01/2003 2003.0 BA Falcon

Joint Locations

1 A/C Liquid line to evaporator joint 9 Compressor front seal
2 Evaporator to accumulator joint 10 Suction hose - Compressor joint
3 A/C Liquid line, Orifice tube joint 11 Discharge hose - Compressor joint
4 High pressure service gauge charge port 12 Low pressure service gauge charge port
5 A/C pressure cut-off switch (pressure 13 Accumulator to suction hose quick -
tranducer) connect joint
6 Compressor pressure relief valve 14 Drain hose for evaporator
7 Condenser - A/C liquid line joint NOTE: V8 has extra quick-connect joint between
8 Condenser - Discharge hose joint suction hose and suction tube at front of LH side-rail.
G73328 en 01/2003 2003.0 BA Falcon

A/C System Discharging and Recovery 8. Carry out the required repairs, then evacuate and
recharge the A/C system. For additional
Special Tool(s) information, refer to the A/C System Evacuation
and Charging procedure in this section.
R-134a A/C Service Centre
176-00002 or equivalent A/C System Evacuation and Charging
Special Tool(s)
R-134a Refrigerant Centre
176-00002 or equivalent
R-134a A/C Refrigerant Centre

R-134a A/C Refrigerant Centre


or equivalent

or equivalent
1. Connect the R-134a A/C Refrigerant Centre to the

low and high pressure service gauge charge
ports.
NOTE: Some R-134a service centres require the
use of an A/C manifold gauge set. For additional 1.2 CFM Vacuum Pump
information, refer to the Manifold Gauge Set 023-R0162 or equivalent
Connection in this section.
2. Empty the Refrigerant Recovery Equipment oil
drain glass container, so that an accurate
measurement can be made of the amount of
refrigerant oil removed from the A/C system in the
Discharging & recovery process.
4.0 CFM Vacuum Pump
3. Recover the refrigerant from the system following 023-R0163 or equivalent
the operating instructions provided by the
equipment manufacturer.
4. Once the service centre has recovered the vehicle
A/C system refrigerant, close the service centre
inlet valve (if so equipped). Then switch off the
power supply.
5. Allow the vehicle A/C system to remain closed for 1. Connect the R-134a A/C Refrigerant Centre to the
about two minutes. Observe the system vacuum low and high pressure service gauge charge
level as shown on the gauge. If the vacuum does ports.
not change, disconnect the recovery station NOTE: Ford Motor Company recommends use of
hose(s). a charging station to carry out evacuation and
charging of the refrigerant system. If a charging
6. If the system pressure rises, repeat Steps 2 station is not available, system charging may be
through 4 until the vacuum level remains stable accomplished using a separate vacuum pump,
for two minutes. charging cylinder, and manifold gauge set. For
7. Record the amount of refrigerant oil collected in additional information, refer to the Manifold Gauge
the Refrigerant Recovery Equipment oil drain Set Connection in this section.
glass container, so that this oil can be replaced in
the charging process.
G73328 en 01/2003 2003.0 BA Falcon

2. Evacuate the system until the low-pressure gauge Measure the amount of oil recovered with
reads at least 99.4kPa (29.5 in-Hg) (vacuum) and refrigerant (refer to Recovery Machine
as close to 101.1kPa (30 in-Hg) as possible. instructions and A/C system Discharging and
Continue to operate the vacuum pump for a Recovery).
minimum of 45 minutes. This amount of oil must be added to the
3. Turn off the evacuation pump. Observe the system before recharging with refrigerant.
low-pressure gauge for five minutes to make sure 2. Compressor Replacement
that the system vacuum is held. If vacuum is not
Rotate the old A/C compressor shaft six to
held for five minutes, leak test the system, service
eight revolutions while collecting the oil in a
the leaks, and evacuate the system again.
clean measuring device. This amount is all
4. To maintain the original total system oil charge, it that is required to be in the replacement
is necessary to compensate for the oil lost when service compressor.
discharging the refrigerant or after replacement of
a system component. For additional information Drain the oil from the service compressor
(approx. 200ml) and remove a quantity of this
on quantity of oil to be added to the system, refer
new oil, so that the amount of oil left in the
to the Refrigerant Oil Replacement Quantity in
this section. service compressor equals the amount of oil
collected from the old compressor.
5. Charge the system with the specified weight of
If 140ml was drained from the old compressor
refrigerant as determined by A/C label and charge
with the correct amount of refrigerant oil, using the than remove 60ml from replacement
compressor. (i.e.140 = 200 - 60).
Replenishment of Refrigerant Oil procedure in this
section. Pour this revised quantity of new oil back into
6. When no more refrigerant is being drawn into the the service compressor. Also add an extra
40ml of new oil to the service compressor, to
system, start the engine and select MAX A/C
account for oil that was removed from the A/C
operation. Adjust the blower motor fan speed to
maximum and allow the remaining refrigerant to system in replacement of the Accumulator.
be drawn into the system. Continue to add If the A/C system has been flushed prior to a
refrigerant into the system until the specified new compressor installation, follow step 7 for
weight of R-134a has been added. Close the refrigerant oil replacement quantity.
charging cylinder valve and allow the system to 3. Accumulator replacement
pull any remaining refrigerant from the hose. Drill two ½ inch holes in the accumulator and
When the suction pressure drops to drain the oil into a calibrated container. Add an
approximately 207kPa (30psi), close the charging equal amount of oil to the new accumulator plus
hose valve. 20 ml for oil not able to be drained from the
accumulator.
Refrigerant Oil Replacement Quantity 4. Condenser, Evaporator replacement
NOTE: During normal A/C operation, oil is circulated Add 40ml of compressor oil for each component
through the system with the refrigerant, and a small replaced. As system has been opened the
amount is retained in each component. When accumulator must be replaced as described in
evacuating or if certain components of the system are step 3.
removed for replacement, some of the refrigerant oil 5. Orifice Tube replacement
will be lost with the component and with the Additional oil is required for orifice tube
refrigerant gas. To maintain the original total system replacement, but as the A/C system has been
oil charge, it is necessary to compensate for the oil opened to atmosphere, the suction accumulator
lost by adding oil to the system with the new part. must also be replaced . Add additional oil for
NOTE: Service A/C compressors are shipped with accumulator as detailed in step 3, and also add
compressor oil (200cc). 10 ml of oil for orifice tube replacement
6. Leak Repair (Hose or tube, O-ring, pressure
1. Refrigerant recovery
switch, charge port repair / replacement)
Each time a system charge is recovered, an Additional oil is required unless you can
amount of oil will also be recovered with the determine no evidence of oil loss (No oil stain
refrigerant. around joint) As the A/C system has been opened
The amount will differ with type of Recovery to atmosphere, the suction accumulator must be
Machine used and time taken to recover replaced . Add additional oil for accumulator as
refrigerant. detailed in step 3, and also add 20 ml for oil loss
The oil balance of the system must be at refrigerant leak.
maintained for compressor durability.
G73331 en 01/2003 2003.0 BA Falcon

7. System Flushing Effect on Oil Quantity A/C System Flushing

Flushing the system will remove all the refrigerant
oil. If a system is flushed prior to a new Vehicles that have an inoperative A/C compressor,
compressor installation, then the total amount of due to internal causes, should have the refrigerant
new oil in the service compressor should be used, system cleaned by flushing. This removes any debris
to maintain an oil capacity level of 200 ml. or contaminants that may be present to prevent
damage to the replacement A/C compressor.
Replenishment of Refrigerant Oil System flushing should be performed prior to the
NOTE: Refrigerant oil should be added to the A/C installation of the replacement A/C compressor. Flush
system with the replacement accumulator before it is only the A/C evaporator core and A/C condenser
installed. The correct oil quantity depends upon which core. Note that suction accumulator and A/C
A/C part has been repaired or replaced. For correct oil evaporator core orifice cannot be flushed.
quantities, refer to Refrigerant Oil Replacement Use Rotunda A/C Refrigerant System Flusher
Quantity in this section. 014-00991 or equivalent.
Alternative 1: Add oil to inlet tube of the accumulator
(long tube that attaches to evaporator firewall joint). CAUTION: This system is designed to be
used only with the Ford A/C system flushing
Alternative 2: Draw in oil through the low pressure
solvent F4AZ-19579- A. Use of other solvents may
charge port before evacuation, as detailed in steps
result in personal injury and/or damage to the
1-4 below.
vehicle and the flusher.
1. Pour the specified amount of refrigerant oil in to a
measuring cylinder. CAUTION: Do not let the flushing solvent
2. Connect manifold gauge hoses as shown in F4AZ-19579-A come in contact with your eyes or
illustration. skin. If eye contamination occurs, flush eyes with
water for 15 to 20 seconds. Remove contaminated
Manifold gauge (high pressure side).. air
clothing, and wash affected skin with soap and
conditioner high pressure charge port.
water. Seek medical attention.
Manifold gauge (centre).. vacuum port.
1. Before removing any refrigerant system
Measuring cylinder (and oil).. air conditioner components, recover the system refrigerant
low pressure charge port. following the A/C System Discharging & Recovery
3. When vacuum pump is run, oil is drawn into air procedure outlined in this section.
conditioning system from low pressure side.
CAUTION: Follow all refrigerant system
4. Switch off vacuum pump after specified amount of
safety and service precautions as outlined.
oil has been drawn into the system.
2. Disconnect the A/C refrigerant lines from the A/C
CAUTION: When handling the oil, please evaporator core. This will isolate the A/C
wear gloves. evaporator core orifice and suction
accumulator/drier from A/C evaporator core.
CAUTION: HFC134a oil is very 3. Disconnect the A/C refrigerant lines from the
hygroscopic (absorbs moisture). Keep the oil condenser core.
container sealed at all times.
4. Clean all dirt and debris from the fittings on the
CAUTION: HFC134a oil reacts with some A/C evaporator core and/or A/C condenser core
plastics. Keep it stored in metal container. to be flushed.
(Plastic bottle should only be used for o-ring 5. Select the proper Flusher machine fittings, clean
lubrication.) and lubricate connections and securely attach
fittings to the A/C evaporator core and/or A/C
CAUTION: Care should be taken not to condenser core. O-rings must be used with these
spill the HFC134a oil on paint work, and fittings to ensure proper leak-free connections.
plastic. If this is accidentally done, wipe
immediately. 6. Follow instructions given on flushing procedure of
the refrigerant system flusher used.
CAUTION: Clearly identify the oils when
transferred to a different container.
G73331 en 01/2003 2003.0 BA Falcon

A/C Hose/Tube Pad Fitting 4. If damaged remove the O-ring seal with a
non-metallic tool.
CAUTION: All refrigerant must be recovered CAUTION: Do not use metal tools to
from the A/C system. remove the O-ring seal. They can cause axial
Removal scratches across the O-ring seal groove
resulting in refrigerant leaks.
1. Recover the refrigerant. Refer to A/C Discharging
and Recovery in this section.
2. Remove the bolt from the air conditioning line
(pad) fitting.
CAUTION: Support the female fitting with
a wrench to prevent the tubes from twisting.
Installation
1. Clean all dirt or foreign material from the fittings.
2. If removed, install a new O-ring seal.
CAUTION: Use only new genuine Ford
black refrigerant O-ring seals which are
3. Pull the air conditioning line (pad) fitting apart. compatible with refrigerant R-134a and
refrigerant oil ND-Oil8. The use of any O-ring
seals other than specified may result in
intermittent leakage during vehicle operation.
Lubricate the O-ring seals with PAG
Refrigerant Compressor Oil ND-Oil 8.
3. Lubricate the inside of the fittings with PAG

Compressor Oil ND-Oil 8.
G73304ab en 01/2003 2003.0 BA Falcon

4. Assemble the male and female pad fittings 2. Before making any hose and tube connections,
together. apply a few drops of compressor oil to the seat of
NOTE: When correctly assembled, the male and o-ring to avoid refrigerant leakage.
female pad fittings should be flush.
Air Conditioning (A/C) Compressor —
I6 Engine
CAUTION: To prevent refrigerant system
contamination, if you are installing a new A/C
compressor because the A/C compressor has
failed internally, you must use the following
procedures:
CAUTION: All refrigerant must be recovered

from the A/C system.
1. Recover the refrigerant. For additional information
refer to A/C system discharging and recovery in
5. Tighten the pad fitting bolt to the specified torque. this section.
NOTE: Once tightened to the specified torque, NOTE: Installation of a new suction accumulator is
further tightening of the pad fitting bolt will not required when repairing the air conditioning system
improve the sealing performance. except when there is physical evidence of system
contamination from a failed A/C compressor damage
6. Charge the system. Refer to Air Conditioning to the suction accumulator, evidence of the A/C
System Evacuation and Charging in this section. system being open to the atmosphere/leaking or
O-Ring Removal and Lubrication
NOTE: If an A/C Flusher is available, carry out the air
1. When removing an o-ring from a tube, use a conditioning (A/C) system flushing procedure in this
wooden or nylon tool to prevent damaging the section.
tube.
NOTE: Always replace the existing o-rings with 2. Install a new A/C orifice tube assembly. For
new genuine Ford O-rings specified for refrigerant additional information, refer to Evaporator Core
HFC-134a, as air conditioning O-rings are made Orifice Tube Assembly in this section.
of a material compatible with refrigerant and 3. Remove the drive belt. For additional information,
refrigerant oil. refer to Section 303-05.
NOTE: The evaporator tube inlet and outlet 4. Disconnect the A/C clutch electrical connector.
green/blue refrigerant O-rings are different
dimensions to the A/C System black refrigerant
O-rings, and should not be mixed. (Refer to
Specifications in this section for O-ring details.)
The evaporator tube green/blue refrigerant
O-rings are also different dimensions from
previous models.
5. Remove the A/C discharge hose assembly bolt

and the suction hose assembly bolt from the side
of the A/C compressor and disconnect the A/C
hose assemblies.
CAUTION: Plug all A/C ports to prevent
contamination from dirt or moisture.
G73304ab en 01/2003 2003.0 BA Falcon


1. Recover the refrigerant. For additional information
refer to A/C system discharging and recoveryin
this section.
NOTE: If an A/C Flusher is available, carry out the air
6. Remove the compressor mounting bolts and the conditioning (A/C) system flushing procedure in this
A/C compressor. section.
2. Install a new A/C orifice tube assembly. For
additional information, refer to Evaporator Core
Orifice Tube Assembly in this section.
4. Disconnect the A/C clutch electrical connector.

NOTE: Each new compressor is supplied with
200cc of ND-Oil8 for the A/C system lubrication.
Refer to Refrigerant Oil Replacement Quantity in
this section prior to fitting a new compressor.
For installation, black compressor mounting
bolt is to be fitted to upper front location (both
I6 & V8). Remaining 3 gold compressor 5. Remove the A/C discharge hose assembly bolt
mounting bolts to be fitted to other 3 and the suction hose assembly bolt from the side
locations. of the A/C compressor and disconnect the A/C
hose assemblies.
Lubricate the new A/C manifold O-ring seals
with PAG Compressor Oil ND-Oil 8. CAUTION: Plug all A/C ports to prevent
8. Recharge the A/C system. For additional contamination from dirt or moisture.
information, refer to A/C system evacuation and
charging in this section.
Air Conditioning (A/C) Compressor —
V8 Engine
CAUTION: To prevent refrigerant system
contamination, if you are installing a new A/C
compressor because the A/C compressor has
failed internally, you must use the following
procedures:
G73305 en 01/2003 2003.0 BA Falcon

6. Remove the bolts and the two lower compressor 2. Disconnect the A/C clutch electrical connector.
mounting spacers and the A/C compressor.
3. Remove the compressor mounting bolts and

7. To install, reverse the removal procedure. position the A/C compressor aside.
NOTE: Each new compressor is supplied with 1. For V8, remove the two lower compressor
200cc of ND-Oil8 for the A/C system lubrication. mounting spacers.
Refer to Refrigerant Oil Replacement Quantity in
this section prior to fitting a new compressor. I6 Compressor
For installation, black compressor mounting
bolt to be fitted to upper front location (both I6
& V8). Remaining 3 gold compressor
mounting bolts to be fitted to other 3
locations. For V8 only, spacers to be fitted
between comp & bracket on two lower comp
mounting bolts.
Lubricate the new A/C O-ring seals with
Compressor Clutch, Compressor
Pressure Relief Valve and Compressor V8 Compressor
Shaft Seal
The compressor clutch, compressor pressure relief
valve and compressor shaft seal are not serviceable.
If any compressor clutch, pressure relief valve or
compressor leakage faults occur, replace the
complete compressor and clutch assembly.
Air Conditioning (A/C) Compressor
Bracket
G73305 en 01/2003 2003.0 BA Falcon

4. Remove the bracket mounting bolts, and the A/C 5. Remove HVAC Assembly. Refer to Section
compressor bracket. 412-02.
V8 Bracket 6. Detach the Foam Insulators from the Heater and
Evaporator Tubes.
I6 Bracket
7. Remove One Screw retaining the Heater Core
mounting clamp to the HVAC.

Evaporator Core 8. Undo One Screw retaining the A/C evaporator
tube retaining plate.
NOTE: The evaporator tube inlet & outlet green/blue
refrigerant O-rings are different dimensions to the A/C
System black refrigerant O-rings, and should not be
mixed. The evaporator tube green/blue refrigerant
O-rings are also different to previous models.
Removal
1. Recover the refrigerant. For additional
information, refer to Discharging and Recovery in
this section.
2. Drain the water from the engine cooling system
(refer to 303-03).
3. Disconnect the evaporator clamp, A/C liquid line,
suction accumulator and Heater Hoses, at the
Firewall. (refer to details in this section).
4. Remove the Instrument Panel, refer to Section
501-02.
G34263 en 01/2003 2003.0 BA Falcon

9. Remove the one screw retaining the HIM Heat insulator and the core face is parallel to the HVAC
sink to the HVAC. opening surface.
NOTE: Refer to Refrigerant Oil Replacement Quantity
in this section prior to recharging the A/C System.
1. Refit all previously removed Components in
reverse order to removal.
CAUTION: Care must be taken when
installing the Evaporator core as the
Aluminium Fins could become damaged and
effect air flow over the Evaporator Core.
CAUTION: Ensure evaporator seal
adequately seals around core to prevent air by
pass.
CAUTION: Ensure evaporator tube inlet
10. Undo the five screws used to retain the Case and outlet green/blue refrigerant ‘O’ Rings are
scroll housing to the HVAC. present prior to assembling the accumulator
and liquid lines.
2. Recharge the A/C System. For additional
information, refer to Discharging and Recovery in
this section.
3. Refill the engine cooling system (refer to section
303-03).
Orifice Tube Assembly
Special Tool(s)
Broken Orifice Extractor
412-035 (T83L-19990-B)
11. Gently remove the Case scroll clear of the

Evaporator Tubes from the HVAC Main Case.
12. Lift the Evaporator Core clear of the HVAC Main
Case.
Fixed Orifice Tube Tool
412-034 (T83L-19990-A)

CAUTION: Ensure liquid line O-ring is

present at the nut joint prior to assembly of the
A/C liquid line.
NOTE: A dirty A/C Orifice tube assembly or A/C liquid
Installation line (condenser to evaporator tube) containing black
refrigerant oil and particles indicates that the A/C
CAUTION: Fit the Evaporator core into the compressor must be inspected.
HVAC Case opening, ensuring that the lower side
of the core rests correctly on the White foam
G34263 en 01/2003 2003.0 BA Falcon

Removal 5. Hold the special tool T-handle stationary and

1. Recover the refrigerant. For additional information rotate the special tool body to remove the A/C
refer to A/C system Discharging and Recovery. orifice tube assembly.
NOTE: Adjustment or repair cannot be made to the
A/C orifice tube assembly. If damaged or blocked, a
new A/C orifice tube assembly must be installed.
NOTE: Install a new A/C orifice tube assembly
whenever a new A/C compressor is installed.
NOTE: The red orifice tube can not be interchanged
with different colour orifice tubes from previous
models.
2. Remove the screw attaching the liquid line
bracket to body adjacent to the charge port, and
remove the saddle clamp and nut adjacent to the
ABS module.
CAUTION: Plug all A/C ports to prevent 6. If the A/C orifice tube assembly is broken, screw
contamination from dirt or moisture. the end of the special tool into the broken A/C
orifice tube assembly.
3. Undo the nut joint half way along the A/C liquid
line. 7. Hold the special tool T-handle stationary and
4. Engage the special tool onto the A/C orifice tube rotate the special tool body to remove the broken
assembly. A/C orifice tube.
Installation
1. Lubricate the O-ring seals on the A/C orifice tube.
Use PAG Compressor ND Oil-8 or equivalent
meeting Ford specification WSH-M1C231-B.
G73311 en 01/2003 2003.0 BA Falcon

2. Place the A/C orifice tube into the special tool. 5. Connect the liquid line at the orifice tube and
tighten the nut after ensuring the liquid line O-ring
is present and undamaged.
3. Using the special tool, insert the A/C orifice tube

into the A/C liquid line (condenser to evaporator
line) until seated. 6. Refit the screw attaching the liquid line bracket to
the body adjacent to the charge port.
7. Refit the saddle clamp and nut adjacent to the
ABS module.
NOTE: Refer to Refrigerant oil Replacement
Quantity in this section prior to recharging to A/C
system.
Quick Joint Clamp
Special Tool(s)
Quick joint clamp removal tool
Removal
from A/C system.
G73311 en 01/2003 2003.0 BA Falcon

1. Needles will release quick joint clamp locking 3. Align the plastic quick joint clamp to suit the quick
tabs. A plate will hold quick joint clamp in to the joint clamp removal tool.
tool. Stopper lever will locate tool to tube joint. NOTE: Guide on quick joint clamp must fit into
slot on tool.
Item Description
1 Stopper Lever Item Description
2 Needles 1 Quick Joint Clamp
3 Plate 2 Stopper Lever
2. Recover the refrigerant. For additional 3 Clamp Removal tool
information, refer to A/C System Discharging and 4 Clamp Guide
Recovery in this section.
4. Push tool onto quick joint clamp using thumbs.
NOTE: Do not bend the needles inside the tool
when inserting.
5. Push with thumbs.
G73319 en 01/2003 2003.0 BA Falcon

6. Quick joint clamp will release (spring open). 2. Wrap quick joint clamp about tube joint.
Remove quick joint clamp removal tool by lifting 1. Squeeze to close quick joint clamp
the stopper lever to remove from A/C tube.
3. Clamp must click

Item Description
1. No gap at (X) joint between both halves of
1 Lift Stopper Lever clamp.
2 Slide off removal tool and clamp
Installation
1. Fully insert tube joint, such that:
1. No gap exists.
2. Lubricate O-Ring seals with PAG Compressor
oil ND-Oil 8.
Suction Accumulator
Special Tool(s)
Quick joint clamp removal
Item Description
1 Female fitting
2 Male fitting
3 O-Ring seals The BA Falcon suction accumulator from December
2003 (BA-19C808-B, post December 2003) has a
different mounting to the earlier version of BA Falcon
accumulator (BA-19C808-A, pre December 2003).
Both the later level accumulator bracket and the
welded body apron brackets have been revised, and
the later level accumulator bracket cannot be fitted to
the earlier level body bracket.
CAUTION: All suction accumulators contain a

dessicant which is very hygroscopic (absorbs
moisture). It is very important to keep the ports of
G73319 en 01/2003 2003.0 BA Falcon

the new accumulator sealed until immediately 4. Disconnect the accumulator inlet tube from the
prior to its installation. A/C evaporator core by removing the E-clamp and
bolt. (Refer to E-Clamp Removal and Installation
CAUTION: All refrigerant must be recovered in this section)
CAUTION: Ensure the evaporator outlet
Removal
tube o-ring (Refer to Specifications in this
1. Recover the refrigerant. For additional section for O-ring details) is present and
information, refer to A/C system discharging and undamaged prior to assembly of the A/C
recovery in this section. suction accumulator.
2. Disconnect the A/C suction hose assembly from
the suction accumulator at the quick connect joint, CAUTION: Plug all A/C ports to prevent
using the quick joint clamp removal tool. (Refer to contamination from dirt or moisture.
section on quick-connect joint removal/assembly.)
5. Remove the suction accumulator.

Installation
CAUTION: Refer to Refrigerant Oil
3. Remove the two suction accumulator mounting Replacement Quantity in this section prior to
nuts. fitting a new accumulator.
Install the new suction accumulator with the
correct amount of PAG Compressor Oil
ND-Oil 8.
Pressure Cut-off Switch (Pressure
Transducer)
information, refer to A/C system discharging and
recovery in this section.
2. Disconnect the A/C pressure cut-off switch
electrical connector (pressure transducer).
G73315 en 01/2003 2003.0 BA Falcon

3. Remove the A/C pressure cut-off switch (pressure sideways & forward (refer to Section 303-03) to
transducer) from the A/C discharge hose obtain tool access for the A/C liquid
assembly. line-condenser joint bolt.
4. To install, reverse the removal procedure. 4. Remove the mounting bolts from the A/C
Lubricate the O-ring seals with PAG condenser core brackets.
CAUTION: Prior to removing the
condenser assembly, insert a sheet of
in this section prior to recharging the A/C system.
cardboard either side of the core to protect the
5. Recharge the A/C system. For additional tubes and fins.
information, refer to A/C system evacuation and NOTE: The condenser assembly can be removed
charging in this section. from the top of the vehicle, if the engine cooling
fan and shroud has been removed and the
Condenser Assembly radiator assembly has been loosened and tilted
rearwards. (refer to Section 303-03)
NOTE: The condenser assembly can be removed
CAUTION: All refrigerant must be recovered from underneath the vehicle, if the air deflector
from the A/C system. has been removed. (refer to Section 501-02)
NOTE: If an A/C condenser core leak is suspected,
the A/C condenser core should be leak tested before
it is removed from the vehicle. For additional
information, refer to Electronic Leak Detection and
Fluorescent Dye Leak Detection in this section.
information, refer to A/C System Discharging and
Recovery in this section. 5. Remove the A/C condenser core.
2. Remove radiator grille sight cover to access front 6. To install, reverse the removal procedure.
of condenser. Lubricate the new A/C condenser core with
3. Remove the bolts from the two hose assemblies the correct amount of PAG Compressor Oil
attached to the condenser inlet & outlet tube ND-Oil 8 or equivalent meeting Ford
fittings. Disconnect the two hose assemblies. specification WSH-M1C231-B. For additional
information, refer to Refrigerant and Oil
CAUTION: Plug all A/C ports to prevent Adding in this section.
contamination from dirt or moisture. Lubricate the O-ring seals with PAG
NOTE: If the vehicle is fitted with a turbo Compressor Oil ND-Oil 8 or equivalent
intercooler, mounted in front of the condenser, the meeting Ford specification WSH-M1C231-B.
intercooler will need to be loosened and slid
G73315 en 01/2003 2003.0 BA Falcon

NOTE: Refer to Refrigerant Oil Replacement Quantity 8. Disconnect the A/C discharge hose assembly
in this section prior to recharging the A/C system. from the compressor.
7. Recharge the A/C system. For additional CAUTION: Plug all ports to prevent
information, refer to A/C system evacuation and contamination from dirt or moisture.
charging in this section. NOTE: Do not insert screwdriver between fittings,
Condenser Inlet Hose Assembly as damage can easily occur.
(Discharge Hose)
from A/C system.
information, refer to A/C Discharging and
2. Remove the bolt from the A/C discharge hose to
A/C condenser core inlet tube fitting and
disconnect the hose asy from the condenser.

Compressor Inlet Hose Assembly (I6 &

V8 — Suction Hose) and Accumulator
Outlet Tube Assembly (V8 — Suction
CAUTION: Plug all A/C ports to prevent Tube)
NOTE: Do not insert screwdriver between fittings, as Special Tool(s)
damage can easily occur.
Quick joint clamp removal tool
3. Remove the nut from the A/C discharge hose
mounting bracket to the radiator support panel.
4. Remove the bolt from the A/C discharge hose to
radiator hose guide on the front cross member
(V8 only).
5. Disconnect the suction hose assembly from the
discharge hose assembly double bracket adjacent The BA Falcon 6-cylinder petrol/LPG compressor inlet
to the radiator hose guide on the front cross hoses (suction hoses) from Feb 2004 have been
member (V8 only). standardised (BA-19997-D) and this is different to the
6. Disconnect the A/C discharge hose assembly early level of BA Falcon petrol/LPG suction hoses
from the condenser core. (BA-19997-A ans BA-19997-C), both in hose material
7. Remove the bolt from the A/C discharge hose to and routing.
compressor fitting. Removal and Installation
G73320 en 01/2003 2003.0 BA Falcon

2. Disconnect the A/C Suction Hose/Tube assembly 10. Recharge the A/C system. For additional
from the suction accumulator at the quick-connect information, refer to A/C system evacuation and
joint, using the quick joint clamp removal tool. charging.
(Refer to section on Quick Joint Clamp
removal/installation.) Condenser to Evaporator tube
3. Disconnect the suction hose/tube from the assembly (A/C liquid line)
accumulator (using hands only).
4. Remove the nut from the suction hose bracket to CAUTION: All refrigerant must be recovered
shock absorber stud. Disconnect the suction hose from the A/C system.
bracket by rotating the bracket on the A/C tube.
CAUTION: Ensure the evaporator tube inlet
CAUTION: Plug all A/C ports to prevent O-ring (refer to Specifications in this section for
contamination from dirt or moisture. O-ring details) is present and undamaged prior to
5. Disconnect the suction hose assembly from the assembly of the A/C liquid line.
discharge hose assembly double bracket adjacent Removal and Installation
to the radiator hose guide on the front cross
member — (V8). 1. Recover the refrigerant. For additional
6. Disconnect the suction tube from the suction hose Recovery in this section.
at the quick connect joint, using the quick joint
clamp removal tool. (Refer to section on Quick 2. Disconnect the A/C liquid line (condenser to
Joint Clamp removal/installation — (V8).) evaporator line) at the evaporator by removing the
evaporator E-clamp and bolt. (refer to E-Clamp
7. Remove the screw attaching the suction tube removal and installation in this section)
bracket to the LH side rail — (V8).
8. Remove the bolt from the A/C suction hose to CAUTION: Plug all A/C ports to prevent
compressor fitting. Disconnect the suction hose contamination from dirt and moisture.
assembly from the compressor.
3. Remove the bolt from the liquid line condenser
CAUTION: Plug all A/C ports to prevent outlet tube joint and disconnect the liquid line from
contamination from dirt or moisture. the condenser.
NOTE: Do not insert screwdriver between fittings NOTE: Do not insert screwdriver between fittings, as
as damage can easily occur. damage can easily occur.
NOTE: If the vehicle is fitted with a turbo intercooler
mounted in front of the A/C condenser, the intercooler
will need to be unbolted and slid sideways and
forward in order to obtain tool access for the A/C
liquid line condenser joint bolt. (refer to Section
303-03)

4. Remove the screw attaching the liquid line
bracket to body adjacent to the charge port, and
remove the saddle clamp and nut adjacent to the
ABS module.
9. To install, reverse the removal procedure. 1. Lubricate O-ring seals with PAG compressor
Lubricate the O-ring seals with PAG oil ND-Oil8.
compressor oil ND-Oil8. NOTE: Refer to Refrigerant Oil Replacement Quantity
CAUTION: The SFLPG (Single Fuel LPG)
suction hose is different to the petrol 6-cylinder 6. Recharge the A/C system. For additional
suction hose, and the SFLPG hose is labelled with information, refer to A/C System Evacuation and
a green stripe. Charging.
G73320 en 01/2003 2003.0 BA Falcon

Evaporator clamp (E-Clamp) 4. Disconnect evaporator sensor plug from HIM

connector.

CAUTION: Ensure the evaporator tube

genuine Ford green/blue refrigerant O-rings are
present and undamaged prior to assembly of the
evaporator clamp.
2. Remove the evaporator clamp bolt located
between the accumulator inlet tube and the A/C
liquid line. 5. Disengage Grommet from heater case.
3. Lift and rotate the evaporator clamp to remove it
from both tubes. The swing plate attached to the
liquid line will rotate off the accumulator inlet tube.
4. To install, reverse removal procedure, ensuring
that the swing plate on the liquid line is swung
onto the accumulator inlet tube prior to starting
the evaporator clamp bolt.
NOTE: Full insertion of both tubes onto the
evaporator is critical prior to assembly of the
evaporator clamp.
5. Recharge the A/C system. For more information,
refer to A/C System Evacuation and Charging in
this section. Item Description
1 Grommet
Air Conditioning Cycling Switch 2 Sensor
(evaporator thermistor)
6. Pull out Sensor.
1. Set A/C controls to face mode. 1. Ensure sleeve on evaporator sensor is straight
2. Remove ICC display screen, Refer to Section between sections A and B.
413-08.
3. Remove glovebox from instrument panel. Refer to
Section 501-12.
G73323 en 01/2003 2003.0 BA Falcon

2. Insert evaporator sensor into heater case in a 5. Insert evaporator sensor plug into HIM connector.
similar fashion to removal procedure.
6. Refit ICC display screen, Refer to Section 413-08.

3. Using a torch and mirror at ICC opening, look into
7. Refit glovebox to instrument panel. Refer to
heater case and ensure sensor is correctly
section 501-12.
directed through the two holes in airmix divider
panel. Engine Cooling Fans (Condenser
Fans)
For removal and installation of engine/condenser
cooling fans, refer to section 303-03.
4. Securely clip grommet into heater case and

ensure that sleeve is still straight and in position
as described in 3 above.
G73323 en 01/2003 2003.0 BA Falcon

412-04-1 Control Components 412-04-1
SECTION : 412-04 Control Components

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................412-04-2
Control Components .............................................................................................................412-04-3
HVAC Integrated Module (“HIM” Module) ............................................................................412-04-3
Climate Control Sensors ......................................................................................................412-04-3
CAN Bus Information ...........................................................................................................412-04-5
HIM Feature and Benefit Summary ......................................................................................412-04-6
HIM Module ...........................................................................................................................412-04-7
Module Configuration ...........................................................................................................412-04-7
HIM Calibration File Down Load ..........................................................................................412-04-7
Cabin Temperature Sensor Calibration Factor ....................................................................412-04-7
HVAC On-Demand Self Test ...............................................................................................412-04-7
DTC Chart ............................................................................................................................412-04-8
PID Chart ...........................................................................................................................412-04-11
Symptom Chart ..................................................................................................................412-04-12
Air Conditioning & HVAC Relay and Fuses .......................................................................412-03-14
Pinpoint Tests ....................................................................................................................412-04-14
Control Components ...........................................................................................................412-04-30
Cabin Temperature Sensor .................................................................................................412-04-30
Sunload sensor/Twilight sensor ...........................................................................................412-04-30
Ambient Temperature Sensor .............................................................................................412-04-30
Evaporator Temperature Sensor (Evaporator Thermistor) .................................................412-04-30
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Lubricants
HVAC Lever Cam Dow Corning Molykote
Grease PG 54 Silicon Grease
Engine Coolant Do not top up the cooling
system with tap water.
Use only Ford Specified
Coolant at a Ratio of 30 -
50 %
A/C System O-Ring PAG ND-Oil 8
Lubrication
A/C System O-Rings Refrigerant O-Ring,
green HNBR, Evaporator
Outlet (large) - part no.
BA19S710A
Evaporator Inlet (small) -
part no. BA19S710B
Description Nm
HVAC Mounting Upper Bolts (4) 6-8
HVAC Mounting Lower Nuts (2) 9 - 12
Evaporator Tube to A/C Tube 12.7 - 17.3
Clamping Bolt
HVAC Hi / Lo Plastic Self Tapping 1.1 - 1.5
Screws
Heater Tube Clamp Retaining Screw 1.1 - 1.5
Evaporator Plastic End Plate 1.1 - 1.5
HIM to HVAC Self Tapping Screws 1.1 - 1.5
Blower Motor to HVAC Self Tapping 1.1 - 1.5
Screws
G86726 en 01/2003 2003.0 BA Falcon

Control Components The Cabin temperature sensor is located in the ICC

facia behind a small grille immediately to the right of
HVAC Integrated Module (“HIM” Module) the ICC display screen and is wired directly to the
BEM. It is used by the ACC climate control system
The introduction of the Ford BA Falcon vehicle brings only. The CTS takes temperature readings via a DC
with it a new concept in Heating, Ventilation and Air operated fan motor drawing air from the car interior
Conditioning control. This new technology is known as through the grill and across a thermistor. When there
the HVAC Integrated Module (“HIM”). is a change in temperature, the value of resistance
The HIM is a self-contained electronic control module changes giving a change in voltage output. This
attached to the passenger side of the HVAC unit. This change is read by the BEM where is translated into a
new generation device contains electric motors, gear CAN message that is read by the HIM. The CTS is
drive mechanisms and a PCB Board which electrically not a serviceable item. If the CTS is faulty, the
and mechanically control the HVAC system. complete ICC should be replaced after prior approval
The HIM incorporates air delivery damper control, gained. Refer to section 413-08 for ICC replacement.
variable blower fan speed control and high speed Whenever the ICC or BEM is replaced, the CTS
serial data communication interconnected to and calibration factor needs to be retaught to the BEM.
exchanging data with many other electrical vehicle The combined Twilight and Sun Load sensor is
sub systems. located in the top of the instrument panel between the
When climate control buttons or knobs are operated, passenger and driver screen air duct. The sensor is
the ICC module sends a CAN message to the HIM. wired directly to the BEM. The Sun load sensor is
The HIM executes the selected function and sends a used by the ACC climate control system only, to
message back to the ICC module to update the adjust the ACC for different sun intensity levels. The
display screen as required for that function. Twilight Sensor provides information about low light
conditions for automatic headlight operation.
The HIM is fitted to all three variants of climate control
systems available in the FORD BA Falcon vehicle The Ambient temperature sensor is located in the
range. The climate control variants are: passenger side external mirror housing and is wired
directly to the HIM. It is used by the ACC climate
ACC Automatic Climate Control with Dual control system only. The Ambient Temperature sensor
Zone capabilities is not a serviceable item. If the sensor is faulty, the
MCC Standard Heating and Air Conditioning complete LH external mirror assembly should be
(Manual Climate Control) replaced.
HTR Heating system only The BEM is located within the ICC assembly. Refer to
Section 413-08 for ICC functions and specifications,
The HIM module is a common component fitted to all
three variants, however, in the event of a service and refer to Section 419-10 for BEM functions and
specifications.
replacement, the HIM requires configuration during
the installation in to a vehicle. Refer to HIM Module Acronyms and Abbreviations
Configuration further in this section.
The following acronyms will be used throughout this
The HIM receives and sends data to various vehicle
section.
sub systems via the CAN bus, including the ICC, BEM
and PCM. A/C Air Conditioning
NOTE: The climate system will operate with the ACC Automatic Climate
ignition key set to RUN position only. Also, the HIM Control
will only respond to diagnostic commands and ACPT A/C Pressure Transducer
services from the WDS test tool while the ignition key
set to RUN position only. BEM Body Electronic Module
(GEM)
Climate Control Sensors CAN Controller Area Network
The climate control system relies on various sensors DTC Diagnostic Trouble Code
located in specific positions throughout the vehicle. DZ Dual Zone
The sensor data is used to control the various HVAC EATC Electronic Air
subsystems such as air distribution, blower fan speed Temperature Control
control, air conditioning and heating.
EEC Electronic Engine Control
Some of the sensor data used by the HVAC system is (part of PCM)
retrieved through the serial CAN bus data system. EVT Evaporator Vent
The Evaporator temperature sensor is located in the Temperature
HVAC air conditioning core and is wired directly to the
FCSD Ford Customer Service
HIM. It is used by the ACC and MCC climate systems Division
only.
A12340 en 01/2003 2003.0 BA Falcon

NVM Electronic Automatic

Temperature Control
PCM Powertrain Control
Module
HIM HVAC Integrated Module
HTR Heater
HVAC Heating, Ventilation & Air
Conditioning
ICC Interior Command Center
MAX Maximum
MCC Manual Climate Control
MIN Minimum
MSG Message
N/A Not Applicable
WDS Worldwide Diagnostic
System
RAM Random Aces Memory
(Loss of data when
power removed)
ROM Read Only Memory
RPM Revolutions Per Minute
A12340 en 01/2003 2003.0 BA Falcon

CAN Bus Information
CAN Bus Electrical System Diagram
Data Transmitted by the HIM Information Receiver ACC MCC HTR

Description
Information Receiver ACC MCC HTR A/C OFF display Icon ICC YES NO NO
Description
Blower fan manual ICC YES NO NO
Air Inlet mode (Fresh / ICC YES YES YES speed selection
Recirc)
Drivers side ICC YES NO NO
Air Outlet mode (Face ICC YES YES YES temperature selection
/ Floor / Screen)
Passenger side ICC YES NO NO
Person display Icon ICC YES YES YES temperature selection
A/C display Icon ICC NO YES NO Ambient temperature ICC YES NO NO
A/C MAX display Icon ICC NO YES NO
A12340 en 01/2003 2003.0 BA Falcon

Information Receiver ACC MCC HTR Sharing of Vehicle Electric control.

Description Sub-Systems Not dependant on engine
Climate control mode ICC YES NO NO Information via vacuum like AU.
(AUTO / SEMI / OFF) Serial CAN data
Blower fan motor PCM YES YES YES bus
operating speed Outlet Air Delivery Electric control.
voltage Mode Control Not dependant on engine
Evaporator core PCM YES YES NO vacuum.
surface temperature Ingress Air Electric control.
A/C Compressor PCM YES YES NO Delivery Control Not dependant on engine
engagement request, vacuum.
(SwitchON) Outlet Air Electric control.
Temperature Not dependant on engine
Information Received by the HIM Control vacuum.
HVAC Blower Fan 14 selectable speeds + Off -
Information Sender ACC MCC HTR
Description Speed Control MCC system.
10 selectable speeds + Off +
Engine RPM PCM YES YES YES Infinitely variable in Auto mode -
Vehicle road speed PCM YES YES YES ACC system
DTC Logging Enable PCM YES YES YES HVAC Blower Fan Self re-setting thermal overload
A/C Load reduction PCM YES YES NO Over Current protection.
Protection
Engine coolant PCM YES NO NO
temperature Vehicle Battery Minimises HVAC blower fan
Voltage Fluctuation speed fluctuation due to vehicle
Engine cylinder count PCM YES NO NO
Compensation system electrical overloads.
Blower / Temperature ICC NO YES YES Automatic Climate Dual air temperature control for
knob positions
Control front seat occupants.
Climate Control push ICC YES YES YES
Evaporator Core Direct connection to HIM.
buttons Temperature
ICC Module type ICC YES YES YES Sensor
(Auto / Manual
Continuous Continuous self diagnosis of
climate) System Fault Self HVAC system operation with
Ignition switch BEM YES YES YES Diagnosis event capture.
accessory position System On-Demand Self Test
Cabin temperature BEM YES NO NO via WDS service tool.
sensor Calibration HVAC operating system
Sun load sensor BEM YES NO NO Upgrade via WDS calibration upgrade via WDS
service tool service tool.
HIM Feature and Benefit Summary Serviceability Easy assembly - align levers, fit
Benefits 3 screws and insert 2
The greatest benefit of the new Climate control connectors (3 with A/C option.)
system is due to the introduction of the serial data
CAN bus network. This reduces the wiring required to
interconnect sensors and electronic control
sub-systems. Sensors are monitored by one
electronic sub-system and then the information is
shared by any other electronic sub-system that is also
connected to the serial CAN bus. This also reduces
the total number of possible failures due to poor
electrical connection. It also has the greater benefit of
a single point connection to monitor and diagnose
many vehicle sub-systems via the serial data CAN
bus and WDS service tool.
A12340 en 01/2003 2003.0 BA Falcon

HIM Module Please refer to FCSD (Ford Customer Service

Division) for latest Climate Control system calibration
Module Configuration version.
Please refer to WDS manual for HIM calibration data
HIM upgrade instructions.
The HIM may be configured to operate in one of three
modes. Cabin Temperature Sensor Calibration
Factor
ACC Automatic Climate Control with Dual
Zone capabilities 1. Whenever a cabin Temperature sensor, ICC or
BEM is replaced the CTS calibration factor needs
MCC Standard Heating and Air Conditioning to be taught to the BEM. Refer to Section 419-10.
(Manual climate control)
2. The CTS mounted on the ICC has a barcode
HTR Heating system only sticker attached to it. To obtain the calibration
HIM configuration is possible only via WDS service factor “Ring the Oasis Hotline” with the Barcode
tool. number they will provide a calibration factor to
Care must be taken to ensure that the module is enter into the BEM using the WDS.
correctly configured to match the HVAC assembly 3. If a BEM is being replaced, the CTS calibration
type that is installed within the vehicle. Incorrect factor can be read from the original BEM by the
configuration of the HIM can result in loss of HVAC WDS using the request read memory block ($21)
system functionality and misdiagnosis of the HVAC command ($0E is the relevant memory block for
system. the CTS calibration factor). It can then be
To configure the following: downloaded into the new BEM using the request
write memory block ($3B) command.
ICC
HVAC On-Demand Self Test
The HIM module has the ability to self diagnose most
BEM internal circuits and components. Continuous self
Refer to Section 419-10. diagnosis is performed while the ignition key is in the
RUN position and sufficient vehicle battery voltage is
PCM available. Further to this, the HIM may be
Refer to Section 303-14. commanded to perform additional self diagnosis by
the WDS service tool. DTC’s will be set as problems
HIM Calibration File Down Load arise, where intermittent or permanent circuit failures
exist, from continuous self diagnosis or On-Demand
The HIM has the provision to accept update HVAC
Self Test by WDS service tool.
system calibration data.
Refer to DTC Chart for individual DTC descriptions. It
The calibration data contains many Climate Control is important to note that when performing On-Demand
system operating parameters for ACC, MCC and HTR
Self Test, the following pre-conditions must be met
operating modes. The system calibration data is
before starting and during the self test.
stored within the HIM’s internal microprocessor
memory. The conditions include:
The Climate Control system calibration version details Ensure vehicle battery voltage is within 12 ~ 14.5
can be checked using the WDS scan tool to request volts.
the data from the HIM via PID “CAL_VER” (EEprom Environment temperature is within 0 ~ +40
Calibration Version.) degrees Celsius.
Please refer to Pin Point Test 412-04-I for further Engine temperature is at normal operating
instructions in the event of failure to completely down temperature.
load the calibration file data from WDS Scan Tool to Record existing DTC’s within the HIM then clear
the HIM assembly. before the test.
HIM Sub Function: Internal Circuit Tests

ACC MCC HTR
Actuator - Face / Demist Yes Yes Yes
Actuator - Floor / Console Yes Yes Yes
Actuator - Recirculation Yes Yes Yes
Actuator - Air Temperature (Cabin) Yes Yes Yes
Actuator - Passenger Air Temperature (Cabin) Yes N/A N/A
A12342 en 01/2003 2003.0 BA Falcon

HIM Sub Function: Internal Circuit Tests

ACC MCC HTR
Actuator - Driver Air Temperature (Cabin) Yes N/A N/A
Sensor - External Air Temperature (Ambient) Yes N/A N/A
Sensor - Evaporator Air Temperature Yes Yes N/A
Blower fan variable speed controller N/A N/A N/A
CAN Bus communication Yes Yes Yes
Ignition supply voltage Yes Yes Yes
Module configuration Yes Yes Yes
Module actuator operating range calibration Yes Yes Yes
DTC Chart NOTE: The codes may be logged due to intermittent
and/or permanent circuit failures.
The following table lists all DTC’s that may be set by
the HIM due to system operation failures.
Displayed DTC Description from MRDB Possible Causes Action
B1242 (Recirculation Door Recirc door jammed. Go to section
Under travel) Recirc lever fouled. 412-02, Pinpoint
Air Flow Recirculation Low battery charge. test D.
Door Driver Circuit Internal module failure (HIM).
Failure
B1250 (Cabin Temperature Invalid data code sent by vehicle Go to PinPoint Test
Sensor) sub-system. P.
Air Temperature
Internal Sensor Circuit
Failure (Cabin
Temperature Sensor)
B1255 Air Temperature Sensor lead disconnected from Go to PinPoint Test
External Sensor Circuit module. A.
Open Sensor failure.
Internal module failure (HIM).
B1257 Air Temperature Sensor leads shorted together. Go to PinPoint Test
External Sensor Circuit Sensor lead shorted to vehicle A.
Short To Ground body.
Sensor failure.
B1262 (Screen/Face Actuator Door jammed. Go to section
under travel) Lever fouled. 412-02, Pinpoint
Servo Motor Defrost Low battery. test E.
Circuit Failure Internal module failure (HIM).
(Screen/Face Actuator)
B1266 Servo Motor Air intake Door jammed. Go to section
Left Circuit Failure Lever fouled. 412-02, Pinpoint
(Passenger Air Low battery. test G.
Temperature Actuator) Internal module failure (HIM).
B1267 (Driver Air Temperature Door jammed. Go to section
Actuator Under travel) Wiring harness fault. 412-02, Pinpoint
Servo Motor Air intake Actuator fault. test H.
Right Circuit Failure Low battery.
(Driver Air Temperature Internal module failure (HIM).
Actuator)
B1676 Battery Pack Voltage Poor Battery charge voltage. Go to PinPoint Test
Out Of Range Battery overcharged. H.
24 volt jump start.
Module internal circuit failure
(HIM).
A12342 en 01/2003 2003.0 BA Falcon


B1947 Climate Control A/C Sensor leads shorted together. Go to PinPoint Test
Post Evaporator Sensor Sensor failure. B.
Circuit Short To Ground Internal module failure (HIM).
B2005 Climate Control Invalid data code sent by vehicle Refer to diagnosis in
Temperature Switch sub-system. Section 413-08.
Out of Range (ICC
temperature dial
setting)
B2006 Blower Motor Switch Invalid data code sent by vehicle Refer to diagnosis in
Out of Range (Blower sub-system. Section 413-08.
fan dial setting)
B2007 Solar Radiation Invalid data code sent by vehicle Refer to BEM
B2890 (Driver/Passenger) sub-system. diagnosis in Section
Sensor Out of Range 419-10 and Sunload
sensor pinpoint test
in section 417-01.
B2010 (Floor/Console actuator Door jammed. Go to section
Under travel) Lever fouled. 412-02, Pinpoint
Servo Motor Panel Low battery. test F.
Door Circuit Failure Internal module failure (HIM).
(Floor/Console
actuator)
B2011 (Floor/Console actuator Linkage disconnected. Go to section
Over travel) Linkage failure. 412-02, Pinpoint
Panel Door Actuator Internal module failure (HIM). test F.
Motor Out of Range
(Floor/Console
actuator)
B2012 (Driver Air Temp Linkage disconnected. Go to section
Actuator Over Travel) Linkage failure. 412-02, Pinpoint
Driver Air intake Wiring harness fault. test H.
Actuator Motor Out of Actuator fault.
Range (Driver Air Temp Internal module failure (HIM).
Actuator)
B2013 (Passenger Air Temp Linkage disconnected. Go to section
Actuator Over travel) Linkage failure. 412-02, Pinpoint
Passenger Air intake Internal module failure (HIM). test G.
Actuator Motor Out of
Range (Passenger Air
Temp Actuator)
B2014 Climate Control A/C Sensor lead disconnected from Go to PinPoint Test
Post Evaporator Sensor module. B.
Open Circuit Sensor failure.
B2141 NVM Configuration Failure to successfully complete Go to PinPoint Test
Failure. HIM calibration file download. I.
Power interruption to HIM module
during file download.
Power interruption to WDS scan
tool during file download.
B2416 (Recirculation Door Linkage disconnected. Go to section
Climate Control Internal module failure (HIM). test D.
Recirculation Actuator
Out of Limits
A12342 en 01/2003 2003.0 BA Falcon


B2477 Module Configuration Module type not configured. Go to PinPoint Test
Failure ICC type message data does not J.
match HIM module configuration.
B2513 Blower (Fan) Circuit HVAC air flow restriction. Go to Pinpoint test L
Failure Internal module failure (HIM). & chapter 412-02,
Pinpoint test A.
B2926 (Screen/Face actuator Linkage disconnected. Go to section
Defrost Actuator Motor Internal module failure (HIM). test E.
Out of Range
(Screen/Face actuator)
C1998 Module Calibration Actuator calibration not Go to PinPoint Test
Failure performed. K.
Failure to complete Self Test
$02.
P1796 CAN Controller Circuit CAN bus wiring fault. Go to PinPoint Test
(Bus Off). M.
U1900 CAN Communication CAN bus wiring fault. Go to PinPoint Test
Bus Fault - Receive Vehicle sub-system failure. M.
Error
U2196 Invalid ‘Engine RPM’ Invalid data code sent by vehicle Refer to PCM
data sub-system. diagnostics in
Section 303-14.
U2197 Invalid ‘Vehicle Speed’ Invalid data code sent by vehicle Refer to PCM
data sub-system. diagnostics in
Section 303-14.
U2199 Invalid ‘Engine Coolant Invalid data code sent by vehicle Refer to PCM
Temperature’ data sub-system. diagnostics in
Section 303-14.
NOTE: The following table lists all DTC’s that maybe
set by the ICC due to climate control related operation
failures.

B2923 Climate control button Climate control button jammed Document and clear
stuck DTC’s. Carry out
Audio Self Test in
section 415-00. If
the DTC is
registered again,
replace the ICC.
Test the
replacement ICC for
correct Climate
Control System
operation.
U2201 Ambient temperature HIM did not have valid data available Clear all DTC’s
data invalid registered in the
HIM. Perform HVAC
On-Demand Self
Test. Refer to
associated Pinpoint
test from the DTC
chart.
A12342 en 01/2003 2003.0 BA Falcon

PID Chart Acronym Description HIM Configuration

ACC MCC HTR
The following table lists all PID’s utilised by the WDS
service tool to access specific functions within the CANDSV CAN Diagnostic YES YES YES
HIM. Specification
Version
Acronym Description HIM Configuration
RECIRDS Recirculation YES YES YES
ACC MCC HTR Door Actual
CCNT Number of YES YES YES Position
Continuous RECIRDTP Recirculation YES YES YES
Trouble Codes Door Target
Set Position
NTCSDT Number of YES YES YES CCACTM Climate Control YES YES YES
Trouble Codes Actuator Modes
Set due to
MOD_ID Module YES YES YES
Diagnostic Test
Configuration
A_CT Evaporator YES YES N/A Check
Temperature
CCMODE Climate Control N/A YES N/A
ETSFD External YES N/A N/A Mode
Temperature
Sensor Filtered BEM_MSG GEM - Body YES YES YES
Electronics
Data
Module CAN
EXT_TEMP External YES N/A N/A Message Receive
Temperature Status
From Sensor
ICC_MSG ACM - Interior YES YES YES
(unfiltered)
Control Center
PBDAP Passenger Blend YES YES YES Module CAN
Door Actual Message Receive
Position Status
PBDTP Passenger Blend YES YES YES PCM_MSG PCM - Powertrain YES YES YES
Door Target Control Module
Position CAN Message
BLENDDR Driver Blend Door YES N/A N/A Receive Status
Position ACCS AC Compressor YES YES N/A
BLENTP Driver Blend Door YES N/A N/A Cycling Request
Target Position CAL_VER EEprom YES YES YES
BLOWVOL HVAC Blower YES YES YES Calibration
Voltage Version
BLOWAP Blower Motor YES YES YES CAL_VRAM Calibration YES YES YES
Speed - Actual Version Currently
Position Loaded in RAM.
BLOWTP Blower Motor YES YES YES NOTE: The following table lists all PID’s utilised by
Speed - Target the WDS service tool to access Climate control
Position functions within the ICC.
LEFTOT Passenger’s YES N/A N/A
Display Set Acronym Description ICC Configuration
Temperature ACC MCC HTR
RIGHTOT Driver’s Display YES N/A N/A TMPKNOBP Temperature N/A YES YES
Set Temperature Selector Status
MC_VREF Vehicle Battery YES YES YES BLWR_FAN Blower Fan N/A YES YES
Voltage Speed
HIM_STAT ECU Diagnostic YES YES YES AC_SEL_SW Air Conditioning N/A YES N/A
Operating State Switch Status
CONPROV Configuration and YES YES YES PANEL_FLR Panel (Face) / N/A YES YES
Programming Floor
Version
A12342 en 01/2003 2003.0 BA Falcon

Acronym Description ICC Configuration Acronym Description ICC Configuration

ACC MCC HTR ACC MCC HTR
FLR_DEF Floor / Defrost N/A YES YES REAR_DEF Rear Defrost N/A N/A N/A
(mix) (heated backlight)
FLOOR Floor N/A YES YES PTMP_DECR Passenger YES N/A N/A
PANEL_FAC Panel (Face) N/A YES YES Temperature
E Decrement
DEF_SCRN Defrost (Screen) YES YES YES PTMP_INCR Passenger YES N/A N/A
Temperature
AUTO Auto YES N/A N/A
Increment
OFF Off YES N/A N/A MODE_UP Mode UP YES N/A YES
RECIRC Recirculation YES YES YES
MODE_DWN Mode DOWN YES N/A N/A
Status
HIM_MSG Missing YES YES YES
FAN_MINUS Fan - YES N/A N/A CANmessage
FAN_PLUS Fan + YES N/A N/A (353) to HIM
TEMP_DECR Temperature YES N/A N/A ACC_POS Ignition key YES YES YES
Decrement accessory
TEMP_INCR Temperature YES N/A N/A position
Increment
Symptom Chart
Refer to 412-02 Symptom Chart.
HIM Wiring Harness Connectors C376 12 and 2 way

1 Circuit 38B (B-O) +Battery Voltage ( V ) to vehicle body electrical ground
Approximately + Battery ( 12 ~ 14V) while engine
running.
2 Circuit 140Z (R-B) Ignition Voltage ( V ) to vehicle body electrical ground
Approximately + Battery ( 12 ~ 14V) while engine
running.
5 Circuit 914P (BR-Y) Note 1
CAN bus to ICC
6 Circuit 914J (BR-Y) Note 1
CAN bus to PCM
7 Circuit 234 (W-L) Voltage ( V ) between circuit pin 682 and 234
Ambient Sensor 1 ~ 5V ignition key ON, connector attached to
HIM.
Reading will depend on Ambient sensor
temperature.
A12342 en 01/2003 2003.0 BA Falcon


8 Circuit 682 (R) Resistance (Ohm) between pins 1 and 3
Sensor GND 2.7K ~ 3.3K ohms
11 Circuit 915P (P-L) Note 1
CAN bus to ICC
12 Circuit 915J (P-L) Note 1
CAN bus to PCM
13 Circuit 1133 (BR) Voltage ( V ) to vehicle body electrical ground
Blower Motor Approximately + Battery ( 12 ~ 14v) while engine
running, blower connected and HIM
disconnected.
14 Circuit 57CB (B) Resistance (Ohm) to vehicle body electrical
Power GND ground
0 ohms approx.
CAUTION: Do not probe terminals with any

type of meter as damage to vehicle systems may
result.
CAUTION: Do not insert probes in to front of

terminal, damage may result. Probe only rear (wire
entry) of connectors.
Dual Zone Actuator Terminal Connections 5 way

1 Potentiometer + Resistance (Ohm) between pins 1 and 3
2.7K ~ 3.3K ohms
2 Potentiometer Resistance (Ohm) between pins 2 and 3
Wiper 0 ~ 3.3K ohms (value dependant on motor output
coupling angle)
3 Potentiometer - Resistance (Ohm) between pins 1 and 3
2.7K ~ 3.3K ohms
4 Motor Connection Diode (D) Continuity between pins 4 and 5
0.5 ~ 0.7V
5 Motor Connection Diode (D) Continuity between pins 4 and 5
0.5 ~ 0.7V
HIM Input Connection D (Evaporator Temperature Sensor 2 Way)

A12342 en 01/2003 2003.0 BA Falcon


1 Sensor ground Voltage ( V ) between HIM terminal connection D
pin 1 and C376 pin 13.
0V (ground)
2 Sensor Supply Voltage ( V ) between HIM terminal connection D
NOTE: With Ignition ON and sensor
disconnected, refer to sensor voltage from
sensor output table B, Pinpoint test B.
Air Conditioning & HVAC Relay and fan circuit is protected with a 40 amp fuse (F5,
Fuses F6-both green) also located in this fuse box.
The three relay coils are protected by a single 15A
The air conditioning compressor cut-out relay (WAC fuse (F2-blue) located in the instrument panel fuse
relay, R3-black) is located in the Engine Compartment box.
Fuse Box.
The HIM electrical circuits are protected with two
The A/C compressor clutch is protected with a 30 amp fuses, one 15 amp (F4-blue) and one 10 amp,
fuse (F11-pink, combined with the engine fuse) (F27-red), both located in the Instrument Panel Fuse
located in the Engine Compartment Fuse Box. Box.
The A/C condenser fans (engine cooling fans) are The HVAC blower fan circuit is protected with a 40
controlled with three relays (R8, R9, R10-all white) amp fuse (F7-green) located in the Engine
located in the Engine Compartment Fuse Box. Each Compartment Fuse Box.
Pinpoint Tests
PINPOINT TEST A : TEMPERATURE SENSOR — AMBIENT (ACC)

NOTE: REFER to Section 412-02 SYMPTOM CHART BEFORE PROCEEDING

A1 WIRING INSPECTION - SHORT TO VEHICLE BODY
Go to A2 if code B1257 is set.
Ensure vehicle battery voltage is within normal operating range Go to A3 if code B1255 is set.
System OK
Using WDS scan tool, perform HVAC On Demand Self Test.
A12342 en 01/2003 2003.0 BA Falcon


A2 VEHICLE WIRING INSPECTION - SHORT TO VEHICLE
BODY
Disconnect the 12 way connector C-376 from the HIM. Using a Yes
resistance meter, attach the negative probe to a good metal body Go to A4
earth connection and check the vehicle wiring continuity from HIM
connector lead 682 Red wire and lead 234 white-Blue wire for short No
circuit to vehicle body. Repair wiring short to vehicle body.
Does the meter read infinite resistance to the vehicle metal body
for both leads?
A3 VEHICLE WIRING INSPECTION - CONTINUITY

With the 12way connector C-376 removed from the HIM and the 2 Yes
way connector removed from the Ambient sensor C-377, use a Go to A4
resistance meter and check the vehicle wiring continuity lead 682 Red
wire and lead 234 White-Blue wire from HIM connector to sensor No
connector. Repair wiring fault.
Does the meter read 0 ohms end to end for each lead?
A4 MODULE FUNCTION CHECK - AMBIENT SENSOR

TEMPERATURE
Reconnect the 12way connector C-376 to the HIM and the 2way Yes
connector C-377 to the Ambient sensor. System OK
Using the WDS Scan Tool, read the EXT_TEMP value (Ambient No
sensor temperature) from the HIM. Go to A5
Compare the value against a temperature probe located near the
Ambient sensor.
NOTE: Accurate operation of the sensor relies on air moving

across the sensor. Therefore, while the vehicle is stationary or at
low speed or operating for a short period of time only, the
display may differ slightly from the true ambient temperature.
Do the temperatures closely match?
A5 SENSOR INSPECTION - RESISTANCE

CHARACTERISTIC
Disconnect the 12way connector C-376 from the HIM. Using a Yes
resistance meter, attach probes across lead 682 Red wire and lead Go to A6
234 White-Blue wire and compare the reading using Table A and a
temperature thermometer located near the sensor. No
Replace Ambient sensor
Is the resistance reading within specification (+/- 5 degC)?
A6 MODULE FUNCTION CHECK - AMBIENT SENSOR

SUPPLY VOLTAGE
Reconnect the 12way connector C-376 to the HIM and the 2way Yes
connector C-377 to the Ambient sensor. System OK.
Using a volt meter, attach the positive probe into rear of connector No
C-376 lead 682 Red wire and negative probe to lead 234 White-Blue Replace HIM.
wire.
Ensure Ignition key is ON and HIM responds to ICC controls.
Using table A, compare the Ambient sensor voltage reading against a
temperature probe located next to the Ambient sensor.
Does the voltage value closely match the temperature (+/- 5
degC)?
A12342 en 01/2003 2003.0 BA Falcon

Table A Temperature Sensor Sensor Voltage

NOTE: Use this table as a guide only. Minor (Celsius) (Ohms)
15 3.7k 2.97
Temperature Sensor Sensor Voltage 20 3.1k 2.74
Degrees Resistance (Volts) 25 2.5k 2.51
(Celsius) (Ohms)
30 2.1k 2.28
-30 13.3k 4.20
35 1.8k 2.05
-25 12.2k 4.14
40 1.5k 1.83
-20 11.1k 4.06
45 1.2k 1.62
-15 9.8k 3.97
50 1.0k 1.43
-10 8.6k 3.86
55 0.8k 1.28
-5 7.4k 3.72
0 6.3k 3.56 NOTE: The Ambient sensor is an integral part of the
Left Hand Side external rear view mirror assembly.
5 5.3k 3.38 Refer to section 501-19 for mirror assembly
10 4.5k 3.18 replacement instructions.
PINPOINT TEST B : TEMPERATURE SENSOR — EVAPORATOR (ACC/MCC)

B1 SYSTEM ON DEMAND SELF TEST

Go to B2 if code B2014 is set.
Ensure vehicle battery voltage is within normal operating range Go to B3 if code B1947 is set.
System OK
B2 SENSOR WIRING INSPECTION

Disconnect the 2 way Evaporator sensor connector D from the HIM Yes
and inspect terminals on the sensor lead assembly for damage or Replace Evaporator sensor
corrosion.
No
Do the terminals appear damaged? Go to B3
B3 SENSOR INSPECTION - RESISTANCE

CHARACTERISTIC
Turn off the Air Conditioner, select face outlet, full cold (not A/C Max), Yes
(‘C’ or ‘Low’ for ACC) and operate HVAC blower at full speed to Go to B4
stabilise the Evaporator sensor temperature.
No
Disconnect the 2 way Evaporator sensor connector D from the HIM. Replace Evaporator sensor
Carefully insert the test probes of a resistance meter in to the REAR
of the Evaporator sensor connector (wire side). Inserting probes in to
front of terminals will damage the sensor assembly and cause
intermittent A/C operation. Compare the sensor resistance value from
Table B with a temperature thermometer located in the face outlet.
Is the resistance reading within specification (+/- 5 degC) as per
table B?
A12342 en 01/2003 2003.0 BA Falcon


B4 MODULE FUNCTION CHECK - EVAPORATOR SENSOR
TEMPERATURE
Reconnect the sensor 2 way connector D to the HIM. Yes
System OK.
Read the A_CT value (Evaporator sensor temperature) from the HIM. No
Go to B5
Does the value closely match the temperature thermometer
located in the face outlet (+/- 5 degC) as per table B?
B5 MODULE FUNCTION CHECK - EVAPORATOR SENSOR

SUPPLY VOLTAGE
Check the Evaporator sensor supply voltage with a voltmeter. Yes
Go to B6
With the Evaporator sensor 2 way connector D inserted in to the HIM,
attach the positive probe to pin 2 (LHS) and the negative probe to pin No
1 (RHS) of the rear of the Evaporator sensor connector. Refer to Replace HIM.
Evaporative sensor connector diagram for correct pin designations.
Using table B, compare the voltage reading against a temperature
probe located in the face outlet with the HVAC Blower fan operating at
high speed.
Does the voltage value closely match the temperature
thermometer located in the face outlet (+/- 5 degC)?
B6 MODULE OUTPUT CHECK - EVAPORATOR SENSOR

SUPPLY VOLTAGE
Remove evaporator sensor plug from HIM. Yes
System OK.
Using a voltmeter, attach the probes to the HIM output terminals for Clear DTC.
the evaporator sensor.
Ensure ignition key is ON. No
Replace HIM.
Is the voltage reading within 4.5-5.5 Volts?
Table B Temperature Sensor Sensor Voltage

NOTE: Use this table as a guide only. Minor (Celsius) (Ohms)
30 1.21k 0.96
Temperature Sensor Sensor Voltage 35 0.98k 0.81
Degrees Resistance (Volts) 40 0.75k 0.68
(Celsius) (Ohms)
45 0.66k 0.57
-30 25.37k 4.16
50 0.55k 0.48
-25 18.90k 3.94
55 0.45k 0.41
-20 14.19k 3.68
-15 10.73k 3.39
-10 8.17k 3.08
-5 6.27k 2.76
0 4.85k 2.44
5 3.78k 2.13
10 2.97k 1.84
15 2.35k 1.56
20 1.87k 1.34
25 1.50k 1.14
A12342 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : ACTUATOR — RECIRCULATION DOOR (ACC / MCC / HTR)

C1 SYSTEM ON DEMAND SELF TEST

Go to C3
Ensure vehicle battery voltage is within normal operating range
(12~14volts) before proceeding with test. No
Using WDS scan tool, clear all DTC’s set in the HIM memory. Go to C2

Is code B1242 set?
C2 SYSTEM ON DEMAND SELF TEST - DTC CHECK

Is code B2416 set? Yes
Go to C3
No
System OK
C3 VISUAL INSPECTION - RECIRC DOOR LEVER

ENGAGEMENT
Check Recirc door HVAC/HIM coupling levers for correct Yes
engagement. Reconnect levers.
Go to C1
Are the levers disengaged?
No
Go to C4
C4 WDS FUNCTIONAL TEST - FRESH / RECIRC

Turn Ignition ON and and run engine. Yes
System OK
Remove glove compartment and visually check operation of the No
Recirc door while selecting Recirc then Fresh using RECIRDTP. Go to C5
Does the Recirc door fully seal at open and closed positions?
C5 VISUAL INSPECTION - RECIRC DOOR OBSTRUCTION

Check Recirc door and Recirc door coupling levers for interference Yes
from external objects. Remove obstructions.
Go to C1
Are there any obstructions?
No
Go to C6
C6 SYSTEM ON DEMAND SELF TEST - FAULT

RECONFIRMATION
Replace HIM
Using WDS scan tool, record all DTC’s set in the HIM memory. System OK
Is code B1242 set again?
A12342 en 01/2003 2003.0 BA Falcon

PINPOINT TEST D : ACTUATOR — SCREEN / FACE DOOR (ACC / MCC / HTR)

D1 SYSTEM ON DEMAND SELF TEST

Go to D2 if code B1262 is set.
Go to D2 if code B2926 is set.
System OK Refer to Section 413-08.
D2 WDS FUNCTIONAL TEST - SCREEN

Go to D3
Select Screen using CCACTM. No
Replace HIM
Does the air flow from the Screen outlet?
D3 WDS FUNCTIONAL TEST - FACE

Select Face using CCACTM. Yes
System OK
Does the air flow from the Face outlet?
No
Replace HIM
PINPOINT TEST E : ACTUATOR — PASSENGER AIR TEMPERATURE MIX. (ACC / MCC / HTR)
NOTE: This actuator is utilized to control air temperature to both passenger and driver by the single zone
manual climate control system. It is used to control only the passenger side air temperature for dual zone
automatic climate control system.
E1 SYSTEM ON DEMAND SELF TEST

Go to E2 if code B1266 is set.
Ensure vehicle battery voltage is within normal operating range Go to E2 if code B2013 is set.
A12342 en 01/2003 2003.0 BA Falcon


E2 WDS FUNCTIONAL TEST - PASSENGER AIR MIX FULL
HOT
Connect WDS Scan Tool. Yes
Go to E3
Turn Ignition ON and and run engine.
Ensure engine is running and at normal operating temperature. No
Ensure engine cooling system is operating
Select Passenger Full Hot using PBDTP. correctly.
Go to E3
Is the airflow from the HVAC hot (LHS for ACC system, Both
sides for MCC / HTR)?
E3 WDS FUNCTIONAL TEST - PASSENGER AIR MIX FULL

COLD
Select Passenger Full Cold using PBDTP. Yes
System OK
Is the airflow from the HVAC cool (LHS for ACC system, Both
sides for MCC / HTR)? No
Replace HIM if DTC code B1266 or B2013 is
set.
NOTE: The temperature test is a subjective check Incorrect temperature performance without the setting
only and careful assessment must be performed to of either DTC after performing the HVAC On Demand
correctly diagnose Full cooling and Full heating Self Test does not necessitate replacement of the
operation from the HVAC. The temperature can vary HIM.
depending on factors such as A/C ON/OFF (where
fitted), environment air temperature drawn in to HVAC
unit and engine coolant system level and temperature.
PINPOINT TEST F : ACTUATOR — FLOOR / CONSOLE DOOR

F1 SYSTEM ON DEMAND SELF TEST

Go to F2 if code B2010 is set.
Ensure vehicle battery voltage is within normal operating range Go to F2 if code B2011 is set.
F2 WDS FUNCTIONAL TEST - FLOOR OPEN

Go to F3
Select Floor using CCACTM. No
Replace HIM
Does the air flow from the Floor outlet?
F3 WDS FUNCTIONAL TEST - FLOOR CLOSED

Select Face using CCACTM. Yes
System OK
Does the air flow from the Floor outlet?
No
Replace HIM
A12342 en 01/2003 2003.0 BA Falcon

NOTE: Very minor bleed of air from Floor outlets is

acceptable.
PINPOINT TEST G : ACTUATOR — DRIVER AIR TEMPERATUR MIX. (ACC)
CAUTION: Use extreme care when probing the harness terminals. Forcing the Multimeter probes
into the terminals will cause damage and intermittent operation of the Actuator.
NOTE: This actuator is utilized to control air temperature to the driver side only for the Dual Zone automatic
climate control system.
NOTE: The temperature test is a subjective check only and careful assessment must be performed to
correctly diagnose Full cooling and Full heating operation from the HVAC. The temperature can vary
depending on factors such as A/C ON/OFF (where fitted), environment air temperature drawn in to HVAC unit
and engine coolant system level and temperature. Incorrect temperature performance without the setting of
either DTC after performing the HVAC On Demand Self Test does not necessitate replacement of the HIM.

G2 WDS FUNCTIONAL TEST - DRIVER AIR MIX FULL HOT

Go to G3
Ensure engine is running and at normal operating temperature.
Select Driver Full Hot using BLENTP. No
Ensure engine cooling system is operating
Is the airflow from the HVAC Right Hand side (Driver) hot? correctly.
Go to G3
G3 WDS FUNCTIONAL TEST - DRIVER AIR MIX FULL COLD

System OK
Ensure engine is running and at normal operating temperature.
Select Driver Full Cold using BLENTP. No
Ensure Air Conditioning system is operating
Is the airflow from the HVAC Right Hand side (Driver) cool? correctly.
Go to G4
G4 ELECTRICAL CHECK - DRIVER AIR MIX ACTUATOR

Check dual zone actuator as per “Dual Zone Actuator Terminal Yes
Connections” in “Connector Diagrams” earlier in this section with the Go to G5
wiring harness disconnected from the dual zone actuator.
No
Are all checks correct? Replace dual zone actuator.
A12342 en 01/2003 2003.0 BA Falcon


G5 ELECTRICAL CHECK - DRIVER AIR MIX ACTUATOR
Remove the Glove box. Refer to Section 501-12. Yes
Go to G6
Disconnect the dual zone actuator wiring harness connector C from
the HIM. No
Disconnect the dual zone wiring harness from Drivers side actuator. Replace wiring harness
Using a resistance meter, check the continuity of all wiring between
both electrical connectors.
Did all wires have Continuity in each corresponding position?

Replace HIM.
Using WDS scan tool, clear all DTC’s set in the HIM memory. System OK
Are codes B1267 or B2012 set?
PINPOINT TEST H : INPUT FUNCTION — BATTERY VOLTAGE (ACC / MCC / HTR)

NOTE: This DTC may be accidentally triggered due to a vehicle jump start from a 24 volt battery system.
H1 SYSTEM ON DEMAND SELF TEST

Go to H2
Using WDS scan tool, record all DTC’s set in the HIM memory. System OK
Is DTC code B1676 set?
H2 MODULE FUNCTION CHECK - BATTERY VOLTAGE

READING
System OK
Start and run engine.
Ensure charging system is within normal vehicle specifications. No
Replace HIM
Read Battery voltage from HIM using MC_VREF.
Using a digital voltmeter, attach positive probe to lead 38B and
negative probe to lead 57CB of 12 way connector C-376 and compare
readings.
Is the MC_VREF value within +/-0.5 volt of the digital voltmeter
reading?
PINPOINT TEST I : INPUT FUNCTION — MODULE INTERVAL EEPROM MEMORY (ACC / MCC / HTR)
NOTE: The setting of this DTC is due to incomplete calibration file download from WDS scan tool to HIM.
Care must be taken to ensure that the HIM calibration file is successfully completed before replacing the HIM.
Disturbances to vehicle battery power or the serial CAN bus can interfere with the process. In the event of
A12342 en 01/2003 2003.0 BA Falcon

repeated unsuccessful file download, the HIM has a basic backup of all data stored in the HIM microprocessor
Read Only Memory (ROM). The HIM microprocessor will use the back up data to provide full HVAC system
functionality but may have some degree of noticeable changes to the Climate Control system operating
performance. Both the ROM backup and EEprom calibration data is utilised by all three HIM variants, namely
ACC, MCC and HTR. A PID “CAL_VRAM” is provided to perform a check to determine which calibration data
is loaded to RAM and being used by the HIM microprocessor.
For Example:
The Basic backup calibration data stored in the HIM ROM version is = 1. The HIM Calibration file data stored
in the HIM EEprom version is = 5, or the same number as your current calibration file version. Using WDS
scan tool, request the data for PID “CAL_VRAM” from the HIM.
If the data returned is = 1 Then the HIM microprocessor has load the Basic backup calibration data to RAM
due to a fault in the EEprom calibration data area.
NOTE: The version number for ROM calibration data is always =1.
It is safe to operate the vehicle in the event of EEprom Calibration file download failure.
If the data returned for PID “CAL_VRAM” is = 5 (or the same number as your current calibration file version)
Then the HIM microprocessor has load the update EEprom calibration data to RAM and there is no problem.
(IE. DTC B2141 will not be set.)

I1 MODULE CHECK - HIM SYSTEM CALIBRATION FILE
DOWNLOAD
Run engine and ensure vehicle battery condition is of normal charge Yes
state. Replace HIM
Connect WDS tester. No
Clear DTC’s in HIM. System OK.
Proceed with HIM calibration file download. Wait until file download
process has successfully completed before proceeding any further.
Wait until file download process has successfully completed before
proceeding any further.
Reset the HIM using the WDS scan tool HIM reset button. Or, switch
OFF the ignition and disconnect the HIM 12 and 2way connectors
C-376 from the HIM for 5 minutes and then reconnect both
connectors.
Turn on the ignition and request DTC status from the HIM.
Is DTC B2141 set?
PINPOINT TEST J : INPUT FUNCTION — MODULE CONFIGURATION (ACC / MCC / HTR)

NOTE: The HIM may be configured to operate in any one of three types of modes. Namely, Dual zone
Automatic climate control (ACC), Single zone with A/C (MCC) or Single zone without A/C (HTR).
Firstly, to ensure trouble free operation, the HIM configuration must match the HVAC system type.
Secondly, the ICC must be the correct type to operate the HVAC system. The DTC will be set while the ICC
system does not match the HVAC system type and all climate functions will be inoperable.
Thirdly, the DTC may also be set while the HIM is not configured. This may be the case for a new spare part
HIM only. The DTC code can not be cleared by the WDS test tool. Setting and Clearing of the DTC is
automatically controlled by the HIM.
A12342 en 01/2003 2003.0 BA Falcon


J1 VISUAL INSPECTION - ICC TYPE MATCH
Is ICC the correct type for HVAC system? Yes
Go to J3
No
Go to J2
J2 ICC TYPE INSPECTION

Install the correct ICC system type. Yes
Go to J3
Check DTC’s stored in HIM using WDS scan tool.
Is the HIM DTC B2477 is set? No
System OK
J3 MODULE FUNCTION CHECK - HIM MODULE

CONFIGURATION CHECK
Using WDS scan tool, check that the HIM configuration is set correctly Yes
and matches the HVAC system type. System OK
DTC will be self Cleared
Is the HIM configured correctly?
No
Set the correct HIM configuration using WDS
scan tool. Refer to “HIM Module Configuration”
earlier in this section.
Check that HIM DTC B2477 is cleared.
PINPOINT TEST K : INPUT FUNCTION — MODULE SERVO ACTUATOR CALIBRATION (ACC/MCC/HTR)

NOTE: This DTC is only set due to the HIM servo Actuators never completing a full calibration process. This
would normally only be the case for a new spare part HIM.
K1 MODULE CALIBRATION CHECK - HIM SERVO

ACTUATORS
Is DTC C1991 set? Yes
Perform HVAC On Demand Self Test.
No
System OK.
PINPOINT TEST L : INPUT FUNCTION — HVAC BLOWER (ACC / MCC / HTR)

NOTE: It is normal for the HVAC Blower to stop operating during excessively high vehicle battery voltage
conditions such as jump starting from a 24 volt power source. The HVAC blower fan will automatically restart
when the vehicle battery voltage returns to normal operating range. The HIM also employs internal HVAC
blower fan speed controller thermal protection. The HVAC blower fan will be disabled when the fan speed
controller heatsink (located within the HIM assembly) has exceeded safe operating temperatures.
Some reasons for fan speed controller heatsink overheat can include,
High temperatures may be artificially produced for reasons such as restricted HVAC air filter by dust or
plastic bag.
Excessive heat drawn in to the HVAC air inlet from the engine bay with the bonnet open.
Face mode selected and all air outlet registers are closed.
The HVAC blower fan should restart after the fan speed controller heat sink has cooled sufficiently and the
Ignition key is then turned OFF and ON.
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NOTE: Ensure that there are no restrictions to HVAC airflow or excessive heat pick-up in to HVAC air intake
before replacement of HIM.

L1 WDS FUNCTIONAL TEST - HVAC BLOWER FAN
OPERATION
Run engine and ensure vehicle battery is at normal charge state. Yes
System OK
Select Face / Floor outlet mode.
Select Recirc inlet mode. No
Go to L2
Select full cold.
Set the HVAC blower fan speed to maximum using WDS scan tool
with PID “BLOWTP.
Is the HVAC Blower fan operating at full speed?
L2 VISUAL INSPECTION - HVAC BLOWER MOTOR POWER

FUSE
Check HVAC blower motor power supply fuse. Yes
Replace the fuse
Is the fuse blown?
No
Go to L3
L3 ELECTRICAL INSPECTION - HVAC BLOWER MOTOR

POWER SUPPLY
Using a voltmeter, check that battery power is available at the HVAC Yes
blower motor 2way connector C-221 Pin 1 lead 118B. Go to L4
Is approx battery voltage present? No
Repair wiring fault
L4 VISUAL INSPECTION - HVAC BLOWER MOTOR

Check HVAC blower motor current draw with a clamp type ammeter Yes
attached on to the HVAC blower fan battery supply lead. Pin 1 of Replace HVAC blower motor.
2way connector C-221 lead 118B.
No
Is the reading greater than 25 Amps? Go to L5
L5 VISUAL INSPECTION - HVAC BLOWER MOTOR

Remove HVAC blower and inspect for lose or damaged impeller. Yes
Replace HVAC blower motor.
Is impeller damaged or lose fit on motor shaft?
No
Go to L6
L6 WDS FUNCTIONAL TEST - HVAC BLOWER FAN

OPERATION
Reinstall the HVAC blower fan motor and operate at mid and full Yes
speeds for 10 minutes each using WDS scan tool with PID Go to L7
“BLOWTP”.
No
NOTE: More time may be required to run the blower at each speed System OK
during low ambient temperature conditions (cold weather).
Does the blower stop operating?
A12342 en 01/2003 2003.0 BA Falcon


L7 WDS DTC CHECK - HVAC BLOWER FAN SPEED
CONTROLLER
Using WDS scan tool check DTC’s in HIM. Yes
Replace HIM fi this DTC is consistently set.
Is DTC B2513 set?
No
System OK
PINPOINT TEST M : INPUT FUNCTION — CAN BUS. (ACC / MCC / HTR)

M1 WDS FUNCTION TEST - REQUEST DIAGNOSTIC

SESSION
Turn ON ignition. Yes
Clear DTC in HIM
Connect WDS Scan Tool. System OK
Request Diagnostic session from HIM.
No
Does HIM acknowledge command? Go to M2
M2 ELECTRICAL INSPECTION - HIM POWER SUPPLY

Using a voltmeter, check that Battery and Ignition power is available Yes
to the HIM with ignition ON. Connect negative probe to vehicle Go to M3
electrical ground point. Connect positive probe to each Pin 1 and then
Pin 2 of HIM 12 way connector C-376. No
Repair power / wiring fault.
Is approx battery power available at both Pins?

SESSION
Check CAN bus wiring. Refer to section 418-00. Yes
Refer to section 418-00 for CAN bus wiring fault
NOTE: Care should be taken to ensure CAN bus wiring fault is not repair instructions.
intermittent.
No
Is there a CAN bus wiring fault? Go to M4

SESSION
Clear DTC in HIM
Connect WDS Scan Tool. System OK
Request Diagnostic session from HIM.
No
Does HIM acknowledge command? Replace HIM
A12342 en 01/2003 2003.0 BA Falcon

PINPOINT TEST N : INPUT FUNCTION — CAN BUS MESSAGE RECEPTION (ACC / MCC / HTR)
N1 WDS FUNCTION TEST - REQUEST HIM DTC’s

Go to N2
Request DTC’s from the HIM. No
System OK
Is DTC code U1900 set?
N2 WDS FUNCTION TEST - REQUEST CAN BUS

COMMUNICATION FAULT PID DATA FOR ICC SYSTEM
Using WDS scan tool, request data from the HIM for PID B902. Yes
Refer to ICC section 413-08.
Is ICC_MSG set?
No
Go to N3

COMMUNICATION FAULT PID DATA FOR BEM SYSTEM
Is BEM_MSG set? Yes
Refer to BEM section 419-10.
No
Go to N4

COMMUNICATION FAULT PID DATA FOR PCM SYSTEM
Is PCM_MSG set? Yes
Refer to ICC section 303-14.
No
System OK
PINPOINT TEST O : INPUT FUNCTION — HIM MODULE INTERNAL RAM MEMORY (ACC / MCC / HTR)
NOTE: The HVAC Climate Control system operation may be unpredictable in the event of this type of failure
condition. Operate the vehicle with great care until the fault is rectified by an authorised service dealer.
NOTE: The setting of this DTC is due to an internal failure of the HIM microprocessor RAM memory.
NOTE: Complete the test below before replacing the HIM.
A12342 en 01/2003 2003.0 BA Falcon


O1 MODULE CHECK - HIM MICROPROCESSOR INTERNAL
RAM CHECK
Run engine and ensure vehicle battery condition is of normal charge Yes
state. Replace HIM.
Connect WDS tester. No
Clear DTC’s in HIM. System OK.
Switch OFF the ignition and disconnect the HIM 12 and 2way
connectors C-376 from the HIM for 5 minutes and then reconnect
both connectors.
Turn the ignition ON and request DTC status from the HIM.
Is DTC code C2784 set?
PINPOINT TEST P : CABIN TEMPERATURE SENSOR OPERATION (HIGH SERIES/ACC)

NOTE: With the ignition key in the ignition or start position, the BEM provides power to the fan motor of the
cabin temperature module. With the ignition switch in the ignition position the BEM reads the analogue
temperature signal from the module and converts the analogue data into degrees Centigrade and transmits
this data on the CAN bus to the climate control system.
DTC’s will not be logged for invalid data when the ignition switch is in the off or accessories position.
The WDS service tool is to be used to program and check the calibration factor loaded into the BEM. This
calibration factor should be the same as the calibration factor identified on the CTS ID label.
P1 CABIN TEMPERATURE SENSOR AIRFLOW

Start the engine and switch on the automatic climate control. Yes
Go to P2
Place a small piece of tissue paper over the cabin temperature grille.
Ensure that the grille is completely covered. No
Check for blockage of the cabin temperature
Does the tissue paper stick to the grille to indicate air being sensor grille and remove any restrictions and
drawn into the cabin temperature sensor? retest.
If result is still No replace the ICC. Section
413-08
P2 CABIN TEMPERATURE SENSOR READING

Using the WDS tester activate and monitor Pid INT_TEMP. Yes
CTS is operating correctly.
Place a thermometer/temperature probe in front of the CTS grille and
check that the reading matches the INT_TEMP information on the No
WDS tester. CTS is faulty. Replace the ICC. Section 413-08
Using a hair dryer or similar blow warm air across the
thermometer/temperature probe and into the CTS grille.
Check that the temperature changes on the thermometer/temperature
probe match the INT_TEMP information on the WDS tester.
Does the temperature change on the thermometer/temperature
probe match the INT_TEMP information on the WDS?
A12342 en 01/2003 2003.0 BA Falcon

NOTE: The cabin temperature sensor is an integral

part of the ICC, and is not a separately serviceable
item. It the sensor is faulty, the complete ICC must be
replaced. Section 413-08
PINPOINT TEST Q : SUNLOAD SENSOR/TWILIGHT SENSOR OPERATION (HIGH SERIES/ACC)


Q1
Refer to Section 417-01, for Sun Load Sensor Pinpoint Test.
NOTE: Activation of the battery saver supply (J3/3, refer Section

419-10) provides power to the sunload.twilight sensor module. With
the ignition on and the battery saver supply active, the BEM reads the
signals from the sensor. The BEM transmits the sunload data over the
CAN bus to the climate control module. This sensor also controls the
Auto Headlight on function. Refer to Auto Headlight section.
NOTE: DTC’s will not be available for invalid data signalled with the
ignition switch in either the accessories or the start position. The
output voltage from the sunload sensor is available at pin (J2/1. refer
section 419-10), it is in the range of five to zero volts.
A12342 en 01/2003 2003.0 BA Falcon

Control Components
For HVAC Integrated Module (HIM), refer to Section
412-02. For Interior Command Centre, refer to
Section 413-08. For Body Electronic Module, refer to
Section 419-10. For Powertrain Control Module, refer
to Section 303-14.
Cabin Temperature Sensor

The cabin temperature sensor is an integral part of
the ICC module, and is not a separately serviceable
item. If the sensor is faulty, the complete ICC must be
replaced (refer to section 413-08)
Sunload sensor/Twilight sensor

1. Remove trim panel from sensor from rearward
facing edge.
2. Using two screwdrivers carefully pry sensor out of
instrument panel.
3. Lift sensor out until wiring prevents further
movement.
4. Tie length of string around wiring below
connector. Disconnect sensor from wiring. N.B. If
wiring returns through access hole, instrument
panel may have to be removed.
5. Assemble in reverse order.
Ambient Temperature Sensor

The ambient temperature sensor is an integral part of
the passenger side external mirror assembly, and is
not a separately serviceable item. If the sensor is
faulty, the complete mirror assembly must be replaced
(Refer to section 501-09).
Evaporator Temperature Sensor

(Evaporator Thermistor)
Refer to Section 412-03 for Removal and Installation.
A12344 en 01/2003 2003.0 BA Falcon

413-01-1 Instrument Cluster 413-01-1
SECTION : 413-01 Instrument Cluster

CONTENTS PAGE
Instrument Cluster .................................................................................................................413-01-2
Principles of Operation .........................................................................................................413-01-4
Instrument Cluster Gauges ..................................................................................................413-01-5
Warning Indicators ...............................................................................................................413-01-5
General Operation ................................................................................................................413-01-7
Audible Warnings .................................................................................................................413-01-7
Instrument Cluster .................................................................................................................413-01-9
Self Tests .............................................................................................................................413-01-9
Functional Tests .................................................................................................................413-01-10
DTC Chart ..........................................................................................................................413-01-11
Pid Chart ............................................................................................................................413-01-12
CAN Data Information ........................................................................................................413-01-13
Symptom Chart ..................................................................................................................413-01-14
Pinpoint Tests ....................................................................................................................413-01-19
Instrument Cluster ...............................................................................................................413-01-26
01/2003 2003.0 BA Falcon

Instrument Cluster
Low Series

1 Hazard Switch 22 Fuel Gauge
2 ABS Multifunction Indicator 23 Average speed/Transmission display
3 Security Indicator 24 Airbag Warning Indicator
4 Tachometer Gauge 25 Foglamps Indicator (If fitted)
5 Low Oil Warning Indicator
6 Brake Fail Warning Indicator
7 Park Brake Warning Indicator
8 High Beam Indicator
9 Alternator Indicator
10 Seatbelt Warning Indicator
11 Low Fuel Indicator
12 Speedometer Gauge
13 Fuel Cut Off Indicator
14 Door Ajar Indicator
15 High Temperature Warning Indicator
16 Multifunction Dimming Switch
17 Trip Computer Switch
18 Throttle Fault Indicator
19 Traction Control Indicator (If fitted)
20 Odometer/Tripmeter display
21 Temperature Gauge
G86736 en 01/2003 2003.0 BA Falcon

XR Series

1 Hazard Switch 23 Average speed/Transmission display
2 ABS Multifunction Indicator 24 Airbag Warning Indicator
3 Security Indicator 25 Foglamps Indicator (If fitted)
4 Tachometer Gauge
5 Low Oil Warning Indicator
7 Park Brake Warning Indicator
8 High Beam Indicator
9 Alternator Indicator
10 Seatbelt Warning Indicator
11 Low Fuel Indicator
13 Fuel Cut Off Indicator
14 Door Ajar Indicator
15 High Temperature Warning Indicator
16 Multifunction Dimming Switch
17 Trip Computer Switch
18 Throttle Fault Indicator
19 Traction Control Indicator (If fitted)
20 Odometer/Tripmeter display
21 Temperature Gauge
22 Fuel Gauge
G86736 en 01/2003 2003.0 BA Falcon

High Series

1 Hazard Switch 23 Airbag Warning Indicator
2 ABS Multifunction Indicator 24 Foglamps Indicator (If fitted)
3 Security Indicator There are three basic levels of instrument cluster, low
4 Tachometer Gauge series, XR series and high series.
5 Low Oil Warning Indicator Vehicle options can dictate the operation of warning
indicators, and some warnings may be fitted, but will
not be illuminated.
7 Park Brake Warning Indicator Instrument clusters is not a serviceable part and
8 High Beam Indicator should be replaced in the event of a fault.
9 Alternator Indicator Refer to Wiring Diagram Section 413-01 for schematic
10 Seatbelt Warning Indicator and connector information.
11 Low Fuel Indicator Principles of Operation
The instrument cluster provides information to the
13 Fuel Cut Off Indicator driver in the form of gauges, warnings and indicators
14 High Temperature Warning Indicator and LCD displays. The instrument cluster uses both
15 Dim up Switch hard-wired interfaces and a CAN communication link
to other electronic modules in the vehicle.
16 Dim down Switch
17 Throttle Fault Indicator When the ignition switch is in the ON position with the
engine off the instrument cluster carries out a display
18 Traction Control Indicator (If fitted) test to verify that the warning/indicator lamps and
19 Odometer/Tripmeter display monitored systems are functioning correctly. The
20 Temperature Gauge warning indicators that illuminate during this display
test are:
21 Fuel Gauge
Anti-lock brake system (ABS) — If fitted
22 Average speed/Transmission display
Air bag system
G86736 en 01/2003 2003.0 BA Falcon

Charging system To change between the odometer, trip A of trip B

Brake warning indicator display modes, the odometer button is pressed. To
reset the trip A and trip B functions, the odometer
Low fuel indicator
button is pressed continually for 1 second with the
Low oil pressure respective trip (A or B) odometer display active is
High temperature indicator reset.
Throttle fault indicator Warning Indicators
Security indicator (3 seconds only)
Air Bag Warning Indicators
Instrument Cluster Gauges
The air bag warning indicator is hardwired to the air
Engine Temperature Gauge bag module. The airbag warning indicator is activated
if the input is connected to ground. Refer to Section
The instrument cluster receives engine temperature Section 502-20b.
information from the PCM to display on the
temperature gauge. If the data is missing or invalid for ABS Warning Indicator
more than 1 minute, the instrument cluster will move
the temperature gauge pointer to the cold position and The anti-lock brake system (ABS) warning indicator is
hardwired directly to the ABS module where fitted.
the high temperature warning light will be activated. A
The ABS warning indicator is activated if the input is
DTC will also be set to indicate this occurrence.
connected to ground. Refer to Section Section
Fuel Gauge 206-09.
The instrument cluster receives the fuel level signal Brake System Warning Indicator
from the fuel sender unit. This is a variable resistor.
The brake system warning indicator is hardwired
When the fuel level is low, the resistance is low, when
the fuel level is high the resistance is high. If a faulty directly to the master cylinder. The brake fail warning
will be activated if the input is connected to ground.
input signal is received, the fuel gauge will then
Refer to Section Section 206-00.
default to the empty position and the low fuel warning
indicator will flash after one minute. A DTC will also Alternator Warning Indicator
be set to indicate this occurrence. The fuel level input
signal is heavily dampened to allow for movement of The PCM controls the charging system and the
fuel in the tank when the ignition is in the ON position. alternator warning indicator. The PCM turns the lamp
The fuel gauge pointer will be moved to zero when off once the system is running, and illuminates it
the ignition is turned off. under fault conditions (including stall conditions).
REFER to Section 414-00. The alternator warning
Speedometer indicator is activated if the input is connected to
Vehicle speed data is received from the PCM. The ground.
PCM compensates for tyre size and axle ratio, and The High Beam Indicator
then outputs vehicle speed information to the
instrument cluster, which is then indicated in km/h on The high beam indicator is hardwired directly to the
the gauge. If there is no valid speed data received by light / Lever Combination switch. The high beam
the instrument cluster for 5 seconds, the speedometer indicator is activated if the input is is switched to
is set to zero and a failure mode DTC is set. supply.
Tachometer Hazard Switch, Left and Right Turn Signal

Indicators
The instrument cluster receives tachometer data from
the PCM. If there is no valid tachometer data received The instrument cluster controls the front, rear and side
by the instrument cluster for 5 seconds, the external indicators as well as the indicator warning in
tachometer is set to zero and a failure mode DTC is the instrument cluster. The inputs for the left and right
set. turn signal indicators are hardwired directly to the
Lever Combination switch. The input is switched to
Odometer supply to activate the signal. The instrument cluster
Distance traveled data is received from the PCM. The will then pulse both the external lamps and the
PCM compensates for tyre size and axle ratio and indicator warning in the instrument cluster at a normal
then outputs the distance traveled to the instrument rate. If a bulb out failure is detected, the flash rate will
cluster which calculats, and electronically displays this increase approx. three times and a DTC will be set to
information in the LCD display. indicate this condition.
In addition, there are 2 trip odometer functions The hazard button on the instrument cluster will
displayable on the LCD. activate the hazard warning, pulsing both the left and
right indicators simultaneously.
G86736 en 01/2003 2003.0 BA Falcon

Lights Indicator High Temperature Indicator

For high series instrument cluster variants, lights on The high temperature indicator is activated by the
indicator is displayed on the LCD to indicate that PCM. When the indicator is first illuminated, an
auto-headlights are have been activated. This audible warning is also activated. This audible
information is controlled by the BEM. warning is repeated every 60 seconds whilst the high
The park lights switch input is hardwired directly to the temperature condition remains.
instrument cluster. The park lights symbol will be Transmission Overheat Indicator
activated, along with an audible warning, if the ignition
is turned off whildt the lights are still on. This warning The transmission overheat indicator consists of the
will not occur when lamps are on with switch in auto high temperature indicator flashing in conjunction with
position (where fitted). the PRND display flashing. It is activated by the PCM.
Park Brake Indicator Transmission Fail Indicator
The park brake switch is hardwired directly to the Transmission fault is indicated with the flashing of the
instrument cluster. The park brake indicator is PRND display on the LCD. It is activated by the PCM.
activated when the park brake input is connected to
ground (Park Brake engaged).
Low Wash Indicator (where fitted)
The park brake indicator will flash and an audible The low wash indicator is located on the instrument
warning will sound if the park brake is on and the cluster LCD. It is activated by the BEM.
vehicle is moving at a speed of greater than 10km/hr. Seatbelt Indicator
The audible warning will last for 20 seconds.
The seatbelt indicator uses information hardwired
Throttle Fault Indicator from the Airbag module using Seatbelt/Airbag Audible
The throttle fault warning indicator is controlled by the input. Refer to Section 501-20a.
PCM module. There are 2 modes for the seatbelt indicator:
Traction Control Indicator 1. Basic Mode: The seatbelt indicator will be
activated when the ignition is turned on. The
The traction control indicator is controlled by the warning light will remain on for the first 3 seconds
traction control module. The traction control indicator regardless of seatbelt status. If the seatbelt is
is illuminated when the traction control is disabled. In unbuckled, the seatbelt warning light is turned on
the event of a TCS failure the traction control indicator for 8 seconds or until the seatbelt buckled input is
be also illuminated. The traction control indicator will activated, whichever occurs first.
flash to indicate a traction control event is currently in
2. Audible Warning Mode: The seatbelt indicator will
progress REFER to Section 206-09.
be activated when the ignition is turned on. The
Low Oil Pressure Warning Indicator warning light will remain on for the first 3 seconds
regardless of seatbelt status. If the seatbelt is
The oil pressure warning is controlled by the PCM. In unbuckled, the seatbelt warning light will stay on
the event of a low oil pressure event, an audible until the seatbelt is buckled. An audible seatbelt
warning will also be sounded. warning and synchronous flashing of the seatbelt
Low Fuel Warning Indicator warning light every 30 seconds will be activated if
the vehicle speed is detected to be more than
The fuel cut offindicator will illuminate when a fuel cut 5km/hr. It will continue until the seatbelt is buckled
out event has occured. It is a hard wired input, or until 5 minutes has elapsed, at which the
activated when switched to ground. warning will be disabled.
Fuel Cut off Indicator The Audible Warning Mode can be enabled or
disabled using the diagnostics command ’see
The low fuel warning indicator is controlled by the programmable options-variant information’ or with the
instrument cluster based on the information from the following procedure:
resistive fuel sender. If the damped value of the fuel
Buckle the seatbelt
sender input is less than approx. 10 litres, the fuel
warning indicator will be illuminated. Set the ignition to the on position without the
vehicle running (RPM < 400)
Door ajar indicator Press and hold the hazard switch
The high series variant has individual door ajar and Unbuckle, then buckle the seatbelt
boot ajar information displayed on the LCD. Other Release the hazard switch
variants have one warning lamp that is activated if any
of the doors/boot are ajar. Activation of the door ajar
indicators is controlled by the BEM.
G86736 en 01/2003 2003.0 BA Falcon

Security Indicator to hold that TRIP button for an additional second, all
resettable functions will be reset and the cluster will
The security indicator is activated for 3 seconds when emit 2 beeps.
the ignition is first turned to the ON position. The
security indicator is continually flashed when the HI Series
ignition is turned to the OFF position. This warning is HI Series clusters send this trip data information to the
attached by either PCM or BEM in the occurrence of a
ICC unit, control of displayed data is conducted with
security event.
the use of ICC mounted trip buttons.
Fog Lights Indication (where fitted)
Average Speed
The fog lamp indicator is activated by a hard-wired The average speed display indicates the average
connection to the fog lamp switch. The fog lamp speed since the last time that the average speed
indicator is activated if the input is connected to function was reset. It is calculated based on distance
supply. information received from the PCM via the CAN
Cruise Indication (where fitted) communication interface and time calculated internally
in the instrument cluster.
The cruise control information is displayed on the LCD
when requested by the PCM. If the cruise control is Travel Time
on, CRUISE is displayed. If the cruise control is active The travel time is the time in minutes since the last
CRUISE SET is displayed. travel time function was reset. It is calculated internal
PRND + 1234 Indication to the instrument cluster.
The PRND information is displayed in the LCD. In Range

addition, Adaptive and Performance modes are The range displays the estimated distance before the
indicated. For the high series vehicles, PERF is vehicle runs out of fuel. This estimation is based on
continually displayed when performance mode is the resistive fuel tank sender input, fuel usage
activated, with no display when in adaptive mode. For received from the PCM and the calculated fuel
other variants, the numbers of the board trip computer consumption based on recent driving style.
display on the LCD are replaced with AdP or PEF to
indicate adaptive and performance mode respectively. When the range reaches 80, 40, 20 or 0, an audible
warning is sounded.
General Operation
Average Economy
Dimming Operation The average economy, uses data since the last
The dimming for the vehicle interior is controlled average economy function was reset. The calculation
through the switches on the instrument cluster. is based on fuel usage and distance information, both
For the high series variants, there are dim up and dim received from the PCM.
down button, for LOW/XR variants, there is a single When car is stationary L/hr is displayed. When car is
dimming button that cycles through 4 fixed dimming detected to be moving, L/100km is displayed.
levels.
NOTE: Trip Computer functions are only updated
The instrument cluster has 2 dimming outputs to whilst engine is running.
control the illumination levels in other parts of the
vehicle. These outputs are switched to ground with a Audible Warnings
pulsed signal. The pulse width modulation for the
signal determines the illumination level. Buzzer Sounds
On Board Trip Computer Function Tone Duration
sequence
LOW/XR Series
Mode One beep 50 ms
The on board computer supplies the driver with Overspeed Three running 300ms for each
information for average speed, travel time, range, tones frequency
average economy and instantaneous economy trip
Airbag 1 beep per 500ms on, 200ms off
data. pulse train time @ 5Hz air bag
The information is displayed on the LH cluster LCD. detection signal
The trip computer display mode is cycled by pressing
Seatbelt 6 beeps, 250ms on, pause for
the TRIP button on the instrument cluster. Single repeated at 750ms between
beep is also emitted. It is possible to reset the
30s intervals beeps
average speed, travel time and average economy
functions by pressing and holding the TRIP button for
1 second while in the appropriate mode. By continuing
G86736 en 01/2003 2003.0 BA Falcon

Function Tone Duration

sequence
Door ajar Three beeps 400ms on, pause for
300ms between
beeps
Park brake Continuous for 500 ms on, 1 second
20 seconds off
High Five beeps at 300ms on, pause for
temperature 30 second 100ms between
intervals beeps
Low oil Four beeps 300ms on, pause for
after 5 second 100ms between
delay beeps
Low fuel Three beeps 300 ms on, pause for
Range repeated at 1s 100 ms between
intervals
Park lights Three beeps 300ms on, pause for
on repeated at 2s 200ms between
intervals beeps
Indicator / One beep 5 ms for the relay on
hazard sound and 5 ms for
the relay off sound
Buzzer Activation
Function Activation
Indicator / Indicator light is turned on
hazard
Mode Increase or decrease of overspeed
threshold, change of overspeed
function status
Overspeed Vehicle indicated speed becomes
greater than the Overspeed threshold
with the overspeed function activated
Airbag Airbag audible request activated
Seatbelt Refer Seatbelt and Airbag Audible
section
Door ajar Door ajar flags set when the car is
started (Revs over 350RPM)
Park brake Park brake input is active and vehicle
speed is more than 10 km/hr
High High temperature request flag on
temperature CAN is set the first time and every 1
minute
Low oil 5 seconds after low oil LED warning is
first activated
Low fuel Range decreases to 80, 40, 20 or 0
Park lights Park lights are on when the ignition is
on being switched off for 20 seconds.
Headlights fail flag set with ignition on
G86736 en 01/2003 2003.0 BA Falcon

Instrument Cluster activated and that all buttons on the cluster (Dim Up,
Dim Down (or Trip computer Mode switch - if fitted),
Inspection and Verification Hazard and Trip reset) are not pressed. Prior to
executing the self test, set continuous DTC’s should
A visual inspection of the vehicle cluster unit and be checked for and cleared. See DTC list for
various electrical connections should be made prior to explanation on codes that the cluster may return.
any detailed tests are performed.
1. To enter the instrument cluster self diagnostic
1. Verify the customer concern by operating the mode, Place the ignition and Parklights in the ON
system. position and select the Self test option on the
2. Visually inspect for obvious signs of mechanical WDS.
or electrical damage. 2. The self-test is deactivated after 5 seconds has
Ensure that battery terminal connection is well elapsed. During the self test, the ignition should
made. If loose / corroded, clean and be held in the ON position.
re-tighten. Any returned trouble codes should then be checked
Check general condition of cluster. Look for for using the WDS unit. Refer to the DTC list for
any physical signs of damage, that might be further actions.
cause of cluster problem. Tests performed during the self test (Duration 5
Check condition of cluster related fuses. seconds).
Visual Inspection Chart Test Performed On: Test Description
Mechanical Electrical Cluster LCD, dial, All Illumination Initiates to Off.
Damaged engine oil Fuse(s) External switch and Illumination values are then
filter Central junction box LCD Illumination progressively raised until the
Low engine oil level (CJB) fuse F30 (7.5A) maximum value is reached.
Engine coolant level CJB fuse F34 (7.5A) NOTE: May not be noticeable
Damaged coolant Circuit in daylight conditions.
thermostat LED(s) Speedometer, All Gauges initiate to minimum
Door adjustment Wiring harness
Tachometer, values. They are then swept
Loose or corroded
Temperature and to their full scale deflection
connector(s) Fuel gauge and back to minimum again.
Damaged instrument
cluster Warning LEDs All warning LEDs are initiated
to be Off. Each warning LED
3. If an obvious cause for an observed or reported is then activated one at a
concern is found, correct the cause (if possible) time, in a clockwise fashion.
Buzzer Buzzer sweep cycle is
4. Verify the following systems are working correctly sounded.
by operating the system.
See DTC List for further details and information
Charging
regarding DTC’s.
Fuel
Cooling
Module Configuration
Turn signals All new instrument clusters are defaulted with the
following information:
Headlamps
The continuous trouble codes should then be checked Odometer set to 0km
for using the WDS unit. See DTC list for explanation Sedan petrol fuel map
on codes that the cluster may return. Upon checking Police mode disabled
for previously set codes, the Self-diagnostic Mode Traction control fitted
should be entered.
Seatbelt audible reminder enabled
Self Tests The instrument cluster is a programmable module,
Diagnostic Self Test Mode which must be configured via the WDS. The WDS is
used to select appropriate data for the vehicle i.e., if
The Diagnostics self test provides an automated the cluster is replaced or any cluster options are to be
means of testing the cluster functionality, allowing the modified.
operator to check for correct operation in one easy
sequence. Faults detected by the cluster will be Data Extraction from existing Cluster:
recorded in the form of DTC’s, as detailed in the DTC If a cluster is to be replaced with a new unit,
section. It is important that for the duration of the test, depending on the condition of the existing cluster, the
the ignition is in the ON position, the Park Lamps are
G86737 en 01/2003 2003.0 BA Falcon

configuration data is read from the existing cluster and the gauge fails, the input (e.g. fuel sender) is
written to the new replacement cluster. checked for validity and user prompted with
further tests / pinpoint tests.
Place key in the ‘ON’ position and select
‘Programmable Module Installation’ on the WDS Button Test
Follow the text screens until successful This test will check for mechanical button problems
Place key in OFF position and install the within the cluster
replacement instrument cluster - See ‘Removal 1. User will be prompted to press each button, with
and Installation’ for details confirmation upon each press. (Stuck / non
Key in the ON position. Follow text screens until operational buttons detected). The cluster buttons
successful. tested are:
Once complete, verify correct operation. 1. Hazard Button
2. Trip Reset Button
Programmable Options:
3. Dim Up Button
Odometer: 4. Dim Down / Trip Computer Button
The odometer can be programmed using the WDS
unit by selecting ‘Update Odometer Value’ The Illumination Test
Odometer value can be programmed to any value This test will check for illumination problems within the
between 0km and 999,999km, providing the following cluster
conditions have been met:
1. Each Illumination channel driven to set levels with
The replacement cluster odometer value is less user confirmation.
than 100km
Multifunction Output Test — LCD / Warning
The replacement cluster has had its odometer set LED / Buzzer
less than three times
Once programmed, the replacement clusters This test will check the following:
odometer will immediately be updated (+0/-1) and a 1. Working LCD segments within the cluster
permanent (unerasable) DTC will be set if the 1. All segments (PRND, Odometer, Cruise, Trip
odometer was set to a value greater than 100km. Data, Overspeed and Low wash symbols)
enabled, then disabled, with user
Fuel Table: confirmation.
The fuel table map can be programmed using the 2. Software controllable LEDs within the cluster
WDS unit by selecting ‘Update Fuel’ options. Upon
selection, the technician will be prompted with 1. All software controllable warning LED’s
questions to determine the fuel table required. The enabled, then disabled, with user
appropriate map is then uploaded to the cluster. confirmation. If a LED fails, the user will be
guided through test to pinpoint the failure. The
Variant Information: LEDs controlled are:
Security Warning
The Variant Information can be programmed using the
WDS unit by selecting ‘Update Variant Information’ Park Brake Reminder
Seatbelt Reminder
option. Upon selection, the technician will be
Low Fuel Warning
prompted with a list of available options for the
replacement cluster. The technician should then High Temp Warning
Throttle Warning
select the appropriate options and upload the data.
Traction Control Warning
The options for the cluster include:
Door Ajar Warning
Traction Control Fitted - Only selected if the 2. Cluster hardwired LED’s NOT tested during
vehicle has a traction control unit fitted. this test include:
Seatbelt Audible Reminder Enabled - Set if user Fog Lights Reminder
requests the seatbelt audible reminder to be High Beam Reminder
enabled by default. Alternator Reminder
Brake Fail Warning
Functional Tests ABS Warning
Gauge Test Fuel Cut Off Warning
3. Buzzer operation within the cluster
This test will check for mechanical gauge problems
within the cluster 1. Buzzer sweep cycle engaged, with user
confirmation of operation.
1. Each gauge is swept / pointed to a particular
value, with user confirmation on gauge position. If
G86737 en 01/2003 2003.0 BA Falcon

Input and Data Test

This test will check for hard wired inputs to the cluster
1. User will be prompted with items to check and
data to verify
1. Park Lights
2. Park Brake
3. Left Turn / Right Turn Switch
4. Autolamps
2. Tests on input status will be conducted, with user
confirmation. Upon failure detected user will be
guided through further tests for that particular
failure.
This test will also check for data errors (Odometer,
Trip data, etc.)
3. User will be prompted with item to check,
verification of data and further tests to conduct will
be provided as required.
DTC Chart
Instrument Cluster Diagnostic Trouble Code (DTC) Index
Display Description Action

B1201 Fuel Sender Circuit Failure Conduct Functional Test: Gauge Test
Conduct Pinpoint Test: ‘Fuel Gauge Circuit Test’
B1342 ECU is faulted / EE checksum Internal data failure, disconnect power, wait 10
failure seconds and re-apply power. Run self test. If DTC
is still present, Conduct Functional Test: Data
Test.
B1499 Lamp Turn Signal Left Circuit Bulb out detected on Left Turn Circuit. Check
Failure bulbs, then conduct Functional Test: Input and
Data Test.
Conduct Pinpoint Test: ‘Turn Signal Input Test’
B1503 Lamp Turn Signal Right Circuit Bulb out detected on Left Turn Circuit. Check
Failure bulbs, then conduct Functional Test: Input and
Data Test.
Conduct Pinpoint Test: ‘Turn Signal Input Test’
B1579 Dim Panel Increase Input Circuit Dim Increase circuit failure or button stuck.
Failure Conduct Functional Test: Button Test.
B1583 Dim Panel Decrease Input Circuit Dim Increase circuit failure or button stuck.
B1875 Turn Signal / Hazard Switch Signal Hazard circuit failure or button stuck. Conduct
Circuit Failure Functional Test: Button Test.
B2675 Trip reset button stuck Trip reset Conduct Functional Test: Button Test.
circuit failure or button stuck.
B2680 Odometer Changed Permanent DTC indicating that Odometer has
been manually reset. - No Action Required
B2681 PRND Sender Failure Invalid PRND data detected, Conduct Functional
Test: Multifunction Output Test. Check PCM
PRND data
B2895 Trip Computer Mode Switch Circuit Trip computer circuit failure or button stuck.
G86737 en 01/2003 2003.0 BA Falcon

Display Description Action

B2896 Odometer Data Failure Internal odometer data failure, disconnect power,
wait 10 seconds and re-apply power. Run self test.
If DTC is still present, Conduct Functional Test:
Voltage Supply Test.
U1900 CAN Communication Bus Fault - Missing message from external module detected.
Receive Error Use WDS to diagnose module and check module
indicated for correct operation.
U2196 Invalid ‘Engine RPM’ data PCM output data failure. Check PCM module.
Conduct Functional Test: Gauge Test
U2197 Invalid ‘Vehicle Speed’ data PCM output data failure. Check PCM module.
U2198 Invalid ‘Fuel Pulse’ data PCM output data failure. Check PCM module.
U2199 Invalid ‘Engine Coolant PCM output data failure. Check PCM module.
Temperature’ data Conduct Functional Test: Gauge Test
U2200 Invalid ‘ODO Count’ data PCM output data failure. Check PCM module.
Conduct Functional Test: Input & Data Test.
Pid Chart
Parameter Name Description Data Type
CCNT Number of Continuous Trouble Codes Set DTC(s)
NTCSDT Number of Trouble Codes Set due to Diagnostic DTC(s)
Test
VBATT_VAL System Battery Voltage Value Volts
LCD_ILLUM LCD Illumination Level % duty cycle on time
PWM_ILLUM Illumination PWM value % duty cycle on time
PWM_DUTY1 PWM Duty Cycle #1 % duty cycle on time
PWM_DUTY2 PWM Duty Cycle #2 % duty cycle on time
ODO_M Odometer Kilometers
TRIP_MET Vehicle Trip Odometer - Metric Kilometers
TRIPB_MET Vehicle Trip Odometer - B - Metric Kilometers
TRIP_TIME Trip Minutes
FUEL_ECON Instantaneous Fuel Economy - Metric l/100km or l/hr
AVG_FUEL Average Fuel Economy - Metric l/100km or l/hr
VEH_SPD Vehicle Speed Kilometers / hour
TRIP_CMP Trip Computer Kilometers
FUEL_LEVEL Fuel Level Input % FULL
SPD_IND Speedometer Gauge Indicator Control KPH
TACH_IND Tachometer Gauge Indicator Control RPM
TEMP_IND Engine Temperature Gauge Pointer Place - Degrees Celsius
Degrees C.
FUEL_SNDR Fuel Sender Ohms
TEMP_GA Temperature Gauge % MAX
CLU_STAT ECU Operating States Default / Std. Diag Mode
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Parameter Name Description Data Type

TRANSGEAR Gear selected Unknown
Reverse
Forward Drive
Forward Drive 2
Forward Drive 3
Forward Drive 4
Forward Drive 5
Park
Drive "D"
Neutral
Invalid Data
DIMMER_S3 Dimmer Switch Input Status NO Keypress
Dimmer Switch
Illumination UP / Dimmer
Switch
Illumination DOWN
Illumination UP + DOWN
FUEL_MODE Fuel Economy Display Mode Litres per 100km
Litres per hr
LCD_DSPL LCD Segment Display On
Off
BEM_MSG BEM Missing Message —
CDU_MSG ACM Missing Message —
ABS_MSG ABS / TCS / IVD Missing Message —
PCM_MSG Powertrain Control Module Missing Message —
PARKBRAK Park Brake Applied Warning Lamp ON/OFF
TONE_REQ Tone request - Airbag fault warning ACTIVE/NON ACTIVE
RESETSW Reset Switch ACTIVE/NON ACTIVE
P_LMP_SW Park Lamps Switch ACTIVE/NON ACTIVE
HAZ_SW Hazard switch ACTIVE/NON ACTIVE
RT_SWITCH Right Turn Switch ACTIVE/NON ACTIVE
LT_SWITCH Left Turn Switch ACTIVE/NON ACTIVE
AUTOLMPSW Autolamp ON Switch ACTIVE/NON ACTIVE
SBLTMP Seat Belt Lamp Driver Output State ACTIVE/NON ACTIVE
MENU_SW Menu Switch ACTIVE/NON ACTIVE
HAZ_WARN Hazard Warning ACTIVE/NON ACTIVE
LMPONWRN Lamp ON ACTIVE/NON ACTIVE
AUD_WARN Audible warning ON ACTIVE/NON ACTIVE
LHS_CURNT * Left Hand Side Indicator Current Draw Amps.
*RHS_CURNT Right Hand Side Indicator Current Amps.
Draw
* Output current value only valid whilst globes are Cluster CAN Transmission Data
being driven.
Damped fuel level
CAN Data Information Instantaneous fuel input
The CAN interface facilitates the information transfer Fuel empty
between the electronic modules in the vehicle and
Fuel sender fail
provides a means for diagnostics interrogation.
Park lamps on
In normal operating conditions, with ignition activated,
the cluster will receive and transmit the following Park brake on
information. Auto headlamps input
Battery voltage level
G86737 en 01/2003 2003.0 BA Falcon

Switches illumination level Tx Module

LCD illumination level Central Overspeed active
Average Speed Display Unit Overspeed mode switch
(CDU)
Average Economy Mode Overspeed up switch
Average Economy Overspeed down switch
Travel Time Reset average speed
Range Reset average economy
Instantaneous Economy mode Reset trip time
Instantaneous Economy External LCD illumination on
Display DTE Body Front right door
Odometer Electrics Front left door
Module
Odometer overflow Rear right door
(BEM)
Rear left door
Cluster CAN Receive Data
Boot lid door
Tx Module Rear demist
Powertrain Engine RPM Low wash warning
Control Vehicle speed Headlamp fail
Module
(PCM) Coolant temperature Hazard flash request
Odometer count Security warning on
Fuel pulse Traction TCS warning
Oil pressure warning Control
Cruise warning System (TCS)
ETC warning
Flash security warning
Manual Transmission
Transmission mode
PRND
Transmission overheat
Transmission fail
Symptom Chart

ABS Warning Indicator always Circuit. Conduct Pinpoint Test ‘ABS warning
activated / inoperative ABS module Test’.
Instrument cluster.
Airbag warning always on. Circuit. Conduct Pinpoint Test ‘Airbag Warning
Airbag module Test’.
Instrument cluster.
Alternator Warning Indicator always Circuit. Conduct Pinpoint Test ‘Alternator
activated / inoperative Instrument cluster. Warning Test’.
Autolamps always activated / Circuit. Conduct Functional Test: Input & Data
inoperative Switch. Test.
Instrument cluster. Conduct Pinpoint Test ‘Autolamps
Indicator Test’.
Audio Illumination inoperative with Circuit - CAN wakeup. Conduct Pinpoint Test ‘CAN wakeup
ignition OFF CDU. Test’.
Instrument cluster.
Brake Fail Warning Indicator always Circuit. Conduct Pinpoint Test ‘Brake Fail
activated / inoperative Switch. Warning Test’.
Instrument cluster.
G86737 en 01/2003 2003.0 BA Falcon


Cruise Control Indication always on / Circuit / CAN. Conduct Functional Test: Multifunction
inoperative PCM. Output Test.
Instrument cluster.
Dimming Functionality inoperative Circuit. Conduct Functional Test: Button test

Instrument cluster Switch
Instrument cluster.
Door Ajar Indicator always on / Circuit / CAN. Conduct Functional Test: Multifunction
Instrument cluster.
Fog Lights Indicator always on / Circuit. Conduct Pinpoint Test ‘Fog Lights
inoperative Switch. Input Test’
Instrument cluster.
Fuel gauge indication incorrect Circuit / CAN - fuel used. Conduct Functional Test: Gauge Test.
Fuel pump module. Conduct Pinpoint Test ‘Fuel Gauge
Instrument cluster. Circuit Test’.
Fuel Cut Off Warning Always Activated Circuit. Conduct Pinpoint Test ‘Fuel Cut Off
Fuel Cut Off Unit. Test’.
Instrument cluster.
Hazards always activated / inoperative Circuit / CAN. Conduct Functional Test: Button Test.
Instrument cluster. Conduct Pinpoint Test ‘Turn Signal
Indicator Test’.
High Temperature Warning always on Circuit / CAN. Conduct Functional Test: Multifunction
/ inoperative PCM. Output Test.
Instrument cluster.
Illumination always on / inoperative Circuit. Conduct Functional Test: Input & Data
(Park Lights Input) Switch. Test.
Instrument cluster. Conduct Pinpoint Test ‘ParkLamps
Input Test’.
Fuel gauge inoperative/indication Circuit / CAN - fuel used. Conduct Functional Test: Gauge Test.
incorrect Fuel pump module. Conduct Pinpoint Test ‘Fuel Gauge
Instrument cluster. Circuit Test’.
Temperature gauge Circuit / CAN. Conduct Functional Test: Gauge Test
inoperative/indication incorrect Cylinder head temperature sensor
(CHT) or engine coolant temperature
sensor (ECT).
PCM.
Instrument cluster.
Indicator Left / Right Turn Signal Circuit. Conduct Functional Test: Input and
always activated / inoperative Switch. Data Test.
Instrument cluster. Conduct Pinpoint Test ‘Turn Signal
Indicator Test’.
Low Fuel Warning always on / Circuit. Conduct Functional Test: Multifunction
inoperative Fuel pump module. Output Test.
Instrument cluster. Conduct Pinpoint Test ‘Fuel Gauge
Circuit Test.
Low Oil Pressure Warning always on / Circuit / CAN. Conduct Functional Test: Multifunction
Instrument cluster.
Low Wash Indicator always on / Circuit / CAN. Conduct Functional Test: Multifunction
inoperative BEM. Output Test.
Instrument cluster.
Odometer / Trip Odometer not Circuit / CAN. Conduct Functional Test Input & Data
incrementing Instrument cluster. Test.
Odometer / Trip Odometer Reset Circuit. Conduct Functional Test: Button Test.
Switch inoperative Instrument cluster Switch
Instrument cluster.
G86737 en 01/2003 2003.0 BA Falcon


Odometer Error (OdOErr is displayed Circuit. Conduct Functional Test: Input & Data
on odometer Instrument cluster. Test.
On Board Computer inoperative Circuit. Conduct Functional Test: Button Test.

Instrument cluster Switch
Instrument cluster.
Park Brake Warning always on / Circuit. Conduct Functional Test: Multifunction
inoperative Switch. Output Test.
Instrument cluster. Conduct Pinpoint Test ‘Park Brake
Test’.
Seatbelt Indicator Warning always on / Circuit / CAN. Conduct Functional Test: Multifunction
inoperative Instrument cluster. Output Test.
Conduct Pinpoint Test ‘Seatbelt Input
Test’.
Security Indicator always on / Circuit / CAN. Conduct Functional Test: Multifunction
inoperative PCM / BEM. Output Test.
Instrument cluster.
The high beam indicator is inoperative Circuit. Conduct Pinpoint Test ‘High Beam
Switch. Indicator Test’.
Instrument cluster.
Speedometer is inoperative/indication Circuit / CAN. Conduct Functional Test: Gauge Test.
incorrect Vehicle speed sensor.
PCM
Instrument cluster.
Tachometer is inoperative/indication Circuit / CAN. Conduct Functional Test: Gauge Test
incorrect PCM.
Instrument cluster.
Throttle Fault Warning always on / Circuit / CAN. Conduct Functional Test: Multifunction
Instrument cluster.
Traction Control Warning always on / Circuit / CAN. Conduct Functional Test: Multifunction
inoperative TCS. Output Test.
Cluster Configuration.
Instrument cluster.
Transmission Fail Warning always on Circuit / CAN. Conduct Functional Test: Multifunction
PCM. Output Test.
Instrument cluster.
Transmission Overheat Warning Circuit / CAN. Conduct Functional Test: Multifunction
always on PCM. Output Test.
Instrument cluster.
PRND Indication inoperative Circuit / CAN. Conduct Functional Test: Multifunction

PCM. Output Test.
Instrument cluster.
Connector A - C171
G86737 en 01/2003 2003.0 BA Falcon


1A Illumination 5W output Pulse width modulated signal switched to ground
(from cluster) corresponding to the selected
illumination level. Less than 5 ohms between the
instrument cluster and illumination destination.
2A CAN low Serial CAN Communications. Less than 5 ohms
between the instrument cluster and diagnostic
connector / surrounding CAN controlled modules.
3A CAN high Serial CAN Communications. Less than 5 ohms
between the instrument cluster and diagnostic
connector / surrounding CAN controlled modules.
4A Fog Lights 0 Voltage with the Fog Lights switch in the OFF
position, Greater than 10 volts with the Fog
Lights switch in the ON position. Less than 5
ohms between the instrument cluster and the
Fog Lamps switch. Greater than 10,000 ohms
between the instrument cluster and ground.
6A Ground 0 Voltage, Less than 5 ohms to chassis Ground
7A Seatbelt/Airbag audible 0 Voltage, Less than 5 ohms between the
Instrument Cluster and Airbag Module. Greater
than 10,000 ohms between the Airbag Module
and ground.
8A Fuel Cut Off 0 Voltage, Less than 5 ohms between the
Instrument Cluster and Fuel Cut Off Switch.
Greater than 10,000 ohms between the Fuel Cut
Off Switch and ground.
9A High beam 0 Voltage with High Beam Multifunction Switch in
the OFF position and greater than 10 volts in the
ON turn position. Less than 5 ohms between the
instrument cluster and the multifunction switch.
Greater than 10,000 ohms between the
instrument cluster and ground.
10A Park lights on 0 Voltage with Park Lamps Multifunction Switch
in the OFF position and greater than 10 volts in
the ON turn position. Less than 5 ohms between
the instrument cluster and the multifunction
switch. Greater than 10,000 ohms between the
11A Auto headlamps 0 Voltage with Auto Headlamps Multifunction
Switch in the OFF position and greater than 10
volts in the ON turn position. Less than 5 ohms
between the instrument cluster and the
multifunction switch. Greater than 10,000 ohms
12A Park brake 0 Voltage, Less than 5 ohms between the
Instrument Cluster and Park Brake. Greater than
10,000 ohms between the Park Brake and
ground.
13A Petrol input 0 voltage, Variable resistance between the
instrument cluster and fuel ground return pin,
from 40 to 280 ohms, depending on the fuel tank
and fuel level. Less than 5 ohms between the
instrument cluster and fuel sender connector pin.
14A Fuel ground return 0 voltage, Less than 5 ohms between the
Instrument Cluster and fuel sender connector
pin.
G86737 en 01/2003 2003.0 BA Falcon


15A Ignition 0 Voltage with key OFF, Greater than 10 volts
with key ON. Greater than 10,000 ohms between
16A Battery Greater than 10 volts with key ON or OFF.
17A Left indicator switch 0 Voltage with turn indicator in the OFF position
and greater than 10 volts in the LH turn position.
Less than 5 ohms between the instrument cluster
and the multifunction switch. Greater than 10,000
ohms between the instrument cluster and
ground.
18A Right indicator switch 0 Voltage with turn indicator in the OFF position
and greater than 10 volts in the RH turn position.
Less than 5 ohms between the instrument cluster
and the multifunction switch. Greater than 10,000
ground.
19A Illumination 25W output Pulse width modulated signal switched to ground
(from cluster) corresponding to the selected
illumination level . Less than 5 ohms between
the instrument cluster and illumination
destination.
Connector B - C171

1B Airbag 0 voltage, Less than 5 ohms between the
Instrument Cluster and Airbag module.
2B Brake fail 0 voltage, Less than 5 ohms between the
Instrument Cluster and ABS module.
3B Indicators supply Greater than 10 volts with key ON or OFF.
4B Right indicator output 0 Voltage with turn indicator in the OFF position.
Alternating between 0 and 10+ volts (from
cluster) in the RH turn position. Less than 5
external indicator globes. Greater than 10,000
ground.
5B CAN wakeup 0 voltage, Less than 5 ohms between the
Instrument Cluster and CDU - CAN wakeup
modules.
6B ABS 0 voltage, Less than 5 ohms between the
Instrument Cluster and ABS module.
G86737 en 01/2003 2003.0 BA Falcon


7B Alternator fail 0 voltage, Less than 5 ohms between the
Instrument Cluster and Alternator module.
8B Left indicator output 0 Voltage with turn indicator in the OFF position.
Alternating between 0 and 10+ volts (from
cluster) in the LH turn position. Less than 5 ohms
between the instrument cluster and external
indicator globes. Greater than 10,000 ohms
Pinpoint Tests
PINPOINT TEST A : VOLTAGE SUPPLY TEST

A1 TEST BATTERY VOLTAGE
Go to A2
Use the Multimeter in the MDS, measure the voltage between the TEST BATTERY VOLTAGE SUPPLY TO THE
Battery (+) pole and ground. CLUSTER.
Is the voltage result obtained within a valid range (11.5 - 13v) ?
No
Check battery / charging circuit. Continue once
valid voltage is obtained.
A2 TEST BATTERY VOLTAGE SUPPLY TO THE CLUSTER

Go to A3
Disconnect Instrument cluster Connector A. TEST IGNITION VOLTAGE AT CLUSTER.
Using a digital Multimeter, measure the voltage between Pin 16 of
connector B (harness side)and ground. No
Check fuse / power HARNESS to cluster.
Is the voltage within a valid range (11.5 - 14.5v)?
A3 TEST IGNITION VOLTAGE AT CLUSTER

Key in ON position (Engine not running). Yes
Disconnect, Check and Re-connect both cluster
Using a digital Multimeter, measure the voltage between connector A, connectors.
pin 15 (harness side) and ground. If fault is found repair and re-test instrument
Is the voltage within a valid range (11.5 - 13v)? cluster.
If still non-operational, contact service center for
cluster replacement authorization.
If granted, install a new Instrument Cluster. See
Removal and Installation and Module
Configuration for details.
TEST the system for normal operation. If
problem still exists, place the original cluster
back to the vehicle.
No
Check fuse / power HARNESS to cluster.
G86737 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : FUEL GAUGE CIRCUIT TEST
B1 CHECK FUEL GAUGE CIRCUIT

Disconnect Fuel Pump Module (Refer to section Section 310-00).
Key in ON position.
Enter the Instrument cluster Fuel Sender Input Value (ohms) menu in
the MDS.
With Fuel Sender input in an open circuit state, Check that the fuel
sender resistance indicated by the WDS is greater than 250 ohms. If it
is less than 250 ohms, go to EDS section and check harness.
On the harness side, short Fuel Sender pin to its ground pin.
Is the resistance indicated by the WDS less than 10 ohms? If it is not
less than 10 ohms, go to EDS section and check harness.
Check fuel sender (Refer to section Section 310-00), Investigate fuel
sender module for normal operation.
PINPOINT TEST C : AIRBAG WARNING TEST
C1 CHECK AIRBAG INPUT RESISTANCE

Check Airbag Module.
Disconnect Instrument cluster Connector B.
Key in ON Position. Start Car. Wait 5 seconds for modules to No
initialize. Execute ‘Voltage Supply’ pinpoint test and
re-test the system for normal operation.
Using a digital Multimeter, measure the resistance between
Instrument cluster Connector B pin 1 (harness side) and ground.
PINPOINT TEST D : ABS WARNING TEST

D1 CHECK ABS INPUT RESISTANCE
Check ABS Module.
Disconnect Instrument cluster Connector B (070).
initialize. Key in Off Position. Check and Re-connect
Connector, Place Key in ON position. Start Car.
Using a digital Multimeter, measure the resistance between Wait 5 seconds for modules to initialize. Check
Instrument cluster Connector B pin 6 (harness side) and ground. ABS Warning. If still active, Execute ‘Voltage
Is the resistance less than 5 ohms? Supply’ pinpoint test and re-test the system for
normal operation.
G86737 en 01/2003 2003.0 BA Falcon

PINPOINT TEST E : BRAKE FAIL WARNING TEST
E1 CHECK BRAKE FAIL INPUT RESISTANCE

Check ABS Module.
Instrument cluster Connector B pin 2 (harness side) and ground. Brake Fail Warning. If still active, Execute
Is the resistance less than 5 ohms? ‘Voltage Supply’ pinpoint test and re-test the
PINPOINT TEST F : ALTERNATOR WARNING TEST
F1 CHECK ALTERNATOR INPUT RESISTANCE

Check Charging system.
Instrument cluster Connector B pin 7 (harness side) and ground. Alternator Warning. If still active, Execute
Is the resistance less than 5 ohms? ‘Voltage Supply’ pinpoint test and re-test the
PINPOINT TEST G : HIGH BEAM INDICATOR TEST
G1 CHECK FOR HIGH BEAM VOLTAGE

Key in Off Position. Check and Re-connect
Disconnect Instrument cluster Connector A. Connector, Place Key in ON position. Place the
Key in ON position. headlamp switch to HIGH beam position. If still
inoperative, Execute ‘Voltage Supply’ pinpoint
Turn the Headlamp switch to HIGH beam position. test and re-test the system for normal operation.
Using a digital Multimeter, measure the voltage between the
Instrument cluster Connector A, Pin 9 (harness side) and ground. No
Is the voltage greater than 10 volts? operation.
G86737 en 01/2003 2003.0 BA Falcon

PINPOINT TEST H : PARK BRAKE TEST
H1 CHECK PARK BRAKE INPUT RESISTANCE

Engage Park Brake. If the resistance less than 5
Disconnect Instrument cluster Connector A. ohms, Key in OFF Position. Check and
Key in ON Position. Re-connect Connector, Place Key in ON
position. Check Park Brake Warning. If still not
Disengage Park Brake. functioning, Execute ‘Voltage Supply’ pinpoint
Using a digital Multimeter, measure the resistance between test and re-test the system for normal operation.
Instrument cluster Connector A pin 12 (harness side) and ground. Otherwise, Check harness connection in EDS
Take note of the resistance. section.
Is there an open circuit? No

Check harness connection in EDS section.
PINPOINT TEST I : THE TURN SIGNAL INDICATOR TEST
I1 TEST FOR VOLTAGE AT INSTRUMENT CLUSTER

INDICATOR INPUT
NOTE: Prior to executing test, Visually check individual globes for Yes
operation. If non operational globe is found, replace and re-test. For Left Indicator, Go to I2. CHECK LEFT HAND
TURN SIGNAL INPUT.
Key in OFF position. For Right Indicator, Go to I4. CHECK RIGHT
HAND TURN SIGNAL INPUT. (Note: Conduct
Disconnect Instrument cluster Connector B. both tests if required.)
Key in ON position.
No
Using a digital Multimeter, measure the voltage between the Check Indicator supply fuse and HARNESS.
Instrument cluster Connector B pin 3 (harness side) and ground.
I2 CHECK LEFT HAND TURN SIGNAL INPUT

Go to I3. TEST FOR VOLTAGE AT
Disconnect Instrument cluster Connector A. INSTRUMENT CLUSTER INDICATOR
Key in ON position. OUTPUT.
Using a digital Multimeter, measure the voltage between the No
Instrument cluster Connector A pin 17 (harness side) and ground. Check Indicator lever and harness.
Place the turn signal switch in the Left hand Indicator position, then
the Off Position.
Is the voltage greater than 10 volts when in Left Position and 0v
when in Off?

INDICATOR OUTPUT
Ensure all cluster connectors are securely fastened and place key in Yes
ON position. No fault found in the LEFT HAND TURN
SIGNAL indicator circuit.
Using a digital Multimeter, measure the voltage output to the left
indicator bulbs harness. (Refer to EDS manual for details). No
Place the turn signal switch in the Left hand Indicator position. Check harnesses, if error remains, execute
‘Voltage Supply’ pinpoint test and re-test the
Does the voltage pulse to greater than 10 volts and then to 0v, In system for normal operation.
time with the flash indicator?
G86737 en 01/2003 2003.0 BA Falcon


I4 CHECK RIGHT HAND TURN SIGNAL INPUT
NOTE: Prior to executing test, Visually check individual globes for Yes
operation. If non operational globe is found, replace and re-test. Go to I5. TEST FOR VOLTAGE AT
INSTRUMENT CLUSTER INDICATOR
Key in OFF position. OUTPUT.
Disconnect Instrument cluster Connector A. No

Key in ON position. Check Indicator lever and harness.
Using a digital Multimeter, measure the voltage between the

Instrument cluster Connector A pin 18 (harness side) and ground.
Place the turn signal switch in the Left hand Indicator position and
then the Off position.
Is the voltage greater than 10 volts when in Right Position and 0v
when in Off?

INDICATOR OUTPUT
Ensure all cluster connectors are securely connected and place key in Yes
ON position. No fault found in the RIGHT HAND TURN
SIGNAL indicator circuit.
Using a digital Multimeter, measure the voltage output to the right
indicator bulbs harness. (Refer to EDS manual for details). No
Place the turn signal switch in the Right hand Indicator position. Check harnesses, if error remains, execute
‘Voltage Supply’ pinpoint test and re-test the
Does the voltage pulse to greater than 10 volts and then to 0v, In system for normal operation.
time with the flash indicator?
PINPOINT TEST J : AUTOLAMPS INDICATOR TEST
J1 TEST OPERATION OF AUTOLAMPS

With Autolamps activated, Is there an open
Disconnect Instrument cluster Connector A. circuit? if yes, Execute ‘Voltage Supply’ pinpoint
Cover up the photo (light) sensor, see EDS section for details. test and re-test the system for normal operation.
Otherwise, Check HARNESS and Autolamps
Key in ON position. switch.
Using a digital Multimeter, measure the resistance between the
Instrument cluster Connector A pin 11(harness side) and ground, No
Whilst activating and de-activating the Autolamps switch. Check HARNESS and Autolamps switch.
With Autolamps de-activated, Is the resistance less than 5

ohms?
G86737 en 01/2003 2003.0 BA Falcon

PINPOINT TEST K : PARKLAMPS INPUT TEST
K1 TEST OPERATION OF PARKLAMPS HARNESS

Execute ‘Voltage Supply’ pinpoint test and
Disconnect Instrument cluster Connector A. re-test the system for normal operation.
Key in ON position.
No
Activate the Park Lamps switch. Using a digital Multimeter, measure Check HARNESS and Autolamps switch.
the voltage between the Instrument cluster Connector A, Pin 10
(harness side) and ground. Take note of this voltage.
De-activate the Park Lamps switch. Using a digital Multimeter,
measure the voltage between the Instrument cluster Connector A, Pin
10 (harness side) and ground. Take note of this voltage.
With Park Lamps activated, Was the voltage greater than 10 volts
and less than 1 volt with Park Lamps de-activated?
PINPOINT TEST L : SEATBELT INPUT TEST
L1 CHECK SEATBELT RESISTANCE

Remove seatbelt. If the resistance greater than
Disconnect Instrument cluster Connector A. 5 ohms, Key in OFF Position. Check and
Key in ON Position. Start Car. Wait 5 seconds for modules to Re-connect Connector, Place Key in ON
initialize. position. Start Car. Wait 5 seconds for modules
to initialize. Check Seatbelt warning. If still not
Using a digital Multimeter, measure the resistance between functioning, Execute ‘Voltage Supply’ pinpoint
Instrument cluster Connector A pin 7 (harness side) and ground. test and re-test the system for normal operation.
Insert Seatbelt. Otherwise, Check seatbelt harness and Module.
Is the resistance less than 5 ohms? No

Check seatbelt harness and Module.
PINPOINT TEST M : FOG LIGHTS INPUT TEST
M1 CHECK FOR FOG LIGHTS INPUT VOLTAGE

If the voltage less than 1 volt when the Fog
Disconnect Instrument cluster Connector A. Lamps are de-activated, Key in Off Position.
Key in ON position. Check and Re-connect Connector, Place Key in
ON position. Check for Fog Lamp Functionality.
Activate the Fog Lights switch. Using a digital Multimeter, measure If still inoperative, Execute ‘Voltage Supply’
the voltage between the Instrument cluster Connector A, Pin 4 pinpoint test and re-test the system for normal
(harness side) and ground. Take note of this voltage. operation. Otherwise, REPAIR the circuit. TEST
De-activate the Fog Lights switch. Using a digital Multimeter, measure the system for normal operation.
the voltage between the Instrument cluster Connector A, Pin 4
(harness side) and ground. Take note of this voltage. No
REPAIR the circuit / Fog Light switch. TEST the
Is the voltage greater than 10 volts when the Fog Lamps are system for normal operation.
activated?
G86737 en 01/2003 2003.0 BA Falcon

PINPOINT TEST N : ILLUMINATION OUTPUT TEST
N1 TEST OPERATION OF CLUSTER ILLUMINATION

OUTPUTS
NOTE: Prior to executing test, Check fuses relating to the illumination Yes
circuit under test. If non operational fuse is found, replace and re-test. Check illumination section of the CDU.
NOTE: The access points for testing the illumination outputs of the No
Cluster is assessable at the connector end of the CDU unit. Please refer to Check harness (Refer EDS section). If harness
the Pin Point test section of the CDU for details. connectivity correct, Execute ‘Voltage Supply’
pinpoint test and re-test the system for normal
NOTE: The signal from the Cluster for the illumination is by means of operation.
Pulse Width Modulation (PWM) and to instigate this signal for the CDU,
follows the steps below:
Key in ON position.
Activate the Park Lights switch.
Use WDS oscilloscope section to measure the PWM output from the
Cluster at the CDU / Switch side of the harness. See EDS section for
details.
Change the brightness and observe the PWM waveform on the WDS.
Is there any changes on the PWM output ?
PINPOINT TEST O : FUEL CUT OFF TEST
O1 OPEN CIRCUIT TEST

Go to O2
Disconnect harness from the Fuel Cutoff sender.
Key in ON position. No
Check harness of the EDS section.
Is the Fuel Cutoff LED switched off?
O2 TEST CONT.
Short the Fuel Cutoff pin at the sender end of the connector to Yes
ground. Circuit is working correctly.
Is the Fuel Cutoff LED switched on when the pin is shorted to No
ground? Check harness of the EDS section and the Fuel
Cutoff circuit.
PINPOINT TEST P : CAN WAKEUP TEST

P1 CHECK CAN WAKEUP INPUT
Check harness and CDU.
Disconnect connector B.
Using a Multimeter to measure the voltage at pin 5 of connect B No
(Cluster Side). Execute ‘Voltage Supply’ pinpoint test and
re-test the system for normal operation.
Is the voltage reading greater than 10Volts?
G86737 en 01/2003 2003.0 BA Falcon

Instrument Cluster 4. Remove the two lower screws.

Removal
1. Drop leaver and move steering column down.
5. Disconnect the two wiring connectors and

carefully remove cluster unit.
2. Pull rubber back to expose the two screw

locations.
Installation
1. Reverse the Removal procedure.
3. Remove the three upper screws.
G86738 en 01/2003 2003.0 BA Falcon

413-06-1 Horn 413-06-1
SECTION : 413-06 Horn

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................413-06-2
Horn ......................................................................................................................................413-06-3
Horn ......................................................................................................................................413-06-4
Symptom Chart ....................................................................................................................413-06-4
Pinpoint Tests ......................................................................................................................413-06-4
Horn ......................................................................................................................................413-06-8
01/2003 2003.0 BA Falcon

413-06-2 Horn 413-06-2
SPECIFICATIONS
Description Nm
Screw M6X18 Taptite 8
G73347 en 01/2003 2003.0 BA Falcon

413-06-3 Horn 413-06-3
Horn
Low series vehicles are fitted with one low note horn,
whilst high series vehicles are fitted with a pair of
tuned horns. One has a high pitch tone and the other
has a low pitched tone.
The horn mylar switch pad is incorporated in the
steering wheel pad providing a large contact
area.When pressed the horn switch pad completes
the circuit to the horns.
The horn system consists of the following
components:
steering wheel pad horn switch
horns
horn relay
The steering wheel pad horn switch is part of the
driver side air bag module. For additional information,
refer to Section 501-20b.
G86736 en 01/2003 2003.0 BA Falcon

413-06-4 Horn 413-06-4
Horn Inspection and Verification

Refer to Wiring Diagram Section 413-06 for schematic 1. Verify the customer concern.
and connector information. 2. Visually inspect for the following obvious signs of
mechanical and electrical damage:
Special Tool(s) Visual Inspection Chart
73III Automotive Meter Mechanical Electrical
105-R0057 or equivalent Horn(s) Central junction box
Horn relay (CJB) fuse.
Steering wheel pad Circuitry
horn switch
3. If the fault is not visually evident, verify the
symptom and proceed to the Symptom Chart.
Symptom Chart

The horn does not sound Loose connections at horn button Go to PinPoint Test A.
contact.
Open wire from horn to horn button.
Open wire from fuse box to horn
button.
Horns defective or out of adjustment.
Fuse burned out.
The horn sounds continuously Horn button defective. Go to PinPoint Test B.

One horn fails to operate (if dual horm Broken or loose wire to the horn. Go to PinPoint Test C.
is fitted). Horn defective or out of adjustment
Pinpoint Tests
PINPOINT TEST A : THE HORN DOES NOT SOUND
A1 CHECK POWER SUPPLY TO HORN RELAY

Disconnect Horn Relay. Yes
Go to A2.
Measure the voltage between horn relay [Circuit 1], harness side and
ground; and between the horn relay [Circuit 385], harness side and No
ground. REPAIR the circuit. TEST the system for normal
Are the voltages greater than 10 volts? operation.
A2 CHECK HORN RELAY

Test the horn relay. Yes
Go to A3.
Is the horn relay OK?
No
INSTALL a new horn relay. TEST the system for
normal operation.
G86737 en 01/2003 2003.0 BA Falcon

413-06-5 Horn 413-06-5

A3 CHECK STEERING WHEEL PAD HORN SWITCH
SIGNAL TO HORN RELAY
Measure the resistance between the horn relay [Circuit 1], harness Yes
side and ground under the following conditions: Go to A4.
No
Steering Wheel Pad Horn Resistance Go to A5.
Switch Position
Pressed Less than 5 ohms
Released Greater than 10,000 ohms
Are the resistances correct?
A4 CHECK CIRCUIT BETWEEN HORN RELAY AND HORN

Disconnect Horn(s). Yes
INSTALL a new horn, REFER to Horn in this
Measure the resistance between the horn relay [Circuit 1A], harness section. TEST the system for normal operation.
side and the LH horn, circuit 1B, harness side or the RH horn , circuit
1C, harness side; and between the horn relay [Circuit 1A], harness No
side and ground. REPAIR the circuit. TEST the system for normal
Is the resistance less than 5 ohms between the horn relay and operation.
the horns and greater than 10,000 ohms between the horn relay
and ground?
A5 CHECK CIRCUIT BETWEEN HORN RELAY AND AIR

BAG SLIDING CONTACT
Disconnect the clockspring. For removal instructions for closkspring, Yes
Section 211-04. Go to A6.
Measure the resistance between the clockspring, circuit 1B, harness No
side and the horn relay [Circuit 4], harness side. REPAIR the circuit. TEST the system for normal
Is the resistance less than 5 ohms? operation.
A6 CHECK THE STEERING WHEEL PAD HORN SWITCH

Deactivate the air bag system. Refer to Section 501-20b . Yes
INSTALL a new air bag sliding contact, REFER
Disconnect Steering Wheel Pad Horn Switch Harness. to Section 501-20b. TEST the system for normal
Measure the resistance between the between the steering wheel pad operation.
horn switch harness, circuit 57CH, harness side and ground under the
following conditions: No
INSTALL a new driver side air bag module,
REFER to Section 501-20b. TEST the system
Steering Wheel Pad Horn Resistance for normal operation.
Switch Position
G86737 en 01/2003 2003.0 BA Falcon

413-06-6 Horn 413-06-6
PINPOINT TEST B : THE HORN SOUNDS CONTINUOUSLY
B1 CHECK HORN CIRCUIT

REPAIR circuit 1A. TEST the system for normal
Disconnect Horn Relay. operation.
Does the horn continue to sound?
No
Go to B2.
B2 CHECK HORN RELAY

Test the Horn Relay. Yes
REINSTALL the horn relay. Go to B3.
Is the horn relay OK?
No
INSTALL a new horn relay. TEST the system for
normal operation.
B3 CHECK CIRCUIT
Disconnect the clockspring. Yes
If equipped with anti-theft, Go to B4. Otherwise,
Does the horn continue to sound? REPAIR the circuit. TEST the system for normal
operation.
No
Go to B5.
B4 CHECK BEM INPUT

Disconnect BEM. Yes
REPAIR circuit 1A. TEST the system for normal
Does the horn continue to sound? operation.
No
REFER to Section 419-10. TEST the system for
normal operation.
B5 CHECK STEERING WHEEL PAD HORN SWITCH

Deactivate the air bag system. Refer to Section 501-20b . Yes
INSTALL a new air bag sliding contact, REFER
Disconnect Steering Wheel Pad Horn Switch Harness.
to Section 501-20b . TEST the system for
Measure the resistance between the steering wheel pad horn switch normal operation.
harness, circuit 57CH, harness side and ground under the following
conditions: No
INSTALL a new driver side air bag module,
REFER to Section 501-20b . TEST the system
Steering Wheel Pad Horn Resistance for normal operation.
Switch Position
G86737 en 01/2003 2003.0 BA Falcon

413-06-7 Horn 413-06-7
PINPOINT TEST C : ONE HORN FAILS TO OPERATE
C1 CHECK HORN 1 FOR OPERATION

Disconnect Horn 2 from wiring harness Yes
Go to C4
Depress horn pad on sterring wheel
Does horn 1 sound? No
Go to C2
C2 CHECK POWER WIRE ON HORN 1

Remove horn relay Yes
Go to C3
Measure resistance of circuit 1A-1B
Is resistance <5 ohms? No
There is a break in the wire. Repair harness and
C3 CHECK EARTH WIRE FROM HORN 1

Remove Horn 1 Yes
Horn must be faulty. Replace horn and retest for
Measure resistance of circuit 57AF to ground correct operation.
Is resistance <5 ohms?
No
C4 CHECK HORN 2 FOR OPERATION

Disconnect Horn 1 from wiring harness Yes
Horn is operating correctly.
Reconnect Horn 2 to wiring harness
Depress horn pad on sterring wheel No
Go to C5
Does horn 2 sound
C5 CHECK POWER WIRE TO HORN 2

Remove horn relay Yes
Go to C6
Measure resistance of circuit 1A-1C
Is resistance <5 ohms? No
C6 CHECK EARTH WIRE FROM HORN 2

Remove Horn 2 Yes
Horn must be faulty. Replace horn and retest for
Measure resistance of circuit 57AG to ground correct operation.
Is resistance <5 ohms?
No
G86737 en 01/2003 2003.0 BA Falcon

413-06-8 Horn 413-06-8
Horn
Removal
1. Remove the grille from between the headlamps.
2. Disconnect the electrical connector(s) .
3. Remove the horn and bracket assembly(s).
2. Remove the nut.
3. Remove the horn.
G73350 en 01/2003 2003.0 BA Falcon

413-07-1 Clock 413-07-1
SECTION : 413-07 Clock

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................413-07-2
Clock .....................................................................................................................................413-07-3
Clock .....................................................................................................................................413-07-4
Symptom Chart ....................................................................................................................413-07-4
Pinpoint Tests ......................................................................................................................413-07-4
Clock .....................................................................................................................................413-07-6
01/2003 2003.0 BA Falcon

413-07-2 Clock 413-07-2
SPECIFICATIONS
Time keeping accuracy Better than 5 seconds
variation per day
Fixings Inter-locking tabs plus
two clips
G73347 en 01/2003 2003.0 BA Falcon

413-07-3 Clock 413-07-3
Clock
To adjust the time displayed, press and hold the left
button (to turn the clock backwards) or the right button
(to turn the clock forwards).
Press momentarily for fine adjustment, or press and

hold for fast adjustment.
G86736 en 01/2003 2003.0 BA Falcon

413-07-4 Clock 413-07-4
Clock
Mechanical
Two clips fully engaged
Interlocking fingers properly engaged
Margins are consistant
Electrical connector connected
Symptom Chart

Illumination not working Wiring fault Go to PinPoint Test A
Cluster fault
Clock fault
Clock not working at all Wiring fault Go to PinPoint Test B

Clock fault
Clock gains / looses time Clock fault Go to PinPoint Test C

Clock minute hand turns at seconds Clock fault - loss of calibration Replace Clock
speed
Clock set buttons not working. Wiring fault Go to PinPoint Test B

Clock fault
Pinpoint Tests
PINPOINT TEST A : ILLUMINATION TEST
A1 CONTROLS CHECK
Turn ignition on. Yes
Functioning correctly
Turn Park Lamps on.
Vary the illumination controls on the IC. No
Go to A2
Does the illumination change?
A2 CONTROLS CHECK CONT.

Yes
Go to A3
Does the IC display illumination vary.
No
Refer to IC diagnostics.
A3 CORRECT CONNECTION CHECK

Remove Clock from Instrument panel. Yes
Go to A4
Is the connector fully engaged?
No
Engage connector and check functionality. Go to
A1 if necessary.
G86737 en 01/2003 2003.0 BA Falcon

413-07-5 Clock 413-07-5

A4 VOLTAGE CHECK
Disconnect Clock. Yes
Replace Clock.
Connect multimeter to pin ?? of Clock wiring connector and measure
voltage while varying IC illumination control switches. No
Does the voltage vary? Go to B1
PINPOINT TEST B : CLOCK NOT WORKING

B1 CORRECT CONNECTION
Remove Clock from Instrument panel. Yes
Continue.
Is the connector fully engaged ?
No
Engage connector and check functionality. Go to
B2 if still not functioning.
B2 VOLTAGE CHECK
Disconnect Clock. Yes
Replace clock.
Set multi meter to measure 12 volts and connect multimeter across
pins. No
For (Y-B) and (B-LG) wires of Clock wiring connector and measure Check wire integrity.
voltage.
Is 12 volts present.
PINPOINT TEST C : CLOCK LOSING / GAINING TIME
C1 VOLTAGE CHECK
Yes
Continue.
Is battery voltage above 12 volts?
No
Refer batter service.
C2 CLOCK CONDITION
Yes
Replace clock.
Does clock loose / gain more than five seconds every 24 hours?
No
Clock functioning correctly.
G86737 en 01/2003 2003.0 BA Falcon

413-07-6 Clock 413-07-6
Clock
Removal
1. To remove the analogue clock, gently slide a flat
blade item ( eg. large screw driver) into the rear
margin, closest to the windscreen, and pry the
clock panel upwards to disengage the two clips.
2. Rotate this end up to disengage the interlocking

fingers attaching the clock panel to the air register
panel.
Installation
1. To install the clock, first make the electrical
connection.
2. Ensure clock functions and illumination varies.
3. Ensure all interlocking fingers are aligned and
rotate the clock panel down wards to drive the
panel home and engage the two clips.
G73350 en 01/2003 2003.0 BA Falcon

413-08-1 Interior Command Centre 413-08-1
SECTION : 413-08 Interior Command Centre

CONTENTS PAGE
Interior Command Centre .....................................................................................................413-08-2
ICC Handling and Storage ....................................................................................................413-08-2
Interior Command Centre .....................................................................................................413-08-4
Principles Operation .............................................................................................................413-08-4
Symptom Chart ....................................................................................................................413-08-9
Service Procedures ............................................................................................................413-08-11
Interior Command Centre (ICC) ...........................................................................................413-08-19
Service Body Computer (BEM) ...........................................................................................413-08-23
Service Remote Key Receiver (RKR) .................................................................................413-08-25
Service Air Register ............................................................................................................413-08-25
Cabin Temperature Sensor ..................................................................................................413-08-26
01/2003 2003.0 BA Falcon

Interior Command Centre 2. Warranty is void if ICC is dropped, handled

roughly or treated outside of these guidelines.
The Interior Command Centre includes audio, climate 3. The ICC must not to be tilted beyond 90 degrees
control and auxiliary controls (i.e.. Door locks, from upright. At no stage can the ICC be shocked
courtesy lamps, interior lamps) displayed in a or excessively vibrated. Such action may damage
centralised area. System status is displayed on a the Audio mechanism. Warranty will be void if
screen built into the instrument panel. these conditions are not met.
The Interior Command Centre screen is 4. The ICC contains many delicate mechanical and
monochromatic for low series screens. High series electrical components. Special care must be
vehicles receive a colour screen. Vehicles with taken. The following are important :
Sat-Nav optioned also receive a colour screen. 1. DO NOT scratch the Class A appearance
Features of each screen are highlighted below:
surfaces.
1. LCD for low series:
2. DO NOT apply excess pressure to the screen
Monochromatic surface at any time.
Uses preset symbols to display information 3. DO NOT apply force in excess of 10 kg to any
2. TFT for high series: appearance surface of the ICC.
Full colour 4. DO NOT touch the pins of the Self-aligning
Reconfigurable screen settings connector at the rear of the Audio Module.
Video input for Sat-Nav, as well as preset 5. DO NOT touch the Cabin Temperature
screens Sensor (refer illustration).
The Interior Command Centre consists of the 6. DO NOT apply pressure to any of the
following base components: switches, knobs or buttons exceeding 5 kg.
Audio features: 7. AVOID all contact with dirt, dust, metal flakes,
metal shavings.
LCD screen
5. The ICC is sensitive to Electro Static Discharge.
Loud button Avoid all contact with static electricity and all
Tuning/Track select precautions must be undertaken to ensure
Auto store adequate grounding of the repair technician and
the ICC Module outside of the vehicle
CD eject button
environment to avoid ESD damage.
CD mode button
6. Avoid all contact with any liquids : soft drinks,
Mode select button water, hot drinks, alcohol, etc. ICC electronic
Audio On/Off/Volume button components will be damaged by any contact with
FM/AM select buttons liquids.
HVAC features: 7. ICC is not to be disassembled except for
recognised service items. The only recognised
A/C on/off
service items are the Body Computer (BEM), Air
Automatic Climate Control On/Off Register and Remote Key Receiver.
Driver/Passenger temp settings These individual components are to be removed
Front windscreen demist in tact as required, according to the Service
Manual requirements. Components are not to be
Air distribution modes tampered with or else component warranty is
Fresh/Recirc air inlet voided.
Blower fan speed 8. ICC storage temperature is never to exceed the
Ambient temperature display range -30°C to +85°C.
Rear demist (heated backlight) 9. Adhesive labels cannot be used on CD’s as they
can peel off and damage internal mechanisms.
Door lock
The use of a disc that deviates from above
Dome lamp industrial standards, use of soiled, scratched,
For further information regarding the function of each dented, cracked, or warped discs and use of
button, please refer to the Owners Guide. pirated discs, etc. will void a warranty claim.
Sumitomo will not accept a warranty claim if any
ICC Handling and Storage part of the audio unit or ICC has been damaged
by the use of an "unsupported" disc.
1. ICC must be handled appropriately. Grab points
are shown in illustrations.
G73346 en 01/2003 2003.0 BA Falcon

CD-DA CD- RED This format is used

TEXT BOOK for Music data and
Text data (title etc).
CD-ROM CD-I GREEN This format is used
BOOK for games and
educational
software. It may
contain Music,
Pictures, Graphics,
Text and
application
software.
CD- CD-R ORANGE This format is
Recordable BOOK one-time
Recordable
Compact Disc.
CD- CD- ORANGE This format is
Recordable RW BOOK multi-write
Rewritable
Compact Disc
10. When refitted to the car, only approved mounting
screws may be used to the specified torques.
11. All mating connectors are to be appropriately
aligned prior to fitment back into the vehicle.
Check that white housing of the main Audio
Self-aligning connector (vehicle-side) is reset
outwards (by pulling the white connector
block rearwards in the car) prior to loading of
the ICC into the Instrument Panel. Failure to
do so may result in permanent damage to both
the vehicle-side connector and the Audio
Module.
G86747 en 01/2003 2003.0 BA Falcon

Interior Command Centre module sends the status to the Instrument Cluster that
displays the relevant jewel.
Principles Operation This flow of control needs to be understood to
correctly diagnose faults with the system. The correct
The ICC (Interior Command Centre) functions are operation of the button or knob should be checked
handled internally by the audio module
using WDS, transmission of the CAN message can be
microprocessor or externally by sending data on the
checked using DTCs as can the validity of the
CAN bus to another module. All the buttons and message content (invalid data DTCs). The
knobs on the ICC are inputs to the Audio
functionality of receiving module can be checked by
microprocessor. Audio functions are executed
following the relevant modules diagnostics.
internally by the audio microprocessor and any screen
information is updated directly by this micro. Climate This checking process usually needs to be done twice
control buttons and knobs are also inputs to the audio for the ICC as a message sent out from the ICC to
micro and can also be checked at the audio module another module triggers a message sent out from that
using WDS. When Climate control buttons or knobs module to the ICC.
are operated, the audio module send a CAN message The ICC can be thought of as a big radio that controls
to the HIM. The HIM executes a function and sends a more than usual number of buttons and a larger than
message back to the audio module to update the normal screen. The actual climate control functions,
screen as required for that function. Sat Nav, and auxiliary button control are done in other
A similar control flow exists for Trip Computer modules.
functions. The Trip button and reset button are inputs The ICC sends CAN Messages to and receives CAN
to the audio module that sends a message to the messages from modules as listed in the following
instrument Cluster. The instrument Cluster does the table;
calculations and sends a CAN message to the audio
ICC CAN Messages
module which then displays the value on the screen.
Transmitted to; Received from;
The Dome Lamp Button, Door lock button and heated
backlight button are also inputs to the audio module. Instrument Cluster PCM
The audio module sends a CAN message to the BEM. HIM Instrument Cluster
In this case it is only the Heated Backlight function BEM HIM
that returns a CAN message to the Audio module as it
is the only one requiring a Screen status update. Traction Control BEM
The traction control button also is an input to the The physical layout of this CAN bus is shown below:
Audio module that sends a message to the traction
control module. In this case the traction control
G86737 en 01/2003 2003.0 BA Falcon

Daisy CAN Wiring Layout
Satellite Navigation control is via the infrared receiver

above the colour screen. It is wired directly to the Sat
Nav module and does not have any interface to the
audio module. The video signal also goes directly to
the colour screen. When the Sat Nav module display
is switched on, a video select line is grounded
between the Sat Nav Module and the Screen module.
This then runs the Sat Nav Video as the back ground
display on the screen and the ICC function become
pop up overlays.
The Cabin Temperature Sensor and remote key
receiver antenna are also directly wired to the BEM
and have no connection to the Audio Module.
If the ICC is replaced, the CTS calibration factor

needs to be retaught to the BEM (refer to section
419-10). The ICC/Audio Security Module
Reconfiguration will be required. WDS must be used
for this operation.
G86737 en 01/2003 2003.0 BA Falcon

Inspection and Verification Normal Condition Possible cause of

abnormality
Visual Inspection Chart CDs load and unload Foreign matter present or
Normal Condition Possible cause of correctly CD mechanism failure -
abnormality refer to Audio diagnostics
All margins even and ICC not fully docked Colour screen switches Faulty button / Screen -
surfaces flush indicating Not all hardware secured on and off using 5 see ICC diagnostics
the interior command Four yellow clips not second press of volume
centre is fully seated and engaged knob
self-aligning connector is Self Aligning connector Screen updates when Faulty button / Screen -
correctly docked. not reset when ICC pressing buttons see ICC diagnostics
installed CTS draws air through Faulty CTS or obstructed
Object obstructing ICC slots in facia (Cabin slots/air way
fitment Temperature Sensor -
BEM connector not made CTS)
/ causing obstruction
No rattles or abnormal Unit not secure
Air registers and Physical damage, foreign sounds Four clips not fitted
thumbwheel control body obstruction or CTS is obstructed
operate through full damaged movement loose components
range of movement Damaged/Loose air
Screen, switches and Physical damage - refer registers
knobs are free of marks to diagnostics to check
and are secure correct operation CAN Information
CD Slot clear of Foreign matter present Refer CAN Message List.
obstruction NOTE: If the ICC is replaced, the CTS calibration
CTS slots free of Foreign matter present factor needs to be retaught to the BEM (refer to
obstructions section 419-10). The ICC/Audio Security Module
Reconfiguration will be required. WDS must be used
for this operation.
DTC Chart
DTC Description Possible Causes Action

B1342 ECU is faulty Faulty Audio unit Document and clear the DTC’s. Carry
out the self test. If the DTC is registered
again replace ICC. Test the system for
correct operation.
B1318 Battery voltage low Low system voltage Document and clear the DTC’s. Run
detected vehicle for 2 minutes. If the DTC is
registered again check / correct battery.
B2103 Antenna not connected Antenna connection not Document and clear the DTC’s. Carry
made/damaged out the self test. If the DTC is registered
again refer to Poor radio reception
symptom in the symptom chart of Audio
diagnostics in Section 415-00.
B2203 CD error CD inserted incorrectly, Document and clear the DTC’s. Remove
data CD inserted all CD’s then reload CD’s and read CM
(continuously monitored) DTC’s. If the
DTC is registered again refer to CD does
not play symptom in the symptom chart
of Audio diagnostics in Section 415-00.
G86737 en 01/2003 2003.0 BA Falcon


2403 Multi CD mechanical BCD stuck etc. Document and clear the DTC’s. Remove
error all CD’s then reload 6 CD’s and play
each momentarily. Read CM DTC’s. If
the DTC is registered again refer to
Unable to load / eject CD’s (multi player
) symptom in the symptom chart of Audio
B2404 Audio steering wheel Audio steering wheel Document and clear the DTC’s. Read
switches faulty switch jammed CM DTC’s If the DTC is registered again
refer to Steering wheel audio switch not
operating symptom in the symptom chart
B2406 Single CD mechanical CD stuck etc. Document and clear the DTC’s. Remove
error and then reload CD. Read CM DTC’s. If
the DTC is registered again refer to
Unable to load / eject CD’s (single player
) symptom in the symptom chart of Audio
B2408 Speaker line short Detects speaker line Document and clear the DTC’s. Carry
shorted to ground or B+ out the self test. If the DTC is registered
again refer to One or more speakers not
operating symptom in the symptom chart
B2409 AM tuner fault No AM signal (Antenna Document and clear the DTC’s. Carry
test) out the self test. If the DTC is registered
B2410 FM tuner fault No FM signal (antenna Document and clear the DTC’s. Carry
again refer to Poor or no radio reception
B2924 Audio button stuck Audio button jammed Document and clear the DTC’s. Read
CM DTC’s. If the DTC is registered
again refer to Audio button not working
B2922 Auxiliary button stuck Auxiliary button jammed Document and clear the DTC’s. Read
again refer to the following symptoms in
the symptom chart.
Traction button not working.
Trip / Reset button no working.
Interior lamp button not working.
Lock/Unlock button not working.
B2923 Climate control button Climate control button Document and clear the DTC’s. Read
stuck jammed CM DTC’s. If the DTC is registered
again refer to Climate control button not
working symptom in the symptom chart.
B2925 Subwoofer speaker Subwoofer line shorted Document and clear the DTC’s. Read
short to ground or B+ CM DTC’s. If the DTC is registered
again refer to Subwoofer not working
G86737 en 01/2003 2003.0 BA Falcon


U2014 Audio subwoofer not Subwoofer Document and clear the DTC’s. Carry
connected disconnected/not fitted out the self test. If the DTC is registered
B2911 Trip computer data Instrument Cluster did Document and clear the DTC’s. Read
invalid not have valid data DTC’s. If the DTC is registered again
available refer to Section 413-01.
U1900 CAN communication CAN messages not Document and clear the DTC’s. Read
fault received DTC’s. If the DTC is registered again
refer to CAN bus diagnostics Section
303-14.
U2201 Ambient temperature HIM did not have valid Document and clear the DTC’s. Read
data invalid data available DTC’s. If the DTC is registered again
PID Chart Command Description
AC_SEL_SW Air Conditioning Switch Status
Command Description
VOLI_SW Volume Increase Switch
CCNT Number of Continuous Trouble
Codes Set VOLD_SW Volume Decrease Switch
NTCSDT Number of Trouble Codes Set due TUNE_UP Tune Increase Switch
to Diagnostic Test TUNE_DN Tune Decrease Switch
AUD_VOL Audio Volume SEEK_UP Seek Increase Switch
AUSTCRES Audio Steering Switch Circuit DEF_SCRN Defrost (Screen)
Resistance PLUS_SW (+) Switch
AUTO_VCG Automatic Volume Control Gain AM_SWT AM Switch
ATNN_RSS Antenna Reception Signal Strength FM_SWT FM Switch
AUDIO_SI Audio Security Identification CD_SWT CD Switch
TMPKNOBP Temperature Selector Status AUTO_SW Autoset
BLWR_FAN Blower Fan Speed EJECT_SW Eject
LCD_SEG LCD Segment Display PRE1_SW Preset 1 Switch
SEC_STAT Security Status PRE2_SW Preset 2 Switch
ACM_STAT ECU Operating State PRE3_SW Preset 3 Switch
MOD_ID Module ID Check PRE4_SW Preset 4 Switch
CONPROV Configuration and Programming PRE5_SW Preset 5 Switch
Version
PRE6_SW Preset 6 Switch
CANDSV CAN Diagnostic Specification
POWER_SW Power Switch
Version
SUB_AMP Subwoofer Amplifier
TCSW Traction Control Switch Status
VID_SRC Video Source
VOL_UP (+) Volume button
AUD_SR CAudio Source
VOL_DN (-) Volume button
CLK_ODV Clock Overlay Display on Video
SEEK_BTN (+) Seek button
LOAD_SW Load Switch pressed
MODE_SW Mode Switch
LOUD_SW Loudness Switch pressed
TRIP_SW Trip
CD_SLOT6 CD in slot 6
TRIP_SW Trip Reset Switch
DOME_SW Dome Lamp Switch
CD_SLOT4 CD_SLOT4
NAV_PRES Navigation
REVRS_INP Reverse
MENU_SW Menu switch
CLK_DSPL Clock Display Enable Status
PANEL_FLR Panel (Face) / Floor
PHONE_AT Phone Transceiver Active
G86737 en 01/2003 2003.0 BA Falcon

Command Description Command Description

FLR_DEF Floor / Defrost (mix) PTMP_DECR Passenger Temperature Decrement
FLOOR Floor PTMP_INCR Passenger Temperature Increment
PANEL_FACE Panel (Face) MODE_UP Mode UP
DEF_SCRN Defrost (Screen) MODE_DWN Mode DOWN
AUTO Auto C_LOCK_SW Central Lock/Unlock Switch Status
OFF Off RUN_POS Run
RECIRC Recirculation Status ACC_POS ACC Position
FAN_MINUS Fan - EATC_HIM EATC (HIM)
FAN_PLUS Fan + BEM_MSG GEM
TEMP_DECR Temperature Decrement CLUST_MSG Instrument Cluster (IC)
TEMP_INCR Temperature Increment PCM_MSG Powertrain Control Module
REAR_DEF Rear Defrost (heated backlight)
Symptom Chart

Illumination not working Wiring fault Refer to service procedure Illumination
Cluster fault fault. (Test A).
ICC fault
Climate control button not working Internal fault Refer to service procedure Climate
CAN fault control button not working. (Test B)
HIM fault Refer to CAN Diagnostics.
Refer to HIM Diagnostics.
Traction button not working Internal fault Refer to service procedure Auxiliary
Wiring fault switch fault (Test C)
Traction module fault Refer to Traction diagnostics.
BEM fault Refer to BEM diagnostics.
Trip/Reset button not working Internal fault Refer to service procedure Auxiliary
Wiring fault switch fault (Test C).
Interior Lamp (Courtesy button) not Internal fault Refer to service procedure Auxiliary
working Wiring fault switch fault (Test C).
Lock/Unlock button not working Internal fault Refer to service procedure Auxiliary
Wiring fault switch fault (Test C).
Visual Damage Internal fault Refer to service procedure ICC visual

damage (Test D)
Display not working Internal fault Refer to service procedure ICC display
Wiring fault fault (Test E).
Cluster fault Refer to Cluster diagnostics.
Automatic Climate Control Obstruction in CTS Check that CTS slots are clear.
Temperature setting higher or lower BEM Fault Refer to HIM diagnostics.
than is expected CTS Fault Refer to BEM diagnostics.
HIM fault
Noisy Not fitted/installed correctly Refer to Inspection and Verification in

CTS obstructed/faulty this section.
Internal fault Refer to BEM diagnostics.
Refer to service procedure Unusual
noise from ICC (Test F)
Air registers not working Internal fault Refer to Inspection and Verification in
this section.
Refer to service procedure Faulty air
register (Test G).
G86737 en 01/2003 2003.0 BA Falcon


Climate control shows flashing "recirc Wiring Fault Refer to CAN diagnostics.
air" symbol or continious "recirc air" HIM Fault Refer to Climate Control diagnostics.
symbol with no other climate control
symbol displayed.
Outside Temperature not working Wiring Fault Refer to CAN diagnostics.

HIM Fault Refer to Climate Control diagnostics.
Navigation not working Internal fault Refer to symptom navigation not

Remote control fault working in Audio Section 415-00.
Navi module fault Refer to Navigation diagnostics.
Wiring fault
Audio button not working Low system voltage Check for low battery voltage.
Internal fault Refer to symptom audio button not
working in Audio Section 415-00.
ICC does not turn on. No Accessory line power. Refer to symptom ICC does not turn
No Ignition line power. on in Audio Section 415-00.
Internal fault. Refer to ignition diagnostics section.
BEM fault. Refer to BEM diagnostics.
Telephone input not working. Internal fault Refer to symptom Telephone input not
Wiring fault working in Audio Section 415-00.
Auxiliary input not working Internal fault

Wiring fault Refer to symptom Auxiliary input not
working in Audio Section 415-00.
Sonar not operating. Internal fault. Refer to symptom Sonar not operating
Wiring fault. in Audio Section 415-00.
ICC not correctly configured. Refer to Sonar diagnostics.
Sonar module fault.
Unable to load / eject CD’s (single CD) Internal fault. Refer to symptom Unable to load /
Faulty CD. eject CD’s (single CD) in Audio
Section 415-00.
Unable to load / eject CD’s (multi CD) Internal fault. Refer to symptom Unable to load /
Faulty CD. eject CD’s (multi CD) in Audio Section
415-00.
CD does not play. Internal fault. Refer to symptom CD does not play in
Faulty CD. Audio Section 415-00.
Poor or no radio reception. Internal fault. Refer to symptom Poor or no radio

Wiring fault. reception in Audio Section 415-00.
Antenna fault.
One or more speakers not operating. Internal fault Refer to symptom One or more
Speaker fault speakers not operating in Audio
Wiring fault Section 415-00.
Subwoofer not working. Internal fault Refer to symptom Subwoofer not

Wiring fault working in Audio Section 415-00.
Amplifier fault
Speaker fault
Steering wheel audio switch not Internal fault Refer to symptom Steering wheel
operating. Wiring fault audio switch not operating in Audio
Switch fault Section 415-00.
G86737 en 01/2003 2003.0 BA Falcon

Service Procedures
Service Procedure Description
Illumination fault (Test A) Identifies an illumination fault.
Climate control button not working (Test B) Tests the ICC climate buttons and knobs for correct
operation and identifies a fault.
Auxiliary switch fault (Test C) Tests the ICC auxiliary buttons for correct operation
and identifies a fault.
ICC visual damage (Test D) Visual inspection of ICC for physical damage.
ICC display fault (Test E) Checks the ICC for correct display operation and
identifies a fault.
Unusual noise from ICC (Test F) Checks for any unusual noises or rattles from the
ICC.
Faulty air register (Test G) Tests the air registers for correct operation.
TEST A : ILLUMINATION FAULT

Using the WDS data logger function activate the
following acronyms.
RUN_POS, ACC_POS, POWER_SW
Test Step Result/Action to Take Acronyms

A1
Turn the ignition on. Yes RUN_POS
Check Pid’s using data logger. Go to A2.
Is the ignition on? No
Repair faulty ignition
system and retest.
A2
Check that the accessories are on. Yes
Check Pid’s using data logger. Go to A3.
Are the accessories on? No
system and retest.
A3
Check to see if the ICC audio is turned on. Yes POWER_SW
Is the audio on? Go to A5.
No
Go to A4.
A4
Push the ICC audio power button. Yes POWER_SW
Check Pid’s using data logger. Go to A5
Does the ICC audio turn on? No
Refer to symptom ICC
does not turn on in the
symptom chart of audio
chapter 415-00.
A5
Turn the vehicle headlights on. Yes
Are the headlights on? Go to A6.
No
Repair faulty lighting
system.
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A6
Check for illumination of the ICC display. Yes
Does the display illuminate? Go to A8
No
Continue.
A7
Remove the ICC. Yes
Measure for battery voltage at the ICC instrument Replace ICC and retest.
panel connector illumination pins. No
Refer to wiring diagrams. Repair faulty vehicle
Does the battery voltage appear? illumination wiring.
A8
Check for illumination of the ICC switches. Yes
Do all the switches illuminate? No fault. ICC functioning
correctly.
No
Continue.
A9
Check for illumination of the ICC switches. Yes
Do any switches illuminate. Replace ICC and retest.
No
Continue.
A10
Check for illumination of the vehicle instrument Yes
panel. Go to A14.
Does the instrument panel illuminate? No
Continue.
A11
Inspect the instrument panel illumination fuse. Yes
Is the fuse blown? Go to A12.
No
Go to A14.
A12
Turn the headlights off and replace the blown Yes
instrument panel illumination fuse with a new one of Go to A13.
correct value. No
Turn the headlights on. Go to A1 and retest.
A13
Remove the ICC. Yes
Turn the headlights off and replace the blown ICC is OK. Repair faulty
instrument panel illumination fuse with a new one of vehicle wiring and retest.
correct value. No
Turn the headlights on. Replace ICC and retest.
Did the fuse blow?
A14
Remove the ICC. Yes
Measure for battery voltage at the ICC instrument Replace ICC and retest.
panel connector illumination pins. No
Refer to wiring diagrams. Repair faulty vehicle
Does the battery voltage appear? illumination wiring.
G86737 en 01/2003 2003.0 BA Falcon

TEST B : CLIMATE CONTROL BUTTON NOT BLWR_FAN, AC_SEL_SW, PANEL_FLR, FLR_DEF,

WORKING FLOOR, PANEL_FACE, DEF_SCRN, AUTO, OFF,
RECIRC, RECIRC, FAN_MINUS, FAN_PLUS,
Using the WDS data logger function activate the TEMP_DECR, TEMP_INCR, REAR_DEF,
following acronyms. PTMP_DECR, PTMP_DECR, PTMP_INCR,
RUN_POS, ACC_POS, POWER_SW, TEMPKNOB, MODE_UP, MODE_DWN

B1
Check Pid’s using data logger. Go to B2
system and retest.
B2
Check that the accessories are on. Yes ACC_POS
Check Pid’s using data logger. Go to B3
system and retest.
B3
Check to see if the ICC audio is turned on. Yes
Is the audio on? Go to B5
No
Go to B4
B4
Push the ICC audio power button.Check Pid’s Yes
using data logger. Go to B5
chapter 415-00
B5
Operate each climate control switch / knob. Yes
Are any switches / knobs sticking or stuck? Replace ICC and retest.
No
Continue.
G86737 en 01/2003 2003.0 BA Falcon


B6
Check that each climate control switch / knob Yes TEMPKNOB,
operates. Go to B7 BLWR_FAN,
Check Pid’s using data logger. No AC_SEL_SW,
Does each switch / knob operate? Replace ICC and retest. PANEL_FLR,
FLR_DEF,
FLOOR,
PANEL_FACE,
DEF_SCRN,
AUTO, OFF,
RECIRC,
FAN_MINUS,
FAN_PLUS,
TEMP_DECR,
TEMP_INCR,
REAR_DEF,
PTMP_DECR,
PTMP_INCR,
MODE_UP,
MODE_DWN,
B7
Control the following Pid’s using the WDS data Yes As per acronym
logger function. No fault.ICC functioning list step B6.
Check for correct function operation for each switch correctly.
/ knob. No
Do all functions operate? Replace ICC and retest.
TEST C : AUXILIARY FAULT
following acronyms.
RUN_POS, ACC_POS, POWER_SW, TCSW,
C_LOCK_SW, DOME_SW, TRIP_SW

C1
Check Pid’s using data logger. Go to C2
Go to C2
C2
Are the accessories on? Go to C3
No
system and retest.
C3
Is the audio on? Go to C5
No
Go to C4
G86737 en 01/2003 2003.0 BA Falcon


C4
Check Pid’s using data logger. Go to C5
chapter 415-00.
C5
Operate each auxiliary switch. Yes
Are any switches sticking or stuck? Replace ICC and retest.
No
Continue.
C6
Check that each auxiliary switch operates. Yes TCSW,
Check Pid’s using data logger. Go to C7 C_LOCK_SW,
Does each switch operate? No DOME_SW,
Replace ICC and retest. TRIP_SW
C7
Control the following Pid’s using the WDS data Yes TCSW,
logger function. No fault.ICC functioning C_LOCK_SW,
Check for correct function operation for each correctly. DOME_SW,
switch. No TRIP_SW
Replace ICC and retest.
TEST D : ICC VISUAL DAMAGE

D1
Inspect the ICC fascia for the following If damage cannot be
Scratches rectified at the dealership
Dints submit a warranty claim.
Defective or peeling paint Include a detailed
Wrong fascia colour description of ICC
Defective or missing print damage.
Broken mounting points
Defective flashing or over trim
Peeling or faulty decals
Foreign substance on fascia
Foreign material jammed into CTS slots
Correct insertion of the ICC fascia
CD slot clear of all obstructions
Rattles or unusual sounds
G86737 en 01/2003 2003.0 BA Falcon


D2
Inspect the ICC buttons and knobs for the If damage cannot be
following rectified at the dealership
Sticking or rubbing knobs submit a warranty claim.
Sticking or stuck buttons Include a detailed
Defective or missing print description of ICC
Wrong buttons fitted damage.
Scratched or damaged buttons
Loose buttons
Foreign material jammed into button gaps
Foreign substance on buttons
Missing buttons
Wrong coloured buttons fitted
Wrong colour illumination
D3
Inspect the ICC display for the following If damage cannot be
Scratched or damaged display rectified at the dealership
LCD leakage in display submit a warranty claim.
Protective sheet left on display during production Include a detailed
Wrong colour illumination description of ICC
Foreign substance on the display damage.
D4
Air Registers
Refer to air register not working symptom in the
symptom chart.
TEST E : ICC DISPLAY FAULT
following acronyms.
RUN_POS, ACC_POS, POWER_SW, LCD_SEG

E1
Check Pid’s using data logger. Go to E2
system and retest.
E2
system and retest.
E3
Is the audio on? Go to E5
No
Go to E4
G86737 en 01/2003 2003.0 BA Falcon


E4
Push the ICC audio power button. Yes
chapter 415-00.
E5
Check operation of the ICC display. Yes
Does the ICC display operate? Go to E6
No
E6
Check operation of the climate control display. Yes
Does only the air recirculation symbol appear? ICC functioning
correctly.Refer to the
climate control section.
No
Continue.
E7
Check operation of the trip computer display. Yes
Is the trip computer display blank? ICC functioning
correctly.Refer to the
instrument cluster section.
No
Continue.
E8
Check for operation of all display segments. Yes LCD_SEG
Check Pid’s using data logger. No fault. ICC functioning
Do all segments operate? correctly.
No
TEST F : UNUSUAL NOISE FROM ICC

F1
Test the ICC for any unusual noises or rattles. Yes
Is there an unusual noise? Go to F2.
No
Retest.
F2
Remove the ICC. Yes
Inspect the ICC to determine if the noise source Go to F4.
can be located. No
Can the noise source be located? Continue.
F3
Refit the ICC and test for unusual noise or rattle. Yes
Ensure that the four yellow mounting clips are fitted Replace ICC and retest.
to the ICC. No
Is there an unusual noise? No fault.
G86737 en 01/2003 2003.0 BA Falcon


F4
Inspect the area causing the unusual noise or rattle. Yes
Is the cause an ICC fault? Replace ICC and retest.
No
Rectify the noise.Replace
the original ICC and
retest.
TEST G : FAULTY AIR REGISTER

G1
Check that all mechanical movements of the air Yes
register operate correctly. Go to G2
Do all mechanical movements operate No
correctly? Replace air register.
G2
Inspect the air register for physical damage? Yes
Is the air register damaged? Replace air register.
No
No fault.
G86737 en 01/2003 2003.0 BA Falcon

Interior Command Centre (ICC) 4. Remove the clock cover fascia by gently lifting at
the point illustrated below using a plastic spatula
Removal similar to a credit card and then run your finger
1. Remove PRND dial or manual gear shift cover by along the top edge.
lifting the cover evenly at the point illustrated NOTE: Using a screw driver or similar may cause
below. damage to the instrument panel.
2. Remove the Console Wing retaining screws. 5. Disconnect antenna connector. Disconnect the 4
connectors under the body computer starting from
Drivers side, working towards the passenger side.
The connector closest to passenger must be
removed last or you may hear relay chattering. If
the vehicle is fitted with satellite navigation a 5th
connector must also be disconnected.
NOTE: Arrows indicate connector lock position.
3. Remove both Console Wings.
G86739 en 01/2003 2003.0 BA Falcon

6. Unscrew the top M5 screw located at the top of 8. Prise the top structure of the CDU away from the
the ICC. Instrument Panel. There are 4 yellow clips which
provide secondary locks into the Instrument
Panel.
Grip Points
9. Once the clip-points have been disengaged, grip

the CDU by its Side Wings and slide it out of the
Instrument Panel.
10. Check that all 4 clips are still attached to the ICC.
If one or more have separated, they may cause a
vehicle rattle & must be removed from the IP and
re-attached to the ICC.
7. Unscrew the 4 lower M6 bolts used to secure the

ICC to the instrument panel.
11. The ICC must be carefully placed on its side on

an appropriate clean, flat surface (less than 5°
angle) to avoid scratching the class A surface
(any part of the ICC module surface visible in the
vehicle) and the screen. Any damage to the class
A surface and/or screen during servicing will void
warranty.
12. To return only the ICC for warranty, the Body
Computer and Antenna Leadwire must be
removed together from the ICC and retained with
the vehicle. When returning the ICC only, the
original antenna and original Body Computer
MUST remain with the vehicle.
G86739 en 01/2003 2003.0 BA Falcon

Installation
1. Ensure that the Main Audio Self-Aligning
Connector is reset. The white centre terminal
block should be pulled to its furthermost outer
position. A distinctive click will be heard as the
connector is reset.
4. When the CDU is in place, tighten the top screw

to 2.1 - 4.3 Nm.
2. Locate the ICC Side Spigots into the Crosscar

Beam Rails and slide the ICC into the Instrument
Panel. Firmly push the ICC to engage the Main
Audio Self Aligning Connector. Do not apply
excessive force. Do not push the screen or the
button panel.
If insertion is stopped before the end of travel,
remove the ICC and ensure that the Main Audio
Self-Aligning Connector is reset. Reset if
necessary. Restart installation process. Do not
apply excessive loading force.
3. Once the lower half of the ICC is in place,

complete the installation by ensuring the 4 trim
clips are fully engaged in the Instrument Panel.
The clips are located on either side of the clock
depression and on either side of the screen. Apply
force at these points to ensure the clips are
engaged in the Instrument Panel. Do not apply
excessive force. Do not push the screen or the
button panel.
G86739 en 01/2003 2003.0 BA Falcon

5. Tighten the 4 lower bolts to 8.9 - 12.1 Nm. 7. Prior to replacing clock cover fascia make note of
CTS calibration factor is fitted. Then replace the
clock cover fascia, console wings and PRND
cover.
6. Reconnect Body Computer connectors, starting

from passenger’s side and working towards
driver’s side, the connector closest to passenger
must be inserted first or you may hear relay
chattering. Navigation connector (if fitted) and the
Radio Antenna connector.
8. If ICC has been replaced then retrain audio and

CTS to vehicle. CTS calibration factor stored in
BEM. Refer to section 419-10.
G86739 en 01/2003 2003.0 BA Falcon

Service Body Computer (BEM) 4. Disconnect the remaining black connector from
Body Computer.
Removal
NOTE: The 6 CD Audio Mechanism for Mid and High
Premium Sound Audio is very fragile. At no stage can
the Audio Module cannot be shocked or excessively
vibrated, especially when rotated beyond 90 degrees.
If the Audio Module is shocked or excessively vibrated
at any stage during removal, service or transport, the
Audio warranty is voided.
1. To access the Body Computer, place the ICC on
its side on a clean surface to prevent damage to
the Class A surface.
2. Remove 4 X M5 screws used to hold the Body
Computer to the Audio module.
5. Disconnect the antenna wire from the Audio
Module and remove Body Computer together with
the antenna cable.
3. If fitted with Satellite Navigation (TFT Screen

connection), remove 2 X M3 screws to separate
connector holder from Body Computer.
6. If only the Body Computer is to be serviced,
remove the antenna cable from the Body
Computer, and retain the antenna cable with the
vehicle.
NOTE: If only the Body Computer is to be
returned, ensure that the original Antenna
Leadwire remains with the vehicle & is fitted to the
replacement Body Computer.
If only the ICC is to be returned, ensure that both
the original Body Computer and original Antenna
Leadwire remain with the vehicle.
Replacement Body Computers are NOT be
supplied with Antenna Leadwires. Serviced ICC’s
are NOT supplied with Body Computers OR
Antenna Leadwires.
G86739 en 01/2003 2003.0 BA Falcon

7. Disconnect the remaining black connector from 3. If fitted with TFT Screen connection, locate
Body Computer. Disconnect the antenna wire connector holder and tighten 2 X M3 screws to
from the Audio Module and remove Body 0.6 Nm.
Computer together with the antenna cable.
4. Position Body Computer as shown on Audio

Installation Module.
NOTE: The 6 CD Audio Mechanism for Mid and High 5. Tighten 4 X M5 screws to 1.0 Nm.
Premium Sound Audio is very fragile. At no stage can
the Audio Module cannot be shocked or excessively
vibrated, especially when rotated beyond 90 degrees.
If the Audio Module is shocked or excessively vibrated
at any stage during removal, service or transport, the
Audio warranty is voided.
1. To install the Body Computer, place the ICC on its
side on a clean surface to prevent damage to the
Class A surface.
2. Connect black connector to Body Computer.
6. As appropriate, clip or screw the Antenna Cable

to the Body Computer using M3 screw tightened
to 0.6 Nm.
7. If BEM has been replaced, after ICC is fitted to

vehicle, the BEM must be retrained to vehicle
using procedure as defined in BEM section (Refer
to section 419-10).
G86739 en 01/2003 2003.0 BA Falcon

Service Remote Key Receiver (RKR) Installation

1. Connect the RKR connector.
Removal
1. Remove 2 X M3 screws used to hold RKR to the
Air Register.
2. Position RKR on Air Register.
2. Remove RKR.
3. Tighten 2 X M3 screws to 0.5 Nm.
3. Disconnect the RKR connector.
Service Air Register

1. Remove the ICC, as described earlier in this
section.
2. Remove the Remote Key Receiver. Refer to
Service Remote Key Receiver in this section
G86742 en 01/2003 2003.0 BA Falcon

3. Remove wire harness from Air Register. Installation

1. Position Air Register.
4. Remove 3 X M5 screws from Air Register.

2. Tighten 3 X M5 screws to 1.5 Nm, top centre
screw first.
5. Remove Air Register.
3. Reposition wire harness to Air Register.
4. Install the Remote Key Receiver. Refer to Service

Remote Key Receiver in this section.
Cabin Temperature Sensor

The Cabin Temperature Sensor is a non servicable
component and if faulty, the entire ICC unit as a
whole should be replaced after obtaining FCSD
approval.
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413-13-1 Parking Aid 413-13-1
SECTION : 413-13 Parking Aid

CONTENTS PAGE
Reverse Sensing System ......................................................................................................413-13-2
System Components ............................................................................................................413-13-3
Other Information .................................................................................................................413-13-4
Parking Aid ............................................................................................................................413-13-6
WDS Test Procedure ...........................................................................................................413-13-6
DTC Chart ............................................................................................................................413-13-6
PID Chart .............................................................................................................................413-13-7
Symptom Chart PAM ...........................................................................................................413-13-8
Pinpoint tests ........................................................................................................................413-13-9
Reverse Sensing System ECU ...........................................................................................413-13-15
Sensors ...............................................................................................................................413-13-16
01/2003 2003.0 BA Falcon

413-13-2 Parking Aid 413-13-2
Reverse Sensing System
The system consists of four ultrasonic sensors sensing zone may be altered causing inaccurate
mounted in the rear bumper, a controller and an audio measurement of obstacles or false alarms.
warning output that is emitted from the rear audio The system is initialized after the ignition is turned on
speakers or a speaker attached to the controller. The and reverse gear selected. An audible tone will then
system measures the distance to the closest obstacle sound for 0.5 seconds.
when reversing and emits a corresponding audible
The Reverse Sensing System will detect objects
warning.
within the sensor range (within approximately 180cm).
The Reverse Sensing System is an auxiliary system The coverage area is decreased around the outer
that is not intended to relieve the driver of their corners of the bumper.
responsibility for exercising due care and attention
when reversing.
The sensors sequentially transmit short ultrasonic
pulses (48kHz) then listen for the echo reflected from
the detected object. The electronic control unit using
triangulation data from the four sensors calculates the
distance. Various sound absorbing/reflecting materials
or operating conditions can have an effect on the
detection range:
Ultrasonic waves, heavy rain and/or conditions
causing disruptive reflections may lead to objects
not being detected by the sensors.
In addition, objects that absorb ultrasonic waves
may not always be detected due to their
unfavorable surface characteristics.
Sensors that are covered in dirt, ice or mud may
cause the system to detect objects incorrectly.
If the vehicle sustains damage to the rear
bumper/fascia, leaving it misaligned or bent, the
G56520 en 01/2003 2003.0 BA Falcon

413-13-3 Parking Aid 413-13-3
When towing a trailer a switch fitted to the Ford

vehicle harness socket is used to disable the system.
If using a bicycle rack on the tow bar then a number
plate lamp and tail lamp should be fitted and plugged
into the trailer socket. This will disable the parking aid,
otherwise a disturbance to the sensor field will occur
when reverse is engaged triggering the continuous
audible warning.
Depending on the type of Reverse Sensing System
fitted to your vehicle, reverse warning tone system
can be increased or decreased in volume. To change
the volume of the Reverse Sensing System warning
tone, turn off the audio system, then use the volume
control to alter warning tone volume. To disable
audible warning tone, set volume to minimum.
System Components
The system comprises:
Qty Description Part Number
1 Control unit without loud 3R23 15K866
speaker LWB & SWB AA
Fairmont Ghia
1 Control unit with loud 3R23 15K866
speaker Fairmont BA
4 Ultrasonic sensor 3.1 3R23 15K859
AAW
4 Decoupling ring 3R23 15A869
AA
When an object is detected within the sensor range, 4 Housings 3R23 15K861
an intermittent warning tone is emitted. As the AA
distance between the object and the sensors 4 Retaining Spring 3R23 15A873
decreases, the warning tone will sound at shorter AA
intervals. A continuous warning tone sounds if the 4 Bezel 3R23 15A872
object is within 45cm of the rear bumper. A summary *AW
of the warning tones is included in the table below.
Sensor
Warning Range Frequency Tone On Tone Off
(cm) Hz
<=45 1200 Continuous 0ms
<=60 1200 75ms 75ms
<=80 1200 75ms 150ms
<=105 1200 75ms 225ms
<=145 1200 75ms 300ms
<=185 1200 75ms 375ms
Hardware Error 600 Continuous
at power up
Error Message 600 Continuous
at power up
Ready Tone, 1200 0.7sec
reverse
engaged
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413-13-4 Parking Aid 413-13-4
Fairmont Module (with speaker)
Sensor Assembly
Item Description Other Information

1 Bezel Painting specifications for Ultrasonic sensors
2 Bumper Fascia
The ultrasonic sensors are painted to match the
3 Housing Element vehicle colour range. Paint is applied to a maximum
4 Retaining Spring thickness of 120µm; additional paint must not be
5 Decoupling Ring applied, as this will effect the operational range of the
sensor.
6 Sensor
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413-13-5 Parking Aid 413-13-5
Aftermarket sensors
Aftermarket sensors are unpainted and are packed in
a cardboard package that exposes the aluminium
membrane for spray painting, once painted remove
the cardboard surround. The membrane has a yellow
chromate finish so that the finish paint can adhere
easily. This coating must be clean and dry before
paint application. Alcohol may be applied with a clean
lint free cloth, ensure the edge of the membrane is
also cleaned. Ultrasonic cleaning must not be used.
Scratched or damaged membranes are
unserviceable; the complete sensor must be replaced.
Aftermarket RPA kits comprising: Sensors, decoupling
rings, housings, retaining springs, contour rings, ecu
and harnesses.
Painting sensors
Paint must be applied to a maximum thickness of
120µm with no runs. A waiting time of 24 hours is
recommended after painting and drying to ensure a
durable finish.
The drying temperature must not exceed 105°C with a
maximum drying time of 30 minutes, exceeding this
will damage / render inoperable the sensor. Sensors
are normally housed in a paint box that exposes only
the areas to be painted.
Storage of unpainted sensors
Storage temperature -57 to 100°
Relative humidity 80%
Storage duration 6 Months
Longer storage times before painting will degrade the
chromate surface.
Operate a first in, first out parts supply.
ESD Protection
All work that is carried where it is possible to touch
the connector pins, proper ESD protection procedures
must be followed. Eg a grounded wrist strap and an
anti static mat.
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413-13-6 Parking Aid 413-13-6
Parking Aid WDS Test Procedures (if WDS is available) or

Symptom chart and Pinpoint tests (if WDS is
Inspection and Verification not available)
1. Verify the customer’s concern by operating the WDS Test Procedure
Reverse Sensing System.
2. Visually inspect the Reverse Sensing System,
Self Test and Functional Tests
referring to the following chart: Self test: Using the WDS Tester it is possible to
Visual Inspection Chart conduct an on demand self test.
Mechanical Electrical The pre-conditions for this test are as follows:
Damage to bumper Ignition is operational Ignition key turned to the ignition on position,
around sensors Check reverse gear is Vehicle must be in reverse Gear.
Damage to parcel able to be selected There must be nothing in the field of view of the
shelf near rear Audio system (rear sensors.
speakers speakers) are
Damage to left hand operational (for AA The Self Test checks application data integrity in ECU
(passenger) side of modules only) and performs attenuation test on all four sensors. The
parcel shelf Sensors are test takes approximately 4.5 seconds to run.
Sensors loose in connected to wiring Any errors are logged as On-demand Diagnostic
bumper loom Trouble Codes (DTCs). If any DTCs are logged
Sensors covered in Battery is charged please go to the DTC Chart for more information.
dirt, snow, ice, etc Diagnostic functions: The Reverse Sensing System
Damage to Module can be requested to either activate or silence
connectors on its speaker with diagnostic commands.
sensors or wiring The speaker can be activated using the WDS
loom
Datalogger function r_chime.
Trailer connector plug
damaged / missing / Module Configuration
loose?
The Reverse Sensing Module has several preset
NOTE: Sonar parking system will NOT operate if configurations to accommodate for various body
reverse gear can not be selected. styles/vehicles.
3. If the cause of the customer concern is not The module can only be configured via the WDS.
visually obvious proceed to:
DTC Chart
DTC Description Possible Cause
B1299 Power Supply Sensor Circuit Short The Sensor Supply circuit is shorted to Ground.
To Ground ie. The voltage at ECU Pin 5 is < 2 V.
Go to PinPoint Test C.
B1342 ECU is Faulted There may be an internal fault in the ECU. Retry
self test.
If DTC is logged again then, replace ECU.
B2477 Module Configuration Failure ECU configuration has failed or not been set.
Configure module using WDS.
C1699 Left Rear Sensor Circuit Short to The Sensor Signal circuit is shorted to supply.
Vbat ie.The voltage at ECU Pin1 is > 8 V.
Go to PinPoint Test A.
C1700 Left Rear Sensor Circuit Failure The Sensor Signal circuit is Open circuit or
Shorted to Ground.
ie. The voltage at ECU pin 1 is < 2 V.
Go to PinPoint Test G.
C1701 Left Rear Sensor Circuit Fault An incorrect signal has been received by the
Sensor. There may be an internal fault in the
ECU or Sensor.
Replace Sensor.
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413-13-7 Parking Aid 413-13-7
DTC Description Possible Cause

C1702 Right Rear Sensor Circuit Short to The Sensor Signal circuit is shorted to supply.
Vbat ie. The voltage at ECU Pin4 is > 8 V.
C1703 Right Rear Sensor Circuit Failure The Sensor Signal circuit is Open circuit or
Shorted to Ground.
ie. The voltage at ECU Pin 4 is < 2 V.
C1704 Right Rear Sensor Circuit Fault An incorrect signal has been received by the
ECU or Sensor.
Replace Sensor.
C1705 Left Rear Center Sensor Circuit The Sensor Signal circuit is shorted to supply.
Short to Vbat ie. The voltage at ECU Pin2 is > 8 V.
C1706 Left Rear Center Circuit Failure The Sensor Signal circuit is Open circuit or
Shorted to Ground.
C1707 Left Rear Center Circuit Fault An incorrect signal has been received by the
ECU or Sensor.
Replace Sensor.
C1708 Right Rear Center Sensor Circuit The Sensor Signal circuit is shorted to supply.
Short to Vbat ie. The voltage at ECU Pin3 is > 8 V.
C1709 Right Rear Center Sensor Circuit The Sensor Signal circuit is Open circuit or
Failure Shorted to Ground.
C1710 Right Rear Center Sensor Circuit An incorrect signal has been received by the
Fault Sensor. There may be an internal fault in the
ECU or Sensor.
Replace Sensor.
PID Chart PID Description
FNT_SENS Parking Aid Front Sensor Status
PID Description
REAR_SENS Parking Aid Rear Sensor Status
Codes Set PARK_SYS Parking Aid System Status
NTCSDT Number of Continuous Trouble DEACTISY Deactivate System
Codes Set due to Diagnostic Test MSTATUS Module Configuration Status
PAM_STAT ECU Operating States LC_DIST Echo value for Left Corner Sensor
SYS_OZ System Output Zone RC_DIST Echo value for Right Corner Sensor
BODY_TYPE Body Type LM_DIST Echo value for Left Middle Sensor
FLT_COND Fault Condition RM_DIST Echo value for Right Middle Sensor
TRAILINS Trailer Installed VER_MID Module Type ID (Version)
TRANSRV Transmission in Reverse BODY_MID Module Type ID (Body Config.)
G56521 en 01/2003 2003.0 BA Falcon

413-13-8 Parking Aid 413-13-8
Symptom Chart PAM

No confirmation (roger) tone when No power or ground feeds to ECU Check if vehicle is in Reverse.
reverse gear selected Check that Audio system is operatonal
(if AA module)
Check Power and Ground feeds to
ECU.
Go to PinPoint Test H (BA module
only). If AA module, replace ECU.
Speaker beeping continuously. ECU fault Check for object behind car.
Replace ECU.
No sound output W iring fault Check that audio system is operational
Speaker Fault (if AA module)
ECU fault Go to PinPoint Test H (BA module
only). If AA module, replace ECU.
Speaker beeping continuously when W iring fault Check that Trailer is Plugged into
trailer connected Speaker Fault vehicle trailer plug.
Audio fault Go to PinPoint Test L.
ECU fault
Trailer plug switch fault
Sensor Connector Diagram

1 Sensor Signal Sensor Connected and with No object in
Sensor’s field of view.
Voltage = approx. 7.8V ± 0.5V
2 Sensor Return 0 Volts
(Ground)
3 Sensor Power Supply 8 - 8.5 Volts
Module Connector Diagram
G56521 en 01/2003 2003.0 BA Falcon

413-13-9 Parking Aid 413-13-9

1 1441 W (SIG_LC) No object in Sensor’s field of view
Sensor Signal LH Corner Voltage = approx. 7.8V ± 0.5V
2 1442 G-W (SIG_LM) As above
Sensor Signal LH Middle
3 1443 G (SIG_RM) As above
Sensor Signal RH Middle
4 1444 L-Y (SIG_RC) As above
Sensor Signal RH Corner
5 1439 Y-R (Sensor_feed) 8.5V ±0.5V
Sensor Feed
6 1440 G-Y (GND) < 0.5V
Sensor ground
7 NC
8 NC
9 NC
10 NC
11 NC
12 57 E B (GND) < 0.5V
Ground
13 140D R-B (KL15) + 12V
Power Reverse switch
14 1355 BR (Disable)
O.C.= trailer not connected
15 NC
16 NC
17 NC
18 NC
19 NC
20 70 SB-W (Diagnose)
Diagnostic Signal
21 NC
22 1347 B-P (Speaker -) When Spkr is activated = approx. 2V less than
Speaker - the Spkr Supply Voltage.
23 1438 G (Speaker +) With Spkr Connected = approx. 1.5V less than
Speaker + VBat
Pinpoint tests
PINPOINT TEST A : SENSOR SHORT CIRCUIT TO VBAT

A1 CHECK SENSOR SIGNAL WIRE
Remove bumper. Refer to Bumper section for instructions for removal Yes
of bumper Go to A2
Unplug sensor. No
Is Voltage < 1V? Go to B1
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413-13-10 Parking Aid 413-13-10

A2 CHECK SENSOR SIGNAL WIRE WITH SENSOR
ATTACHED
Plug in sensor Yes
Go to A3
Measure voltage on sensor signal wire.
Is voltage > 5V? No
Go to C1
A3 CHECK SENSOR SIGNAL WIRE WITH SENSOR

ATTACHED AND OBJECT DETECTED BY SENSOR
Plug in sensor. Yes
Go to A4
Monitor voltage on sensor signal wire.
Place your hand in front of the sensor. No
Internal short circuit in sensor. Replace sensor.
Does the voltage drop when your hand is placed in front of the Retest system for correct operation.
sensor?
A4 CHECK CONTINUITY OF THE SENSOR SIGNAL WIRE

BETWEEN THE SENSOR AND THE ECU
Unplug Reverse Sensing System ECU and sensor Yes
Open circuit in wiring loom. Please refer to
Measure resistance of sensor signal wire between sensor connector
schematics section for information on wiring.
and ECU connector.
Is resistance = open circuit? No
Replace Reverse Sensing System ECU. Retest
PINPOINT TEST B : SENSOR SHORT CIRCUIT TO VBAT

B1 CHECK RESISTANCE BETWEEN SENSOR SIGNAL
WIRE AND SENSOR SUPPLY WIRE
Unplug Reverse Sensing System ECU and sensor. Refer to removal Yes
and installation section of entry for instructions for accessing module. Internal short circuit in ECU. Replace Reverse
Sensing System ECU. Retest for correct
Measure resistance between sensor signal wire and sensor supply
operation.
wire
Short circuit in wiring loom. Check wiring loom
for short circuit. Please refer to schematics
section for information on wiring.
PINPOINT TEST C : SENSOR POWER SUPPLY SHORT CIRCUIT TO GROUND

C1 CHECK SENSOR SUPPLY WIRE
Remove bumper. Refer to Bumper section for instructions for removal Yes
of bumper Go to C2
Unplug all 4 sensors. No
Measure voltage on sensor supply wire. Go to C3
Is Voltage > 7V?
G56521 en 01/2003 2003.0 BA Falcon

413-13-11 Parking Aid 413-13-11

C2 CHECK SENSOR SIGNAL WIRE WITH SENSOR
ATTACHED
Plug in each sensor ( one at a time ) Yes
Internal short circuit in sensor. Replace sensor.
Measure voltage on sensor supply wire.
Retest system for correct operation.
Is voltage < 5V ?
No
Retest for correct operation. If the same Fault is
constantly present, Replace ECU.
C3 CHECK RESISTANCE BETWEEN SENSOR SUPPLY,

SENSOR EARTH WIRE AND VEHICLE GROUND
Unplug Reverse Sensing System ECU and sensor. Yes
Short circuit in wiring loom. Check wiring loom
Measure resistance between sensor supply wire, and sensor ground for short circuit. Please refer to schematics
wire and vehicle ground.
Is resistance = short circuit?
No
Go to C4.
C4 CHECK CONTINUITY OF THE SENSOR SUPPLY WIRE

BETWEEN THE SENSOR AND THE ECU
Unplug Reverse Sensing System ECU and sensor. Yes
Measure resistance of sensor supply wire between sensor connector
and ECU connector.
Replace Reverse Sensing System ECU. Retest
PINPOINT TEST D : RESISTANCE TEST

D1 CHECK RESISTANCE BETWEEN SENSOR SIGNAL
WIRE AND SENSOR RETURN WIRE (IE.GROUND)
Unplug connector from Reverse Sensing System ECU. Refer to Yes
removal and installation section of entry for instructions for accessing Short circuit in wiring loom. Locate fault and
module. repair harness. Please refer to schematics
Remove bumper from vehicle. Refer to Bumper section for
instructions for removal of bumper No
Unplug sensor from wiring loom. Go to D2
Measure resistance between sensor signal wire and sensor return

(ground) wire or vehicle ground.
Is measured resistance short circuit?
D2 CHECK CONTINUITY OF SENSOR SIGNAL WIRE

Check continuity of sensor signal wire between the Reverse sensing Yes
system ECU and sensor connectorS. Fault in wiring loom. Locate fault and repair
harness. Please refer to schematics section for
Is there an open circuit in the harness? information on wiring.
No
Go to C1
G56521 en 01/2003 2003.0 BA Falcon

413-13-12 Parking Aid 413-13-12
PINPOINT TEST E : VOLTAGE TEST

E1 MEASURE VOLTAGE OF SENSOR SIGNAL WIRE AT
REVERSE SENSING ECU CONNECTOR
Measure voltage of sensor signal wire at Reverse Sensing ECU Yes
connector. Go to E2
Is voltage >7V? No
Go to E3
E2 CHECK SENSOR SIGNAL WIRE WITH SENSOR

ATTACHED AND OBJECT DETECTED BY SENSOR
Plug in sensor. Yes
Retest for correct operation. If the same Fault
Measure voltage on sensor signal wire.
Code is constantly present, Replace ECU.
Place your hand in front of the sensor.
No
Does the voltage vary when your hand is placed in front of the Go to A1
sensor? ( 2V - 8V )
E3 CHECK SENSOR SUPPLY WIRE

Measure voltage on sensor supply wire. Yes
Go to D1
Is Voltage > 7V
No
Go to C1
PINPOINT TEST F : NO SOUND FROM SPEAKER (BA MODULES ONLY)

F1 CHECK SPEAKER SUPPLY WIRE
Measure voltage on speaker supply wire whilst speaker is still Yes
connected. Refer to removal and installation section of entry for Go to H1
instructions for accessing module.
No
Is the measured voltage > 9V? Go to G1
PINPOINT TEST G : NO SOUND FROM SPEAKER — PART 2

G1 MEASURE FOR SHORT BETWEEN SPEAKER SUPPLY
WIRE AND VEHICLE GROUND
Unplug Reverse Sensing System ECU and speaker. Yes
Fault in wiring loom. Locate fault and repair
Measure resistance between speaker supply wire and vehicle ground.
wiring. Please refer to schematics section for
Is measured resistance short circuit? information on wiring.
No
Go to G2
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413-13-13 Parking Aid 413-13-13

G2 CHECK CONTINUITY OF SPEAKER SUPPLY WIRE
Check continuity of speaker supply wire between the Reverse Yes
Sensing System ECU and speaker connectors Fault in wiring loom. Locate fault and repair
Is the measured resistance open circuit? information on wiring.
No
Fault in Reverse sensing system ECU. Replace
ECU. Retest for correct operation.
PINPOINT TEST H : NO SOUND FROM SPEAKER - PART 3

H1 CHECK SPEAKER SIGNAL WIRE
Measure voltage on speaker signal wire whilst speaker is still Yes
connected. Refer to removal and installation section of entry for Go to H2
instructions for accessing module.
No
Is the measured voltage > 9V? Go to I2
H2 CHECK SPEAKER SIGNAL WIRE VOLTAGE WHILST

TOGGLING SPEAKER ON AND OFF
Measure voltage on the speaker signal wire whilst toggling the Yes
speaker on/off using the WDS function test Speaker is faulty. Replace speaker. Retest for
correct operation.
Does speaker voltage drop by at least 2V when speaker is
switched on? No
Go to I1
PINPOINT TEST I : NO SOUND FROM SPEAKER - PART 4

I1 MEASURE FOR SHORT BETWEEN SPEAKER SIGNAL
WIRE AND SPEAKER SUPPLY WIRE
Unplug Reverse Sensing System ECU and speaker Yes
Measure resistance between speaker signal wire and speaker supply wiring. Please refer to schematics section for
wire.
information on wiring.
Is measured resistance short circuit?
No
Go to I3
I2 MEASURE FOR SHORT BETWEEN SPEAKER SUPPLY

WIRE AND VEHICLE GROUND
Unplug Reverse Sensing System ECU and speaker Yes
Measure resistance between speaker supply wire and vehicle ground
Is measured resistance short circuit? information on wiring.
No
Go to G2
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413-13-14 Parking Aid 413-13-14

I3 CHECK CONTINUITY OF SPEAKER SIGNAL WIRE
Check continuity of speaker supply wire between the Reverse Yes
Sensing System ECU and speaker connectors Fault in wiring loom. Locate fault and repair
Is the measured resistance open circuit? information on wiring.
No
Fault in Reverse sensing system ECU. Replace
ECU. Retest for correct operation.
PINPOINT TEST J : CHECK TRAILER PLUG SWITCH

J1 CHECK TRAILER PLUG SWITCH SIGNAL WIRE
Remove Trailer plug and access wire connections. Yes
Go to J2
Measure voltage on Trailer Switch Signal wire.
Is Voltage > 9V No
Go to J3
J2 CHECK TRAILER PLUG SWITCH

Measure voltage on Trailer Plug Switch Signal wire while operating Yes
switch by opening and closing the Trailer Plug Connector Cover Replace ECU. Retest system for correct
operation.
W ith the Cover OPEN
Is voltage < 1.5V ? No
Go to J4
J3 CHECK CONTINUITY OF WIRE BETWEEN THE ECU

AND TRAILER PLUG
Unplug Reverse Sensing System ECU. Yes
Go to J5
Measure resistance of signal wire between ECU Trailer input ( Pin 14
) and the Trailer plug. No
Is resistance = short circuit? Open circuit in wiring loom. Please refer to
J4 CHECK GROUND ON SWITCH

Measure for continuity to ground between the trailer switch and Yes
vehicle ground. Replace Trailer plug.
Is resistance = short circuit? No
J5 CHECK CONTINUITY OF WIRE BETWEEN THE ECU

AND GROUND
Unplug Reverse Sensing System ECU. Yes
Short circuit in wiring loom. Please refer to
Measure resistance of signal wire between ECU Trailer input ( Pin 14
) and Vehicle Ground.
Is resistance = short circuit? No
Replace ECU.
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413-13-15 Parking Aid 413-13-15
Reverse Sensing System ECU 5. Remove the electrical connector from module.
Removal
1. Lower the rear seats.
6. Use a stubby phillips head screw driver to remove

the two screws, and remove the module.
2. Remove Fir trees on parcel shelf
Installation
1. To install, reverse the removal process.
3. Remove anchor point from top of parcel shelf.
4. Lift up parcel shelf and move it up of the way. For

additional information refer to section 501-05.
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413-13-16 Parking Aid 413-13-16
Sensors
Removal
1. Detach bumper from vehicle. For additional
information refer to Bumper in section 501-19.

1 Disconnect wiring from sensor. 7 Remove main body of sensor.
2 Remove sensor from holder by gently 8 Remove bezel.
prying catches on holder. 9 Remove Decoupling ring.
3 Remove sensor. Installation
4 Remove retaining spring. 1. To install, reverse the removal process.
5 Pull spring out gently so that spring is not
damaged.
6 Remove main body of sensor holder from
bezel by gently prying catches on the main
body.
G56524 en 01/2003 2003.0 BA Falcon

414-00-1 Charging System - General Information 414-00-1
SECTION : 414-00 Charging System - General

Information
CONTENTS PAGE
Description and Principles of Operation ................................................................................414-00-2
01/2003 2003.0 BA Falcon

414-00-2 Charging System - General Information 414-00-2
Description and Principles of disconnected while the engine is running or

damage may occur to the rectifier and/or control
Operation box semi-conductor devices. For this reason the
The charging system consists of an alternator, practice of using a slave battery to start the
alternator regulator, battery, charge indicator light and engine, then reconnecting the original battery
the necessary wiring to connect to the components. whilst the engine is running must not be
All vehicles are equipped with a non-adjustable attempted. It is likewise inadvisable to break or
integral electronic regulator. Six cylinder vehicles use make any other connections in the alternator
a Mitsubishi alternator and eight cylinder vehicles use circuit while the engine is running.
a Visteon alternator. These alternators are essentially 5. Alternator Main Output Cable
the same internally but the exterior casing varies. The cable connecting the alternator and the
Both the Mitsubishi (6 Cyl.) and Visteon (8 Cyl.) battery is ’live’ even when the engine is not
alternators are three phase alternating current (AC) running. Care must be taken not to earth this
generators with integrally mounted diodes that convert live cable if it should ever be removed, or
the AC into direct current (DC) suitable for charging damage to the cable will occur.
the battery. The alternator must never be run with the
Charging system troubles such as low alternator main output cable disconnected either at the
output, no alternator output (indicated by the indicator alternator or battery end while the field
light being on while the engine is running), or remains energised or the rectifiers may be
alternator output voltage too high, require testing of damaged.
both the alternator and the alternator regulator.
6. Arc Welding. The possibility of damage to the
Alternator regulator failures are usually not recognized semiconductor devices during arc welding
except by the direct effect on the alternator output, operations on a vehicle is very slight. However, it
and, hence, consequently battery discharge. As the is a worthwhile precaution to isolate the control
regulator is the control valve for the alternator, it acts box and alternator by disconnecting their wiring
to protect the battery by preventing excessive voltage connectors prior to carrying out any arc welding
output. on the vehicles.
Discharge of the battery to ground through the
alternator is prevented by the diodes of the alternator Removal notes
which permit current flow in one direction (to the 7. Ensure battery shroud is not damaged or
battery) only. A discharged battery is not always due dislodged during battery removal.
to charging system defects. Excessive use of lights
and accessories while the engine is either off or 8. Use a universal battery removal tool to enable
removal of battery with shroud in situ.
running at low idle; corroded battery cables and
connectors; low acid level in the battery; or prolonged 9. Ensure shroud and venting pipes are installed
disuse of the battery, which would permit correctly.
self-discharge; are all possible reasons which should
be considered when a battery is run down or low in
charge.
The procedures which follow will assist in a logical
sequence of pinpointing specific troubles.
Always determine the cause of failure as well as
making the repair.
1. Polarity and connections. The alternator is for
use on negative earth electrical systems only.
Polarity cannot be reversed by ’flashing’ the field
terminals as with the dynamo. Any attempt to do
so will damage the alternator.
2. Refitting Vehicle Battery. Reversed battery
connections will damage the alternator rectifiers.
When refitting, first fit the positive (+) connector to
the battery positive (+) terminal. Then fit the
negative (-) connector to the negative (-) battery
terminal.
3. Battery Charging. First disconnect the battery
negative cable, thus isolating the alternator from
the battery and external charging equipment.
4. Battery Connections. The battery must never be
G34560 en 01/2003 2003.0 BA Falcon

414-01-1 Battery, Mounting and Cables 414-01-1
SECTION : 414-01 Battery, Mounting and Cables

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................414-01-2
Battery and Cables ................................................................................................................414-01-3
Battery ....................................................................................................................................414-01-4
Pinpoint Tests ......................................................................................................................414-01-4
Component Tests .................................................................................................................414-01-4
Battery and Cables ................................................................................................................414-01-6
Battery Shroud .......................................................................................................................414-01-6
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Battery
All vehicles - 53 A/H 12 Volt 520 Cold Cranking
(Amps) 95 Reserve Capacity (Min)
Description Nm
Battery Hold Down Support Bolt 2-4
G86840 en 01/2003 2003.0 BA Falcon

Battery and Cables

Vehicles are equipped with a 12 volt
maintenance-free battery.
The battery and cable system consists of the following
components:
battery
battery cable assembly
battery tray
Ford Motor Company strongly recommends that
lead-acid batteries be returned to an authorized
recycling facility for disposal.
WARNING: Keep out of the reach of children.

Batteries contain sulfuric acid. Avoid contact with
skin, eyes, or clothing. Also, shield your eyes
when working near batteries to protect against
possible splashing of the acid solution. In case of
acid contact with skin or eyes, flush immediately
with water for a minimum of 15 minutes and get
prompt medical attention. If acid is swallowed, call
a physician immediately. Failure to follow these
WARNING: Batteries normally produce

explosive gases which can cause personal injury.
Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When
charging or working near a battery, always shield
your face and protect your eyes. Always provide
ventilation.
WARNING: When lifting a plastic-cased

battery, excessive pressure on the end walls
could cause acid to spew through the vent caps
resulting in personal injury or damage to the
vehicle or to the battery. Lift with a battery carrier
or with your hands on opposite corners.
WARNING: To avoid accidental deployment

and possible injury, the backup power supply
must be depleted before repairing or installing
any front or side air bag supplemental restraint
system (SRS) components and before repairing,
installing, adjusting or striking components near
the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers,
seats and hood latches. Failure to follow these
procedures may result in personal injury. Refer to
the appropriate vehicle shop manual to determine
location of the front air bag sensors. To deplete
the backup power supply energy, disconnect the
battery ground cable and wait at least one minute.
Be sure to disconnect auxiliary batteries and
power supplies (if equipped). Failure to follow
these instructions may result in personal injury.
G86841 en 01/2003 2003.0 BA Falcon

Battery 3. If the inspection reveals obvious concern(s) that

can be readily identified, service as required.
Inspection and Verification 4. If an obvious cause for a concern is found, correct
the cause before proceeding to the next step.
system. 5. Measure the open circuit battery voltage. If the
battery voltage is less than 12.0 volts, test and
2. Visually inspect for obvious signs of mechanical recharge the battery before continuing with
or electrical damage. diagnosis
6. If the fault is not visually evident, proceed to the
Mechanical Electrical pinpoint test below.
Battery Battery cables
Battery mounting Battery posts
Pinpoint Tests
PINPOINT TEST A : BATTERY CONDITION

A1 TEST BATTERY CONDITION
NOTE: Failure to fully charge the battery before retesting may cause Yes
Does the meter read, Good Battery? Return the
false readings. battery to service. Refer to Section 414-00.
Verify the battery condition using the Battery Analyzer. Does the meter read, Good Recharge? Charge
the battery and return to service. Refer to
Is the battery OK? Section 414-00.
Does the meter read, Good charge & Retest
Fully Charge the battery and retest. Refer to
Section 414-00.
No
Does the meter read. Replace Battery?
INSTALL a new battery.
Does the meter read. Bad cell replace?
INSTALL a new battery.
Component Tests important that it be given a thorough visual

examination to determine if it has been damaged. The
Battery Tests presence of moisture on the outside of the case
Tests are made on a battery to determine the state of and/or low electrolyte level in one or more of the cells
charge and also the condition. The aim of these tests are indications of possible battery damage.
is to check if the battery is good, needs recharging, or Battery Capacity Test
must be replaced. If a battery has failed, is low in
charge, or requires water frequently, good service A battery can be tested by determining its ability to
demands that the reason for this condition be found. It deliver current. This may be determined by
may be necessary to follow trouble shooting conducting a Battery Capacity Test. A high rate
procedures to locate the cause of the trouble. discharge tester (Battery-Starter) in conjunction with a
Hydrogen and oxygen gases are produced during voltmeter is used for this test.
normal battery operation. This gas mixture can 1. Turn the control knob on the Battery-Starter
explode if flames or sparks are brought near the vent Tester to the OFF position.
openings of the battery. The sulphuric acid in the 2. Turn the voltmeter selector switch to the 16 or 20
battery electrolyte can cause a serious burn if spilled volt position.
on the skin or spattered in the eyes. It should be
flushed away with large quantities of clear water. 3. Connect both positive test leads to the positive
battery post. The voltmeter clips must contact the
Visual Check battery posts and not the high rate discharge
tester clips. Unless this is done the actual battery
Some batteries incorporate a single one-piece cover terminal voltage will not be indicated.
which completely seals the top of the battery and the
individual cell connectors. This cover must not be 4. Turn the load control knob in a clockwise direction
pierced with test probes to perform individual cell until the ammeter reads approx. three times the
tests. Before attempting to test a battery, it is ampere hour rating of the battery. (A 61 ampere
G86842 en 01/2003 2003.0 BA Falcon

hour battery should be tested at 180 ampere

load.)
5. With the ammeter reading the required load for 15
seconds, note the voltmeter reading. Avoid
leaving the high discharge load on the battery for
periods longer than 15 seconds.
6. If the voltmeter reading is 9.6 volts or more, the
battery has good output capacity and will readily
accept a charge, if required. Check the specific
gravity. If the specific gravity reading is 1.230 or
below, add water if necessary and charge the
battery until it is fully charged. The battery is fully
charged when the cells are all gassing freely and
the specific gravity ceases to rise for three
successive readings taken at hourly intervals.
Additional battery testing will not be necessary
after the battery has been properly charged.
7. If the voltage reading obtained during the capacity
test is below 9.6 volts, check the specific gravity
of each cell.
8. If the difference between any two cells is more
than 50 points (0.050), the battery is not
satisfactory for service and should be replaced.
9. If the difference between cells is less than 50
points (0.050), the battery should be charged
according to the charging schedule. In some
cases the electrolyte level may be too low to
obtain a specific gravity reading. In such cases
water should be added until the electrolyte level
just covers the ring in the filler well, then charge
the battery at 35 amperes for the maximum
charging time indicated in specifications, for
capacity of the battery being tested.
10. After the battery has been charged, repeat the
capacity test. If the capacity test battery voltage is
still less than 9.6 volts, replace the battery. If the
voltage is 9.6 or more the battery is satisfactory
for service.
11. If the battery is found to be discharged only,
check for a loose drive belt, loose electrical
connections, charging system performance, and
make a battery drain test.
Battery Drain Test
This test will determine if there is any external load
that would cause unwanted battery discharge.
Disconnect the battery ground cable and connect the
positive lead of a voltmeter to the cable. Connect the
negative leads of the voltmeter to the battery negative
post. With all circuits off, the meter should read
<50mA. Any battery external load will cause the
voltmeter to read full battery voltage.
G86842 en 01/2003 2003.0 BA Falcon

Battery and Cables

Removal
1. Disconnect the battery cables.
2. Remove the battery.
Item Description
1 Battery Assembly
2 Bolt M8x190
3 Battery Hold-Down Clamp
3. Remove the hold down bolts.
4. Remove the hold-down.
5. Remove the battery.
Installation
Battery Shroud
Removal
1. Remove shroud as shown in figure.
Item Description
1 Clip
2 Battery Shield
3 Venting Tube
Installation
G86843 en 01/2003 2003.0 BA Falcon

414-02-1 Alternator and Regulator 414-02-1
SECTION : 414-02 Alternator and Regulator

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................414-02-2
Alternator ..............................................................................................................................414-02-3
Description ...........................................................................................................................414-02-3
Operation .............................................................................................................................414-02-3
Alternator and Regulator .......................................................................................................414-02-5
Symptom Chart ....................................................................................................................414-02-5
Component Tests .................................................................................................................414-02-6
Pinpoint Tests ......................................................................................................................414-02-7
Alternator Installation — 6 Cylinder ....................................................................................414-02-14
Alternator Installation — 8 Cylinder ....................................................................................414-02-14
01/2003 2003.0 BA Falcon

SPECIFICATIONS

Description Specification Pulley Securing Torque 98 - 137 Nm
Mitsubishi LC30 6 Cylinder Rectifier Riveted
Current Output 110 Amps @ Ambient B+ Nut 8 +/- 1.2
Temp
Set Voltage 14.5 Volts @ 20°C
Alternator Speed (RPM) 1300/32
/ Output Current (Amps) 2500/81
in Hot 5000/102
Earth Polarity Negative
Mass 6.3 kg
Regulator Performance - 14.5 +/- 0.3 V
Set voltage
Regulator Performance - -5 mV/°C
Temp Compensation
Synthetic Resistance: L 10 - 100 W / 12 V
terminal to Battery
Speed In Use 1000 - 19000 r / min
Rotor Inertia 3.4 x 10-3 kg m2
Pulley Pitch Diameter 51.25 mm +/- 0.5
Rear Fan Diameter 96.5 mm
Visteon 8 Cylinder
Current Output 130 Amps @ Ambient
Temp
Set Voltage 14.45 Volts @ 25°C
Alternator Speed (RPM) 1300/32
/ Output Current (Amps) 2500/81
in Hot 5000/102
Earth Polarity Negative
Mass 6.3 kg
Regulator Performance - 14.45 +/- 10.3 mV/°C
Set voltage
Regulator Performance - 14.45 +/- 10.3 mV/°C
Temp Compensation
Output Ramp Up Time 7s
Max Speed In Use 19600 r / min
Max Ambient Temp 115 °C
Description Nm
Mitsubishi LC30 6 Cylinder
Retaining Bracket Bolts 25 Nm
Bearing Retainer Plate 7.7 +/- .8 Nm
Through Bolts 8.8 +/- .8 Nm
Pulley Securing Torque 98 - 137 Nm
Rectifier Riveted
B+ Nut 8 +/- 1.2
Mitsubishi LC30 8 Cylinder
Retaining Bracket Bolts 25 Nm
Bearing Retainer Plate 7.7 +/- .8 Nm
Through Bolts 8.8 +/- .8 Nm
G86726 en 01/2003 2003.0 BA Falcon

Alternator field coil. This circuit is connected back to the load

distribution point and is a protected circuit.
Description
CAUTION: DO NOT reverse battery sense and
Both the Mitsubishi (6 Cyl.) and Visteon (8 Cyl.)
warning lamp connections as this will destroy the
alternators are three phase alternating current (AC)
warning lamp circuitry. If replacing the alternator
generators with integrally mounted diodes that convert
warning lamp bulb, use of a bulb over 2 Watts
the AC into direct current (DC) suitable for charging
capacity may cause voltage regulator failure.
the battery.
The alternator is inherently self current limiting and Operation
the diodes (shown in the circuit diagrams in Fig 2 & 4)
With the ignition switch turned on and the engine
prevent reverse current flow from the battery. The
running, the flow of current through the rotor field coil
alternator consists of the following major parts:
energises the twelve pole rotating electromagnet. The
The Stator: a laminated frame which carries the three rotation of the energised rotor unit induces an A.C.
phase star connected output winding in slots. voltage in the three phase stator winding. This is
The Rotor: comprising the slip rings and field (exciter) converted into D.C. by the diode rectifiers and
windings. It is constructed of interfaced poles or conducted to the B+ terminal.
fingers which form alternate north and south poles. The electronic regulator operation is similar to that of
The field winding is wound concentric with the shaft the conventional electro-mechanical regulator in that
inside the claw and has its ends connected to the slip the field current is varied to maintain the output
rings. voltage within close limits. However, switching is
The rectifier pack contains eight output diodes on the performed by a transistor instead of vibrating
six cylinder alternator (as shown in Fig 2), and six contacts.
output diodes on the eight cylinder alternator (as The rectifiers, which only conduct current flow in the
shown in Fig 4). The diodes are arranged in a three one direction through the alternator output diodes,
phase bridge connection having three diodes of prevent the battery (which is directly and permanently
positive polarity and three diodes of negative polarity. connected to the alternator output terminal) from
The two end heads carry the ball races. The drive discharging through the alternator. This characteristic
end head incorporates the mounting lug, while the slip of the rectifiers eliminates the need for a cut-out relay,
ring end head contains the brush gear, regulator and (However, the battery must always be connected with
rectifier pack. the negative terminal to ground. Failure to connect a
The electronic regulator is integrated with the battery with the correct polarity will damage the
alternator assembly. The regulator consists of a static alternator and regulator. Disconnect the negative
compact assembly, consisting of a Hybrid circuit, battery lead when using a battery charger.)
transistor and diode, soldered to a printed circuit As the speed of the rotor increases, the induced
board. voltage in the stator winding increases, causing more
The electronic voltage regulator and the brush current to flow to satisfy the load requirements.
gear are an integral assembly mounted on the slip However, the inductive reactance of the stator winding
ring end head. The regulator is not adjustable and provides an automatic self-regulating upper limit on
if tested and found defective it must be replaced. the current output of the alternator.
The regulator senses the battery voltage via the
B+ Battery Connection battery sense wire and controls this voltage by
The B connection is used to connect the alternator to switching the alternator excitation field current on and
the Power Distribution Box (PDB) located in the front off. If battery voltage is below regulated voltage, the
right hand side of the engine bay. power transistor is switched on. When the battery
voltage exceeds the specified limit, the transistor is
’I’ Warning light switched off, causing output voltage to drop. A diode
The ’I’ circuit (or ignition circuit), is used to turn on the protects the transistor and regulator circuitry from
voltage regulator. This circuit is powered up with the voltage transients when the field is switched off by the
ignition key in the ON position. This circuit is also transistor. Switching the regulator on and off ensures
used to turn the indicator lamp on, if there is a fault in the output voltage is maintained constant at the
the charging system operation or associated wiring required regulated level.
circuits.
’A’ Battery sense (V8 only)

The ’A’ circuit (or battery sense circuit) is used to
sense the battery voltage. This voltage is used by the
regulator to determine the alternator output. This
circuit is also used to supply power to the alternator
G86727 en 01/2003 2003.0 BA Falcon

8 Cylinder Visteon Alternator 6 Cylinder Mitsubishi Alternator Regulator Circuit

Diagram
8 Cylinder Visteon Alternator Regulator Circuit

Diagram
6 Cylinder Mitsubishi Alternator
G86727 en 01/2003 2003.0 BA Falcon


Alternator and Regulator
Inspection and Verification Battery Battery charge
Alternator drive belt Main Fuse (140A)
WARNING: Batteries contain Sulfiric Acid. Alternator pulley Electrical connectors
Avoid contact with skin, eyes, or clothing. Also, Electrical connections
shield your eyes when working near batteries to Battery charge
protect against possible splashing of the acid warning indicator
solution. In case of acid contact with skin or eyes, Other electrical
flush immediately with water for a minumumof 15 systems malfunctions
minutes and get prompt medical. If acid is 3. If the inspection reveals obvious concern(s) that
shallowed, call a physician. can be readily identified, service as required.
4. Measure the open circuit battery voltage. If the
WARNING: Batteries normally produce battery voltage is less than 12.0 volts, test and
explosive gases which can pause personal injuiry. recharge the battery before continuing with
Therefore, do not allow flames, sparks or lighted diagnosis.
substances to come the near. When charging or
working near a battery, always shield your face 5. Observe charging system warning indicator status
and protect your eyes. Always provide ventilation. against the following conditions:
The charging system warning indicator will
WARNING: When lifting a plastic-cased illuminate with the ignition switch in RUN and
battery, excessive pressure on the end walls the engine OFF.
could cause acid to spew through the vent caps The charging system warning indicator will be
resulting injuiry or demage to the vehicle or to the OFF with the engine running. c) The charging
battery. Lift with a battery carrier or with your system warning indicator will be OFF with the
hands on opposite corners. ignition switch OFF.
1. Verify the customer’s concern by operating the 6. Check the battery voltage before and after starting
vehicle to duplicate the concern. the engine to determine if the battery voltage
2. Inspect to determine if one of the following increases.
mechanical or electrical concerns apply: Refer to the Normal Charging System Voltages
chart.
Symptom Chart

Charging system warning indicator is A Circuit 36 (Y/W). GO to Pinpoint Test A.
ON with the engine running (the Circuit 36 (Y/W).
battery voltage does not increase) Main Fuse (140 A).
I Circuit 904 (GY/R).
Voltage Regulator.
Alternator
Charging system warning indicatoris Voltage Regulator connector. GO to Pinpoint Test B.
OFF with the ignition switch inthe RUN I Circuit 904 (GY/R).
position and the engineOFF (battery Main Fuse (140 A).
voltage does notIncrease) Voltage Regulator.
Loose or damaged Alternator.
Harness connector
Charging system warning indicatoris Alternator. GO to Pinpoint Test C.
ON with the engine running andthe Voltage Regulator
battery voltage increases
Charging system warning indicatoris Charging system warning indicator GO to Pinpoint Test D.
OFF with the ignition switch inthe RUN lamp bulb.
position and the engineOFF (battery Instrument cluster.
voltage increases) Alternator.
Voltage Regulator.
G86728 en 01/2003 2003.0 BA Falcon


Charging system warning Circuit 36 (Y/W). GO to Pinpoint Test E.
indicatoroperates correctly but the Main Fuse (140A).
batteryvoltage does not increase. Loose or damaged harness connector.
Battery cables.
Alternator.
Voltage regulator
The battery is dead or will not Corroded terminal(s). GO to Pinpoint Test F.
staycharged or low battery or Loose connection(s).
alternator voltage High key-off load.
Alternator.
Voltage Regulator
Charging system warning Loose connection(s). Replace/Repair as required.
indicatorflickers/is intermittent . I Circuit loose.
A Circuit loose.
Alternator.
Voltage regulator
The system overcharges A Circuit 36 (Y/W). GO to Pinpoint Test G.
(batteryvoltage greater than 15.5 volts) Alternator (low output).
Voltage regulator.
I Circuit 904 (GY/R)
Battery leakage or damage A Circuit 36 (Y/W). GO to Pinpoint Test H.

Alternator.
Voltage regulator.
Battery
The voltage gauge reads high or low Alternator (low output). GO to Pinpoint Test I.
Voltage regulator.
Voltage gauge.
Instrument cluster/wiring
The alternator is noisy Loose bolts/brackets. GO to Pinpoint Test J.

Drive belt.
Alternator/Pulley
Radio interference Alternator. GO to 413-08.

Wiring/routing.
In-vehicle entertainment system
Component Tests must be removed from the engine for testing of the
regulator.
Alternator Tests
1. Ensure that the ignition is switched off.
Perform an alternator output test before testing the
2. Disconnect the battery earth cable.
Voltage Regulator. Use care when connecting any
test equipment to the alternator system, as the 3. Remove the leads from the alternator main (B+).
alternator output terminal is connected to the battery 4. Connect the + lead of a moving coil 100 amp
at all times. ammeter to the B + terminal of the alternator.
Alternator Output Test-Off Engine When the alternator Connect the - lead to the B + terminal in the
output test is conducted off the vehicle, a test bench wiring harness.
must be used. Follow the procedure given by the test 5. Connect the positive lead of a good quality
bench equipment manufacturer. When the alternator voltmeter to the alternator B+ terminal. Connect
is removed from the vehicle for this purpose always the negative lead to ground.
disconnect a battery cable as the alternator output 6. Connect the battery earth cable.
connector is connected to the battery at all times.
7. Connect the carbon pile rheostat or the switched
On Engine lamp bank to the battery terminals. (Ensure that
the load control is in the off position).
A variable load such as a Carbon pile rheostat must
be available to place across the battery. A switched 8. Connect a tachometer to the engine.
lamp bank of 800 Watt capacity is a suitable 9. Start the engine and slowly increase engine
substitute for a carbon pile. All output testing is to be speed to obtain 6000 rpm alternator speed.
made with the alternator warm. Run alternator on full 10. Adjust the carbon pile or lamp bank until a
load for 5 minutes prior to making tests. The regulator constant voltage of 14.0 is achieved.
cannot be isolated from the circuit when carrying out
this test. If rated output is not achieved, the alternator 11. The ammeter should now register the rated
output.
G86728 en 01/2003 2003.0 BA Falcon

12. Reduce engine speed to idle rpm and remove the 3. Readjust the alternator speed if necessary.
battery load. 4. Read the regulator output voltage within one
minute and compare with specifications. The
CAUTION: Never remove the battery load
electronic regulator is temperature compensated
while the engine is running at speed.
and a decrease in regulated voltage of 0.07V will
13. Switch off the engine and remove the battery occur.
earth cable.
Terminal A I Alt B+ Batt Eng To
14. Remove the test meters and replace the original
Bat Gnd
wiring to the alternator.
Key OFF 12V 0V 12V 12V 0V
15. Replace the battery earth cable. Should the
alternator fail to produce the rated output it must Key ON - 12V 1-3V 12V 12V 0V
be removed from the vehicle for further tests and Engine OFF
repairs. Engine 12- 12- 12-15V 12- 0V
running 15V 15V 15V
Voltage Regulator
NOTE: The alternator must always be connected to
the battery during testing otherwise the diodes might
be damaged.
1. Connect a voltmeter between the B + terminal
and the alternator housing.
2. Increase the alternator speed to 6000 rpm. Set
the load current to 5 amps.
Pinpoint Tests
CAUTION: Do not make jumper connections

except as directed. Improper connections may
damage the voltage regulator test terminals.
CAUTION: Do not allow any metal object to

come in contact with the alternator housing and
internal diode cooling fins.
PINPOINT TEST A : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING (THE BATTERY VOLTAGE DOES NOT INCREASE)
A1 CHECK CIRCUIT 36 (Y/W)

Measure the voltage between the B+ terminal on the alternator Circuit Yes
36 (Y/W). Go to A2
Is the voltage equal to battery positive voltage (B+)? No
REPAIR Circuit 36 (Y/W).
Test the system for normal operation.
A2 CHECK CIRCUIT 36 (Y/W)

Go to A3
Disconnect Alternator connector C161.
Measure the voltage between alternator connector Pin C161-A Circuit No
36 (Y/W) and ground. REPAIR Circuit 36 (Y/W).
Is the voltage equal to battery positive voltage (B+)?
G86728 en 01/2003 2003.0 BA Falcon


A3 CHECK I CIRCUIT 904 (GY/R) FOR AN OPEN
Connect Alternator connector C161. Check C390. Yes
Go to A4
Key in ON position.
Measure the voltage between the alternator I - terminal, Circuit 904 No
(GY/R) and ground. Repair Circuit 904 (GY/R) for an open or short.
Measure the voltage between the alternator I - terminal, Circuit
904 (GY/R) and ground.
A4 CHECK THE ALTERNATOR OUTPUT

With the engine running, ground the F pin on the alternator regulator. Yes
REPLACE the voltage regulator.
Does the battery voltage increase and the charging system Test the system for normal operation.
warning indicator turn off?
No
REPLACE the alternator.
PINPOINT TEST B : THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION
SWITCH IN THE RUN POSITION AND THE ENGINE OFF (BATTERY VOLTAGE DOES NOT INCREASE)
B1 INSPECT ALTERNATOR CONNECTOR C161

Disconnect Alternator connector C161. Yes
Go to B2
Check alternator connector for bent, or damaged pins.
Ensure connector C390 is installed in PDB. No
Is the connector OK? REPAIR Connector C161 as necessary.
B2 CHECK THE ALTERNATOR GROUNDS

Check all ground connections between the alternator voltage regulator Yes
and the battery. Go to B3
Are the ground connections OK? No
REPAIR Connections as necessary.
B3 CHECK I CIRCUIT 904 (GY/R)

Connect Alternator connector C161. Check C390. Yes
Key in ON position.
Measure the voltage between the alternator I - terminal, Circuit 904 No
(GY/R) and ground. Repair Circuit 904 (GY/R) for an open.
Is the voltage greater than 1 volt?
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING (THE BATTERY VOLTAGE INCREASES)
C1 CHECK CONNECTOR C161

Make sure that connector C161 is correctly mated to the alternator Yes
and making contact. Go to C2
Is the connection OK? No
REPAIR connector C161 as necessary.
C2 CHECK THE ALTERNATOR OUTPUT VOLTAGE

With the engine running at 2000 rpm, measure the voltage output at Yes
the alternator B+ terminal. REPLACE voltage regulator.
Is the voltage output less than 16 volts?
No
Go to H1
PINPOINT TEST D : THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION
SWITCH IN THE RUN POSITION AND THE ENGINE OFF (THE BATTERY VOLTAGE INCREASES)
D1 CHECK THE CHARGING SYSTEM WARNING

INDICATOR OPERATION
Key in ON position. Yes
Go to D2
Disconnect The alternator connector C161.
Ground the alternator connector C161 I circuit with the ignition switch No
in the RUN position and the engine OFF. REPAIR connector C161, I Circuit 904 (GY/R)
as necessary.
Ensure connector C390 is correctly assembled. Test the system for normal operation.
Is the warning indicator ON?
D2 CHECK THE ALTERNATOR

Connect C161 connector. Yes
Observe the warning indicator.
Is the warning indicator ON?
No
PINPOINT TEST E : THE CHARGING SYSTEM WARNING OPERATES CORRECTLY BUT THE BATTERY
VOLTAGE DOES NOT INCREASE.
E1 CHECK CIRCUIT 36 (Y/W)

Go to E2
Measure the voltage between the B+ terminal on the alternator Circuit
36 (Y/W). No
Is the voltage equal to battery positive voltage (B+)? REPAIR Circuit 36 (Y/W) as necessary.
G86728 en 01/2003 2003.0 BA Falcon


E2 CHECK THE ALTERNATOR CONNECTORS
Check the battery terminals and alternator connectors C161 & Yes
C390for corrosion and tightness. Perform the Alternator On-Vehicle Tests;
REFER to Component Tests in this section.
Are all the connectors clean and tight?
No
REPAIR the connectors as necessary.
PINPOINT TEST F : THE BATTERY IS DEAD OR WILL NOT STAY CHARGED OR LOW BATTERY OR
ALTERNATOR VOLTAGE
F1 CHECK THE BATTERY DRAIN

PERFORM Battery - Drain Testing.
Make sure that all interior and exterior lamps and switches are off. REFER to Component Tests in this section.
Check the battery drain.
No
Is the drain greater than 0.5 amps? Go to F2
F2 CHECK THE ALTERNATOR OUTPUT

Check the alternator output. Perform Alternator On-Vehicle Tests; Yes
refer to Component Tests in this section. Go to F3
Is the alternator OK? No
F3 CHECK THE BATTERY CONDITION

Check the battery capacity. with the Midtronic handheld battery tester. Yes
Go to F4
Is the battery OK?
No
REPLACE the battery.
F4 CHECK OTHER ELECTRICAL SYSTEMS FOR DRAINS

Check the drains from electronic modules. Perform the test for Yes
Battery-Electronic Drains Which Shut Off When the Battery Cable is RECHARGE the battery.
Disconnected; refer to Component Tests in this section. Test the system for normal operation.
Are the electronic modules OK? No
REPLACE the module or REPAIR the circuit
causing the electrical drain as necessary.
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST G : THE SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15.5
VOLTS)
G1 CHECK FOR A VOLTAGE DROP

Go to G2
Check for voltage drop from the battery positive post and the voltage
regulator ’A’ terminal. No
Is the voltage drop less than 0.5 volts? REPAIR Circuit 36 (Y/W) for high resistance as
necessary.
G2 CHECK THE BATTERY VOLTAGE

With the engine running, turn off all accessories. Yes
Go to G3
Increase the engine speed and monitor the voltage at the battery.
Does the battery voltage remain less than 15 volts? No
Go to G6
G3 CHECK THE ALTERNATOR FOR LOW VOLTAGE

Go to G5
Measure the voltage at the voltage regulator F terminal.
Does the voltage equal battery voltage? No
Go to G4
G4 CHECK FOR GROUNDED SLIP RINGS

Disconnect The alternator connector C161.
Remove the voltage regulator from the alternator.
No
Measure the resistance from both alternator slip rings to ground. REPLACE the voltage regulator.
Is the resistance greater than 1K ohms?
G5 CHECK THE WARNING SYSTEM INDICATOR

OPERATION
With the engine running, increase the engine speed, check the Yes
indicator operation and check for a battery voltage increase. REPAIR circuit 904 (GY/R) as necessary.
Does the battery voltage increase above 15 volts or does the
indicator flicker? No
Test the system for normal operation
G6 CHECK THE WARNING SYSTEM INDICATOR

OPERATION
With the engine running, increase the engine speed, check the Yes
indicator operation and check for a battery voltage increase. REPAIR circuit 904 (GY/R) as necessary.
Does the battery voltage increase above 15 volts or does the
indicator flicker? No
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST H : BATTERY LEAKAGE OR DAMAGE
H1 CHECK FOR ACID LEAKAGE OR DAMAGE

Check for acid damage to the vehicle harnesses and to the body. Yes
REPAIR the damaged areas as necessary.
Is there acid damage?
No
Go to H2
H2 CHECK THE CHARGING SYSTEM FOR

OVERCHARGING
With the engine running, turn off all the accessories. Increase the Yes
engine speed and monitor the voltage at the battery. Go to G1
Does battery voltage increase more than 15 volts? No
Go to H3
H3 CHECK THE BATTERY MOUNTING

Make sure the battery is properly mounted and level in the battery Yes
tray. Go to H4
Is the battery properly mounted? No
Install the battery.
H4 CHECK FOR BATTERY CONTACT

Make sure that there are no fasteners or other parts contacting the Yes
battery case causing excess pressure. REMOVE or REPOSITION these items as
necessary.
Is there anything contacting the battery case? Test the system for normal operation.
No
Go to H5
H5 CHECK THE BATTERY LEAKAGE OR DAMAGE

Check the battery case for damage such as cracks or poor seals. Yes
The charging system is OK.
Is the battery OK? Test the system for normal operation.
No
REPLACE the battery.
PINPOINT TEST I : THE VOLTAGE GAUGE READS HIGH OR LOW

I1 CHECK THE BATTERY VOLTAGE
With the engine running, turn off all accessories. Increase the engine Yes
speed and monitor the voltage at the battery. Go to G1
Is the battery voltage more than 15 volts? No
Go to I2
G86728 en 01/2003 2003.0 BA Falcon


I2 CHECK THE VOLTAGE GAUGE OPERATION
With the engine running, monitor the voltage gauge reading and the Yes
battery voltage. The charging system is operating normally.
Are the voltage readings consistent? No
Check Instrument Cluster section to continue
diagnostics.
PINPOINT TEST J : THE ALTERNATOR IS NOISY

J1 CHECK FOR ACCESSORY DRIVE NOISE
Check the drive belt for damage and verify the installation. Yes
Go to J2
Check the alternator mounting for loose bolts or misalignment.
Check for a bent alternator pulley. No
For further diagnostics, refer to the Accessory
Is everything OK? Drive System section.
J2 SUBSTITUTE A KNOWN GOOD ALTERNATOR

INSTALL the original alternator and CHECK
Disconnect The alternator connector C161. other accessories to FIND the cause of the
Install a known good alternator. noise.
Start up the engine. No
Is the noise present with a known good alternator? REPLACE the alternator.
RETEST the system for normal operation.
G86728 en 01/2003 2003.0 BA Falcon

Alternator Installation — 6 Cylinder Alternator Installation — 8 Cylinder

Removal Removal
1. Disconnect the battery ground cable. For 1. Disconnect the battery ground cable. For
additional information, refer to Section 414-01. additional information, refer to Section 414-01.
2. Remove the Front End Accessories Drive belt, 2. Remove the Front End Accessories Drive belt,
For additional information, refer to Section For additional information, refer to Section
303-05. 303-05.
3. Remove the Nut from connector B on the 3. Remove the Nut on the B connector and remove
alternator and remove wiring from alternator. wiring from Alternator Wiring Harness.
4. Remove the 5 M8 Bolts holding the Alternator in 4. Remove the 4 Upper Bracket bolts.
place.
5. Remove the 2 lower retaining bolts and remove

the alternator.
5. Remove the Alternator.

1. To reinstall, reverse the Removal Procedure. 1. To reinstall, reverse the Removal Procedure.
G86729 en 01/2003 2003.0 BA Falcon

415-00-1 Entertainment System — General Information 415-00-1
SECTION : 415-00 Entertainment System —

General Information
CONTENTS PAGE
Audio System ........................................................................................................................415-00-2
Self Tests .............................................................................................................................415-00-2
Function Tests ......................................................................................................................415-00-2
DTC Chart ............................................................................................................................415-00-3
Symptom Chart ....................................................................................................................415-00-4
PID Chart .............................................................................................................................415-00-5
Service Procedures ..............................................................................................................415-00-6
01/2003 2003.0 BA Falcon

Audio System Parameter identifiers (PID’s)

Module configuration
Principles of Operation
Module Configuration
The following diagnostics are available by connecting
the WDS tester to the diagnostic link connector The CDU has the following configuration options:
located on the right hand side of the fuse box. Audio security
Sonar parking enable/disable on premium sound
audio
Module configuration is carried out by using the WDS
tester.
Self Tests
The following tests are carried out within seconds,
during the On Demand Self Test.
Antenna connection
Speaker line short circuit
Subwoofer connection
Speaker tone test
AM signal strength check
The WDS tester will support the following modes FM signal strength check
Self tests Subwoofer speaker short circuit
Service Procedures (Using the Data Logger Trip computer data unavailable
function )
Invalid vehicle speed data
Diagnostic trouble codes (DTC’s)
Invalid ambient temperature data
On Demand Self Test
Step Test Action
1 Connect WDS tester —
Turn radio on
Tune FM radio to known station and set
one of the presets.
Carry out self test
2 Speaker tone test function Listen to speakers.
Tone to each speaker is 1.5 sec on and
0.5 sec off.
Sequence.
Front right > rear right > rear left > front
left
NOTE: Subwoofer output is not tested
3 Is DTC logged Refer to DTC chart
4 For AM signal strength tune to known AM —
station set a preset and repeat the above
test
Function Tests
Function test Description

Steering wheel switch test Tests steering wheel switches and wiring and identifies
faulty circuit
ICC switch test Tests audio switch functionality and identifies faulty switch
or function
Input status test
Subwoofer Is Subwoofer connected
G68759 en 01/2003 2003.0 BA Falcon

Function test Description

Auxiliary Is Auxiliary input connected
Navigation Is Navigation signal present
Sonar parking Is Sonar parking aid set
Phone Is Phone mute input enabled
Multi CD test Checks for presence of CD’s in mechanism
DTC Chart

B1342 ECU is faulty Faulty Audio unit Document and clear the DTC’s. Carry
out the self test. If the DTC is registered
again replace ICC. Test the system for
correct operation.
B1318 Battery voltage low Low system voltage Document and clear the DTC’s. Run
detected. vehicle for 2 minutes. If the DTC is
registered again check / correct battery.
B2103 Antenna not Antenna connection not Document and clear the DTC’s. Carry
connected made/damaged out the self test. If the DTC is registered
symptom in the symptom chart.
B2203 CD error CD inserted incorrectly, Document and clear the DTC’s.
data CD inserted Remove all CD’s then reload CD’s and
read CM (continuously monitored)
DTC’s. If the DTC is registered again
refer to CD does not play symptom in
the symptom chart.
B2403 Multi CD mechanical CD stuck etc. Document and clear the DTC’s.
error Remove all CD’s then reload 6 CD’s
and play each momentarily. Read CM
refer to Unable to load / eject CD’s
(multi player ) symptom in the symptom
chart
B2404 Audio steering wheel Audio steering wheel Document and clear the DTC’s. Read
switches faulty switch jammed CM DTC’s If the DTC is registered
again refer to Steering wheel audio
switch not operating symptom in the
symptom chart.
B2406 Single CD CD stuck etc. Document and clear the DTC’s.
mechanical error Remove and then reload CD. Read CM
refer to Unable to load / eject CD’s
(single player ) symptom in the
symptom chart.
B2408 Speaker line short Detects speaker line Document and clear the DTC’s. Carry
shorted to ground or B+ out the self test. If the DTC is registered
again refer to One or more speakers not
operating symptom in the symptom
chart.
B2409 AM tuner fault No AM signal (Antenna Document and clear the DTC’s. Carry
G68759 en 01/2003 2003.0 BA Falcon


B2410 FM tuner fault No FM signal (antenna Document and clear the DTC’s. Carry
again refer to Poor or no radio reception
B2924 Audio button stuck Audio button jammed Document and clear the DTC’s. Read
again refer to Audio button not working
B2922 Auxiliary button stuck Auxiliary button jammed Document and clear the DTC’s. Read
again refer to the following symptoms in
the symptom chart of ICC diagnostics
413-08.
Traction button not working.
Trip / Reset button no working.
Interior lamp button not working.
Lock/Unlock button not working.
B2925 Subwoofer speaker Subwoofer line shorted Document and clear the DTC’s. Read
short to ground or B+ CM DTC’s. If the DTC is registered
U2014 Audio subwoofer not Subwoofer Document and clear the DTC’s. Carry
connected disconnected/not fitted out the self test. If the DTC is registered
B2923 Climate control Climate control button Document and clear the DTC’s. Read
button stuck. jammed. CM DTC’s. If the DTC is registered
again refer to Climate control button not
working symptom in the symptom chart
of ICC diagnostics 413-08.
B2911 Trip computer data Instrument cluster did Document and clear the DTC’s. Read
invalid. not have valid data DTC’s. If the DTC is registered again
available. referto instrument cluster section
413-01.
U1900 CAN communication CAM messages not Document and clear the DTC’s. Read
fault. received. DTC’s. If the DTC is registered again
referto CAN bus diagnostics section
303-14.
U2201 Ambient temperature HIM did not have valid Document and clear the DTC’s. Read
data invalid. data available. DTC’s. If the DTC is registered again
refer toRefer to HIM section 412-00.
Symptom Chart

Audio button not working. Low system voltage Service Procedure: Audio Button not
Internal fault working. (Test A)
Navigation not working. Internal fault Service Procedure: Navigation not

Remote control fault working. (Test J)
Navi module fault
Wiring fault
Telephone input not working Internal fault Service Procedure: Telephone input
Wiring fault not working. (Test K)
Telephone fault
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Auxiliary input not working Input fault Service Procedure: Auxiliary input not
Wiring fault working. (Test L)
Source fault
Sonar not operating Internal fault Service Procedure: Sonar not

Wiring fault operating. (Test M)
ICC not correctly configured
Sonar module fault
ICC does not turn on Internal fault Service Procedure: ICC does not
Wiring fault operate. (Test E)
Speaker fault
Antenna fault
Unable to load/eject CDs ( Single CD ) Internal fault Service Procedure: Single CD player
Faulty CDs mechanical fault (Test B)
CD does not play Internal fault Service Procedure: CD focus error

Faulty CD (Test D)
Poor or no radio reception Internal fault Service Procedure: Poor radio

Wiring fault reception (Test H)
Antenna fault
One or more speakers not operating Internal fault Service Procedure: Speaker fault (Test
Speaker fault G)
Wiring fault
Subwoofer not working Internal fault Service Procedure: Subwoofer fault

Wiring fault (Test F)
Amplifier fault
Speaker fault
Steering Wheel audio switch not Internal fault Service Procedure: Audio steering
operating Wiring fault wheel switch not functioning (Test I)
Switch fault
PID Chart Command Description

MODE_SW Mode Switch
Command Description
NAV_PRES Navigation
Codes Set REVRS_INP Reverse
MENU_SW Menu switch
NTCSDT Number of Trouble Codes Set due
to Diagnostic Test CLK_DSPL Clock Display Enable Status
AUD_VOL Audio Volume PHONE_AT Phone Transceiver Active
AUSTCRES Audio Steering Switch Circuit VOLI_SW Volume Increase Switch
Resistance VOLD_SW Volume Decrease Switch
AUTO_VCG Automatic Volume Control Gain TUNE_UP Tune Increase Switch
ATNN_RSS Antenna Reception Signal Strength TUNE_DN Tune Decrease Switch
AUDIO_SI Audio Security Identification SEEK_UP Seek Increase Switch
LCD_SEG LCD Segment Display PLUS_SW (+) Switch
SEC_STAT Security Status AM_SWT AM Switch
ACM_STAT ECU Operating State FM_SWT FM Switch
MOD_ID Module ID Check CD_SWT CD Switch
CONPROV Configuration and Programming AUTO_SW Autoset
Version EJECT_SW Eject
CANDSV CAN Diagnostic Specification PRE1_SW Preset 1 Switch
Version
VOL_UP (+) Volume button
VOL_DN (-) Volume button
SEEK_BTN (+) Seek button
G68759 en 01/2003 2003.0 BA Falcon

Command Description Command Description

PRE5_SW Preset 5 Switch CD_SLOT6 CD in slot 6
PRE6_SW Preset 6 Switch CD_SLOT5 CD in slot 5
POWER_SW Power Switch CD_SLOT4 CD_SLOT4
SUB_AMP Subwoofer Amplifier CD_SLOT3 CD in slot 3
VID_SRC Video Source CD_SLOT2 CD in slot 2
AUD_SR Audio Source CD_SLOT1 CD in slot 1
CLK_ODV Clock Overlay Display on Video RUN_POS Run
LOAD_SW Load Switch pressed ACC_POS ACC Position
LOUD_SW Loudness Switch pressed
Service Procedures
Service Procedure Description
Audio button not working (Test A) Tests the ICC audio switches for correct operation
and identifies a fault.
Single CD player mechanical fault (Test B) Tests the loading, ejection and operation of the single
CD player and identifies a fault.
Multi CD player mechanical fault (Test C) Tests the loading, ejection and operation of the multi
CD player and identifies a fault.
CD focus error (Test D) Tests single and multi CD players for correct
ICC does not operate (Test E) Identifies a fault when the ICC does not operate.
Subwoofer fault (Test F) Tests the subwoofer system for correct operation and
identifies a fault.
Speaker fault (Test G) Tests the speaker system for correct operation and
identifies a fault.
Poor radio reception (Test H) Tests for poor radio reception and identifies a fault.
Audio steering wheel switch not functioning (Test I) Tests the audio steering wheel switches for correct
Navigation not working (Test J) Tests for connection of the navigation system to the
ICC and tests the remote control operation.Identifies
faults.
Telephone input not working (Test K) Checks the telephone input function and identifies a
fault.
Auxiliary input not working (Test L) Tests the auxiliary input function and identifies a fault.
Sonar not operating (Test M) Tests for operation of the sonar function in a vehicle
with sonar fitted and identifies a fault.
TEST A : AUDIO BUTTON NOT WORKING

Using the WDS data logger function activate the following acronyms.
RUN_POS, ACC_POS, POWER_SW, VOLI_SW, VOLD_SW, SEEK_BTN, MENU_SW, TUNE_UP,
TUNE_DN, AM_SWT, FM_SWT, CD_SWT, AUTO_SW, PRE1_SW, PRE2_SW, PRE3_SW, PRE4_SW,
PRE5_SW, PRE6_SW, LOUD_SW, LOAD_SW, EJECT_SW

A1
Check pid’s using data logger. Go to A2
system and retest.
G68759 en 01/2003 2003.0 BA Falcon


A2
Check that the accessories are on.. Yes ACC_POS
Check pid’s using data logger Go to A3
system and retest
A3
Is the audio on? Go to A5
No
Go to A4
A4
Check pid’s using data logger. Go to A5
Go to ICC does not turn
on symptom in the
symptom chart.
A5
Operate each audio switch / knob. Yes
Are any switches / knobs sticking or stuck? Replace ICC and retest.
No
Continue.
A6
Check that each audio switch / knob operates. Yes POWER_SW,
Check pid’s using data logger. Go to A7 VOLI_SW,
Does each audio switch / knob operate? No VOLD_SW,
Replace ICC and retest. SEEK_BTN,
MENU_SW,
TUNE_UP,
TUNE_DN,
AM_SWT,
FM_SWT,
CD_SWT,
AUTO_SW,
PRE1_SW,
PRE2_SW,
PRE3_SW,
PRE4_SW,
PRE5_SW,
PRE6_SW,
LOUD_SW,
LOAD_SW,
EJECT_SW
A7
Control the following Pid’s using the WDS data Yes As per acronym
logger function. Go to A8 list step A6.
Check for correct function operation for each switch No
/ knob. Replace ICC and retest.
Do all functions operate?
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A8
Check that the ICC function for each audio switch Yes
operates correctly. No fault. ICC functioning
Do all functions operate? correctly.
No
TEST B : SINGLE CD PLAYER MECHANICAL FAULT
RUN_POS, ACC_POS, POWER_SW, CD_SWT, EJECT_SW, CD_SLOT1

B1
Check pid’s using data logger. Go to B2
system and retest.
B2
system and retest.
B3
Is the audio on? Go to B5
No
Go to B4
B4
on symptom in the
symptom chart.
B5
Push the CD button. Yes CD_SWT
Does the CD button operate? No
B6
Check that the ICC displays "no CD" when the CD Yes
button is pressed. Go to B9
Does the ICC display "no CD" No
Go to B7
B7
Press the ICC eject button. Yes EJECT_SW
Does the CD eject button operate? No
G68759 en 01/2003 2003.0 BA Falcon


B8
Check to see if the CD ejected when the eject Yes CD_SLOT1
button was pressed. Go to B9
Check pid’s using data logger. No
Did the CD eject? Replace ICC and retest.
B9
Insert a known good original genuine CD. Yes CD_SLOT1
Ensure that the CD is inserted with the label facing Go to B10
up. No
Check pid’s using data logger. Replace the ICC and
Is the CD inserted? retest.
B10
Check that the CD plays correctly. Yes
Does the CD play correctly? Go to B11
No
Go to CD does not play
symptom in the symptom
chart.
B11
Replace ICC
B12
Check to see if the CD ejected when the eject Yes CD_SLOT1
button was pressed. No fault. ICC functioning
Check pid’s using data logger. correctly.
Did the CD eject? No
TEST C : MULTI CD PLAYER MECHANICAL FAULT

RUN_POS, ACC_POS, POWER_SW, CD_SWT, EJECT_SW, LOAD_SWT, CD_SLOT1, CD_SLOT2,
CD_SLOT3, CD_SLOT4, CD_SLOT5, CD_SLOT6, PRE6_SW

C1
Check pid’s using data logger. Go to C2
system and retest.
C2
system and retest.
C3
Is the audio on? Go to C5
No
Go to C4
G68759 en 01/2003 2003.0 BA Falcon


C4
on symptom in the
symptom chart.
C5
Push the CD button. Yes CD_SWT
Does the CD button operate? No
C6
Check that the ICC displays "NO DISC" when the Yes
CD button is pressed. Go to C9
Does the ICCdisplay "NO DISC" No
Go to C7
C7
C8
Eject all CD’s from the ICC. Yes CDSLOT1,
Check pid’s using data logger. Go to C9 CDSLOT2,
Did all CD’s eject? No CDSLOT3,
Replace ICC and retest. CDSLOT4,
CDSLOT5,
CDSLOT6
C9
Press the ICC load button. Yes LOAD_SW,
Check pid’s using data logger. Go to C9 PRE6_SW
Does the CD load button operate? No
Replace ICC
C10
Load 6 known good original genuine CD’s. Yes CDSLOT1,
Ensure that the CD’s are inserted with the label Go to C11 CDSLOT2,
facing up. No CDSLOT3,
Check pid’s using data logger. Replace the ICC and CDSLOT4,
Did all CD’s load? retest. CDSLOT5,
CDSLOT6
C11
Check that all CD’s play correctly. Yes
Do all the CD’s play correctly? Go to C12
No
Go to CD does not play
symptom in the symptom
chart.
C12
G68759 en 01/2003 2003.0 BA Falcon


C13
Eject all CD’s from the ICC. Yes CDSLOT1,
Check pid’s using data logger. No fault. ICC functioning CDSLOT2,
Did all CD’s eject? correctly. CDSLOT3,
No CDSLOT4,
Replace ICC and retest. CDSLOT5,
CDSLOT6
TEST D : CD FOCUS ERROR

RUN_POS, ACC_POS, POWER_SW, CDSLOT1

D1
Check pid’s using data logger. Go to D2
system and retest.
D2
system and retest.
D3
Is the audio on? No
Go to D4
D4
on symptom in the
symptom chart.
D5
Insert a known good original genuine CD. Yes CDSLOT_1
Ensure that the CD is inserted with the label facing Go to D6
up. No
Check pid’s using data logger. Replace the ICC and
Is the CD inserted? retest.
D6
Does the CD play correctly? ICC functioning correctly.
No
Continue
G68759 en 01/2003 2003.0 BA Falcon


D7
Insert the ICC head cleaning CD and operate as Yes CDSLOT_1
per procedures. Go to D8
Remove the head cleaning CD. No
Insert a known good original genuine CD. Replace the ICC and
Ensure that the CD is inserted with the label facing retest.
up.
Check pid’s using data logger.
Is the CD inserted?
D8
Does the CD play correctly? ICC functioning correctly.
No
TEST E : ICC DOES NOT OPERATE


E1
Check pid’s using data logger. Go to E2
system and retest.
E2
system and retest.
E3
Is the audio on? No
Go to E4
E4
Check pid’s using data logger. No fault. ICC functioning
Does the ICC audio turn on? correctly.
No
Continue.
E5
Check to see if the ICC fuse is blown. Yes
Is the fuse blown? Go to E6
No
Go to E8
E6
Replace the blown ICC fuse with a new fuse of Yes
correct value. Go to E7
Does the fuse blow again? No
Retest ICC
G68759 en 01/2003 2003.0 BA Falcon


E7
Remove the ICC. Yes
Replace the blown ICC fuse with a new fuse of Repair/replace wiring as
correct value. per wiring procedure
Does the fuse blow again? Install the ICC and
replace blown fuse.
Retest ICC.
No
ICC is faulty. Replace with
a new ICC and retest.
E8
Check that the battery voltage is greater than 10.5 Yes
Volts with the ignition on. Go to E9
Is the battery voltage greater than 10.5Volts? No
Rectify vehicles power
supply and retest.
E9
Remove the ICC. Yes
Inspect both halves of the ICC self-aligning Go to E10
connector. No
Is the self-aligning connector damaged? Go to E12
E10
Inspect both halves of the ICC self-aligning Yes
connector. Replace the ICC.Replace
Are both halves of the connector damaged? the instrument panel self-
aligning connector.
No
Continue.
E11
Inspect the self- aligning connector on the Yes
Instrument panel. Replace the instrument
Is this half of the connector faulty? panel self- aligning
connector.Re-fit ICC and
retest.
No
E12
Check for a ICC supply voltage of 10.5 Yes
Volts minimum at the ICC instrument panel Replace ICC and retest.
self-aligning connector. No
Refer to vehicle wiring diagram. Repair wiring to the ICC
instrument panel
connector and retest.
TEST F : SUBWOOFER FAULT


F1
Check pid’s using data logger. Go to F2
system and retest.
G68759 en 01/2003 2003.0 BA Falcon


F2
system and retest.
F3
Is the audio on? Go to F5
No
Go to F4
F4
on symptom in the
symptom chart.
F5
Tune to a known radio station. Yes
Is the subwoofer speaker working correctly? No Fault.
No
Continue.
F6
Check the subwoofer amplifier fuse. Yes
Is the fuse OK? Go to F8.
No
Continue.
F7
Remove the faulty fuse and replace with a new fuse Yes
of correct value. Go to F8.
Does the fuse blow again? No
Retest for correct
operation.
F8
Check the amplifier power and ground connections. Yes
Are connections correct? Go to F9
No
Repair/replace wiring as
per wiring
procedureReplace fuse if
blown and retest.
F9
Check connections between the amplifier and Yes
subwoofer speaker. Go to F10.
Are connections correct? No
per wiring
procedureReplace fuse if
blown and retest.
G68759 en 01/2003 2003.0 BA Falcon


F10
Check that the wiring connections between the ICC Yes
and amplifier. Go to F11.
Are connections correct? No
per wiring procedure
Replace fuse if blown and
retest.
F11
Replace the subwoofer amplifier.Replace the fuse if Yes
blown. Original amplifier is faulty.
Is the subwoofer speaker working correctly? Retest with a new
amplifier.
No
Refit the original amplifier
and continue.
F12
Replace the subwoofer speaker. Yes
Replace the fuse if blown. Original subwoofer is
Is the subwoofer speaker working correctly? faulty. Retest with a new
subwoofer.
No
Replace the ICC. Refit the
original subwoofer
speaker. Replace fuse if
blown and retest.
TEST G : SPEAKER FAULT


G1
Check pid’s using data logger. Go to G2.
No
system and retest.
G2
system and retest.
G3
Is the audio on? Go to G5.
No
Go to G4.
G68759 en 01/2003 2003.0 BA Falcon


G4
on symptom in the
symptom chart.
G5
Cycle the ICC balance and fade controls. Yes
Inspect the ICC balance and fade displays. Go to G6.
Do the balance and fade displays operate? No
G6
Cycle the ICC balance and fade controls. Yes
Check for correct operation of all speakers. No fault.
Do all speakers operate correctly? No
Continue.
G7
Check vehicle speaker wiring for short to power or Yes
ground. Go to G8.
Is wiring OK? No
G8
Substitute any faulty speakers with a new speaker. Yes
Do all speakers operate correctly? Original speaker is
faulty.Fit new speaker and
retest.
No
Continue.
G9
Remove the ICC. Yes
Check for continuity of vehicle speaker wires Replace ICC and retest.
between the ICC instrument panel connector and No
any faulty speaker. Repair/replace wiring as
Refer to wiring diagram. per wiring procedure
Are connections correct?
TEST H : POOR RADIO RECEPTION

RUN_POS, ACC_POS, POWER_SW, ATNN_RSS

H1
Check pid’s using data logger. Go to H2
system and retest.
G68759 en 01/2003 2003.0 BA Falcon


H2
Check to see if the ICC audio is turned on. Yes POWER_SW
Is the audio on? Go to H4.
No
on symptom in the
symptom chart.
H3
Check pid’s using data logger. Go to H4.
on symptom in the
symptom chart.
H4
Turn on the heater backlight. Yes ATNN_RSS
Check for poor AM and FM radio reception. Go to H5.
Is the radio reception poor? Go to H6
NOTE: Tinting of the rear window may affect radio
reception.
H5
Check that the rear window FM Antenna and the Yes
AM antenna are not damaged. Go to H6
Are the antennas OK? No
Replace / rectify faulty
antenna.
H6
Check reception with engine running. Yes RUN_POS,
Start the vehicles engine. Go to H7 ATNN_RSS
Is the radio reception poor? Correct operation.
H7
Check / repair the vehicles suppressor and the Yes ATNN_RSS
antenna module ground connection. Go to H8.
Is the radio reception poor? Fault rectified. Retest
ICC.
H8
Check that the on glass antenna module has power Yes
connected. Go to H12.
Is there power to the module? No
Continue.
H9
Check the antenna fuse. Yes
Is the fuse blown? Go to H10.
No
Go to H12.
H10
Remove the faulty fuse and replace with a new fuse Yes
of correct rating. Go to H11.
Does the fuse blow? No
Retest.
G68759 en 01/2003 2003.0 BA Falcon


H11
Check for a short in the antenna module wiring. Yes
Is the wiring OK? Replace the antenna
module and retest.Ensure
that the faulty fuse is
replaced.
No
per wiring
procedureEnsure that the
faulty fuse is replaced.
H12
Check the antenna module by substituting with Yes ATNN_RSS
another module. Install original antenna
Check pid’s using data logger. module and Go to H13.
Is the radio reception poor? No
Original antenna module
is faulty.
H13
Check antenna rear coaxial cable and connection Yes
at left hand cowl side. Go to H14.
Is cable / connection OK. No
Rectify faulty cable /
connection and retest.
H14
Remove the ICC. Yes
Check that the coaxial cable and connections to the Replace ICC and retest.
ICC are OK. No
Is cable / connection OK? Rectify faulty cable /
connection and retest.
TEST I : AUDIO STEERING WHEEL SWITCH NOT FUNCTIONING
RUN_POS, ACC_POS, POWER_SW, VOL_UP, VOL_DN, SEEK_BTN, MODE_SW

I1
Check pid’s using data logger. Go to I2.
system and retest.
I2
system and retest.
I3
Is the audio on? Go to I5.
No
Go to I4.
G68759 en 01/2003 2003.0 BA Falcon


I4
on symptom in the
symptom chart.
I5
Check that each steering wheel audio switch Yes VOL_UP,
functions correctly. Correct operation VOL_DN ,
Check pid’s using data logger. No SEEK_BTN,
Does each switch function correctly? Continue MODE_SW
I6
Remove steering wheel airbag as per airbag Yes
removal procedure. Go to I7
Disconnect audio steering wheel connection. No
Do switch resistance check Replace switches
Volume- 0 Ohm
Volume+ 560 Ohm
Seek 1,560 Ohm
Media 3,360 Ohm
Is switch resistance correct
I7
Check wiring connection between ICC Instrument Yes
panel connector and steering column Go to I8
Is wiring OK? No
I8
Check wiring connection between steering wheel Yes
clock spring and audio steering wheel switches. Go to I9
Is wiring OK? No
I9
Remove ICC and check resistance readings at ICC Yes
instrument panel connector. Replace faulty ICC with a
Are resistance readings correct? new ICC and retest.
No
Replace original ICC and
retest.
TEST J : NAVIGATION NOT WORKING

RUN_POS, ACC_POS, POWER_SW, NAV_PRES

J1
Check pid’s using data logger. Go to J2
system and retest.
G68759 en 01/2003 2003.0 BA Falcon


J2
Check pid’s using data logger. Go to J3
system and retest.
J3
Is the audio on? Go to J5
No
Go to J4
J4
Check pid’s using data logger. Go to K5
on symptom in the
symptom chart.
J5
Turn on the navigation display using the navigation Yes NAV_PRES
remote control. ICC functioning correctly.
Does the navigation display appear? Continue
J6
Select the ICC navigation diagnostics display as Yes
per procedures. Go to J7.
Does the navigation diagnostics display No
appear? Repeat procedure.
Replace ICC if
diagnostics screen does
not operate.
J7
Check the IR response on the navigation Yes
diagnostics display. Go to J9
Does the IR response state OK? No
Continue
J8
Check that the navigation system / wiring is correct Yes
as per navigation procedures. Replace ICC and retest.
Is the system / wiring O.K No
Rectify faulty system /
wiring and retest.
J9
Check that the REM response toggles between OK Yes
and NG on the diagnostics display when the remote ICC functioning correctly.
control is operated. Refer to navigation
Does the response toggle? diagnostics.
No
Continue
G68759 en 01/2003 2003.0 BA Falcon


J10
Check that the REM response toggles between OK Yes
and NG using a known good remote control. Original remote control is
Does the response toggle? faulty.
No
TEST K : TELEPHONE INPUT NOT WORKING
RUN_POS, ACC_POS, POWER_SW, PHONE_AT

K1
system and retest.
K2
system and retest.
K3
Check to see if the ICC audio is turned on Yes
Is the audio on? Go to K5
No
Go to K4
K4
on symptom in the
symptom chart.
K5
Check that the ICC telephone input function Yes PHONE_AT
operates when a telephone signal is inputted. No fault. ICC functioning
Check pid’s using data logger. correctly.
Does the telephone input function operate? No
Continue
K6
Check that the telephone input system / wiring is Yes
correct as per procedures Replace ICC and retest.
Is the system / wiring OK? No
Repair faulty system /
wiring and retest.
G68759 en 01/2003 2003.0 BA Falcon

TEST L : AUXILIARY INPUT NOT WORKING

RUN_POS, ACC_POS, POWER_SW, AUD_SR

L1
Check pid’s using data logger. Go to L2
system and retest.
L2
system and retest.
L3
Is the audio on? Go to L5
No
Go to L4
L4
on symptom in the
symptom chart.
L5
Check that the ICC auxiliary input function Yes AUD_SR
operates. No fault. ICC functioning
Does the auxiliary input function operate? correctly.
No
Continue
L6
Check that the auxiliary input system / wiring is Yes
correct as per procedures. Replace ICC and retest.
Is the system /wiring OK? No
Repair faulty system
/wiring and retest.
TEST M : SONAR NOT OPERATING
RUN_POS, ACC_POS, POWER_SW, REVRS_INP

M1
Check pid’s using data logger. Go to M2
system and retest
G68759 en 01/2003 2003.0 BA Falcon


M2
system and retest.
M3
Is the audio on? Go to M5
No
Go to M4
M4
on symptom in the
symptom chart.
M5
Check that the rear speakers mute and a sonar Yes REVRS_INP
beeping alert sounds when the vehicle is placed in No fault. ICC functioning
reverse. correctly.
Does the sonar operate correctly? Continue
M6
Check that the sonar system / wiring is correct as Yes
per procedures. Replace ICC and retest.
Is the system / wiring OK? No
Repair faulty system /
wiring and retest.
G68759 en 01/2003 2003.0 BA Falcon

415-01-1 Audio Unit 415-01-1
SECTION : 415-01 Audio Unit

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-01-2
Audio System ........................................................................................................................415-01-3
Audio System ........................................................................................................................415-01-4
Audio System Security ..........................................................................................................415-01-5
Audio Unit .............................................................................................................................415-01-5
Amplifier ................................................................................................................................415-01-5
Steering Wheel Audio Controls .............................................................................................415-01-5
Capacitor ...............................................................................................................................415-01-5
Ground Strap ........................................................................................................................415-01-5
01/2003 2003.0 BA Falcon

415-01-2 Audio Unit 415-01-2
SPECIFICATIONS
Description Nm
Intake manifold suppressor bolt 19 - 24
Steering wheel switch screws 1.8 - 2.2
Ground strap belt - engine 40.3 - 54.7
Ground strap belt - chassis 10.2 - 13.8
G73347 en 01/2003 2003.0 BA Falcon

415-01-3 Audio Unit 415-01-3
Audio System controls. Suitable audio units are portable cassette

players, CD players, DVD or MP3 players.
The audio system consists of the following For this function to be enabled, an aux jumper
components: harness available through Ford must be connected.
Audio unit
Amplifier (where fitted)
Steering wheel controls
The audio controls on the steering wheel allows the
driver to control volume, media selection, memory
presets and radio station and CD track seek. The
audio controls are located on the left side of the
steering wheel.
There are 3 audio units available with features as
indicated in the following table.
Feature Low Mid High
Series Series Series
AM/FM stereo radio X X X
CD player single disc X Vehicles are equipped with 4, 6 or 11 speakers
CD player 6 disc in X X depending on the equipment level. Refer to Section
dash 415-03.
100 watt power output X X The subwoofer amplifier incorporates "thermo
250 watt power output X protection" which shuts down the output when the
luggage compartment temperature exceeds 90°C.
Subwoofer amplifier X
This automatically protects the unit from internal
Steering wheel remote X X X damage during times of extreme heat. Should this
control: volume, mode, situation occur, allow the unit to cool down or open
tuner scan & seek & cd the deck lid for a short period. The unit will return to
track increment normal operation after the temperature drops to an
Speed dependant X X X acceptable level.
volume
Radio Frequency Interference Suppression
Speed dependant bass X X X
The radio ignition interference capacitor reduces
Sound position control X X X
interference transmitted through the radio speakers by
Digital signal X the engine ignition and electrical system.
processing (dsp)
studio, stadium, hall
CD compression X
clock X X
Telephone interface X X X
and mute
Navigation audio X X X
interface
Sonar parking audio X
interface
Auxillary audio input X X X
Output power limiting to X X X
10% thd (total harmonic
distortion)
System diagnostics X X X Item Description
Refer to the owners manual for complete operating 1 Interference capacitor attached here
guidelines.
All audio systems include an Auxillary audio input
function, where an external device can be connected
to provide audio functionality via the vehicle audio
G73348 en 01/2003 2003.0 BA Falcon

415-01-4 Audio Unit 415-01-4
Audio System
G73349 en 01/2003 2003.0 BA Falcon

415-01-5 Audio Unit 415-01-5
Audio System Security 3. Remove the steering wheel audio control screws.
NOTE: Some steering wheels are leather
wrapped and should be protected when removing
WARNING: All audio systems fitted are the steering wheel controls.
protected by an electronic security system, which
renders it inoperative if removed from its Remove the steering wheel audio control.
originally fitted vehicle. Owner provided security Disconnect the electrical connectors.
cards are not required as the audio system links
to other electronics in that vehicle. All audio units
will be coded when they leave the factory and
re-training can only be carried out by using the
WDS tester.
Audio Unit
1. See information in Section 413-08 for Audio Unit
removal and installation.
Amplifier
Removal
1. Remove left hand side interior quarter trim.
2. Remove 2 rivets. Installation
3. Remove amplifier and disconnect wiring. 1. Reverse the removal procedure.
NOTE: When reinstalling screws set gap between
switch buttons and horn pad to 0.7mm.
Capacitor
Removal
1. Follow removal procedure shown in figure.
Item Description
1 Amplifier
2 Rivets
3 Bracket
Installation
1. Connect wiring to amplifier.
2. Locate amplifier in position. Item Description
3. Install 2 rivets. 1 Interference capacitor attached here
4. Refit interior quarter trim. Installation
Steering Wheel Audio Controls 1. Reverse the removal procedure.
Removal Ground Strap

1. Disconnect the battery ground cable. For Removal
additional information, refer to Section 414-01. 1. Disconnect the battery cables. For additional
2. Remove the steering wheel air bag. For additional information, refer to Section 414-01.
information, refer to Section 501-20B.
G73356 en 01/2003 2003.0 BA Falcon

415-01-6 Audio Unit 415-01-6
2. Remove bolts
I6
V8
Installation
1. Reverse the removal procedure, torque to
specifications.
G73356 en 01/2003 2003.0 BA Falcon

415-02-1 Antenna 415-02-1
SECTION : 415-02 Antenna

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-02-2
Antenna .................................................................................................................................415-02-3
Antenna .................................................................................................................................415-02-4
GENERAL PROCEDURES
Antenna Grid Wire Repair .....................................................................................................415-02-5
Antenna — Sedan .................................................................................................................415-02-6
Antenna — Wagon ................................................................................................................415-02-6
Antenna — Ute .....................................................................................................................415-02-6
Antenna Lead — in Cable .....................................................................................................415-02-6
01/2003 2003.0 BA Falcon

415-02-2 Antenna 415-02-2
SPECIFICATIONS
Description Nm
Antenna module 10.2-13.8
G56749 en 01/2003 2003.0 BA Falcon

415-02-3 Antenna 415-02-3
Antenna
All vehicles are equipped with On Glass Antenna’s
which consist of the following components:
On glass printed elements
Amplifier module
Cable assemblies
Sedan
The sedan antenna uses a combination of the heated
backlite grid (FM) and several elements on the glass
above the heated backlite (AM).
The amplifier module is located on the left hand side
C pillar structure.
Wagon
The wagon antenna is located on the left hand rear
quarter glass and uses the inner elements for FM and
the outer elements for AM.
The amplifier module is located on the upper side rail
directly above the center of the left hand side quarter
glass.
Ute
The ute antenna uses elements on the backlite as
well as the two quarter glass’s. The heated backlite
elements are used for FM and the two quarter glass
elements as well as the elements above the heated
backlite are used for AM.
The amplifier module is located on the left hand side
quarter panel adjacent to the heated backlite
connection. Wiring attached to the quarter trims links
the AM elements between the rear and side glass’s.
Window Tint Warning
Window tinting is not recommended on glass with
printed antenna elements.
Metallised window tint material significicantly
degrades radio reception on both the AM and FM
bands.
Non metallised dye based tint material is an
improvement over metallised tint material but still
degrades radio reception.
G56750 en 01/2003 2003.0 BA Falcon

415-02-4 Antenna 415-02-4
Antenna
G56751 en 01/2003 2003.0 BA Falcon

415-02-5 Antenna 415-02-5
GENERAL PROCEDURES
Antenna Grid Wire Repair

1. To maintain optimum radio performance breaks in
the heated backlight or antenna elements grids
must be repaired.
2. Repair kits are available through automative
accessory outlets, and repair instructions must be
followed to ensure a satisfactory and permanent
fix.
G56752 en 01/2003 2003.0 BA Falcon

415-02-6 Antenna 415-02-6
Antenna — Sedan 3. Disconnect the in line trim wiring to module

connector.
Removal
1. Remove the left hand side C pillar trim. Refer to
Section 501-05/2.
2. Remove the module attachment bolt.
3. Disconnect the coaxial connector, antenna
element connector and power connector.
4. Remove the module attachment bolt.

5. Disconnect the coaxial and power connectors.
6. Disconnect the right hand quarter glass button
terminal and the right hand rear glass button
terminal.
7. Remove the right hand side quarter trim panel.
Installation Refer to Section 501-05.
1. To install, reverse the procedure. Installation
1. To install, reverse the procedure.
Antenna — Wagon
Antenna Lead — in Cable
Removal
1. Remove the headliner. Refer to Section 501-05. Removal
2. Remove the module attachment bolt. 1. Remove the instrument panel. Refer to Section
3. Disconnect the coaxial connector, antenna 501-12
element connector and power connector. 2. Remove CDU assembly. Refer to Section 413-08
Installation 3. Disconnect the antenna connector from the

1. To install, reverse the procedure. instrument panel CDU mounting bracket.
4. Remove the antenna cable from the instrument
Antenna — Ute panel assembly.
1. Disconnect the left hand quarter glass button 1. To install, reverse the procedure.
terminal and the two left hand rear glass
terminals.
2. Remove the left hand side quarter panel trim.
G56753 en 01/2003 2003.0 BA Falcon

415-03-1 Speakers 415-03-1
SECTION : 415-03 Speakers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-03-2
Speakers ...............................................................................................................................415-03-3
Model and Usage .................................................................................................................415-03-3
Speakers — Door Mounted ..................................................................................................415-03-4
Speakers — Package Tray ...................................................................................................415-03-4
Speaker — Package Tray Subwoofer ..................................................................................415-03-4
Speaker — Tweeter A-pillar ..................................................................................................415-03-4
Speaker — Wagon Rear Quarter Panel ...............................................................................415-03-5
Speaker — Ute Rear Quarter Panel .....................................................................................415-03-5
01/2003 2003.0 BA Falcon

415-03-2 Speakers 415-03-2
SPECIFICATIONS
Description Nm
Door speakers 1.2-1.8
Package tray speakers excluding 1.2-1.8
subwoofer
Wagon quarter panel speakers 1.2-1.8
Subwoofer 1.5-1.9
G43920 en 01/2003 2003.0 BA Falcon

415-03-3 Speakers 415-03-3
Speakers
The Falcon sedan range has three speaker variants
depending on model and option. All speakers are
rated at 25 watts nominal with the exception of the
subwoofer, which is 150 watts.
4 speaker system for base level audio.
6 speaker system for mid level audio.
11 speaker system for premium audio. The 11
speakers are contained in 7 speaker assemblies.
The Falcon wagon range uses a 4 speaker system
The Falcon Ute range has 3 speaker variants
depending on model and option
2 speaker system for base vehicle.
4 speaker system for mid vehicle.
6 speaker system for mid option audio.
Model and Usage
Description Front speakers Rear speakers Tweeters Subwoofer
Sedan 4 speaker 1R23-18808-BA 1R23-18808-BA — —
Sedan 6 speaker 1R23-18808-EA 1R23-18808-BA WR2A-18808- —
DA/FA
Premium sound WR2A-18808-CA WR2A-18971-FA WR2A-18808- 1R23-18971-GA
DA/FA
Wagon 1R23-18808-BA 1R23-18971-EA — —
Ute 2 speaker 1R23-18808-BA — — —
Ute 4 speaker 1R23-18808-BA 1R23-18808-GA — —
Ute 6 speaker 1R23-18808-EA 1R23-18808-GA WR2A-18808- —
DA/FA
G43921 en 01/2003 2003.0 BA Falcon

415-03-4 Speakers 415-03-4
Speakers — Door Mounted Speaker — Package Tray Subwoofer

1. Remove the front door trim panel. For additional 1. Remove the package tray trim panel. For
information refer to Section 501-05. additional information refer to Section 501-05.

1 Door trim panel 1 Package tray
2 Speaker 2 Screw
2. Remove the speaker retaining screws. 3 Body sheetmetal
3. Remove the speaker and disconnect the electrical 4 Speaker
connector. 5 Foam gasket
4. To install, reverse the procedure 2. Remove the foam gasket located on top of the
speaker.
Speakers — Package Tray
3. Remove the speaker retaining screws.
Removal and Installation 4. Remove the speaker and disconnect the electrical
1. Remove the package tray trim panel. For connector.
additional information refer to Section 501-05. 5. To install, reverse the procedure
Speaker — Tweeter A-pillar

1. Remove the A-pillar trim. For additional
information refer to Section 501-05.
Item Description
1 Package tray
2 Speaker
3. Remove the speaker and disconnect the electrical
connector. Item Description
4. To install, reverse the procedure 1 A-Pillar trim panel
2 Dashboard
G43922 en 01/2003 2003.0 BA Falcon

415-03-5 Speakers 415-03-5
Item Description Speaker — Ute Rear Quarter Panel

3 Rivet
4 Tweeter
1. Remove the quarter trim panel. For additional
5 Body sheetmetal
2. Remove the rivet attaching the tweeter bracket to
the sheetmetal .
connector.
4. To install, reverse the procedure
Speaker — Wagon Rear Quarter Panel

1. Remove the C pillar to quarter panel trim. For
additional information refer to Section 501-05.
Item Description
1 Quarter trim panel
2 Screw
3 Body sheetmetal
4 Speaker
connector .
Item Description
1 Screw
2 Electrical connector
3 Body sheetmetal
4 Speaker
connector.
G43926 en 01/2003 2003.0 BA Falcon

417-01-1 Exterior Lighting 417-01-1
SECTION : 417-01 Exterior Lighting

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................417-01-3
Exterior Lighting .....................................................................................................................417-01-4
Twilight Sensor/Sun Load Sensor ........................................................................................417-01-4
Headlamps .............................................................................................................................417-01-5
Symptom Chart ....................................................................................................................417-01-8
Pinpoint Tests ......................................................................................................................417-01-9
Turn Signal and Hazard Lamps ...........................................................................................417-01-15
Symptom Chart ..................................................................................................................417-01-20
Pinpoint Tests ....................................................................................................................417-01-20
Stop Lamps ..........................................................................................................................417-01-23
Symptom Chart ..................................................................................................................417-01-27
Pinpoint Tests ....................................................................................................................417-01-27
Fog Lamps ...........................................................................................................................417-01-30
Symptom Chart ..................................................................................................................417-01-32
Pinpoint Tests ....................................................................................................................417-01-32
Parking, Rear and License Lamps .......................................................................................417-01-34
Symptom Chart ..................................................................................................................417-01-39
Pinpoint Tests ....................................................................................................................417-01-40
Reverse Lamps ....................................................................................................................417-01-42
Symptom Chart ..................................................................................................................417-01-45
Pinpoint Tests ....................................................................................................................417-01-45
GENERAL PROCEDURES
Headlamp Adjustment ..........................................................................................................417-01-48
Headlamp Assembly ............................................................................................................417-01-52
Headlamp Bulb — High Beam H7 .......................................................................................417-01-52
Headlamp Bulb — Low Beam H4 ........................................................................................417-01-52
Turn Signal Bulb ..................................................................................................................417-01-53
01/2003 2003.0 BA Falcon

(Continued)
Parklamp Bulb ......................................................................................................................417-01-53

Auxiliary Lamp .....................................................................................................................417-01-53
Auxiliary Lamp Bulb .............................................................................................................417-01-53
Fog Lamp .............................................................................................................................417-01-54
Fog Lamp Bulb .....................................................................................................................417-01-54
Tail Lamp Assembly — Sedan ............................................................................................417-01-54
Tail Lamp Assembly — Wagon ...........................................................................................417-01-55
Tail Lamp, Reverse Lamp and Rear Indicator Bulb — Sedan And Wagon .........................417-01-55
Tail Lamp Assembly — Style Side Box ...............................................................................417-01-55
Rear Light Bulbs Replacement — Style Side Box ...............................................................417-01-56
Reverse Light Replacement — Style Side Box ...................................................................417-01-56
Tail Lamp Assembly — Tray ................................................................................................417-01-56
Rear Light Bulbs Replacement — Cable/Chassis and Tray ................................................417-01-57
Licence Plate Lamp Assembly .............................................................................................417-01-57
Licence Plate Bulb ...............................................................................................................417-01-58
Rear Licence Plate Lamp Replacement — Style Side Box .................................................417-01-58
Rear Licence Plate Lamp Replacement — Chassis/Cab and Tray .....................................417-01-58
Side Indicator Lamps ...........................................................................................................417-01-58
High Mount Stop Lamp — Sedan (Except LWB) .................................................................417-01-59
High Mount Stop Lamp — XR Series Sedan ......................................................................417-01-59
High Mount Stop Lamp Bulb — Wagon ...............................................................................417-01-59
High Mount Stop Lamp — LWB ...........................................................................................417-01-60
Twilight Sensor/Sun Load Sensor ........................................................................................417-01-60
01/2003 2003.0 BA Falcon

SPECIFICATIONS
BULB USAGE UNIT TYPE

Park Lamp 5W wedge
Auxiliary Lamp 5W wedge Cool
Blue
High/Low Beam 60/55W H4
High Beam 55W H7
Fog Lamp (XR) 55W H3
Turn Signal amber 21W
Side Indicator amber 5W wedge
Stop/Tail Lamp 21/5W
High Mount Stop Lamp 21cp or 18 W
wedge
High Mount Stop Lamp (XR, Sealed LED
rear spoiler option & LWB)
Licence Plate Lamp 5W wedge
Reverse Lamp 21W
Luggage Compartment 10W
Interior Dome Lamp 10W
Front Reading Lamps 5W
Front Footwell Lamp 3W
Rear Reading Lamps 5W
Rear Centre Console Lamp 3W
Glove Compartment 4W
Cigarette Lighter 2W
Door Mounted Interior Lamp 3W
Instrumentation / Display / Service by
Warning Lamps Technician
Automatic Transmission Control Service by
Indicator Technician
Description Nm
Head lamp Bolts 3.2-4.5
Tail lamp Screws (Sedan & Wagon) 2.5-2.9
Tail lamp screws (Style Side Box Ute) 4.5-6.3
Position Lamp (Ghia, Fairlane & LTD) 0.5
G86726 en 01/2003 2003.0 BA Falcon

Exterior Lighting
The exterior lighting consists of the following:
headlamps
side lamps/front turn signal lamps
rear lamps
high-mounted stop lamps
fog lamps
parking lamps
reversing lamps
license plate lamps
fog lamp switch
multifunction switch
brake pedal position (BPP) switch
The headlamp switch is integrated into the
multifunction switch.
Twilight Sensor/Sun Load Sensor
The combined twilight and sun load sensor is
contained in a compact package, which is installed on
the instrument panel of a vehicle. It measures both
the sunlight intensity and twilight.
The twilight sensor provides the information about low
light conditions and is used to control automatic
headlights (where fitted).
The Sun Load sensor is used by the automatic
climate control system, to adjust the ACC settings for
different sun intensity levels.
G86727 en 01/2003 2003.0 BA Falcon

Headlamps
C-159 RH High Beam Headlamp

1 12A (G-O) 0 voltage, less than 5 ohms between RH high
RH high beam headlamp power beam headlamp and high beam headlamp relay
input
2 Circuit 57AJ (B) 0 voltage, less than 5 ohms between RH high
RH high beam headlamp ground beam headlamp and chassis ground
C-159 RH Low Beam Headlamp

1 12C (G-O) 0 voltage, less than 5 ohms between RH low
input
2 13A (R-B) 0 voltage, less than 5 ohms between RH low
RH low beam headlamp power beam headlamp and low beam headlamp relay
input
3 Circuit 57AJ (B) 0 voltage, less than 5 ohms between RH low
RH low beam headlamp ground beam headlamp and chassis ground
G86728 en 01/2003 2003.0 BA Falcon

C-160 LH High Beam Headlamp

1 12D (G-O) 0 voltage, less than 5 ohms between LH high
LH high beam headlamp power beam headlamp and high beam headlamp relay
input
2 Circuit 57AC (B) 0 voltage, less than 5 ohms between LH high
LH high beam headlamp ground beam headlamp and chassis ground
C-160 LH Low Beam Headlamp

1 12E (G-O) 0 voltage, less than 5 ohms between LH low
LH high beam headlamp power beam headlamp and high beam headlamp relay
input
2 13C (R-B) 0 voltage, less than 5 ohms between LH low
LH low beam headlamp power beam headlamp and low beam headlamp relay
input
3 Circuit 57AD (B) 0 voltage, less than 5 ohms between LH low
LH low beam headlamp ground beam headlamp and chassis ground
G86728 en 01/2003 2003.0 BA Falcon

C-163 Power Distribution Box (PDB)

1 Circuit 18 (O) 0 voltage, less than 5 ohms between
Multifunction switch low beam Multifunction switch and low beam headlamp
headlamp input relay
2 Circuit 20 (G-R) 0 voltage, less than 5 ohms between
Multifunction switch high beam Multifunction switch and high beam headlamp
3 12B (G-O) 0 voltage, less than 5 ohms between RH high
input
4 Circuit 12G (G-O) 0 voltage, less than 5 ohms between RH low
LH High beam headlamp power beam headlamp and low beam headlamp relay
input
5 13A (RG-B) 0 voltage, less than 5 ohms between LH high
RH low beam headlamp power beam headlamp and high beam headlamp relay
input
6 13C (R-B) 0 voltage, less than 5 ohms between LH low
LH low beam headlamp power beam headlamp and low beam headlamp relay
input
G86728 en 01/2003 2003.0 BA Falcon

C-167 Multifunction Switch

1 Circuit 18 (O) 0 voltage, less than 5 ohms between
Multifunction switch low beam Multifunction switch and low beam headlamp
2 Circuit 20 (G-R) 0 voltage, less than 5 ohms between
Multifunction switch high beam Multifunction switch and high beam headlamp
3 Circuit 57CL (B) 0 voltage, less than 5 ohms between
Multifunction switch ground Multifunction switch and chassis ground
Multifunction switch Power Distribution
Box (PDB):
fuse 15 (15A)
fuse 16 (15A)
fuse 24 (15A)
fuse 25 (15A)
relay 4 (40A)
relay 5 (40A)
Circuitry
Lamp bulbs
G86728 en 01/2003 2003.0 BA Falcon

Symptom Chart

Both headlamps are inoperative Battery Go to PinPoint Test A
Circuitry
Multifunction switch C-167
The low beams are inoperative PDB: Go to PinPoint Test B

relay 5
Circuitry
The high beams are inoperative PDB: Go to PinPoint Test C

relay 4
Circuitry
One low beam headlamp is inoperative PDB: Go to PinPoint Test D

fuse 24 (15A)
fuse 25 (15A)
Circuitry
Headlamp bulb
One high beam headlamp is PDB: Go to PinPoint Test E
inoperative fuse 15 (15A)
fuse 16 (15A)
Circuitry
Headlamp bulb
The headlamps are on continuously PDB: Go to PinPoint Test F

relay 4
relay 5
Circuitry
The flash-to-pass feature is inoperative Multifunction switch C-167 Perform the Multifunction switch
testing in Section 211-05.
Pinpoint Tests
Both headlamps are inoperative
Possible causes:
Battery
Multifunction Switch C-167
Circuit 57CL (B) open
PINPOINT TEST A : BOTH HEADLAMPS ARE INOPERATIVE

A1 CHECK THE MULTIFUNCTION SWITCH GROUND
Disconnect: Multifunction switch C-167. Yes
Perform the Multifunction switch testing in
Measure the resistance between Multifunction switch C-167, circuit
Section 211-05.
57CL (B), harness side and ground.
No
Repair circuit 57CL (B).
G86728 en 01/2003 2003.0 BA Falcon

The low beams are inoperative Circuit 13 (R-B) open or short to ground
Possible causes:
Low beam headlamp relay
Circuit 18 (O) open
PINPOINT TEST B : THE LOW BEAMS ARE INOPERATIVE

B1 CHECK CIRCUIT 13 (R-B) FOR A SHORT TO GROUND
Disconnect: RH low beam headlamp C-159 or LH low beam Yes
headlamp C-160. Repair circuit 13 (R-B).
Measure the resistance between RH low beam headlamp C-159,
circuit 13A (R-B), harness side or LH low beam headlamp C-160, No
circuit 13C (R-B), harness side and ground. Go to B2
B2 CHECK CIRCUIT 13 (R-B) FOR AN OPEN

Disconnect: Low beam headlamp relay, PDB C-163 relay 5 (40A). Yes
Go to B3
Measure the resistance between RH low beam headlamp C-159,
circuit 13A (R-B), harness side or LH low beam headlamp C-160, No
circuit 13C (R-B), harness side and low beam headlamp relay, PDB Repair circuit 13 (R-B).
C-163 relay 5 (40A), circuit 13 (R-B), harness side. Test the system for normal operation.
B3 CHECK CIRCUIT 18 (O) FOR AN OPEN

Go to B4
Measure the resistance between the low beam headlamp relay, PDB
C-163 relay 5 (40A), circuit 18 (O), harness side and Multifunction No
switch C-167, circuit 18 (O), harness side. Repair circuit 18 (O).
Is the resistance less than 5 ohms? Test the system for normal operation.
B4 CHECK THE MULTIFUNCTION SWITCH

Perform the Multifunction switch testing in Section 211-05. Yes
Replace the low beam headlamp relay
Is the Multifunction switch operating correctly? Test the system for normal operation
No
See Multifunction switch in Section 211-05.
The high beams are inoperative Circuit 12 (G-O) open or short to ground
Possible causes:
Headlamp high beam relay
Circuit 20 (G-R) open
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : THE HIGH BEAMS ARE INOPREATIVE

C1 CHECK CIRCUIT 12 (G-O) FOR A SHORT TO GROUND
Disconnect: RH high beam headlamp C-159 or LH high beam Yes
headlamp C-160. Repair circuit 12 (G-O).
Measure the resistance between RH high beam headlamp C-159,
circuit 12A (G-O), harness side or LH high beam headlamp C-160, No
circuit 12C (G-O), harness side and ground. Go to C2
C2 CHECK CIRCUIT 12 (G-O) FOR AN OPEN

Disconnect: Headlamp high beam relay, PDB C-163 relay 4 (40A). Yes
Go to C3
Measure the resistance between RH high beam headlamp C-159,
circuit 12A (G-O), harness side or LH high beam headlamp C-160, No
circuit 12C (G-O), harness side and headlamp high beam relay, PDB Repair circuit 12 (G-O).
relay 4 (40A), circuit 12 (G-O), harness side. Test the system for normal operation.
C3 CHECK CIRCUIT 20 (G-R) FOR AN OPEN

Disconnect: Multifunction Switch C-167. Yes
Go to C4
Measure the resistance between the headlamp high beam relay, PDB
C-163 relay 4 (40A), circuit 20 (G-R), harness side and Multifunction No
switch C-167, circuit 20 (G-R, harness side. Repair circuit 20 (G-R).
C4 CHECK THE MULTIFUNCTION SWITCH

Replace the high beam headlamp relay.
Is the Multifunction switch operating correctly? Test the system for normal operation.
No
See Multifunction switch in Section 211-05.
One low beam headlamp is inoperative

Possible causes:
Circuit 13 (R-B) short to ground
Circuit 57 (B) open
PINPOINT TEST D : ONE LOW BEAM HEADLAMP IS INOPERATIVE

D1 CHECK THE HEADLAMP LOW BEAM VOLTAGE INPUT
Disconnect: Inoperative low beam headlamp. Yes
Repair circuit 57 (B).
Turn ON low beam headlamps.
Measure the voltage between RH low beam C-159, circuit 13A (R-B),
harness side or LH low beam C-160, circuit 13C (R-B), harness side No
and ground. Repair circuit 13 (R-B).
G86728 en 01/2003 2003.0 BA Falcon

One high beam headlamp is inoperative

Possible causes:
Circuit 12 (G-O) short to ground
Circuit 57 (B) open
PINPOINT TEST E : ONE HIGH BEAM HEADLAMP IS INOPERATIVE
E1 CHECK THE HEADLAMP HIGH BEAM VOLTAGE INPUT

Disconnect: Inoperative high beam headlamp. Yes
Turn ON high beam headlamps.
Measure the voltage between RH high beam C-159, circuit 12A (G-O
), harness side, RH low beam C-159, circuit 12C (G-O ), harness side, No
LH low beam C-160, circuit 12E (G-O ), harness side or LH high Repair circuit 12 (G-O).
beam C-160, circuit 12D (G-O), harness side and ground. Test the system for normal operation.
The headlamps are on continuously

Possible causes:
Low beam headlamp relay
Circuit 18 (O) short to ground
Circuit 13 (R-B) short to power
High beam headlamp relay
Circuit 20 (G-R) short to ground
Circuit 12 (G-O) short to power
PINPOINT TEST F : THE HEADLAMPS ARE ON CONTINUOUSLY
F1 CHECK THE MULTIFUNCTION SWITCH

Go to F2
Are the headlamps illuminated?
No
Section 211-05.
F2 CHECK CIRCUIT 18 (O) FOR A SHORT TO GROUND

Measure the resistance between Multifunction switch C-167, circuit 18 Yes
(O), harness side and ground. Repair circuit 18 (O).
No
Go to F3
F3 CHECK CIRCUIT 20 (G-R) FOR A SHORT TO GROUND

Measure the resistance between Multifunction switch C-167, circuit 20 Yes
(G-R), harness side and ground. Repair circuit 20 (G-R).
No
Go to F4
G86728 en 01/2003 2003.0 BA Falcon


F4 CHECK HEADLAMP LOW BEAM RELAY
Disconnect: Low beam headlamp relay, PDB C-163 relay 5 (40A). Yes
Go to F5
Are the headlamps illuminated?
No
Install a new low beam headlamp relay.
F5 CHECK CIRCUIT 13 (R-B) FOR A SHORT TO POWER

Measure the voltage between the low beam headlamp relay, PDB Yes
C-163 relay 5 (40A), circuit 13 (R-B) harness side and ground. Repair circuit 13 (R-B).
No
Go to F6
F6 CHECK THE HEADLAMP HIGH BEAM RELAY

Disconnect: High beam headlamp relay, PDB C-163 relay 4 (40A). Yes
Repair circuit 12 (G-O).
Are the headlamps illuminated? Test the system for normal operation.
No
Install a new high beam headlamp relay.
PINPOINT TEST G : TWILIGHT SENSOR/SUN SENSOR NOT WORKING

NOTE: The sunload sensor must not be covered with a dash mat or other item, as this will prevent the
optimum performance of the automatic climate control system and the automatic headlamp operation.
G1 CHECK HEADLAMPS
Turn on the ignition. Yes
Go to G2
Turn the headlamp switch to AUTO position.
Cover the Sun Sensor. No
Go to G3
Do the headlamps turn on after 2 Seconds?
G2 CHECK HEADLAMPS
With the ignition on and the headlamp switch in the AUTO position, Yes
uncover the Sun Sensor. System OK.
Shine a torch on the light sensor. No
Do the headlamps turn off after 15 Seconds? Go to G3
G3 CHECK DTC LOG

Turn off the ignition. Yes
Go to G4
Connect WDS.
Turn on the ignition. No
Refer to BEM Diagnostics.
Is DTC $9790 or $9791 logged?
G86728 en 01/2003 2003.0 BA Falcon


G4 CHECK PIN J 1/18 FREQUENCY
Disconnect J1 from BEM. Yes
Go to G5
Turn Head lamp Switch to AUTO position.
Turn Ignition ON. No
Go to G6
Using CRO on WDS back probe J 1/18.
Are the following values as specified?Sensor Covered:J1=
approx 400HzSensor uncovered and torch shining:J1 = approx
50Hz
G5 CHECK IN J 2/6 VOLTAGE

Disconnect J2 from BEM. Yes
Refer to BEM Diagnostics
Turn Head lamp Switch on AUTO.
Turn Ignition ON. No
Go to G7
Using Voltmeter back probe J 2/6.
Are the following values as specified?Sensor Covered:J2 =
approx 0.7VSensor uncovered and torch shining:J2 = approx
4.5V
G6 CHECK CIRCUIT 234D CONTINUITY

Disconnect harness connector from Sun Sensor. Yes
Go to G7
Check for short to B+, short to ground and continuity of circuit 234D.
Is circuit 234D OK? No
Check & Repair circuit 234D.
G7 CHECK CIRCUIT 234E CONTINUITY

Go to G8
Check for short to B+, short to ground and continuity of circuit 234E.
Is circuit 234E OK? No
Check & Repair circuit 234E.
G8 CHECK CIRCUIT CN 1-3 RESISTANCE

Go to G9
Back probe CN1 - 3 with an ohmmeter to ground.
Is the following value as specified?Less than 1 ohm No
Check & Repair ground circuit to Sun Sensor.
G9 CHECK CIRCUIT CN 2-2 RESISTANCE

Replace Sun Sensor.
Turn Ignition ON.
Back probe CN2 - 2 with an ohmmeter to ground. No
Check & Repair Power Supply Circuit to Sun
Is the following value as specified?Battery voltage to be 9-13 Sensor. (including Head Lamp Switch assembly)
volts with ignition OFF.
G86728 en 01/2003 2003.0 BA Falcon

Turn Signal and Hazard Lamps

C-44 Wagon LH Tail Lamp

1 Circuit 3A (G) 0 voltage, less than 5 ohms between LH turn
LH turn signal power input signal and cluster
2 Circuit 57EJ (B) 0 voltage, less than 5 ohms between LH tail
LH tail lamp ground lamp and chassis ground
C-45 Wagon RH Tail Lamp

1 Circuit 2A (G-L) 0 voltage, less than 5 ohms between RH turn
RH turn signal power input signal and cluster
2 Circuit 57EK (B) 0 voltage, less than 5 ohms between RH tail
RH tail lamp ground lamp and chassis ground
C-46 LH Side Marker
G86729 en 01/2003 2003.0 BA Falcon


1 Circuit 3B (G) 0 voltage, less than 5 ohms between LH side
LH side marker power input marker and cluster
2 Circuit 57BL (B) 0 voltage, less than 5 ohms between LH side
LH side marker ground marker and ground
C-77 RH Tail Lamp

RH tail lamp ground lamp and ground
C-78 LH Tail Lamp

LH tail lamp ground lamp and ground
C-154 RH Side Marker
G86729 en 01/2003 2003.0 BA Falcon


1 Circuit 2B (G-L) 0 voltage, less than 5 ohms between RH side
RH side marker power input marker and cluster
2 Circuit 57AQ (B) 0 voltage, less than 5 ohms between RH side
RH side marker ground marker and ground
C-159 RH Turn Signal

2 Circuit 57AP (B) 0 voltage, less than 5 ohms between RH turn
RH turn signal ground signal and ground
C-160 LH Turn Signal

2 Circuit 57BG (B) 0 voltage, less than 5 ohms between LH turn
LH turn signal ground signal and ground
G86729 en 01/2003 2003.0 BA Falcon


1 Circuit 2 (G-L) 0 voltage, less than 5 ohms between cluster and
RH turn signal feed Multifunction switch
2 Circuit 3 (G) 0 voltage, less than 5 ohms between cluster and
LH turn signal feed Multifunction switch
3 Circuit 8 (G-B) 0 voltage, less than 5 ohms between
Turn signal flasher feed Multifunction switch and ignition relay
C-171 Cluster

1 Circuit 2 (G-L) 0 voltage, less than 5 ohms between cluster and
RH turn signal feed Multifunction switch
2 Circuit 2C (G-L) 0 voltage, less than 5 ohms between cluster and
RH turn signal lamp power input RH turn signal lamps
3 Circuit 3 (G) 0 voltage, less than 5 ohms between cluster and
LH turn signal feed Multifunction switch
4 Circuit 3C (G) 0 voltage, less than 5 ohms between cluster and
LH turn signal lamp power input LH turn signal lamps
5 Circuit 383C (Y) Greater than 10 volts, 10,000 ohms between
Hazard lights B+ input hazard lights input and chassis ground
G86729 en 01/2003 2003.0 BA Falcon

C-705 Ute Cab Chassis RH Tail Lamp

1 Circuit 2B (G-L) 0 voltage, less than 5 ohms between RH tail
RH turn signal power input lamp and cluster
2 Circuit 57A (B) 0 voltage, less than 5 ohms between RH tail
C-707 Ute Cab Chassis LH Tail Lamp

1 Circuit 3B (G) 0 voltage, less than 5 ohms between LH tail
LH turn signal power input lamp and cluster
2 Circuit 57B (B) 0 voltage, less than 5 ohms between LH tail
C-706 Ute Style Side Box RH Tail Lamp

1 Circuit 2B (G-L) 0 voltage, less than 5 ohms between RH tail
RH turn signal power input lamp and cluster
G86729 en 01/2003 2003.0 BA Falcon

C-708 Ute Style Side Box LH Tail Lamp

1 Circuit 3B (G) 0 voltage, less than 5 ohms between LH tail
LH turn signal power input lamp and cluster
2 Circuit 57E (B) 0 voltage, less than 5 ohms between LH tail
Multifunction switch Junction Box (JB):
fuse 17 (15A)
Circuitry
Turn Signal and
Hazard Lamp Bulbs
Cluster
Symptom Chart

The turn signal lamps are inoperative Circuitry Go to PinPoint Test H
Cluster
The turn signal lamps are always on Multifunction switch Go to PinPoint Test I
Cluster
One turn signal/hazard lamp is Circuitry Go to PinPoint Test J
inoperative
The hazard lamps are inoperative Circuitry Go to PinPoint Test K
Cluster
The hazard lamps are always on Cluster Perform the cluster testing in Section
413-01.
Pinpoint Tests Cluster C-171
Circuit 2C (G-L) or 3C(G) open or short to ground
The turn signal lamps are inoperative
Possible causes:
Circuit 8 (G-B) open or short to ground
Circuit 2 (G-L) or 3 (G) open or short to ground
G86729 en 01/2003 2003.0 BA Falcon

PINPOINT TEST H : THE TURN SIGNAL LAMPS ARE INOPERATIVE
H1 CHECK MULTIFUNCTION SWITCH INPUT VOLTAGE

Go to H2
Turn ON ignition.
Measure the voltage between the Multifunction switch C-167, circuit 8 No
(G-B), harness side and ground. Repair circuit 8 (G-B).
H2 CHECK THE MULTIFUNCTION SWITCH

Turn OFF ignition. Yes
Go to H3
Perform the Multifunction switch testing in Section 211-05.
Is the Multifunction switch functioning correctly? No
Replace the Multifunction switch, see Section
211-05.
H3 CHECK CLUSTER INDICATOR INPUT

Connect: Multifunction switch C-167. Yes
Go to H4
Disconnect: Cluster C-171.
Turn ON ignition. No
Repair circuit.
Turn ON inoperative indicator. Test the system for normal operation.
Measure the voltage between inoperative indicator harness side and
ground
for RH indicator use cluster C-171, circuit 2 (G-L), harness
side and ground.
for LH indicator use cluster C-171, circuit 3 (G), harness
side and ground.
H4 CHECK INDICATOR LAMP POWER INPUT FOR A

SHORT TO GROUND
Turn OFF ignition. Yes
Repair circuit.
Disconnect: Inoperative lamp. Test the system for normal operation.
Measure the resistance between the inoperative lamp, harness side
and ground No
Go to H5
for RH indicator use circuit 2 (G-L), harness side and
ground.
for LH indicator use circuit 3 (G), harness side and ground.
H5 CHECK INDICATOR LAMP POWER INPUT FOR AN

OPEN
Measure the resistance between the inoperative lamp, harness side Yes
and cluster C-171, harness side Perform the cluster testing in Section 413-01.
for RH indicator measure between, inoperative lamp, circuit Test the system for normal operation.
2 (G-L), harness side and cluster C-171, circuit 2C (G),
harness side.
No
Repair circuit.
for LH indicator measure between, inoperative lamp, circuit Test the system for normal operation.
3 (G), harness side and cluster C-171, circuit 3C (GL),
harness side.
G86729 en 01/2003 2003.0 BA Falcon

The turn signal lamps are always on Circuit 2C (G-L) or 3C (G) short to power
Possible causes:
Circuit 2 (G-L) or 3 (G) short to power
Cluster C-171
PINPOINT TEST I : THE TURN SIGNAL LAMPS ARE ALWAYS ON
I1 CHECK THE MULTIFUNCTION SWITCH

Go to I2
Are the turn signals always on?
No
Section 211-01.
I2 CHECK CLUSTER
Disconnect: Cluster C-171. Yes
Repair circuit 3C (G) if LH lights are illuminated
Are the turn signals always on? or circuit 2C (G-L) if RH lamps are illuminated.
No
Go to I3
I3 CHECK INDICATOR LAMP POWER INPUT FOR AN

OPEN
Measure the voltage between malfunctioning indicator, harness side Yes
and ground Repair circuit.
for RH indicator use cluster C-171, circuit 2 (G-L), harness Test the system for normal operation.
side and ground.
No
for LH indicator use cluster C-171, circuit 3 (G), harness Perform the cluster testing in Section 413-01.
side and ground. Test the system for normal operation.
One turn signal/hazard lamp is inoperative

Possible causes:
Circuit 2 (G-L) or 3 (G) open
Circuit 57 (B) open
PINPOINT TEST J : ONE TURN SIGNAL HAZARD LAMP IS INOPERATIVE
J1 CHECK INOPERATIVE LAMP INPUT

Disconnect: Inoperative lamp. Yes
Turn ON ignition.
Turn ON hazard lights.
No
Measure the voltage between the inoperative lamp, harness side and Repair circuit 2 (G-L) or 3 (G).
ground Test the system for normal operation.
for RH lamp use circuit 2 (G-L), harness side and ground.
for LH lamp use circuit 3 (G), harness side and ground.
G86729 en 01/2003 2003.0 BA Falcon

The hazard lamps are inoperative

Possible causes:
Circuit 383C (Y) open or short to ground
Cluster C-171
PINPOINT TEST K : THE HAZARD LAMPS ARE INOPERATIVE
K1 CHECK CIRCUIT 383C (Y) VOLTAGE

Disconnect: cluster. Yes
Perform the cluster testing in Section 413-01.
Measure the voltage between cluster C-171, circuit 383C (Y), harness Test the system for normal operation.
side and ground.
Repair circuit 383C (Y).
Stop Lamps
C-39 High Mount Stop Lamp

1 Circuit 10D (G-R) 0 voltage, less than 5 ohms between stop lamp
Stop lamp power input and brake switch
2 Circuit 57EL (B) 0 voltage, less than 5 ohms between stop lamp
Stop lamp ground and chassis ground
G86730 en 01/2003 2003.0 BA Falcon


1 Circuit 10A (G-R) 0 voltage, less than 5 ohms between stop lamp

1 Circuit 10B (G-R) 0 voltage, less than 5 ohms between stop lamp
C-77 Sedan Right Tail Lamp

1 Circuit 10B (G-R) 0 voltage, less than 5 ohms between stop lamp
C-78 Sedan Left Tail Lamp C-78
G86730 en 01/2003 2003.0 BA Falcon


C-191 Brake Switch

1 Circuit 10AA (G-R) 0 voltage, less than 5 ohms between the brake
Brake switch power input switch and ignition relay
2 Circuit 10Y (G-R) 0 voltage, less than 5 ohms between the brake
Brake switch output to stop lamps switch and stop lamps
C-710 Ute After Market High Mount Stop Lamp

1 Circuit 10C (G-R) 0 voltage, less than 5 ohms between stop lamp
2 Circuit 140M (R-B) 0 voltage, less than 5 ohms between stop lamp
and reverse lamps
G86730 en 01/2003 2003.0 BA Falcon


2 Circuit 57A (B) 0 voltage, less than 5 ohms between stop lamp

2 Circuit 57B (B) 0 voltage, less than 5 ohms between stop lamp

2 Circuit 57B (B) 0 voltage, less than 5 ohms between stop lamp
G86730 en 01/2003 2003.0 BA Falcon


2 Circuit 57D (B) 0 voltage, less than 5 ohms between stop lamp
Brake switch Junction Box (JB):
fuse 7 (15A)
Circuitry
Stop Lamp bulbs
Symptom Chart

Both stop lamps are inoperative Junction Box (JB): Go to PinPoint Test L
fuse 7 (15A)
Circuitry
Brake switch
One or more stop lamps are Circuitry Go to PinPoint Test M
inoperative Stop Lamp bulbs
The stop lamps are continuously on Circuitry Go to PinPoint Test N
Brake switch
Pinpoint Tests
Possible causes:
Circuit 10AA (G-R) open or short to ground.
Brake switch C-191.
Circuit 10Y (G-R) open or short to ground .
PINPOINT TEST L : THE STOP LAMPS ARE INOPERATIVE
L1 CHECK THE BRAKE SWITCH INPUT VOLTAGE

Disconnect: brake switch C-191. Yes
Go to L2.
Turn ON ignition.
Measure the voltage between the brake switch C-191, circuit 10AA No
(G-R), harness side and ground. Repair circuit 10AA (G-R).
L2 CHECK THE CIRCUIT 10Y (G-R) FOR A SHORT TO

GROUND
Measure the resistance between the brake switch C191, circuit 10Y Yes
(G-R), harness side and ground. Repair circuit 10Y (G-R)
No
Go to L3.
G86730 en 01/2003 2003.0 BA Falcon


L3 CHECK CIRCUIT 10 (G-R) FOR AN OPEN
Disconnect: Inoperative tail lamp. Yes
Perform the brake switch testing in Section
Measure the resistance between the brake switch C191, circuit 10Y 206-06.
(G-R), harness side and inoperative tail lamp (one of the following): Test the system for normal operation.
SWB Left tail lamp C-78, circuit 10A (G-R), harness side
SWB Right tail lamp C-77, circuit 10B (G-R), harness side No
Repair circuit 10 (G-R).
SWB High mount stop lamp C-39, circuit 10D (G-R), Test the system for normal operation.
harness side
LWB High mount stop lamp C-39, circuit 10Z (G-R),
harness side
Wagon Left tail lamp C-44, circuit 10A (G-R), harness side
Wagon Right tail lamp C-45, circuit 10B (G-R), harness side
Wagon High mount stop lamp C-39, circuit 10 (G-R),
harness side
Ute non-SSB Left tail lamp C-707, circuit 10C (G-R),
harness side
Ute non-SSB Right tail lamp C-705, circuit 10A (G-R),
harness side
Ute SSB Left tail lamp C-708, circuit 10C (G-R), harness
side
Ute SSB Right tail lamp C-706, circuit 10A (G-R), harness
side
One or more stop lamps are inoperative

Possible causes:
Circuit 10 (G-R) open.
Circuit 57 (B) open.
G86730 en 01/2003 2003.0 BA Falcon

PINPOINT TEST M : ONE OR MORE STOP LAMPS ARE INOPERATIVE
M1 CHECK CIRCUIT 10 (G-R) FOR AN OPEN

Disconnect: Inoperative stop lamp. Yes
Turn ON ignition. 206-06.
Measure the voltage between the brake switch C-191, circuit 10AA Test the system for normal operation.
(G-R), harness side and inoperative tail lamp.
No
SWB LH tail lamp C-78, circuit 10A (G-R), harness side
SWB RH tail lamp C-77, circuit 10B (G-R), harness side Test the system for normal operation.
SWB High mount stop lamp C-39, circuit 10D (G-R),
harness side
LWB High mount stop lamp C-39, circuit 10Z (G-R),
harness side
Wagon LH tail lamp C-44, circuit 10A (G-R), harness side
Wagon RH tail lamp C-45, circuit 10B (G-R), harness side
Wagon High mount stop lamp C-39, circuit 10 (G-R),
harness side
Ute cab chassis LH tail lamp C-707, circuit 10C (G-R),
harness side
Ute cab chassis RH tail lamp C-705, circuit 10A (G-R),
harness side
Ute style side box LH tail lamp C-708, circuit 10C (G-R),
harness side
Ute style side box RH tail lamp C-706, circuit 10A (G-R),
harness side
The stop lamps are continuously on

Possible causes:
Brake switch C-191
Circuit 10 (G-R) short to power
PINPOINT TEST N : THE STOP LAMPS ARE CONTINUOUSLY ON

N1 CHECK THE CIRCUIT 10Y (G-R) FOR A SHORT TO
POWER
Disconnect: brake switch C-191. Yes
Are the stop lamps illuminated? Test the system for normal operation.
No
206-06.
G86731 en 01/2003 2003.0 BA Falcon

Fog Lamps
C-163 Power Distribution Box (PDB)

1 Circuit 37H (Y) Greater than 10 volts and 10,000 between fog
Battery to fog lamp relay lamp relay and ground
2 Circuit 57AX (B) 0 volts, less than 5 ohms between fog lamp relay
Fog lamp relay ground and ground
3 477 (SB) 0 volts, less than 5 ohms between fog lamp
Fog lamp switch to fog lamp relay switch and fog lamp relay
4 478A (BR-W) 0 volts, less than 5 ohms between fog lamp relay
Fog lamp relay to fog lamps and fog lamps
C-360 LH Fog Lamp
G86731 en 01/2003 2003.0 BA Falcon


1 Circuit 57AZ (B) 0 volts, less than 5 ohms between LH fog lamp
LH fog lamp ground and ground
2 Circuit 478C (BR-W) 0 volts, less than 5 ohms between LH fog lamp
LH fog lamp power input and fog lamp relay
C-362 RH Fog Lamp

1 Circuit 57AY (B) 0 volts, less than 5 ohms between RH fog lamp
RH fog lamp ground and ground
2 Circuit 478B (BR-W) 0 volts, less than 5 ohms between RH fog lamp
RH fog lamp power input and fog lamp relay
C-363 Fog Lamp Switch

1 Circuit 1045M (BR) 0 volts, less than 5 ohms between fog lamp
Fog lamp switch power input from switch and tail lamp relay.
tail lamp relay
2 Circuit 477 (SB) 0 volts, less than 5 ohms between fog lamp
Fog lamp switch to fog lamp relay switch and fog lamp relay
Fog lamp switch. Power Distribution
Box (PDB):
Fuse 18 (20A)
Relay 1 (20A)
Circuitry
Fog Lamp bulbs
G86731 en 01/2003 2003.0 BA Falcon

Symptom Chart

Both fog lamps are inoperative. Power Distribution Box (PDB): Go to PinPoint Test O
Fuse 18 (20A)
Relay 1 (20A)
Circuitry
Fog lamp switch
One fog lamp is inoperative. Circuitry Go to PinPoint Test P
Both fog lamps are on continuously. Power Distribution Box (PDB): Go to PinPoint Test Q
Relay 1 (20A)
Circuitry
Fog lamp switch
Pinpoint Tests Fog lamp relay
Circuit 57AX (B) open
Circuit 478 (BR-W) open or short to ground
Possible causes:
Circuit 1045M (BR) open or short to ground
Fog lamp switch C-363
Circuit 477 (SB) open or short to ground
PINPOINT TEST O : BOTH FOG LAMPS ARE INOPERATIVE
O1 CHECK THE FOG LAMP SWITCH TO FOG LAMP RELAY

VOLTAGE
Disconnect: Fog lamp relay, PDB C-163 relay 1 (20A). Yes
Go to O5
Turn ON fog lamps.
Measure the voltage between fog lamp relay, PDB C-163 relay 1, No
circuit 477 (SB), harness side and ground. Go to O2
O2 CHECK CIRCUIT 1045M (BR) VOLTAGE

Disconnect: Fog lamp switch C-363. Yes
Go to O3
Measure the voltage between fog lamp switch C-363, circuit 1045M
(BR), harness side and ground. No
Is the voltage greater than 10 volts? Repair circuit 1045M (BR)
O3 CHECK CIRCUIT 477 (SB) FOR A SHORT TO GROUND

Measure the resistance between fog lamp relay, PDB C-163 relay 1, Yes
circuit 477 (SB), harness side and ground. Repair circuit 477 (SB).
No
Go to O4
O4 CHECK CIRCUIT 477 (SB) FOR AN OPEN

Measure the resistance between the fog lamp relay, PDB C-163 relay Yes
1, circuit 477 (SB), harness side and fog lamp switch C-363, circuit Perform the fog lamp switch testing in Section
477 (SB), harness side. 000-00.
No
Refer Circuit 477 (SB).
G86731 en 01/2003 2003.0 BA Falcon


O5 CHECK CIRCUIT 37H (SB) VOLTAGE
Measure the voltage between fog lamp relay, PDB C-163 relay 1, Yes
circuit 37H (SB), harness side and ground Go to O6
Repair circuit 37H (SB)Test the system for
normal operation.
O6 CHECK CIRCUIT 57AX (B) FOR AN OPEN

circuit 57AX (B), harness side and ground. Go to O7
Repair circuit 57AX (B)Test the system for
normal operation.
O7 CHECK CIRCUIT 478 (BR-W) FOR A SHORT TO

GROUND
circuit 478A (BR-W), harness side and ground. Repair circuit 478 (BR-W).
No
Go to O8.
O8 CHECK CIRCUIT 478 (BR-W) FOR AN OPEN

Disconnect: RH fog lamp C-362. Yes
Replace fog lamp relay, PDB C-163 relay 1
Measure the resistance between fog lamp relay, PDB C-363 relay 1, (20A).
circuit 478A (BR-W), harness side and RH fog lamp C-362, circuit Test the system for normal operation
478B, harness side.
Repair circuit 478 (BR-W).
Test the system for normal operation
One fog lamp is inoperative

Possible causes:
Circuit 478 (BR-W) open
Circuit 57 (B) open
PINPOINT TEST P : ONE FOG LAMP IS INOPERATIVE
P1 CHECK THE VOLTAGE TO THE INOPERATIVE FOG

LAMP
Disconnect: Inoperative fog lamp. Yes
Turn On Fog LampS.
Measure the voltage between RH fog lamp C-362, circuit 478B
(BR-W), harness side or LH fog lamp C-360, circuit 478C (BR-W), No
harness side and ground. Repair circuit 478 (BR).
G86731 en 01/2003 2003.0 BA Falcon

Both fog lamps are on continuously

Possible causes:
For lamp switch C-363
Circuit 477 (SB) short to power
Fog lamp relay
Circuit 478 (BR-W) short to power
PINPOINT TEST Q : BOTH FOG LAMPS ARE ON CONTINUOUSLY

Q1 CHECK FOG LAMP SWITCH
Disconnect: Fog lamp switch C-363. Yes
Go to R2
Are the fog lamps illuminated?
No
Perform the fog lamp switch testing in Section
000-00.
Q2 CHECK CIRCUIT 478 A (BR=W) FOR A SHORT TO

POWER
Disconnect: Fog lamp Relay, PDB C-163 Relay 1. Yes
Repair circuit 478 (BR-W). Test the system for
Are the fog lamps illuminated? normal operation.
No
Go to Q3
Q3 CHECK CIRCUIT 477 A (SB) FOR A SHORT TO POWER

Measure the voltage between fog lamp relay, PDB C-163 relay 1, Yes
circuit 477 (SB), harness side and ground Repair circuit 477 (SB).
No
Replace fog lamp relay, PDB C-163 relay 1
(20A).
Parking, Rear and License Lamps

G86731 en 01/2003 2003.0 BA Falcon


1 Circuit 14A (BR) 0 voltage, less than 5 ohms between LH rear
LH rear lamp power input lamp and tail lamp relay

1 Circuit 14B (BR) 0 voltage, less than 5 ohms between RH rear
RH rear lamp power input lamp and tail lamp relay
C-77 Sedan RH Tail Lamp

1 Circuit 14B (BR) 0 voltage, less than 5 ohms between RH rear
C-78 Sedan LH Tail Lamp
G86732 en 01/2003 2003.0 BA Falcon


1 Circuit 14A (BR) 0 voltage, less than 5 ohms between LH rear
C-81 License Lamp

1 Circuit 14 (BR) 0 voltage, less than 5 ohms between license
License lamp power input lamp and tail lamp relay
2 Circuit 57A (B) 0 voltage, less than 5 ohms between license
License lamp ground lamp and chassis ground
C-159 RH Parking Lamp

1 Circuit 14D (BR) 0 voltage, less than 5 ohms between RH parking
RH parking lamp power input lamp and tail lamp relay
2 Circuit 57AL (B) 0 voltage, less than 5 ohms between RH parking
RH parking lamp ground lamp and chassis ground
C-160 LH Parking Lamp
G86732 en 01/2003 2003.0 BA Falcon


1 Circuit 14A (BR) 0 voltage, less than 5 ohms between LH parking
LH parking lamp power input lamp and tail lamp relay
2 Circuit 57AE (B) 0 voltage, less than 5 ohms between LH Parking
LH parking lamp ground Lamp and chassis ground

1 Circuit 175 (B-Y) 0 voltage, less than 5 ohms between
Multifunction switch parking lamps Multifunction switch and tail lamp relay
input from tail lamp relay
C-331 Junction Box (JB)

1 Circuit 175 (B-Y) 0 voltage, less than 5 ohms between tail lamp
Multifunction switch parking lamps relay and Multifunction switch
input from tail lamp relay
G86732 en 01/2003 2003.0 BA Falcon

C-334 Junction Box (JB)

1 Circuit 14E (BR) 0 voltage, less than 5 ohms between tail lamp
Parking lamp power input relay and parking, rear and license lamps

1 Circuit 14D (BR) 0 voltage, less than 5 ohms between RH rear
2 Circuit 57A (B) 0 voltage, less than 5 ohms between LH tail

1 Circuit 14B (BR) 0 voltage, less than 5 ohms between LH rear
2 Circuit 57B (B) 0 voltage, less than 5 ohms between LH tail
G86732 en 01/2003 2003.0 BA Falcon


1 Circuit 14D (BR) 0 voltage, less than 5 ohms between RH rear
2 Circuit 57B (B) 0 voltage, less than 5 ohms between RH tail

1 Circuit 14B (BR) 0 voltage, less than 5 ohms between LH rear
2 Circuit 57D (B) 0 voltage, less than 5 ohms between LH tail
Multifunction switch Junction Box (JB):
fuse 23 (15A)
relay 4 (20 A)
Circuitry
Parking, rear and
license lamp bulbs
Symptom Chart

The parking, rear and license lamps Junction Box (JB): Go to PinPoint Test R
are inoperative fuse 23 (15A)
relay 4 (20 A)
Circuitry
G86732 en 01/2003 2003.0 BA Falcon


One or more parking, rear or license Circuitry Go to PinPoint Test S
lamps are inoperative
The parking, rear and license lamps Junction Box (JB): Go to PinPoint Test T
are on continuously relay 4 (20 A)
Circuitry
Pinpoint Tests Circuit 175 (B-Y) open
The parking, rear and license lamps are
inoperative Circuit 57CL (B) open
Circuit 14 (BR) open or short to ground
Possible causes:
circuit 38G (Y-R) open or short to ground
Tail lamp relay, JB relay 4 (20A)
PINPOINT TEST R : THE PARKING, REAR AND LICENCE LAMPS ARE INOPERATIVE
R1 CHECK TAIL LAMP RELAY INPUT VOLTAGE

Disconnect: Tail lamp relay, JB relay 4. Yes
Go to R2
Measure the voltage between tail lamp relay, JB relay 4, circuit 38G
(Y-R), harness side and ground. No
Is the voltage greater than 10 volts? Repair circuit 38G (Y-R).
R2 CHECK CIRCUIT 14 (BR) FOR A SHORT TO GROUND

Measure the resistance between tail lamp relay, JB C-334 relay 4, Yes
circuit 14E (BR), harness side and ground Repair circuit 14 (BR)
No
Go to R2
R3 CHECK CIRCUIT 14 (BR) FOR AN OPEN

Disconnect: RH Headlamp park lamp C-159. Yes
Go to R4
Measure the resistance between tail lamp relay, JB C-334 relay 4,
circuit 14E (BR), harness side RH headlamp park lamp C-159, circuit No
14D (BR), harness side. Repair circuit 14 (BR).
R4 CHECK CIRCUIT 175 (B-Y) FOR AN OPEN

Go to R5
Measure the resistance between tail lamp relay, JB C-331 relay 4,
circuit 175 (B-Y), harness side and Multifunction switch C-167, circuit No
175 (B-Y), harness side Repair circuit 175 (B-Y))
R5 CHECK MULTIFUNCTION SWITCH

Replace the tail lamp relay.
Is the Multifunction switch functioning correctly? Test the system for normal operation.
No
Replace the Multifunction switch, see Section
211-05.
G86732 en 01/2003 2003.0 BA Falcon

One or more parking, rear or license lamps

are inoperative
Possible causes:
Circuit 14 (BR) open or short to ground
Circuit 57 (B) open
PINPOINT TEST S : ONE OR MORE PARKING, REAR OR LICENCE LAMPS ARE INOPERATIVE
S1 CHECK TAIL LAMP RELAY INPUT VOLTAGE

Disconnect: Inoperative parking, rear or license lamp. Yes
Turn ON the parking lights. Test the system for normal operation.
Measure the voltage between the inoperative lamp:
No
LH parking lamp C-160, circuit 14A (BR), harness side
Repair circuit 14 (BR).
RH parking lamp C-160, circuit 14D (BR), harness side Test the system for normal operation.
Sedan LH tail lamp C-78, circuit 14A (BR), harness side
Sedan RH tail lamp C-77, circuit 14B (BR), harness side
Wagon LH tail lamp C-44, circuit 14A (BR) harness side
wagon right tail lamp C-45, circuit 14B (BR) harness side
Ute, non-SSB, LH rear lamp C-707, circuit 14B (BR)
harness side
Ute, non-SSB, RH rear lamp C-705, circuit 14D (BR)
harness side
Ute, SSB, LH rear lamp C-708, circuit 14B (BR) harness
side
Ute, SSB, RH rear lamp C-706, circuit 14D (BR) harness
side
License plate lamp C-81, circuit 14 (BR), harness sideand
ground
The parking, rear and license lamps are on

continuously
Possible causes:
Tail lamp relay
Circuit 175 (B-Y) short to ground
Circuit 14 (BR) short to power
PINPOINT TEST T : THE PARKING, REAR AND LICENCE LAMPS ARE ON CONTINUOUSLY
T1 CHECK MULTIFUNCTION SWITCH

Go to T2
Are the parking, rear and license lamps illuminated?
No
Section 211-05.
G86732 en 01/2003 2003.0 BA Falcon


T2 CHECK CIRCUIT 175 (B-Y) FOR A SHORT TO GROUND
Measure the resistance between Multifunction switch C-167, circuit Yes
175 (B-Y), harness side and ground. Repair circuit 175 (B-Y).
No
Go to T3
T3 CHECK TAIL LAMP RELAY

Disconnect: Tail lamp relay, JB C-334 relay 4. Yes
Repair circuit 14 (BR).
Are the parking, rear and license lamps illuminated? Test the system for normal operation
No
Replace the tail lamp relay.
Reverse Lamps
C-12 Inhibitor switch and PRNDL switch

1 Circuit 140 (W-R) 0 voltage, less than 5 ohms between inhibitor
switch and PRNDL switch and ignition relay
2 Circuit 140X (R-B) 0 voltage, less than 5 ohms between inhibitor
switch and PRNDL switch, and reverse lamps
C-26 Reverse Lamp Switch

1 Circuit 140 (W-R) 0 voltage, less than 5 ohms between reverse
lamp switch and ignition relay
2 Circuit 140X (R-B) 0 voltage, less than 5 ohms between reverse
lamp switch and reverse lamps
G86732 en 01/2003 2003.0 BA Falcon


1 Circuit 140A (R-B) 0 voltage, less than 5 ohms between LH reverse
LH reverse lamp power input lamp and either inhibitor switch and prndl switch
or reverse lamp switch

1 Circuit 140B (R-B) 0 voltage, less than 5 ohms between RH reverse
RH reverse lamp power input lamp and either inhibitor switch and prndl switch
C-77 Sedan RH Tail Lamp

1 Circuit 140B (R-B) 0 voltage, less than 5 ohms between RH reverse
G86732 en 01/2003 2003.0 BA Falcon

C-78 Sedan LH Tail Lamp

1 Circuit 140A (R-B) 0 voltage, less than 5 ohms between LH reverse
LH reverse lamp power input lamp and either inhibitor switch and prndl switch

1 Circuit 140A (R-B) 0 voltage, less than 5 ohms between RH reverse
C-714 Ute Back Up Lamp

1 Circuit 140 (R-B) 0 voltage, less than 5 ohms between back up
LH back up lamp power input lamp and either inhibitor switch and prndl switch
2 Circuit 57C (B) 0 voltage, less than 5 ohms between back up
LH back up lamp ground lamp and chassis ground
G86732 en 01/2003 2003.0 BA Falcon


Inhibitor switch and Junction Box (JB):
PRNDL switch Fuse 15 (15A)
Reverse lamp switch
Circuitry
Reverse lamp bulbs
Symptom Chart

The reversing lamps are inoperative Power Distribution Box (PDB): Go to PinPoint Test U
Fuse 15 (20A)
relay 4 (20 A)
Circuitry
Inhibitor switch and PRNDL switch
Reverse lamp switch
The individual reversing lamp is Circuitry Go to PinPoint Test V
inoperative
The reversing lamps are on Circuitry Go to PinPoint Test W
continuously Inhibitor switch and PRNDL switch
Reverse lamp switch
Pinpoint Tests Circuit 140 (W-R) open or short to ground
Circuit 57 (B) open
The reversing lamps are inoperative
Possible causes:
Circuit 140X (R-B) open or short to ground
Inhibitor switch and PRNDL switch C-26
Reverse lamp switch C-12
PINPOINT TEST U : THE REVERSE LAMPS ARE INOPERATIVE
U1 CHECK CIRCUIT 140X (R-B) VOLTAGE

Disconnect either: Yes
(manual) Reverse Lamp Switch C-26. Go to U2
(automatic) Inhibitor switch and PRNDL switch C-12. No

Repair circuit 140X (R-B).
Turn ON ignition.
Measure the voltage between (manual) Reverse Lamp Switch C-26,
circuit 140X (R-B), harness side or (automatic) Inhibitor switch and
PRNDL switch C-12, circuit 140X (R-B), harness side and ground.
U2 CHECK CIRCUIT 140 (W-R) FOR A SHORT TO GROUND

Measure the resistance between (manual) Reverse Lamp Switch Yes
C-26, circuit 140 (W-R), harness side or (automatic) Inhibitor switch Repair circuit 140 (W-R).
and PRNDL switch C-12, circuit 140 (W-R), harness side and ground. Test the system for normal operation.
Go to U3
G86732 en 01/2003 2003.0 BA Falcon


U3 CHECK CIRCUIT 140 (W-R) FOR AN OPEN
Disconnect: Inoperative tail lamp. Yes
Go to U4
Measure the resistance between (manual) Reverse Lamp Switch
C-26, circuit 140 (W-R), harness side or (automatic) Inhibitor switch No
and PRNDL switch C-12, circuit 140 (W-R), harness side and Repair circuit 140 (W-R).
inoperative tail lamp, circuit 140 (R-B), harness side. Test the system for normal operation.
U4 CHECK CIRCUIT 57ER (B) FOR AN OPEN

Measure the resistance between inoperative tail lamp, circuit 57 (B), Yes
harness side and ground. Perform the inhibitor switch and PRNDL switch
or reverse lamp switch testing in Section 307-01.
No
The individual reversing lamp is inoperative

Possible causes:
Circuit 140 (W-R)
open
Circuit 57 (B) open
PINPOINT TEST V : THE INDIVUDUAL REVERSING LAMP IS INOPREATIVE
V1 CHECK THE VOLTAGE TO THE INOPERATIVE

REVERSING LAMP
Set the parking brake. Yes
Repair circuit 57(B).
Key in ON position. Test the system for normal operation.
Disconnect: inoperative reversing lamp.
No
Select REVERSE. Repair circuit 140(W-R).
Measure the voltage between the: Test the system for normal operation.
sedan left tail lamp C-78, circuit 140A (R-B) harness side-
sedan right tail lamp C-77, circuit 140B (R-B) harness side
wagon left tail lamp C-44, circuit 140A (R-B) harness side.
wagon right tail lamp C-45, circuit 140B (R-B) harness side.
Ute, non-SSB, right tail lamp C-705, circuit 140A (R-B) harness side.
Ute, non-SSB, left tail lamp C-707, circuit 140C (R-B) harness side.
Ute, SSB, back up lamp C-714, circuit 140 (R-B) harness side and
ground.
Is the voltage greater than 10 V?
The reversing lamps are on continuously

Possible causes:
Inhibitor switch and PRNDL switch C-26
Reverse lamp switch C-12
Circuit 140 (W-R) short to power
G86732 en 01/2003 2003.0 BA Falcon

PINPOINT TEST W : THE REVERSING LAMPS ARE ON CONTINUOUSLY
W1 CHECK CIRCUIT 140 (W-R) FOR A SHORT TO POWER

Disconnect either: Yes
(manual) Reverse Lamp Switch C-26. Repair circuit 140 (W-R).
(automatic) Inhibitor switch and PRNDL switch C-12.
No
Measure the voltage between (manual) Reverse Lamp Switch C-26,
Perform the inhibitor switch and PRNDL switch
circuit 140 (W-R), harness side or (automatic) Inhibitor switch and
or reverse lamp switch testing in Section 307-01.
PRNDL switch C-12, circuit 140 (W-R), harness side and ground.
G86732 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Headlamp Adjustment Driving Beam
Low Beam 1. The driving beam is fixed internally within the

headlamp relative to the low beam. Whenever the
(Refer to diagram on following page.) low beam aim is adjusted the driving beam is also
1. To adjust the headlamp aim in accordance with adjusted.
this specification, a flat vertical test screen as
shown is required. Alternatively an approved
headlamp aim testing device may be used.
2. The vehicle must have the correct tyre pressure,
must be unloaded, have a fully filled tank and the
hand brake must be in the fully released position.
3. The vehicle must be placed on a flat horizontal
surface and carefully positioned 10 metres from
the test screen.
4. Gently rock vehicle to obtain correct horizontal
vehicle attitude.
5. Measure H the height of the headlamp low beam
bulb centre above ground. For different lamps and
vehicles this height will vary due to vehicle
production tolerance.
6. Set the horizontal breakline on the test screen to
a height h = H-e where e is the aim setting
dimension.
7. Measure A the distance between the low beam
bulb centres. Using this dimension set up the low
beam aim centre C and construct the 15 inclined
breakline from this point on the test screen.
8. Switch on the low beam lights and cover all lamps
except the one that is being aimed.
9. Using the horizontal and vertical aim adjusting
screws shift the light pattern of the headlamp on
the test screen until the light/dark boundaries of
the light pattern coincides with the breaklines on
the test screen. The low beam pattern should now
be centred on point C.
10. Repeat the above procedure to adjust the

remaining headlamp.
High Beam
1. The high beam aim is fixed internally within the
headlamp relative to the low beam. Whenever the
low beam aim is adjusted the high beam aim is
also adjusted.
G86734 en 01/2003 2003.0 BA Falcon

G86734 en 01/2003 2003.0 BA Falcon

Fog Lamp Adjusment (XR Only)

(Refer to diagram on following page.)
1. To adjust the foglamp aim in accordance with this
specification, a flat vertical test screen as shown
is required.
2. The vehicle must have the correct tyre pressure,
must be unloaded, have a fully filled tank and the
hand brake must be in the fully released position.
3. The vehicle must be placed on a flat horizontal
surface and carefully positioned 5 metres from the
test screen.
4. Gently rock vehicle to obtain correct horizontal
vehicle attitude.
5. Measure H the height of the foglamp bulb centre
above ground. For different lamps and vehicles
this height will vary due to vehicle production
tolerance.
6. Set the horizontal line on the test screen to a
height h = H-e where e is the aim setting
dimension.
7. Switch on the fog lights and cover all lamps
except the one that is being aimed.
8. Using the vertical aim adjusting screw (accessible
from under the bumper with an 6 mm Allen key or
Phillips screw driver) shift the light pattern of the
foglamp on the test screen until the centre of the
of the light pattern Point C coincides with the line
at h on the test screen.
9. Repeat the above procedure to adjust the

remaining fog lamp.
G86734 en 01/2003 2003.0 BA Falcon

G86734 en 01/2003 2003.0 BA Falcon

Headlamp Assembly 3. Remove the rubber boot from the lamp back face.
Removal
WARNING: Bulbs become hot to touch and
can cause burns if not allowed to cool before
handling.
1. Raise the hood.
2. Disconnect the 3 lamp wiring connectors.
3. Remove the front bumper & bumper absorber
(Refer to section 501-19).
4. Release retaining spring clip and withdraw bulb.

5. Remove bulb from holder.
Installation
NOTE: Hold the replacement Quartz Halogen bulb
with a clean cloth or tissue to prevent contact with
glass. If the glass is touched, the skin’s natural oils
will contaminate the bulb. Wipe the bulb clean using
methylated spirits before installing.
1. Push bulb into holder.
4. Remove 4 bolts from the lamp. 2. Install the bulb and retain it with the spring clip.
5. Pull lamp slighty forward and upwards to dislodge 3. Install the rubber boot, installing the inner
retainers. aperture to the bulb first, followed by the outer
6. Gently move lamp slightly inboard and rock aperture to the lamp body. Ensure the rubber boot
forward to remove ensuring indicator bulb clears has sealed correctly and is not deformed.
fender opening. 4. Reconnect wiring to the bulb and test.
Installation
Headlamp Bulb — Low Beam H4
1. Connect lamp wiring harness.
2. Reverse removal procedure. Removal
3. Check and adjust headlamp aim if necessary. 1. Switch the headlamps off and allow sufficient time
to cool.
Headlamp Bulb — High Beam H7 2. Disconnect wiring from bulb.
Removal 3. Remove the rubber boot from the lamp back face.
1. Switch the headlamps off and allow sufficient time 4. Release retaining spring clip and withdraw bulb.
to cool. Installation
2. Disconnect wiring from the bulb closest to the NOTE: Hold the replacement Quartz Halogen bulb
centre of the vehicle. with a clean cloth or tissue to prevent contact with
glass. If the glass is touched, the skin’s natural oils
will contaminate the bulb. Wipe the bulb clean using
methylated spirits before installing.
1. Install the bulb and retain it with the spring clip.
2. Install the rubber boot, installing the inner
aperture to the bulb first, followed by the outer
aperture to the lamp body. Ensure the rubber boot
has sealed correctly and is not deformed.
3. Reconnect wiring to the bulb and test.
G86735 en 01/2003 2003.0 BA Falcon

Turn Signal Bulb Installation

Removal
1. Turn the front wheel inward to allow access to the Auxiliary Lamp
3 lower front fender splash shield push pin rivets
and screw. Carefully peel back the splash shield Removal
to expose the turn signal wiring connector. 1. Switch the lamps off and allow sufficient time to
cool.
2. Remove the lower air deflector from the front
bumper.
Item Description
1 Fender splash shield
2 Firtree Cip - 6.5x25mm (x2)
Item Description
3 Scrivets - 6mm (x10)
1 Wiring harness
4 Screw - 5mm (x1)
2 Self-tapping screw
5 Screw - 5mm (x2)
3 Firtree clip
2. Turn the bayonet-style connector anti-clockwise 4 Air deflector retaining screw
approximately 1/8 of a turn to free the bulb holder.
3. Disconnect the wiring harness from the lamp bulb.
Installation
1. Reverse the removal procedure. 4. Remove the three self-tapping screws used to
retain the lamp.
Parklamp Bulb Installation
Removal
1. Switch the headlamps off and allow sufficient time Auxiliary Lamp Bulb
to cool.
Removal
2. Gently rotate anticlockwise and pull bulb holder
from the lamp. NOTE: Switch the lamps off and allow sufficient time
to cool.
1. Remove the lower air deflector from the bottom of
the front bumper.
2. Disconnect the terminal.
3. Remove the bulb retainer by rotating in an
anti-clockwise direction.
4. Remove the bulb from the bulb by pulling
outwards.
Installation
1. Install the new bulb.
2. Refit the bulb retainer into the lamp housing and
rotate 1/8 turn clockwise until the bulb retainer is
fully positioned. Note that the bulb retainer will
3. Remove bulb from the holder by pulling outwards. only fit correctly in one position.
3. Connect the terminal to the bulb retainer.
G86741 en 01/2003 2003.0 BA Falcon

4. Refit the lower air deflector. Tail Lamp Assembly — Sedan

Fog Lamp Removal
Removal
1. Switch the foglamps off and allow sufficient time
to cool.
2. Remove the air lower air deflector.
3. Push the lamp inward with your palm.
4. Disconnect the lamp wiring.
5. Remove the lamp assembly from the car.
Installation
Fog Lamp Bulb

Removal
1. Remove the foglamp assembly from the bumper 1. Open decklid.
as above. 2. Remove interior quarter trim.
3. Disconnect wiring connector to tail lamp and
squeeze rubber grommet through hole.
4. Remove two retaining screws on the inboard side
of tail lamp assembly.
5. Insert a thin flat head screwdriver or similar object
having a flat blade to the forward side of the
outboard stud and gently prise it off the plastic
retainer, being careful to protect any paint from
damage.
6. Remove the lamp assembly.
7. Discard mating ball stud insert.
Installation
1. Replace plastic ball stud insert.
2. Unclip retaining clip and remove bulb. 2. Pull the wiring assembly in and ensure the rubber
Installation grommet is correctly seated to body panel.
NOTE: Hold the replacement Quartz Halogen bulb 3. Install lamp into vehicle ensuring locating tab is
with a clean cloth or tissue to prevent contact with over the sheetmetal tab.
glass. If the glass is touched, the skin’s natural oils 4. Install the two retaining screws.
will contaminate the bulb. Wipe the bulb clean using 5. Connect the wiring connector and refit the rear
methylated spirits before installing. quarter interior trim.
1. Install the bulb and retain it with the spring clip. 6. Close the decklid.
2. Test.
3. Clip lamp insert into the lamp assembly.
G86741 en 01/2003 2003.0 BA Falcon

Tail Lamp Assembly — Wagon Tail Lamp, Reverse Lamp and Rear
Removal
Indicator Bulb — Sedan And Wagon
1. Open the liftgate. Removal
1. Follow steps 1, 4, 5 of Tail Lamp Assembly
Removal and Installation procedure, so that lamp
assembly is free from vehicle. It is not necessary
to disconnect the electrical wiring from vehicle.
2. Remove the rear quarter interior trim.

3. Disconnect wiring connector to tail lamp and
squeeze rubber grommet through hole.
4. Remove the two retained screws, one on the
inboard side and another one on the top of the tail 2. Remove bulb holder from socket by rotating
lamp assembly. holder anti-clockwise approximately 1/8th turn
until free from socket.
5. Insert a thin flat head screwdriver or similar object
having a flat blade to the forward side of the Stop and tail lamp - (clear twin filaments bulb)
outboard stud and gently prise it off the plastic Indicator lamp - (amber bulb)
retainer, being careful to protect any paint from Reverse lamp - (clear bulb)
damage.
3. Remove bulb from holder by rotating
6. Remove the tail lamp assembly. anti-clockwise approximately 1/8th turn.
1. Pull the wiring assembly in and ensure the rubber 1. Install bulb in holder by gently pushing bulb into
grommet is correctly seated to body panel. holder and rotating bulb clockwise.
2. Insert the locating peg to the upper inboard 2. Insert bulb and holder assembly into socket. Note:
square hole on the body panel and push the the holder cannot be inserted into the incorrect
outboard stud into the plastic retainer. socket. Rotate holder clockwise until firm in
3. Install the two retained screws. socket.
4. Connect the wiring connector and refit the rear 3. Follow the procedure given in this section for
quarter interior trim. installation of the tail lamp assembly.
5. Close the liftgate.
Tail Lamp Assembly — Style Side Box
Removal
1. Open tailgate.
2. Remove two bolts on taillight edge.
G86747 en 01/2003 2003.0 BA Falcon

3. Remove lamp, pulling away at 45 degrees. 2. Carefully insert the tail lamp assembly, snapping
the two retaining tabs into place.
3. Install the two bolts.
Reverse Light Replacement — Style

Side Box
Removal
1. Remove the two bolts attaching the reverse light.
Item Description
1 Bolt (x2)
2 Tail lamp wiring
3 Tail lamp pin location guide
4 Tail lamp assembly
4. Disconnect wiring.
Installation
Item Description
1 Reverse lamp
Rear Light Bulbs Replacement — Style 2. Carefully insert a flat blade under the lens.
Side Box 3. Disconnect the bulb connector.
Removal 4. Remove the bulb to be replaced.
1. Remove the two bolts from the inside of the Installation
tailgate. 1. Insert a new bulb and replace the wiring
2. Carefully pull the tail lamp assembly from the connector.
liftgate pillar by releasing the two retaining tabs. 2. Replace the lens and install the two bolts.
Tail Lamp Assembly — Tray

Removal
1. Remove M6 nuts from lamp mounting bracket.
Item Description
1 Brake/Tail lamp
2 Indicator lamp
3. Disconnect the wiring connector.
4. Carefully pull out the bulb to be replaced. Item Description
Installation
2 Nut - M6
1. Insert the new bulb and replace the wiring
connector.
G86747 en 01/2003 2003.0 BA Falcon

Rear Light Bulbs Replacement —

Cable/Chassis and Tray
Removal
1. Release the retaining clip and swivel aside the
plastic frame that secures the lens.
Item Description
1 Reversing lamp
2 Indicator lamp
3 Tail lamp
4 Brake lamp
2. Remove the lens from the lamp assembly.
3. Remove the blown bulb by gently pressing the
bulb down and turning it anti-clockwise.
Item Description
Installation
1 Bolt
1. Insert a new bulb, replace the lens and close the
2 Nut - M6 plastic frame with the retaining clip.
4 Ute chassis Licence Plate Lamp Assembly
5 Mointing bracket Removal
Installation 1. Gently insert a flat blade or similar object under
1. Reverse the removal procedure. one side of lamp assembly and gently press on
the locking tab.
2. Lift the lamp assembly out of the bumper or
applique.
G86752 en 01/2003 2003.0 BA Falcon

Installation Rear Licence Plate Lamp Replacement

1. Connect the wiring connector. — Chassis/Cab and Tray
2. Position lamp assembly and push into bumper or
applique until locking tabs engage.
1. Push off the rubber band and pull off the cap.
Licence Plate Bulb
Removal
1. Remove lamp assembly as above leaving the
wiring connected.
2. Turn bulb holder approximately 1/8th turn
anti-clockwise until it is free.
3. Pull bulb out from socket.
Installation
NOTE: Tabs prevent the bulb holder from being
inserted into the lamp assembly at the incorrect
orientation. Do not apply force.
Rear Licence Plate Lamp Replacement Item Description

— Style Side Box 1 Retaining bolt
2 Licence plate housing
2. Remove the bulb by gently pressing it down and
1. Carefully insert a flat blade under one side of the
turning it anti-clockwise.
lamp assembly. Press gently on the locking tab.
3. Insert a new bulb and replace the cap in the
rubber band.
Side Indicator Lamps

Removal
1. Turn front wheel outward.
2. Remove front splash shield fixings behind wheel,
and peel splash shield back.
2. Lift the lamp assembly out of the bumper.

4. Turn the bulb holder approximately 1/8th turn
anti-clockwise until it is free. Pull the bulb from the
socket.
5. Replace the bulb and bulb holder, connect the
wiring connector and push the lamp assembly into
the bumper until the locking tabs engage.
Item Description
1 Fender splash shield
2 Firtree Cip - 6.5x25mm (x2)
3 Scrivets - 6mm (x10)
4 Screw - 5mm (x1)
5 Screw - 5mm (x2)
G86752 en 01/2003 2003.0 BA Falcon

3. Remove bulb holder by turning anti-clockwise 2. Disconnect wiring connector to stop lamp.
about 45 degrees.
4. Remove bulb from holder by pulling straight out.
Installation
High Mount Stop Lamp — Sedan

(Except LWB)
Removal
1. From inside the luggage compartment remove the
bulb holder from the base of the lamp.
2. From inside the vehicle remove the parcel shelf
trim.
3. Unscrew lamp assembly from spoiler.
Installation
NOTE: Lamp is a sealed unit and must be replaced
as a complete assembly.
High Mount Stop Lamp Bulb — Wagon

Removal
1. Raise the liftgate and detach the clip-on cover
from the lamp.
2. Detach the bulb holder from the lamp.
3. Gently prise the lamp from the panel, dislodging

the front legs first.
Installation
1. Slot rear hooks of lamp into panel, then snap in
front legs.
2. Replace the trim.
3. Install the bulb holder in the lamp.
NOTE: There is no bulb fitted to holder when a
spoiler mounted HMSL is fitted.
High Mount Stop Lamp — XR Series

Sedan Item Description
Removal 1 High mount stop lamp
1. Unbolt rear spoiler and lift from bootlid. 2 Screw receptacle
3 Screw
4 High mount brake light lens
5 High mount brake light housing
6 Tail gate
3. Remove the wedge base bulb from the bulb
holder.
Installation
1. Install the bulb in the bulb holder.
2. Install the bulb holder in the lamp.
3. Install the cover on the lamp.
G86760 en 01/2003 2003.0 BA Falcon

High Mount Stop Lamp — LWB

Removal
1. Remove the rear clips holding the roof trim from
inside the vehicle.
2. Disconnect lamp wiring.
3. Remove the two screws connecting the lamp to

the vehicle roof.
Installation
NOTE: Lamp is a sealed unit and must be
replaced as a complete assembly.
Twilight Sensor/Sun Load Sensor

For removal and installation of twilight sensor/sun
load sensor, refer to section 412-04.
G86760 en 01/2003 2003.0 BA Falcon

417-02-1 Interior Lighting 417-02-1
SECTION : 417-02 Interior Lighting

CONTENTS PAGE
Interior Lighting .....................................................................................................................417-02-2
Interior Lighting .....................................................................................................................417-02-3
Visual Inspection Chart ........................................................................................................417-02-3
Symptom Chart ....................................................................................................................417-02-3
Pinpoint Tests ......................................................................................................................417-02-4
Interior Lamp .........................................................................................................................417-02-7
Map Reading Lamp ...............................................................................................................417-02-7
Front Vanity Lamp .................................................................................................................417-02-7
Luggage Compartment Lamp — Wagon ..............................................................................417-02-7
Luggage Compartment Lamp — Sedan ...............................................................................417-02-8
Console Lamp (Lo Series) ....................................................................................................417-02-8
Console Lamp (High Series) .................................................................................................417-02-8
01/2003 2003.0 BA Falcon

Interior Lighting
The interior lighting consists of the following:
Interior lamp
Console lamp
Map reading lamp and bulb
Luggage compartment lamp
Vanity mirror lamp
Interior lamp switch
Illuminated entry module
G46749 en 01/2003 2003.0 BA Falcon

Interior Lighting Visual Inspection Chart

Principles of Operation Normal Condition Possible cause of
abnormality
The interior lamps are supplied positive power from Fuse Not blown Extra accessories added
the BEMs battery saver circuit. This positive supply
drawing more current.
turns off 15 minutes after the ignition is turned off or
Wiring short circuit
door/ lamp activity ceases. Operating the Audio with Faulty switch (if
ignition off also activates the battery saver power
applicable)
supply to energise the on glass antenna amplifier.
Pressing the remote entry unlock button or courtesy Globe filament in tact Bulb life exceeded
lamp switch, opening the boot, wagon liftgate or any Vibration damage
of the doors will also activate the battery saver power Switch turns circuit on Physical damage or heat
supply. and off damage
The negative side of the courtesy lamps are also Ensure air can circulate
supplied from the BEM - refer to circuit diagrams for around lamp
details. These can be switched by the BEM using the Lens, housing etc are not Physical damage or heat
WDS tool. damaged damage
Reading lamps and glove box lamps are switched to Ensure air can circulate
regular ground through their respective switches. For around lamp
sedan, the luggage compartment lamp is switched to
ground through the decklid latch ajar switch.
Symptom Chart
Symptom Chart

Courtesy Lamp button on ICC not Blown Globe Check globe
working
Function disabled Press courtesy lamp switch for five

second to reactivate function - see
owners manual
Internal ICC Fault Diagnose button functionality - refer

ICC diagnostics Section 413-08
BEM Fault Check BEM switches lamp on and off -

refer BEM diagnostics Section 419-10
Damaged Lamp Unit Check for damage to terminal and

connections
Damaged Wiring Check continuity of wiring to BEM

Courtesy Lamps not turning on when Blown Globe Check globe
doors opened
Function disabled Press courtesy lamp switch for five

second to reactivate function - see
owners manual
Internal ICC Fault Diagnose button functionality - refer

ICC diagnostics Section 413-08
BEM Fault Check BEM door inputs and that it

switches lamp on and off - refer BEM
diagnostics Section 419-10

connections
Damaged Wiring Check continuity of wiring from lamp to

BEM
Reading lamps not working Blown Globe Check globe
G46750 en 01/2003 2003.0 BA Falcon



connections
Glove Box lamp not working Blown Globe Check globe


connections

Luggage Compartment Lamp not Blown Globe Check globe
working


connections
Pinpoint Tests
PINPOINT TEST A : LUGGAGE COMPARTMENT LAMP
A1 INITIAL CHECK
Open Boot. Yes
Does the Luggage compartment lamp illuminate?
No
Continue
A2 FILAMENT CONDITION
Remove globe and check filament (use multi-meter if necessary). Yes
Continue
Is the filament OK ?
No
Change globe and recheck
A3 WDS CHECK
Use WDS and turn lamps on (See BEM diagnostics for switch input Yes
status). Continue
Does the lamp turn on? No
Go to A6
A4 WDS CHECK Cont.

Check latch switch using WDS (See BEM diagnostics for switch input Yes
status). Functioning correctly.
Is switch functioning OK? No
Continue
G46750 en 01/2003 2003.0 BA Falcon


A5 WIRING CONDITION
Disconnect wiring from boot latch and check switch function with Yes
multi-meter by latching and unlatching the unit. Check wiring to boot latch switch.
Refer wiring circuits and diagnostics.
Refer wiring schematic for connection detail.
Is switch OK ? No
Replace latch
A6 CIRCUIT INTEGRITY
Check integrity of wiring (including fuse and globe) from BEM to lamp. Yes
Refer BEM diagnostics.
Are fuse, wiring and globe OK ?
No
Replace fuse, globe or wiring as required and
recheck system.
PINPOINT TEST B : GLOVE BOX / READING LAMP
B1 VISUAL CHECK
Open Glove Box / switch on reading lamp. Yes
Does the Glove Box / reading lamp illuminate?
No
Continue
B2 FILAMENT CONDITION
Remove globe and check filament (use multi-meter if necessary). Yes
Continue
Is the filament OK ?
No
Change globe and recheck.
B3 WIRING CONDITION
Disconnect wiring from glove box / reading switch and check switch Yes
function with multi-meter. Refer wiring schematic for connection detail. Check wiring to switch / globe.
Refer wiring circuits and diagnostics.
Is switch OK ?
No
Replace switch.
PINPOINT TEST C : COURTESY LAMPS

C1 ICC CONTROLLED FUNCTIONALITY
Refer to ICC section of owners manual (a five second press of the Yes
courtesy lamp switch will toggle modes) Continue
Is the courtesy lamp function controlled by the Interior No
Command Centre enabled? Enable function by pressing the courtesy lamp
switch on ICC for longer than five seconds.
Recheck operation
G46750 en 01/2003 2003.0 BA Falcon


C2 VISUAL CHECK
Open Doors. Yes
Functioning correctly.
Do the courtesy lamps illuminate?
No
Continue - to check lamps that do not illuminate.
C3 WDS SELF – TEST

Use WDS and turn courtesy lamps on (See Body Electronics Module Yes
diagnostics). Continue
Do the lamps turn on? No
Go to C5
C4 WDS SELF – TEST Cont.

Check door switch using WDS (See BEM diagnostics for switch input Yes
status). System is operating - recheck system
Is switch functioning OK? No
Continue with BEM diagnostics to check door
inputs to BEM
C5 CIRCUIT INTEGRITY
Check integrity of wiring (including fuse and globe) from BEM to lamp. Yes
Refer BEM diagnostics.
Are fuse, wiring and globe OK?
No
Replace fuse, globe or wiring as required and
recheck system.
G46750 en 01/2003 2003.0 BA Falcon

Interior Lamp
Removal
1. Unclip the interior lamp lens.
Item Description
1 Bezel
2 Roof Trim Panel
2. Remove the bulb from the lamp.
Item Description
Installation
1 Roof Trim Panel
1. Install the bulb into the lens.
2 Bezel
2. Refit the lens into the bezel, inserting the knob
3 Bulb end first.
4 Lens
Front Vanity Lamp
2. Remove the bulb.
Installation Removal
1. Install lamp bulb. Refer to Map Reading Lamp removal.
2. Refit the interior lamp lens. Installation
Refer to Map Reading Lamp installation.
Map Reading Lamp
Luggage Compartment Lamp —
Removal Wagon
1. Unclip the lens from the bezel using a screwdriver
on the end of the lens opposite the knob. Removal
1. Refer to Map Reading Lamp removal.
Installation
1. Refer to Map Reading Lamp installation.
Item Description
1 Bezel
2 Roof Trim Panel
G46754 en 01/2003 2003.0 BA Falcon

Luggage Compartment Lamp — Sedan

Removal
1. Remove lamp as shown.
Item Description
1 Black Insulator (earth)
2 Negative earth
3 Negative
4 Positive
5 Positive Insulator
6 Red Insulator (feed)
Installation
Console Lamp (Lo Series)
Removal
1. Remove console lamp as shown in figure.
Installation
Console Lamp (High Series)

G46754 en 01/2003 2003.0 BA Falcon

418-00-1 Module Communications Network 418-00-1
SECTION : 418-00 Module Communications

Network
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................418-00-2
Communications Network .....................................................................................................418-00-3
Communications Network .....................................................................................................418-00-4
Symptom Chart ....................................................................................................................418-00-4
Pinpoint Tests ......................................................................................................................418-00-9
GENERAL PROCEDURES
Communication Circuit Wiring Repair .................................................................................418-00-22
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Heat shrink tube overlap 12.7 (0.5)
mm (inch)
Wire insulation removal 37.2 (1.5)
length (twist side) mm
(inch)
Wire insulation removal 19.5 (0.75)
length (receiving side)
mm (inch)
Raychem SCT® Heat ESB-M99D56-A2
Shrink Tubing, Motorcraft
part number WT-5627
G86726 en 01/2003 2003.0 BA Falcon

Communications Network
The module communications network consists of the
following items:
High Speed Controller Area Network (HS-CAN)
communications network.
International Standards Organization (ISO) 9141
communications network
Anti-lock Braking System and Traction Control
System (ABS/TCS) {*or ABS Module}
Interior Command Centre (ICC) {*or ACM}
Body Electronics Module (BEM)
HVAC Integrated Module (HIM)
Instrument Cluster (IC) {*or Cluster}
Parking Aid Module (PAM) {*or Sonar Module}
Powertrain Control Module (PCM) {*or EEC-B}
Restraints Control Module (RCM) {*or ARS}
Data Link Connector (DLC)
NOTE: The abbreviations shown in { } may also be
shown on wiring diagrams.
G86727 en 01/2003 2003.0 BA Falcon

Communications Network The following modules are linked to the HS-CAN

communication network:
Refer to Wiring Diagram Section 418-00 for schematic Anti-lock Braking System and Traction Control
and connector information. System ABS/TCS - Operation only, diagnostics
via ISO9141
Special Tool(s)
Audio Control Module (ACM)
73III Automotive Meter Body Electronics Module (BEM)
105-R0057 or equivalent
HVAC Integrated Module (HIM)
Instrument Cluster (IC)
Powertrain Control Module (PCM)
The HS-CAN network is terminated at one end by the
PCM, with the other end terminated by the IC.
Worldwide Diagnostic System Additionally, the DLC and the remaining HS-CAN
(WDS) modules are connected to this bus.
For information on operation of individual modules
please refer to the relevant sections.
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical
Principles of Operation damage.
The vehicle has two module communications Visual Inspection Chart
networks. Electrical
The High Speed Controller Area Network (HS-CAN), Wiring harness
which is an unshielded twisted pair cable (data bus Electrical connectors
plus, CAN High, circuit 914 [BR-Y] and data bus Central junction box (CJB) Fuses
minus, CAN Low, circuit 915 [P-L]); and the Modules:
International Standards Organization (ISO) 9141 ABS/TCS module
network which is a single wire (circuit 70 [SB-W]). The
ABS/EVAC FILL module
diagnostic tool can connect to both networks through
the Data Link Connector (DLC). This makes diagnosis ACM
and testing of these systems easier by allowing one BEM
smart tester to be able to diagnose and control any HIM
module on the two networks from one connector.
IC
The ISO 9141 communication network does not
permit inter-module communication. When the PAM
diagnostic tool communicates to modules on the ISO PCM
9141 communication network, the diagnostic tool must RCM
ask for all information; the modules cannot initiate
communications. 3. If the concern remains after the inspection,
connect the diagnostic tool to the Data Link
The ISO 9141 communication network will not Connector (DLC) and select the vehicle to be
function if the wire is shorted to ground or battery tested from the diagnostic tool menu. If the
voltage. Also, if one of the modules on the ISO 9141 diagnostic tool does not communicate with the
communication network loses power or shorts vehicle:
internally, communications to that module will fail.
1. Check that the program card is correctly
The following modules are linked to the ISO9141 installed.
communication network (for diagnostics only):
2. Check the connections to the vehicle.
Anti-lock Braking System and Traction Control
System (ABS/TCS) - Diagnostics only, 3. Check the ignition switch position is in RUN.
operation via HS-CAN If the diagnostic tool still does not communicate with
ABS/EVAC FILL module the vehicle, go to Pinpoint Test M.
Parking Aid Module (PAM) (if equipped) 4. Go to Pinpoint Test A.
Restraints Control Module (RCM)
G86728 en 01/2003 2003.0 BA Falcon

Symptom Chart

ABS/TCS module does not respond to Circuit or connection on ISO-9141 Go to PinPoint Test B .
the diagnostic tool (WDS) communication network.
ABS/TCS module.
Power and ground circuits.
ABS/EVAC FILL module does not Circuit or connection on ISO-9141 Go to PinPoint Test J .
respond to the diagnostic tool (WDS) communication network.
ABS/EVAC FILL module.
Power and ground circuits .
RCM does not respond to the Circuit or connection on ISO-9141 Go to PinPoint Test C.
diagnostic tool (WDS) communication network.
RCM.
PAM does not respond to the Circuit or connection on ISO-9141 Go to PinPoint Test D .
PAM.
IC does not respond to the diagnostic Circuit or connection on CAN Go to PinPoint Test E .
tool (WDS) communication network.
IC.
PCM does not respond to the Circuit or connection on CAN Go to PinPoint Test F .
PCM.
ACM does not respond to the Circuit or connection on CAN Go to PinPoint Test G .
ACM.
BEM does not respond to the Circuit or connection on CAN Go to PinPoint Test H .
BEM.
HIM does not respond to the Circuit or connection on CAN Go to PinPoint Test I .
HIM.
No ISO 9141 network communication Circuit or connection on the ISO 9141 Go to PinPoint Test K .
network.
ISO 9141 network modules.
No HS-CAN network communication Circuit or connection on the HS-CAN Go to PinPoint Test L .
network. HS-CAN network modules.
No module/network communication - Data link connector (DLC). Go to PinPoint Test M .
no power to the diagnostic tool Central junction box (CJB) Fuse
(Courtesy Lamp).
Circuits.
Diagnostic tool.
G86728 en 01/2003 2003.0 BA Falcon


NOTE: Connector view is looking into the front of the
connector (wiring half).
Data Link Connector (DLC) - C174

70C (SB-W) —
ISO Communications
914K ( BR-Y) —
HS-CAN Communications (High)
915K ( P-L) —
HS-CAN Communications (Low)
In-line connector - C119

70 (SB-W) —
ISO Communications
70A (SB-W) —
ISO Communications
914P ( BR-Y) —
915P ( P-L) —
G86728 en 01/2003 2003.0 BA Falcon

Connector C364 (ICC, Section 413-08)

914M (BR-Y) —
915M ( P-L) —
914N (BR-Y) —
915N ( P-L) —
Connector C150 (ABS, Section 206-09)

70 (SB-W) —
ISO Communications
914H (BR-Y) —
915H (P-L) —
G86728 en 01/2003 2003.0 BA Falcon

Connector C386 (ABS, Section 206-09)

70 (SB-W) —
ISO Communications
Connector C189 (Occupant Restraints, Section 501-20B)

70B (SB-W)
ISO Communications
G86728 en 01/2003 2003.0 BA Falcon

Pinpoint Tests
PINPOINT TEST A : DATA LINK DIAGNOSTICS NETWORK TEST

A1 DATA LINK DIAGNOSTICS NETWORK TEST

Test passed. RETURN to the Symptom Chart of
Run the data link diagnostics network test. the section for the module in question.
Is SYSTEM PASSED obtained?
No
If no response from the diagnostic tool, Go to
PinPoint Test H
If CKT70, CKT914, or CKT915 = SOME ECUS
NO RESP/NOT EQUIP, REFER to the Symptom
Chart.
If CKT70 = ALL ECUS NO RESP/NOT EQUIP,
Go to PinPoint Test K
Go to PinPoint Test L
Go to PinPoint Test L
If module in question is NO RESPONSE/NOT
EQUIPPED, REFER to the Symptom Chart.
If module in question is NO RESPONSE ON
CKT914 (BUS+) or NO RESPONSE ON
CKT915 (BUS-), REFER to Symptom Chart.
PINPOINT TEST B : ABS/TCS MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)
B1 CHECK ABS/TCS C150 CIRCUIT 70 (SB-W) FOR DAMAGE

Go to B2
Disconnect ABS/TCS C150.
Inspect ABS/TCS C150 for damage. No
REPAIR the ABS/TCS C150. CARRY OUT the
Is the ABS/TCS C150 OK? DATA LINK DIAGNOSTICS test.
B2 CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND

ABS/TCS C150 FOR OPEN
Measure the resistance between ABS/TCS C150, circuit 70 (SB-W), Yes

harness side and DLC C174, circuit 70C (SB-W), harness side. Go to B3
REPAIR the circuit(s) as necessary. CARRY
OUT the DATA LINK DIAGNOSTICS test.
B3 CHECK FOR CORRECT ABS/TCS OPERATION
Disconnect all ABS/TCS connectors. Yes

INSTALL a new ABS/TCS module. Refer to
Check for:
Section 206-09. CARRY OUT the DATA LINK
Corrosion DIAGNOSTICS test.
Pushed-out pins No
Connect all ABS/TCS connectors and make sure they seat correctly. The system is operating correctly at this time.
Concern may have been caused by a loose, or a
Operate the system and verify the concern is still present. corroded connector. CLEAR the DTCs. REPEAT
Is the concern still present? the self-test.
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : RCM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)
NOTE: For connector circuit information on C189,
refer to chapter 501-20b.

C1 CHECK RCM C189 CIRCUIT 70B (SB-W) FOR DAMAGE

Go to C2
Deactivate the air bag system. Refer to Section 501-20b.
Disconnect RCM C189. No
REPAIR the RCM C189. CARRY OUT the
Inspect RCM C189 for damage. DATA LINK DIAGNOSTICS test.
Is the RCM C189 OK?
C2 CHECK CIRCUIT 70B (SB-W) BETWEEN DLC C174 AND RCM

C189 FOR OPEN
Measure the resistance between RCM C189, circuit 70B (SB-W), Yes
harness side and DLC C174, circuit 70C (SB-W), harness side. Go to C3
C3 CHECK FOR CORRECT RCM OPERATION
Disconnect all RCM connectors. Yes

INSTALL a new RCM module. Refer to Section
Check for: 501-20b. CARRY OUT the DATA LINK
Pushed-out pins No
Connect all RCM connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST D : PAM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)
refer to module connector diagram in chapter 413-13.
D1 CHECK PAM C369 CIRCUIT 70 (SB-W) FOR DAMAGE

Go to D2
Disconnect PAM C369.
Inspect PAM C369 for damage. No
REPAIR the PAM C369. CARRY OUT the DATA
Is the PAM C369 OK? LINK DIAGNOSTICS test.
D2 CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND PAM

C369 FOR OPEN
Measure the resistance between PAM C369, circuit 70 (SB-W), Yes

harness side and DLC C174, circuit 70C (SB-W), harness side. Go to D3
G86728 en 01/2003 2003.0 BA Falcon


D3 CHECK FOR CORRECT PAM OPERATION
Disconnect all PAM connectors. Yes

INSTALL a new PAM module. Refer to section
Check for: 413-13. CARRY OUT the DATA LINK
Pushed-out pins
No
Connect all PAM connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST E : IC MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)

E1 CHECK IC C171 CAN CIRCUITS 914L (BR-Y) and 915L (P-L)
FOR DAMAGE

Go to E2
Disconnect IC C171.
Inspect IC C171 for damage. No
REPAIR IC C171. CARRY OUT the DATA LINK
Is the IC C171 OK? DIAGNOSTICS test.
E2 CHECK CAN HIGH AND CAN LOW CIRCUITS 914L (BR-Y)

AND 915L (P-L) BETWEEN DLC C174 AND IC C171 FOR OPEN
Measure the resistance between IC module C171, circuit 914L Yes

(BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness Go to E3
side.
No
Measure the resistance between IC module C171, circuit 915L (P-L), REPAIR the circuit(s) in question. CARRY OUT
harness side and DLC C174, circuit 915K (P-L), harness side. the DATA LINK DIAGNOSTICS test.
Are the resistances less than 5 ohms?
E3 CHECK FOR CORRECT IC OPERATION
Disconnect all IC connectors. Yes

INSTALL a new IC module. Refer to section
Pushed-out pins No
Connect all IC connectors and make sure they seat correctly. The system is operating correctly at this time.
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST F : PCM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)

F1 CHECK PCM C301 CAN CIRCUITS 914G (BR-Y) AND 915G
(P-L) FOR DAMAGE

Go to F2
Disconnect PCM C301.
Inspect PCM C301 for damage. No
REPAIR PCM C301. CARRY OUT the DATA
Is the PCM C301 OK? LINK DIAGNOSTICS test.
F2 CHECK CAN HIGH AND CAN LOW CIRCUITS 914G (BR-Y)

AND 915G (P-L) BETWEEN DLC C174 AND PCM C301 FOR
OPEN
Measure the resistance between PCM module C301, circuit 914G Yes
(BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness Go to F3
side.
No
Measure the resistance between PCM module C301, circuit 915G REPAIR the circuit(s) in question. CARRY OUT
(P-L), harness side and DLC C174, circuit 915K (P-L), harness side. the DATA LINK DIAGNOSTICS test.
F3 : CHECK FOR CORRECT PCM OPERATION
Disconnect all PCM connectors. Yes

INSTALL a new PCM module. Refer to section
Check for:
303-14. CARRY OUT the DATA LINK
Pushed-out pins No
Connect all PCM connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST G : ICC MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)
G1 CHECK ACM C364 CAN CIRCUITS 914M (BR-Y) AND 915M

(P-L) FOR DAMAGE

Go to G2
Disconnect ACM C364.
Inspect ICC C364 for damage. No
REPAIR ICC C364. CARRY OUT the DATA
Is the ICC C364 OK? LINK DIAGNOSTICS test.
G86728 en 01/2003 2003.0 BA Falcon


G2 CHECK CAN HIGH AND CAN LOW CIRCUITS 914M (BR-Y)
AND 915M (P-L) BETWEEN DLC C174 AND ICC C364 FOR
OPEN
Measure the resistance between ICC module C364, circuit 914M Yes
(BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness Go to G3
side.
No
Measure the resistance between ICC module C364, circuit 915M REPAIR the circuit(s) in question. CARRY OUT
G3 CHECK FOR CORRECT PCM OPERATION
Disconnect all ACM connectors. Yes

INSTALL a new ACM module. Refer to section
Pushed-out pins
No
Connect all ICC connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST H : BEM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)
H1 CHECK BEM C173 CAN CIRCUITS 914N (BR-Y) AND 915N

(P-L) FOR DAMAGE

Go to H2
Disconnect BEM C173.
Inspect BEM C173 for damage. No
REPAIR BEM C173. CARRY OUT the DATA
Is the BEM C173 OK? LINK DIAGNOSTICS test.
H2 CHECK CAN HIGH AND CAN LOW CIRCUITS 914 (BR-Y) AND
915 (P-L) BETWEEN DLC C174 AND BEM C173 FOR OPEN
Measure the resistance between BEM module C173, circuit 914N Yes
(BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness Go to H3
side.
No
Measure the resistance between BEM module C173, circuit 915N REPAIR the circuit(s) in question. CARRY OUT
H3 CHECK FOR CORRECT BEC OPERATION
Disconnect all BEM connectors. Yes

INSTALL a new BEM module. Refer to Section
Pushed-out pins No
Connect all BEM connectors and make sure they seat correctly. The system is operating correctly at this time.
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST I : HIM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL (WDS)

I1 CHECK HIM C376 CAN CIRCUITS 914P (BR-Y) AND 915P (P-L)
FOR DAMAGE

Go to I2
Disconnect HIM C376.
Inspect HIM C376 for damage. No
REPAIR HIM C376. CARRY OUT the DATA
Is the HIM C376 OK? LINK DIAGNOSTICS test.
I2 CHECK CAN HIGH AND CAN LOW CIRCUITS 914 (BR-Y) AND
915 (P-L) BETWEEN DLC C174 AND HIM C376 FOR OPEN
Measure the resistance between HIM module C376, circuit 914P Yes
(BR-Y), harness side and DLC C174, circuit 914K (BR-Y), harness Go to I3
side.
No
Measure the resistance between HIM module C376, circuit 915P REPAIR the circuit(s) in question. CARRY OUT
I3 : CHECK FOR CORRECT HIM OPERATION
Disconnect all HIM connectors. Yes

INSTALL a new HIM module. Refer to Section
Pushed-out pins No
Connect all HIM connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST J : ABS/EVAC FILL MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL
(WDS)
J1 CHECK ABS/EVAC FILL C386 CIRCUIT 70 (SB-W) FOR

DAMAGE

Go to J2
Disconnect ABS/EVAC FILL C386.
Inspect ABS/EVAC FILL C386 for damage. No
REPAIR ABS/EVAC FILL C386. CARRY OUT
Is the ABS/EVAC FILL C386 OK? the DATA LINK DIAGNOSTICS test.
J2 CHECK CIRCUIT 70 (SB-W) BETWEEN DLC C174 AND

ABS/EVAC FILL C386 FOR OPEN
Measure the resistance between ABS/EVAC FILL C386, circuit 70 Yes

(SB-W), harness side and DLC C174, circuit 70C (SB-W), harness Go to J3
side.
No
Is the resistance less than 5 ohms? REPAIR the circuit(s) as necessary. CARRY
G86728 en 01/2003 2003.0 BA Falcon


J3 : CHECK FOR CORRECT ABS/EVAC FILL OPERATION
Disconnect all ABS/EVAC FILL connectors. Yes

INSTALL a new ABS/EVAC FILL module. Refer
Check for: to Section 206-09. CARRY OUT the DATA LINK
Pushed-out pins
No
Connect all ABS/EVAC FILL connectors and make sure they seat The system is operating correctly at this time.
correctly. Concern may have been caused by a loose, or a
corroded connector. CLEAR the DTCs. REPEAT
Operate the system and verify the concern is still present. the self-test.
Is the concern still present?
PINPOINT TEST K : NO MODULE / NETWORK COMMUNICATION- ISO 9141 NETWORK
K1 CHECK THE SCAN TOOL FOR DAMAGE
Inspect scan tool tester circuit 70 pin for dam-age. Yes

Go to K2
Is the scan tool OK?
No
REPAIR the scan tool tester as necessary.
CARRY OUT the DATA LINK DIAGNOSTICS
test.
K2 CHECK THE DLC C174 FOR DEMAGE

Go to K3
Inspect DLC C174 circuit 70C (SB-W).
Is DLC C174 OK? No
REPAIR the DLC C174. CARRY OUT the DATA
LINK DIAGNOSTICS test.
K3 CHECK PAM CIRCUIT 70 (SB-W) FOR OPEN
Disconnect PAM C369. Yes

Go to K4
Measure the resistance between PAM C369, circuit 70 (SB-W),
harness side and DLC C174, circuit 70C (SB-W). No
Is the resistance less than 5 ohms? REPAIR circuit 70 (SB-W) between the DLC
C174 and PAM C369. CARRY OUT the DATA
K4 CHECK CIRCUIT 70 (SB-W) FOR SHORT TO GROUND AND

POWER - PAM MODULE DISCONNECTED

Go to K10
Enter the following diagnostic mode on the diagnostic tool: DATA
LINK DIAGNOSTICS Test. No
Did the diagnostic tool indicate SYSTEM PASSED? Go to K9
K5 CHECK RCM CIRCUIT 70B (SB-W) FOR OPEN

Go to K6
Disconnect RCM C189.
Measure the resistance between RCM C189, circuit 70B (SB-W), No
harness side and DLC C174, circuit 70C (SB-W). REPAIR circuit 70 (SB-W) between the DLC
C174 and RCM C189. CARRY OUT the DATA
Is the resistance less than 5 ohms? LINK DIAGNOSTICS test.
G86728 en 01/2003 2003.0 BA Falcon


POWER - RCM DISCONNECTED

Go to K11
K7 CHECK ABS/TCS CIRCUIT 70 (SB-W) FOR OPEN
Disconnect ABS/TCS C150. Yes

Go to K8
Measure the resistance between ABS/TCS C150, circuit 70 (SB-W),
harness side and DLC C174, circuit 70C (SB-W). No
Is the resistance less than 5 ohms? REPAIR circuit(s) 70 (SB-W) between the DLC
C174 and ABS/TCS C150. CARRY OUT the
DATA LINK DIAGNOSTICS test.

POWER-ABS/TCS MODULE DISCONNECTED

Go to K12
K9 CHECK THE EVAC AND FILL C386 FOR DAMAGE

REPAIR the circuit between the ABS/TCS
Inspect the EVAC and fill C386 circuit 70 (SB-W).
module C150, EVAC and fill C386 and the DLC
Is DLC C174 OK? C174. CARRY OUT the DATA LINK
DIAGNOSTICS test.
No
REPAIR the EVAC and fill C386. CARRY OUT
the DATA LINK DIAGNOSTICS test.
K10 CHECK FOR CORRECT PAM OPERATION
Disconnect all PAM connectors. Yes

INSTALL a new PAM module. Refer to Section
Pushed-out pins
No
Connect all PAM connectors and make sure they seat correctly. The system is operating correctly at this time.
Concern may have been caused by a loose or
K11 CHECK FOR CORRECT RCM OPERATION
Disconnect all RCM connectors. Yes

INSTALL a new RCM module. Refer to Section
Check for: 501-20b. CARRY OUT the DATA LINK
Pushed-out pins No
Connect all RCM connectors and make sure they seat correctly. The system is operating correctly at this time.
G86728 en 01/2003 2003.0 BA Falcon


K12 CHECK FOR CORRECT ABS/TCS OPERATION
Disconnect all ABS/TCS connectors. Yes

Check for: Section 206-09. CARRY OUT the DATA LINK
Pushed-out pins
No
Connect all ABS/TCS connectors and make sure they seat correctly. The system is operating correctly at this time.
PINPOINT TEST L : NO MODULE / NETWORK COMMUNICATION - HS-CAN NETWORK
L1 CHECK DIAGNOSTIC TOOL TESTER CIRCUITS 914 AND 915

FOR DAMAGE
Inspect diagnostic tool tester circuits 914 and 915 for damage. Yes
Go to L2
Is the diagnostic tool tester OK?
No
REPAIR the diagnostic tool. CARRY OUT the
DATA LINK DIAGNOSTICS test.
L2 CHECK DLC C174 CIRCUITS 914K AND 915K FOR DAMAGE

Go to L3
Inspect DLC C174 circuits 914K and 915K. Check the pins and the
wires for damage. No
Is the DLC C174 OK? REPAIR DLC C174. CARRY OUT the DATA
L3 CHECK CIRCUITS 914 (BR-Y) AND 915 (P-L) FOR SHORT TO

BATTERY AND SHORT TO GROUND WITH PCM C301
DISCONNECTED

Go to L10
Disconnect PCM C301.
Key in ON position. No
Go to L4
LINK DIAGNOSTICS Test.
Did the diagnostic tool indicate SYSTEM PASSED?

BATTERY AND SHORT TO GROUND WITH ABS/TCS C150
DISCONNECTED

Go to L11
Connect PCM C301.
Disconnect ABS/TCS C150. No
Go to L5
Key in ON position.
G86728 en 01/2003 2003.0 BA Falcon


BATTERY AND SHORT TO GROUND WITH HIM C376
DISCONNECTED

Go to L12
Connect ABS/TCS C150.
Disconnect HIM C376. No
Go to L6
Key in ON position.

BATTERY AND SHORT TO GROUND WITH THE IN-LINE C119
DISCONNECTED

REPAIR the circuit in question between in-line
Connect HIM C376.
C119 and HIM C376. REFER to Communication
Disconnect In-line C119. Circuit Wiring Repair in this section. CARRY
Key in ON position.
Enter the following diagnostic mode on the diagnostic tool: DATA No
LINK DIAGNOSTICS Test. Go to L7

BATTERY AND SHORT TO GROUND WITH BEM C173
DISCONNECTED

Go to L13
Connect In-line C119.
Disconnect BEM C173. No
Go to L8
Key in ON position.

BATTERY AND SHORT TO GROUND WITH ICC C364
DISCONNECTED

Go to L15
Connect BEM C173.
Disconnect ICC C364. No
Go to L9
Key in ON position.
Enter the following diagnostic mode on the diagnostic tool:
DATA LINK DIAGNOSTICS Test.
G86728 en 01/2003 2003.0 BA Falcon


BATTERY AND SHORT TO GROUND WITH IC C171
DISCONNECTED

Go to L16
Connect ICC C364.
Disconnect IC C171. No
Check all circuits 914 (BR-Y) and 915 (P-L) for
Key in ON position. short to battery and short to ground. REPAIR the
Enter the following diagnostic mode on the diagnostic tool: circuit(s) as necessary. REFER to
Communication Circuit Wiring Repair in this
DATA LINK DIAGNOSTICS Test. section. CARRY OUT the DATA LINK
Did the diagnostic tool indicate SYSTEM PASSED? DIAGNOSTICS test.
L10 CHECK FOR CORRECT PCM OPERATION

INSTALL a new PCM module. Refer to Section
Disconnect all PCM connectors. 303-14. CARRY OUT the DATA LINK
Check for: DIAGNOSTICS test.
Corrosion
No
Pushed-out pins The system is operating correctly at this time.
Connect all PCM connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
L11 CHECK FOR CORRECT ABS/TCS OPERATION

Disconnect all ABS/TCS connectors. Section 206-09. CARRY OUT the DATA LINK
Corrosion
No
Connect all ABS/TCS connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
L12 CHECK FOR CORRECT HIM OPERATION

INSTALL a new HIM module. Refer to Section
Disconnect all HIM connectors. 412-04. CARRY OUT the DATA LINK
Corrosion
No
Connect all HIM connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
G86728 en 01/2003 2003.0 BA Falcon


L13 CHECK CIRCUITS 914P (BR-Y) AND 915P (P-L) FOR SHORT
TO BATTERY AND SHORT TO GROUND WITH BEM C173 AND
IN-LINE C119 DISCONNECTED

Connect In-line C119.
Disconnect In-line C119.
Go to L14
Check circuits 914P and 915P for short to battery and short to ground
between BEM C173 and In-line C119 No
REPAIR the circuit in question between BEM
Do the circuits 914P and 915P PASS? C173 and In-line C119. REFER to
Communication Circuit Wiring Repair in this
section. Connect BEM C173 and In-line C119.
CARRY OUT the DATA LINK DIAGNOSTICS
test.
L14 CHECK FOR CORRECT BEM OPERATION

INSTALL a new BEM module. Refer to Section
Disconnect all BEM connectors. 419-10. CARRY OUT the DATA LINK
Corrosion
No
Connect all BEM connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
L15 CHECK FOR CORRECT ICC OPERATION

INSTALL a new ACM module. Refer to Section
Disconnect all ICC connectors. 413-08. CARRY OUT the DATA LINK
Corrosion
No
Connect all ICC connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
L16 CHECK FOR CORRECT IC OPERATION

INSTALL a new IC module. Refer to Section
Disconnect all IC connectors. 413-01. CARRY OUT the DATA LINK
Corrosion
No
Connect all IC connectors and make sure they seat correctly. corroded connector. CLEAR the DTCs. REPEAT
G86728 en 01/2003 2003.0 BA Falcon

PINPOINT TEST M : NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC

TOOL
M1 CHECK DIAGNOSTIC TOOL CONNECTOR
Inspect diagnostic tool pins for damage. Yes

Go to M2
Are the pins OK?
No
REPAIR the diagnostic tool connector. TEST the
M2 CHECK DATA LINK CONNECTOR (DLC) C174 FOR DAMAGE

Go to M3
Inspect DLC C174 pins for damage.
Are the pins OK? No
REPAIR DLC C174. TEST the system for
normal operation.
M3 CHECK VOLTAGE CIRCUIT 956 (OG/LG) TO DIAGNOSTIC

TOOL
Measure the voltage between DLC C174 pin 16, circuit 956 (OG/LG), Yes
and ground. Go to M4
operation.
M4 CHECK THE DLC GROUND CIRCUIT 57 (BK) AND CIRCUIT

570 (BK/WH)
Measure the resistance between DLC C174 pin 4, circuit 57 (BK); Yes
C174 pin 5, circuit 570 BK/WH, and ground. REPAIR the diagnostic tool. TEST the system
No
REPAIR the circuit(s) in question. TEST the
G86728 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Communication Circuit Wiring Repair 4. Bend the wires back in a straight line.
NOTE: Wait for the solder to cool before moving
Special Tool(s) the wires.
Heat Gun
1. Disconnect the battery ground cable. Refer to
Section 414-01.
2. Strip the wires.
5. Position the (A) heat shrink tube over the (B) wire
repair.
Overlap the heat shrink tube on both wires.
3. Solder the wires.

1. Install the heat shrink tube.
2. Twist the wires together.
3. Solder the wires together.
NOTE: Use rosin core mildly activated (RMA)
solder, not acid core solder.
6. Use the heat gun to heat the repaired area until

adhesive flows out both ends of the heat shrink
tube.
7. Reconnect the battery ground cable.
G86729 en 01/2003 2003.0 BA Falcon

419-07-1 Satellite Navigation 419-07-1
SECTION : 419-07 Satellite Navigation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................419-07-2
Satellite Navigation ................................................................................................................419-07-3
GPS (Global Positioning System) ........................................................................................419-07-3
Component Layout ...............................................................................................................419-07-3
Satellite Navigation ................................................................................................................419-07-5
Symptom Chart ....................................................................................................................419-07-5
Pinpoint Tests ......................................................................................................................419-07-6
Navigation System Module ..................................................................................................419-07-14
Navigation System Antenna .................................................................................................419-07-14
Navigation System Display Module .....................................................................................419-07-14
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Module mounting bracket 8.0 ± 1.5
G88869 en 01/2003 2003.0 BA Falcon

Satellite Navigation Unfavorable satellite constellations in conjunction

with the mounting position of the GPS antenna (in
How does the system work? this case GPS reception may be obstructed for a
The movement of the vehicle is measured by sensors longer period of time)
that are integrated in the navigation computer. The In valleys and in mountainous regions
distance driven is recorded by an electronic signal If the GPS antenna has been properly installed,
from the speedometer and the rotary movements of sufficient GPS reception should be present about 95%
bends by the gyroscope (a rotary measurement of the driving time. If interference in the reception
system). The information from these sensors is, occurs more frequently, improper mounting of the
however, not always exact. Measurements could be GPS antenna may be the cause. In this case, we
affected by skidding of the wheels, varying tyre recommend you contact your Authorised Ford Dealer.
pressure due to changes in temperature, etc. By However, the navigation system is able to
comparison of these signals with the digitized compensate reception problems over a period of a
CD-ROM map it is possible to correct any few minutes without functional interference.
inaccuracies of the sensors and to determine the
position of the vehicle quite precisely. In order to Component Layout
correct the data, a signal from the GPS satellites is The navigation system comprises of four main
required for a period of several minutes.
components.
GPS (Global Positioning System) Remote Control
The GPS System is based on the reception of The remote control is required for
navigation signals from a total of 27 GPS satellites activation/deactivation of the system and the
orbiting the earth at a height of 21,000 kilometers, utilization of the navigation functions. The remote
once every 12 hours. To determine a 3D position (with control utilizes an Infra-Red (IR) transmitter with the
longitude, latitude and height), signals from at least 4 corresponding IR receiver located on top of the
satellites must be received. This allows an accuracy display. To achieve best results point the remote
of about 30m to 100m which is further improved by control toward the display when activiating any
other sensors. functions.
Start-up Behavior
When the vehicle is parked for a long period of time,
the satellites move on during this period. Therefore,
when the ignition is turned on again it can take a few
minutes before the navigation system can pick up
enough satellites and evaluate the received signals.
When starting up, the navigation system may tell you:
’You are leaving the digitized area’. The navigation
system supposes the vehicle is in an off-road position.
If there are other roads in this position, the system
may send an inappropriate message. This means that
the navigation system supposes the vehicle is on one
of the other roads. When the vehicle has been at a
standstill for a longer period of time, the navigation
function may be temporarily inhibited. The system will
operate reliably again once the GPS reception is G.P.S Antenna
available in sufficient quality.
The GPS antenna (located under the rear package
Limited GPS Reception tray cover) is used to receive signals transmitted by
GPS satellites. For optimum performance of the
Functional disturbance may also occur if GPS
navigation system, do not place objects on the right
reception is interrupted or interference occurs over a
hand side of the rear package tray. Metallic
distance of several kilometers.
compound window tinting can also obstruct GPS
GPS reception may be interrupted or interference signal reception and is not recommended for
could occur: installation on the rear windscreen.
In between high buildings
Processor
In multiple story car parks or garages, in tunnels
and under bridges The processor (located inside the boot compartment
In forests or tree-lined streets under the rear package tray cover) controls the
navigation related functions including screen display
During heavy rain showers output. The map DVD (map database) is located
G88870 en 01/2003 2003.0 BA Falcon

inside the navigation processor. The map DVD can be

removed and inserted using the front panel switch
(ignition switch must be in the ’ACC’ or ’ON’
positions).
Display
The display (located on the instrument panel) is
shared between the GPS, Audio and Climate Control
systems.
G88870 en 01/2003 2003.0 BA Falcon

Satellite Navigation
Symptom Chart
Does not start with ACC ON

Dark screen (nothing appears on ICC Display Go to PinPoint Test A
screen).
The display does not show navigation ICC Display Go to PinPoint Test B
screen even though ON/OFF button is Navigation
pressed. Remote Control
The respective screens do not appear ICC display Go to PinPoint Test B
when AUDIO A/C buttons are pressed.
The navigation screen does not ICC display Go to PinPoint Test B
appear and no audio sounds are Navigation
produced. Audio
The screen appears abnormal

The screen does not change to night ICC display Go to PinPoint Test C
screen mode.
The navigation screen becomes out of ICC display Go to PinPoint Test D
sync.
The colours of the navigation screen ICC display Go to PinPoint Test E
are abnormal (RGB signal abnormal). Navigation
The menu becomes dark when MAP, ICC display Go to PinPoint Test B
MENU or DEST button is pressed. Navigation
Remote Control
The sound is abnormal

Only the sounds from the audio Audio Go to PinPoint Test F
system can be output from the
speakers.
Only the front speaker cannot output Navigation Go to PinPoint Test F
the audio system sounds. Audio
Only the rear speaker cannot output Audio Go to PinPoint Test F
the audio system sounds.
The navigation functions are abnormal

A map disc cannot be loaded. Navigation Go to PinPoint Test B
The screen does not display a map Navigation Go to PinPoint Test G
when the MAP button is pressed (only
the "Disc Caution" screen is shown).
The map turns white or blue (the Navigation Go to PinPoint Test H
switches and the vehicle’s current
position mark are shown).
The screen does not change to the ICC display Go to PinPoint Test I
night screen mode. Navigation
The vehicle’s current position mark GPS antenna Go to PinPoint Test J
deviates considerably.
G88871 en 01/2003 2003.0 BA Falcon


The GPS mark does not appear on the GPS antenna Go to PinPoint Test K
display.
There is no voice guidance. Navigation Go to PinPoint Test L

Audio
The vehicle’s current position mark Navigation Go to PinPoint Test M
turns on its own (the map turns on its GPS antenna
own).
The direction of travel and the Navigation Go to PinPoint Test N
movement of the vehicle’s current Speed Sensor
position mark are opposite of each
other.
Pinpoint Tests
List of Caution Messages
Caution Message Description Action
Disk player error. Have vehicle Appears when there is an error in Turn the ignition switch from OFF
serviced. communication with the DVD to ON.*¹
player.
Disk read error. Check disk. Appears if a type of DVD disc that Load a correct type of disc.
differs from a map disc is used.
Disk temp high. Appears when the DVD has Move the vehicle to a cool place in
reached a high temperature. the shade and turn the ignition
switch OFF. After the navigation
ECU and the map disc has cooled
down sufficiently, turn the ignition
switch back ON.
Incorrect disk format. Appears when a DVD of a different Load a correct type of disc.
system is loaded.
No disk detected. Appears when no DVD is loaded. Load a correct type of disc.
Please close disk cover before Appears when the DVD cover is Close the cover.
using system. open.
Program disk is inserted. Appears when a program DVD Load a correct type of disc.
disc is inserted.
*¹ If the same caution screen appears after the ignition
switch is turned back ON, replace the navigation
ECU.
PINPOINT TEST A : DARK SCREEN (NOTHING APPEARS ON SCREEN)
A1
Is the B+ or ACC on the vehicle the correct capacity? Yes
Replace the fuse with one with the specified
capacity.
No
Go to A2
A2
Measure the voltage B+, ACC, GND. Yes

Repair the CDU display.
Is the power system to the CDU display normal?
No
Inspect the wiring harnesses and connectors.
G88871 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : THE DISPLAY DOES NOT SHOW THE NAVIGATION SCREEN EVEN THOUGH THE
ON/OFF BUTTON (ON THE REMOTE CONTROL) IS PRESSED (THE SCREEN DOES NOT CHANGE)
B1
Apply the parking brake and turn the ignition switch to ACC or IG. Yes
Go to B2
Measure the voltage B+, ACC, GND.
No
Is the power system to the navigation ECU normal? Inspect the wiring harnesses and connectors.
B2
Measure the voltage of the wires Red, Green, Blue, Video Return and Yes
Videa Ground. Go to B3
Are the connections and the continuity of the wiring harnesses No

and connectors between the CDU display and the navigation Inspect the wiring harnesses and connectors.
ECU normal?
B3
Videa Ground on Navigation ECU. Repair the CDU display.
Are the video output signals of the navigation ECU normal? No

Repair the navigation ECU.
NOTE: To recheck the symptom after inspecting the

wiring harnesses and connectors, turn the ignition
switch OFF. Then, turn it back ON and start
troubleshooting from the beginning.
PINPOINT TEST C : THE SCREEN DOES NOT OPERATE IN THE DIM OR NIGHT MODE
C1
Is TAIL signal normal in the vehicle signal check of the service Yes
check screen? Repair the Navigation Unit display.
No
Area to inspect: TAIL
PINPOINT TEST D : THE NAVIGATION SCREEN BECOMES OUT OF SYNC
D1

Go to D2
Is the power system of the navigation ECU normal?
No
D2
Measure the voltage across Video Synchronisation Signal, Video Yes

Return, Video Ground. Go to D3

and connectors between the CDU display and the navigation Inspect the wiring harnesses and connectors.
ECU normal?
G88871 en 01/2003 2003.0 BA Falcon


D3
Measure the voltage Video Synchronisation Signal, Video Return, Yes

Video Ground on Navigation ECU. Check the display.

Repair the CDU display.
PINPOINT TEST E : THE COLORS OF THE NAVIGATION SCREEN ARE ABNORMAL

E1
Are the colors abnormal on the screens other than the navigation Yes
screen? Go to E2
No
E2
Are the colors normal in the navigation color bar check of the Yes
service check screen? Check the CDU display.
No
Go to E3
E3

Go to E4
No
E4
Videa Ground. Go to E5

and connectors between the display and the navigation ECU Inspect the wiring harnesses and connectors.
normal?
E5
Videa Ground on Navigation ECU. Check the CDU display.

PINPOINT TEST F : ONLY THE SOUNDS FROM THE AUDIO SYSTEM ARE OUTPUT FROM THE
SPEAKERS
F1

Go to F2
No
G88871 en 01/2003 2003.0 BA Falcon


F2
Measure the voltage AUO+, AUO-, MUTE. Yes

Repair the audio system.
Are the connections and the continuity of the wiring harnesses Repair navigation ECU.
and connectors between the navigation and the power amplifier
normal? No
PINPOINT TEST G : THE SCREEN DOES NOT DISPLAY A MAP WHEN THE "I AGREE" BUTTON IS
PRESSED (ONLY THE "DISCCAUTION"SCREEN IS SHOWN)
G1
Apply the parking brake and turn the ignition switch to ACC or ON. Yes
Replace the map disc.
Does the same caution screen appear even if actions have been Repair the navigation ECU.
taken for the respective caution screen as described in the table
below? No
Normal
PINPOINT TEST H : THE MAP SCREEN TURNS WHITE OR BLUE (THE SWITCHES AND THE
VEHICLE’S CURRENT POSITION MARK ARE NOT SHOWN)
H1
Does the map appear if the map display scale is set to the widest Yes
range? Correct the vehicle’s current position and
recheck.
No
Go to H2
H2
Using a soft cloth, wipe the map disc, and insert the disc in the player. Yes
Then, turn the ignition switch from OFF to ON. Determine that the condition is normal (the
cause was the dirty disc).
Is the system okay?
No
Replace the map disc.
PINPOINT TEST I : THE SCREEN DOES NOT CHANGE TO THE NIGHT SCREEN MODE

I1
Is the picture quality adjustment set to the Day Screen mode? Yes
The Day Screen mode will not show the Night
Screen mode.
No
Go to I2
G88871 en 01/2003 2003.0 BA Falcon


I2
Does the screens other than the navigation screen appear in the Yes
night mode when the tailight switch is ON? Check the display.
No
Go to I3
I3
Does it make a beep sound when each of the switches is pressed Yes
on the navigation remote control? Repair the navigation ECU.
No
Inspect the connections the continuity of the
wiring harnesses and connectors between the
navigation ECU and the CDU display.
Areas to inspect : Remote
PINPOINT TEST J : THE REMOTE CONTROL IS NON-OPERATIONAL (ONLY ON THE NAVIGATION

SCREEN)
J1
Areas to inspect : Remote Yes

Repeair the navigation ECU.
Are the connections the continuity of the wiring harnesses and
connectors between the navigation ECU and the CDU display No
normal? Inspect the wiring harnesses and connectors.
PINPOINT TEST K : THE VEHICLE’S CURRENT POSITION MARK DEVIATES CONSIDERABLY
K1
Does the GPS mark appear on the screen? Yes
Go to K2
No
Inspect the wiring harness and connectors.
K2
Does it occur in a particular location? Yes
The current position mark could deviate in an
area in which the vehicle’s actual location is
difficult to determine.
(Immediately after leaving a parking area, etc.
Parallel running roads, high-rise roads, loop
roads, etc.)
No
Go to K3
K3
Is the system currently undergoing a distance correction? (Does Yes
the AUTO CORRECTION button appear green on the distance Wait and see until the correction is completed
correction screen?) (for 10km or more). The AUTO CORRECTION
button will turn blue upon completing the
correction.
No
Go to K4
G88871 en 01/2003 2003.0 BA Falcon


K4
Is SPD (vehicle speed) normal in the vehicle signal check of the Yes
navigation check menu on the service check screen? Go to K5
No
Areas to inspect: SPD
K5
Correct the current position. Drive the vehicle for a while with the Yes
GPS mark shown and observe the display for a while. Okay.
No
PINPOINT TEST L : THE GPS MARK DOES NOT APPEAR ON THE DISPLAY
L1
Move the vehicle to an area with an unobstructed view. (The signals Yes
from the satellites cannot be received at times in an area that is Go to L2
surrounded by buildings.)
No
Is the GPS antenna connected securely? Check whether the Securely connect the GPS antenna. Repair any
wiring harness is being pinched or is kinked sharply. abnormal conditions of the wiring harness.
L2
Are there any retrofit accessories such as theft-deterrent Yes
devices? Go to L3
No
Replace the GPS antenna.
Replace the navigation ECU.
L3
The GPS mark appears on the display when the power (including Yes
backup power) to a retrofit accessory is turned OFF. The reception sensitivity of the GPS could be
affected if a retrofit accessory that receives
Is the system okay? radiowave signals is installed. In this case,
change the position in which the retrofit
accessory is installed.
No
Replace the GPS antenna.
Replace the navigation ECU.
NOTE: Use a ground plate if the GPS antenna is

mounted inside the vehicle. The reception sensitivity
of the GPS could become affected if a ground plate is
not used. In addition, the GPS reception sensitivity
could become affected if a film is affixed to the glass.
In that case, mount the GPS antenna on the outside
of the vehicle.
G88871 en 01/2003 2003.0 BA Falcon

PINPOINT TEST M : THERE IS NO VOICE GUIDANCE
M1
When the volume in the volume setting of the menu screen is Yes
turned to maximum, is there a voice announcement that says Voice guidance cannot be given in the cases
"The guidance will be given at this volume"? listed below. Check again.
A destination has not been set.
The vehicle is not being driven along the route.
(The remaining distance does not appear at the
bottom left area of the current position screen.)
The "Guidance in other modes" has not been
set. (No voice guidance will be given at this time
on a screen other than the map screen.)
No
Go to M2
M2
Measure the voltage AUO+, AUO-. Yes

Go to M3
Are the connections the continuity of the wiring harnesses and
connectors between the navigation ECU and the speaker wiring No
harness normal? Inspect the wiring harnesses and connectors.
M3
Does the sound of the audio unit (radio, CD, etc.) come out from Yes
the speakers? Repair the navigation ECU.
No
Inspect the Audio unit.
PINPOINT TEST N : THE VEHICLE’S CURRENT POSITION MARK TURNS ON ITS OWN (THE MAP
TURNS ON ITS OWN)
N1
Has the ignition switch been turned to ACC or IG when the Yes
vehicle is placed on a turntable? If the ignition switch is turned to ACC or IG while
the vehicle is turned around, the turning speed
at that time is stored in memory as a reference
value. With the vehicle stopped, turn the ignition
switch from OFF to ACC or IG and recheck the
condition.
No
Go to N2
N2
On the service check screen, does the vehicle signal of Yes
navigation check show the SPD to be normal? Repair the navigation ECU.
No
Areas to inspect: SPD
G88871 en 01/2003 2003.0 BA Falcon

PINPOINT TEST O : THE DIRECTION OF TRAVEL AND THE MOVEMENT OF THE VEHICLE’S
CURRENT POSITION MARK ARE OPPOSITE OF EACH OTHER
O1
On the service check scree, does the vehicle signal of navigation Yes
check show the REV to be normal? Repeair the navigation ECU.
No
Areas to inspect : REV
G88871 en 01/2003 2003.0 BA Falcon

Navigation System Module 5. Remove mounting bracket from processor, four

bolts.
1. Remove Parcel Shelf as described in Section
501-05 Interior Trim and Ornamentation.
2. Remove Navigation Bracket mounting bolts (x3).
Tightening torque 8Nm.
NOTE: Navigation bracket is held in position by
guide tabs.
Navigation System Antenna

1. Remove Parcel Shelf as described in Section
501-05 Interior Trim and Ornamentation.
2. Disconnect antenna and remove.
3. Remove map DVD. Navigation System Display Module

NOTE: Ignition must be "ON" position, then push Removal and Installation
the front panel switch on the processor. Refer to section 413-08 for instructions.
4. Slide processor and bracket assembly out.

NOTE: Disconnect main connector and G.P.S
antenna lead wire.
G88872 en 01/2003 2003.0 BA Falcon

419-08-1 Cellular Phone 419-08-1
SECTION : 419-08 Cellular Phone

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................419-08-2
Mobile Telephone Wiring ......................................................................................................419-08-3
Mobile Telephone Platform ...................................................................................................419-08-3
Cellular Phone .......................................................................................................................419-08-4
Mobile Telephone Platform ...................................................................................................419-08-5
Mobile Telephone Kit ............................................................................................................419-08-5
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Bracket to console mounting screw 1
G34328 en 01/2003 2003.0 BA Falcon

Mobile Telephone Wiring 2. Storage of the hands free phone system in the
console whilst not in use.
All Falcon models are supplied with mobile telephone
wiring to facilitate installation of mobile telephones
including a mute function to interrupt the radio. All
models have wiring to facilitate mobile phone audio
interface to the radio. This feature enables the phone
audio to operate through the vehicles speakers.
The two connectors are located behind the fuse panel
on the right hand side of the instrument panel.
Mobile Telephone Platform

The cellular phone attaches to the centre console
through the phone platform to allow:
1. Access to the phone, suitable for hands free use.
G34330 en 01/2003 2003.0 BA Falcon

Cellular Phone
Mobile Phone C-192

297 Accessory +VE —
57CS Ground —
37A Battery 12V —
823 Mute —
Mobile Phone C-204

724 Audio Input — —
725 Audio Input + —
G34333 en 01/2003 2003.0 BA Falcon

Mobile Telephone Platform 4. Screw the bracket into the console body.
1. Join the front and back plates together by using
the screw bosses as a guide.
5. Replace the console bump stops currently fitted

with new larger bumps stops provided.
6. To remove, unscrew bracket mounting to console.
2. Screw plates together. Mobile Telephone Kit

1. Fit presenter arm to console (with phone holder
attached as per the above instructions).
2. Drill hole (diameter 25mm), using template
provided (see overleaf), in base of console
directly in line of presenter arm mounting.
3. Assemble the arm to the mounting bracket using

the pin provided.
3. Move passenger seat forward and remove bolt at

rear of console, clipping in console wing LHS.
4. Unclip and remove "T" bar surround then unscrew
and remove left and right console wings and
tissue box holder.
G34331 en 01/2003 2003.0 BA Falcon

5. Loosen hardware as indicated to allow flexibility in

the console side panel.
6. Feed wiring through the drilled hole in the console

floor (concealing hole made under carpet) to
reach under console side. Feed wiring forward to
front of console.
7. Conceal wiring under console side.

8. Feed wiring through to wiring connector C192 &
C204 as shown in Wiring - General Information -
Component location views 700-06-00-1.
G34331 en 01/2003 2003.0 BA Falcon

Template for drilling hole in console base:
1. Fold paper at dotted line and fit into console in place of carpet with arrow facing forwards
2. Drill 25mm hole at point marked
Facing toward front of console
DRILL HERE
419-10-1 Body Electronics Module (BEM) 419-10-1
SECTION : 419-10 Body Electronics Module (BEM)

CONTENTS PAGE
Body Electronics Module ......................................................................................................419-10-2
Body Electronics Module ......................................................................................................419-10-9
Symptom Chart ..................................................................................................................419-10-13
Pinpoint Tests ....................................................................................................................419-10-24
GENERAL PROCEDURES
Remote Key Teaching ........................................................................................................419-10-30
Receiver Resynchronization ...............................................................................................419-10-30
Dealer DST Ignition Key Teach Mode ................................................................................419-10-30
Customer DST Ignition Key Teach .....................................................................................419-10-30
Lost Keys ............................................................................................................................419-10-30
Customer Key Erasure ........................................................................................................419-10-30
PCM Parameter Reset ........................................................................................................419-10-30
Cabin Temperature Sensor Calibration Factor ...................................................................419-10-30
Changing BEM ....................................................................................................................419-10-31
The BEM and Remote Receiver .........................................................................................419-10-32
01/2003 2003.0 BA Falcon

Body Electronics Module delay determined by the vehicle road speed and the
position of the wipe potentiometer. As the vehicle
General Description speed increases above 8km/h, the dwell time will be
The Body Electronics Module, hereafter referred to as reduced. When the vehicle speed is decreased then
BEM, combines a transponder Challenge /Response the wiper dwell time will extend.
immobilisation system with the Body electronics Vehicle speed information is sent to the BEM via the
functions. The BEM interfaces with a Integrated CAN BUS.
Command Centre (ICC). There are two levels of BEM; When the wiper dwell potentiometer is fitted to the
a High series and a Low series; these are identified
wiper switch, five dwell positions can be selected.
as BEM/H and BEM/L.
Over the speed range zero to 80 km/h 11 increments
All current, resistance, frequency figures are ± 10% of 8 km/h adjust the wiper dwell time. When the
unless specified otherwise. All voltage readings will be vehicle accelerates from zero to 8km/h the next wipe
as specified. will be brought forward to provide a Wipe On Take Off
function. With no speed information to the BEM from
the CAN BUS the wiper dwell time will be as follows:
Position 1, 4.1 secs.
Front Wipe After Wash Control, Low Series

When activating the wash switch with the ignition
turned on, there will be a small delay of 0.4 seconds
before the wipers operate until the washer switch is
released. A further three wipes will be performed
before parking at the bottom of the windscreen. If
intermittent wipe function is active, it will be
Accessories Line Status suspended whilst the wash function is in progress and
The BEM reports the status of the Accessories line via resume once the wash switch is deactivated.
the CAN BUS. The Accessories line is high when the
Wash function will also be suspended if the engine is
ignition switch is in the Accessories and Ignition
being started.
positions and open in the Start position.
Switching the ignition switch to the off position will
Heated Backlight Timer cancel the wash function.
The Heated back light may be activated when the
Front Wipe After Wash Control, (High Series)
ignition switch is in the Ignition or accessories
position. Pressing the heated backlight switch Activating the front washer switch momentarily with
momentarily is reported over the CAN BUS. Once the the ignition switch in the on position on a high series
message is received by the BEM, the Backlight relay vehicle will activate the washers for a period of 1.2
is activated by pin J2/10 (cct 686 violet) being seconds. If a longer period is required than this then
switched low. The relay will remain energised for 15 hold the washer switch in the on position for the
minutes or until the backlight switch is activated again desired period of time, after the washer motor is
or the ignition switch is turned to the off position. activated 0.4 seconds the wipers will perform
During the engine starting process the timer will be approximately three wipes then park. If the
suspended, once the engine is started, the timer will intermittent wipe function is active, it will be
resume the timed period. suspended whilst the wash function is in progress and
resume once the wash switch is deactivated.
Front Intermittent Wiper Timer
Wash function will be cancelled if the engine is being
Vehicles may be fitted with Variable Dwell; Speed started.
Dependant Wiper and Wipe on take off functions. If
Switching the ignition switch to the off position will
the wiper dwell potentiometer is not connected then
also cancel the wash function.
the wiper dwell will be fixed to a period of 7 seconds.
Switching the front intermittent wiper switch to the Washer Fluid level (High series)
intermittent position whenever the ignition switch is
turned on will enable the intermittent function. With the ignition switch in the Accessories, Ignition or
Whenever the intermittent function is enabled, the Start position; the status of the washer bottle is
front wiper output will be activated for a period of 0.8 updated via the CAN bus. For a change of state to be
seconds to initiate a single wipe. This is followed by a
G43560 en 01/2003 2003.0 BA Falcon

observed, the condition must be present for a period overridden by any of the following actions, a door
longer than 20 seconds. opened, ignition turned from off to the on position or a
remote key activation.
Power Window Control
With the ignition key in the off position and activating
With the ignition switch in the accessories or ignition the panic function, the courtesy lamps will be turned
position, the power window relay is switched low.
on. Activation of remote door unlock, boot release or
Switching the ignition switch to the start position will
deactivation of the panic function will cause an entry
deactivate the relay. Switching the ignition switch to delay to occur. (20 seconds on, 6.4 seconds fade to
the off position will allow the power window relay to
off). Whilst the ignition is in the off position and a door
remain activated for a period of 1 hour. If a door is
lock command is executed with all doors closed, the
opened, the time will be reduced to 40 seconds from courtesy lamp will be immediately deactivated.
the time the door is opened to comply with Australian
design rule 42. Remote key unlock press will activate If no remote key has been taught, then the courtesy
power supply pressing on lock button will activate. lamp will deactivate in a shorter time than usual ie. 3
minutes when the doors are opened regardless of the
Analogue Clock Interface (High Series) ignition key position. The courtesy lamp will turn on in
The BEM provides battery power for the analogue 1 second remain on for 3 minutes then fade out in 1
clock at all times and connects to the Clock’s second.
illumination line to the graphics illumination signal The courtesy lamp can be turned on and off via CAN
from the cluster. diagnostics.
A police blackout mode is available to turn off the
Cabin Temperature Module (High Series) battery saver circuit. To enter or exit this mode, hold
With the ignition key in the ignition or start position, the courtesy manual switch for longer than 10
the BEM provides power to the fan motor of the cabin seconds. This function has been added to discourage
temperature module. With the ignition switch in the wiring modifications for the emergency services.
ignition position the BEM reads the analogue
temperature signal from the module and converts the Battery Saver Supply
analogue data into degrees Centigrade and transmits When the battery saver is active it provides power to
this data on the CAN bus to the climate control the courtesy lamps, boot lamp and glove box lamp
system. Note: DTC’s will not be logged for invalid circuits. It also supplies power to the sunload/twilight
data when the ignition switch is in the off or sensor, Audio antenna amplifier and the transceiver
accessories position. Calibration factor is programmed light ring illumination.
into the BEM using diagnostic command.
The battery saver is activated with any of the following
Sunload / Twilight Sensor Module (High Series) actions:
Activation of the battery saver supply (J3/3) provides The ignition key in the accessories, ignition or
power to the sunload/twilight sensor module. With the start position.
ignition on and the battery saver supply active, the Operating the remote key door unlock, lock, boot
BEM reads the signals from the sensor. The BEM and panic.
transmits the sunload data over the CAN bus to the
The battery saver function has a number of
climate control module. This sensor also controls the operational modes, these are tabulated below.
Auto Headlight on function. Refer to Auto Headlight
section. Normal Mode Battery Saver ON,
Courtesy OFF
NOTE: DTC’s will not be available for invalid data
signalled with the ignition switch in either the Saver Mode Battery Saver OFF,
accessories or the start position. The output voltage Courtesy OFF
from the sunload sensor is available at pin J2/1; it is in Courtesy Mode Battery Saver ON,
the range of five to zero volts. Courtesy ON
Dash Mode Battery Saver ON,
Courtesy Lamp operation with illuminated Entry Courtesy ON
and Exit Delays EXIT Mode Battery Saver ON,
With the ignition in the Accessories, Ignition or Start Courtesy ON, 20 sec
position, and if, any door is open then the courtesy delay, 6.4 sec fade
lamp will be on. With all doors closed, the courtesy Police Mode Battery Saver OFF,
lamp will be off. With the ignition in the off position
Courtesy OFF
and any door open, the Courtesy lamp will be on until
the battery saver times out at 15 minutes. If in the Audio Keyless Play Battery Saver ON,
meantime the door is closed then the courtesy lamp Courtesy OFF
will remain on for 20 seconds then fade to off over a
period of 6.4 seconds. The delay period will be
G43560 en 01/2003 2003.0 BA Falcon

Normal Mode (Battery Saver On, Courtesy Off) Door and Boot Ajar Status
The battery saver circuit will be in normal mode; when The BEM will report the ajar status of the four Doors
the BEM is powered up or reset, by removing and and Boot individually via the CAN bus.
replacing the BEM fuse; it will be in Normal Mode.
Normal mode will be entered from saver mode if the Manual Boot/Tailgate Release
ignition key is turned from off to the accessories, The manual boot/tailgate release switch is enabled
ignition or start position, a door is opened then closed, when any door is unlocked or battery saver is active.
operating the remote key door or boot functions. The switch is disabled 10 minutes after ignition off if
all doors locked. When pressed the BEM will output a
Saver Mode (Battery Saver Off, Courtesy Off) 12 Volt pulse to the release solenoid for a period of
The BEM will go into saver mode after 15 minutes 0.8 seconds. No output is available if the vehicle
with the ignition in the off position as long as the last speed exceeds 12 km/h. If no CAN speed data is
event of opening and closing a door has occurred. It available then the BEM will default to 0kmh and the
may also enter saver mode 15 minutes after pressing release function will be enabled.
the door lock button, unlock button, panic button or
boot button whichever occurred last. Remote key Boot /Tailgate Release
Pressing the boot release button the BEM will output
Courtesy Mode (Battery Saver on, Courtesy On) a 12 volt pulse of 0.8 seconds in duration to the
The transition from normal mode to courtesy mode release solenoid. It will also cause the hazard lamps
can occur with ignition key out of the lock, Door to flash once for a duration of 1.6 seconds. The
opened. Remote key unlock command, boot unlock, courtesy lamp will illuminate for 20 seconds then fade
panic or dash switch with a one second fade in. The for 6.4 seconds.
transition back to normal mode from Courtesy mode
can occur after remote key lock command, Ignition Central Locking
key from off to Ignition, Accessories or start position
or the dash switch with a one-second fade out. If the Manual Central Locking Functions
BEM is in courtesy mode due to a boot open Manual central locking can be initiated by the
command, when the doors are closed and the ignition following actions:
is off the BEM will enter Exit mode.
Pressing the central door-locking switch once will lock
Dash Mode (Battery Saver on, Courtesy On) the doors if unlocked, pressing the switch again will
unlock the doors. Inserting the mechanical key into
The courtesy lamp may be turned on via the CAN bus the driver’s door exterior lock will unlock only the
by holding the dash switch in the on position for 1 driver’s door. To open the passenger doors press the
second. To turn off hold the dash switch for 1 second central locking switch with the driver’s door open. If
with the door closed, a one-second fade will occur the drivers door is closed after a manual unlock then
when the BEM returns to Normal Mode. pressing the central locking switch will first lock the
drivers door then a second press will unlock all doors.
Exit Mode (Battery Saver On, Courtesy On, Exit
Delay 20 secs. 6.4 Secs Fade) If the soldier button is pressed downwards then all
doors will lock. If drivers door opens when soldier
This mode is entered from courtesy mode with the
button pressede all doors will unlock the soldier
action of closing the boot or closing the doors with the
ignition off. The BEM will return to courtesy mode if button. Opening the interior door handle half way will
unlock the driver’s door. Unlocking any passenger
during the delay or fade period a door is opened, a
interior door lock handle will unlock all doors. If the
door is unlocked or a remote key (except lock)
command is received. On completion of the exit driver’s door is slammed when in the locked mode,
the BEM will command a driver’s door unlock.
mode, the BEM will resume normal mode.
In the event of a crash signal being received by the
Door Trigger Disable Mode, Courtesy off) BEM from the airbag system via the CAN bus, an
This mode may be entered from any other mode by unlock all doors will be actioned. During a power up or
holding the dome dash switch for a period of 5 reset, the status of the doors will be unchanged to
seconds. It does not require any wiring modifications avoid a lock out action.
to be undertaken. To restore normal operations again
Remote Central Locking Functions with Boot
hold the dome dash switch for 5 seconds.
Release and Panic Alarm
NOTE: Police and Taxi Mode can be set under Remote entry and panic functions only operate with
personalised settings in WDS. the ignition switch in the off position. Two modes of
These settings control horn (control by BEM) courtesy operation are possible, Two stage unlocking or single
lamp enabling, battery saver control, & taximode of stage unlocking. This feature may be activated or
door locks. deactivated for each remote key programmed to the
vehicle. To toggle between these modes hold the lock
G43560 en 01/2003 2003.0 BA Falcon

and unlock buttons down simultaneously for a period then change back again. Then teach the next key and
of 3 seconds. In two stage unlock, pressing the unlock so on. As each key is taught, the door locks will cycle.
button once will unlock the driver’s door, the hazards Turning the ignition switch to off or on position will exit
will flash once, a second press or holding down button teach mode. Again the door locks will change state to
for 3 sec. will unlock the remaining doors and again indicate the mode has been exited.
flash the hazards once. In single stage unlocking, NOTE: it is important that all keys that are to be
pressing the unlock button, will unlock all doors and taught to the system are taught in the same teach
flash the hazards once. In both modes pressing the sequence.
lock button, will lock all doors and flash the hazards
twice. Seat Memory and Priority Key Control (High
Pressing the panic button will activate the panic alarm Series)
for a period of 30 seconds, unless the ignition is On the high series vehicle, the priority key control is
turned on or the panic button is pressed a second activated when the driver’s door is unlocked with a
time. The hazards will flash and the horn will sound at remote key. The BEM is able to identify the remote
a frequency of 5 Hz while the panic function is active. key by the order they were taught to the BEM. When
Pressing the boot/tailgate, release button will output a the BEM identifies the key used it sends data to the
12 volt pulse for 0.8 seconds. A hazard flash of 1.0 seat module via pins J2/22 (seat memory data) and
second is enabled via the CAN bus. J2/23 (seat memory enable). Data stored in the seat
memory is acted upon according to the remote key
A confirmation of door lock is possible by pressing the
remote lock button; if locked the horn will bip 0.016 number.
sec and a hazard Flash of 0.5 secs. Automatic Headlamps with Twilight Sensing and
When a door is open then a door ajar will be detected Delayed Turn-Off
or a transponder key is detected in the ignition, a door Setting the headlamp switch to the automatic position
lock attempt will result in the horn issuing a door ajar allows the BEM to control the headlamp relay from
warning of 8 pulses in rapid succession. The BEM will ambient light information from the twilight sensor,
action a door unlock, the hazards will flash two long ignition switch and the driver’s door. The headlamp
and two short pulses, the Cluster smartshield warning switch is ignored in automatic mode.
jewel will be turned on and the courtesy lamp will be
on. If a successful lock is achieved then the system To avoid the headlamps being turned on and off by
will revert to normal operation. sudden changes in light level ie moving trees, moving
cars etc, The BEM uses a combination of hysteresis
Automatic Door Relock and delay strategies. When the ignition switch is in the
If a remote key is used to unlock the doors and no accessories or ignition on position, the BEM
door is opened, the ignition is not turned on. The headlamp relay output driver is controlled by changes
doors will automatically relock after 45 seconds. in ambient light level. The BEM also controls the relay
to provide a headlamp delay when the ignition is
RF Remote Key turned from on to off and it is dark. If the driver’s door
The RF remote key signals are received by the RF is opened within the delay period then the time is
receiver module all the time. The data is only passed shortened.
to the BEM, when the ignition is in the off position, Case Twilight Ignition / Driver BEM
and the remote key has been trained to the BEM. If Sensor Accessory Door Headlamp
the Receiver receives a number of invalid status Relay Output
transmissions, it is possible for the receiver to
1 Light On N/A Off
resynchronise to a single remote key. If a remote key
has not been used for a long time, the receiver may 2 Light to On N/A Delayed On
not respond, should this happen, press the remote Dark to Off 2 secs
key button 3 times in succession and it will be 3 Dark to On N/A Delayed Off
resynchronised to the receiver. Light to On 15
secs
RF Remote Key Teach (up to 8 keys)
4 Light On to Off N/A Off
To enter teach mode turn the ignition switch from off
5 Dark On to Off Closed Delayed On
to accessories and within 5 seconds press the rear
demist switch 3 times; remote key teach mode will be to Off 120
secs
entered. When the mode is entered then the door
locks will change state. 6 Dark On to Off Open Delayed On
to Off 20
Once the mode is entered then all the remote keys secs
will be erased. To teach the keys press any remote
7 Light Off N/A Off
keys button; to acknowledge the new key has been
stored in memory the door locks will change state
G43560 en 01/2003 2003.0 BA Falcon

Case Twilight Ignition / Driver BEM the light condition is BRIGHT the BEM will respond by
Sensor Accessory Door Headlamp setting a delayed turn off.
status Relay Output
Electronic Immobilisation
8 Light to Off N/A Off
Dark The immobilisation interfaces with four systems in the
vehicle, the associated components are as follows:
9 Dark Off Closed If already on,
to then delay Ignition key with embedded Digital Signature
Open 20 secs from Transponder (DST). The ignition key also has a
On to Off mechanical encoded key and electronic
10 Dark Off N/A Off transponder technology. The ignition key is the
11 Dark to Off N/A Off authority to start and drive the vehicle. For the
BEM to respond the ignition key must be inserted
Light
into the ignition lock and the transceiver antenna
12 Light Off to On N/A Off field.
The Auto headlamp control has a number of inbuilt Transceiver Ignition lock assembly (TILA): The
safety features to ensure that the headlamps remain TILA in addition to the steering lock, ignition and
operational even if a connector is disconnected whilst starter functions interfaces the ignition key (DST)
running. and the BEM through the transceiver circuit. The
It is possible to adjust the Auto Headlamp Transitions TILA consists of a transceiver and a transmit and
from Off to On in Diagnostics Mode from the factory receive antenna attached to the lock barrel. The
default setting. Adjustment of the on to Off transition antenna is used to transmit to and receive date
can also be selected in diagnostics mode. from the transponder.
There are 8 possible setting available in each mode. Body Electronics Module (BEM): The BEM is
The System performs diagnosis of the twilight sensor responsible for verifying that the DST ignition key
and the output circuitry via a dedicated feedback. is valid by issuing a challenge and the receiving a
Diagnostics runs independently of the main Auto response; this received data is then compared
Headlamp circuitry. with the values stored in the BEM memory. If a
match is made the BEM will mobilise. The BEM
When the auto headlamp feature is selected and the
will then receive a challenge from the Power
ignition is in the run or accessories position, Control module (PCM) over the CAN bus. The
diagnostics of the Auto Headlamps and twilight sensor
BEM will then respond to the PCM also over the
will occur every time auto headlamps are required to
CAN bus.
turn on. Diagnostics will also run if the headlamps are
required to turn off. Power Control Module (PCM): The PCM is
responsible for allowing the vehicle to start, sends
Twilight Sensor Diagnostics a challenge to the BEM, once a valid response
An error message out of range DTC will be displayed has been received from the BEM allows the
if the PWM frequency is above 420 Hz for the darkest engine to continue to run. If not, the engine will be
condition or below 1 to 47Hz for the lightest condition. stalled.
If no PWM signal is received, the error message will Transceiver Lock assembly (TILA)
read Open or Short circuit to ground and DTC will be
displayed.
The Auto Headlamp output has a failsafe mechanism
in that the relay output will be maintained should an
output driver fail. If the Twilight Sensor fails and Auto
Headlamps is selected then the BEM will default to a
failsafe strategy as follows. When the Ignition or
accessories are turned on, the headlamps will be on
and when the ignition is off the Headlamps will turn
off. Whenever an Auto headlamp output failure is
detected, a warning buzzer (from the cluster) will
sound for a limited time when the ignition is turned
from on to off and next time the ignition is turned from
off to on. The buzzer will sound on the ignition
transitions until the fault is rectified.
During a power reset and Twilight Sensor data is not The TILA comprises a Transceiver with an ignition key
available the BEM will assume a dark condition and light ring, steering lock and ignition starter switch that
turn the Auto headlamps on until sufficient twilight will perform the following functions:
sensor data is available. Once the data is available if
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The Transceiver provides an electrical/RF interface provide an interface between the RF remote Keys and
between the BEM and the transponder housed in the the BEM. The receiver is a superheterodyne design
ignition key head. The transceiver generates a low that converts the AM encoded signals from the RF
frequency field that is radiated by the integrated remote keys into data that is validated by the BEM.
antenna, and used to transmit and receive signals Once validated the command sent to the receiver is
from the transponder. The transceiver may be acted upon by the BEM. Ie lock or unlock etc.
removed by loosening the retaining screw and sliding The range of the remote keys may be reduced by the
the assembly off the lock housing. When replacing the use of aftermarket window tinting, heavy rain, snow,
transceiver it is important that the tightening torque for hail, close proximity to trees. Strong RF signals on or
the retaining screw is observed. near the frequency of the receiver may cause
This is 19.5 Nm Max for the original screw. de-sensitisation.
The Ignition Key light Ring illuminates as part of the The receiver obtains battery power from the BEM fuse
courtesy lamp function with illuminated entry and exit all the time. The receiver detects any valid signals
delays. from any remote key. If a signal is detected, the
The Steering Lock Assembly is part of the steering receiver will be turned on. After the signal has been
column and cannot be removed. The lock assembly received, the receiver will resume polling to await the
provides mechanical security by locking the steering next transmission.
column by way of a locking bolt that engages once Refer to WDS tests for fault finding. The receiver unit
the ignition key is removed from the lock and the is a servicable item. If faulty refer to ICC section of
steering column rotated. A lock barrel is located in the service manual for procedure for removal and
lock housing and when the ignition key is inserted replacement.
allows the ignition switch to be turned to Accessories,
Ignition and start positions. Cabin Temperature Sensor (CTS)
The CTS is located behind the instrument fascia panel
CAUTION: As an added security feature the as part of the ICC. The CTS takes temperature
lock bolt will fire into the locked position and readings via a DC operated fan motor drawing air
remain permanently locked if the lock is turned from the car interior through the grill and across a
with the barrel removed, if this happens the whole thermistor. When there is a change in temperature,
steering column must be removed and replaced. the value of resistance changes giving a change in
To replace the lock barrel, insert the barrel into the voltage output. This change is read by the BEM where
lock until the pin locks into the housing. it is translated into a CAN message that is read by the
HIM.
The Ignition Starter Switch provides electrical
contact of the battery supply to the accessories,
ignition and starter circuits. In the start position, a
lamp proofing circuit is provided with a ground. The
start position is spring loaded to return to the ignition
position. The switch mechanism cannot be removed
and is not serviceable.
The TILA wiring harness also provides an interface to
the pedal height motor assembly.
Remote Receiver Module
The CTS is not a servicable item. If the CTS is faulty

the complete ICC should be replaced as per
procedure for ICC replacement, after prior approval
gained.
WDS to be used to program and check calibration
factor loaded into BEM. This calibration factor should
be the same as the calibration factor identified on the
CTS ID label.
P & A BEM
The RF receiver module is mounted inside the The P & A BEM is programmed in an immobilised
passenger compartment at the top of the ICC to state. To install a new P & A BEM, DST ignition key
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teach, CTS calibration factor loading and PCM Acknowledgment of a successfully taught first key will
parameter reset functions need to be performed. be by cycling the door locks once, twice for the
second key and so on.
BEM and PCM security status can be identified by the
BEM’s mobilisation status and current status of the Acknowledgment will normally occur within 2.5
PCM communications PID’s respectively. CTS seconds of inserting the key and turning to the ignition
calibration factor can be read by the WDS. If a on position. Turn the ignition to the off position and
calibration factor has not been loaded then DTC will remove the key, immediately insert the next key to be
be set on the BEM until a valid calibration factor is taught and turn to the ignition on position. If a key
loaded. cannot be programmed then no acknowledgment will
be received.
Normal Operation — BEM Mobilisation Dealer teach mode will be terminated by the following
With the ignition switch in the off position, the BEM conditions:
will be in the armed state. Turning the ignition key to Interruption to the BEM power.
the accessories, ignition or start position will cause Leaving the ignition in the off position for 10 seconds.
the BEM to commence a challenge of the ignition
key’s Digital Signature Transponder (DST). Each time Turning the ignition to the on position with a DST key
a new challenge is made the old challenges are that has been programmed; once more than two keys
flagged as used. If the response is known by the BEM have been taught.
then it will mobilise. Failure of the challenge will result Once eight keys have been taught.
in the mobilisation state changing to immobilised and Exiting the Dealer teach mode will be confirmed by a
a transponder DTC will be logged to identify the type door lock cycle.
of error. If an incorrect response is received a new
challenge will begin, this will be repeated until a Customer Spare DST Key Teach Mode
correct response is received or the ignition is turned The customer key teach mode allows the owner
off. If an attempt is made to scan the BEM, it will shut limited teach and delete key function. To enter
down for a set period, after this time the BEM will customer key teach mode, the owner must have two
resume with a new random challenge. Once a valid valid keys that are already taught to the BEM. Insert
response is received and the BEM mobilised then the one of the trained keys into the ignition lock and turn
challenges will stop. to the accessories position, turn to off and remove the
Normal Operation PCM Enabling key. Within 5 seconds insert the second key and turn
to the ignition on position. At this point the door locks
Once the ignition switch is in the accessories, ignition should cycle to indicate the teach mode has been
or start position, the BEM will look for a pre-challenge entered. To teach additional keys to the BEM, insert
request from the PCM, and respond with a challenge the new key and turn to the ignition position, if
request message. Any challenges from the PCM will successful the door lock cycling will indicate the
cause the BEM to respond with a not ready, reading number of keys taught. Once acknowledgment has
transponder message. Once the BEM has mobilised, occurred turn the key to off and insert the next key to
it will request a challenge from the PCM and wait for be taught. Up to additional 6 keys may be taught in
the challenge message from the PCM to appear on this way.
the CAN bus. The BEM will calculate a response from
information learnt from the PCM and transmit a For key deletion only the keys that are not taught to
response code. A challenge acknowledgment the BEM will be deleted. The two known keys used to
message from the PCM shall indicate to the BEM that enter teach mode plus any additional keys taught will
the response has been accepted. PCM be valid, all other keys will be erased. To exit teach
communication status may be monitored using BEM mode leave the ignition on for longer than 10
diagnostics. seconds. An acknowledgment will be received when
the BEM exits teach mode.
Dealer DST Key Teach Mode
PCM Parameter Reset
This mode is used by dealers to teach new DST keys
to a replacement BEM. The mode can also erase DST A PCM parameter reset will be required if either a
keys. To enter this mode using the WDS tester ensure BEM or a PCM are replaced in the field or a dealer
that the ignition is turned to the off position. Entry into DST ignition key teach is performed. If PCM
the mode and deletion of the PCM ID is confirmed by parameter reset invoked by WDS it will also require
a mode acknowledgment. the entry of a CTS calibration factor.
Select the anti-theft status screen, and then select The BEM must be mobilised by turning the ignition to
Transponder Dealer Teach Mode. Insert DST key 1 the on position using a taught DST Key. Using the
into the ignition lock, then turn to the ignition on WDS tester select PCM parameter reset function,
position. For each DST key, the BEM will record the complete the steps indicated on the WDS screen.
DST unique identification number and program the
DST with its own encryption code key.
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Body Electronics Module Boot shut

Glovebox open
Inspection and Verification Do not sit in the Drivers seat
On Demand Self Test During this test, it is important to make visual
observations.
Using the WDS Tester it is possible to conduct an on
demand self test. The total time for the test is 14 seconds the following
table gives the order and function being tested.
The pre-conditions for this test are as follows:
NOTE: We can categorise the tests as visible and
Ignition key in the ignition switch and turned to the invisible to the operator. The following is a table of
ignition on position tests/operations to be performed. It will do different
Headlamp switch in Auto position tasks at 1 second intervals.
Time (second) Visible Tests Invisible Tests Precondition Comments

0 (start) Door Lock Driver Door Lock Relay energised for
feedback 200ms
1 Memory Seat #1 Seat Module Data !!!Do not sit on the High series only
line seat DTC may be set if
Open circuit* option is not fitted.
Short to battery
2 Driver Door Unlock Driver Door Lock Relay energised for
feedback 200ms
Memory Test*
4 Horn Relay Horn Relay line 100ms On, 100ms
Open circuit* Off,100ms on,
Short to battery 400ms off, 100ms
on, 100ms
Off,100ms on, Off
5 Front wash motor Key in ignition High series only
position
6 Battery Saver Leave open "glove Battery Saver left on
box" or turn on "map for rest of test
lamp" to observe
Transceiver TX Battery Saver
Data Line active.
Open circuit*
Short to battery
TILA Challenge Battery Saver
TILA - Key ID activeKey in ignition
unknown position
TILA - Faulty
transponder
TILA
disconnected
TILA - Faulty or
fixed code
transponder
7 Front wiper motor Wiper Feedback Key in ignition 1 wipe (Turn on for
position 700ms)
Front wiper switch Key in ignition High series only
potentiometer* position
Out of Range
Circuit Failure
8 Boot Release Boot Release Boot needs to be Relay energised for
feedback shutBattery Saver 800ms
must be active DTC will be set on
utes.
G43561 en 01/2003 2003.0 BA Falcon

Time (second) Visible Tests Invisible Tests Precondition Comments

Immobilisation Key in ignition Must follow TILA
transfer* position challenge
– message not sent
from PCM (missing
message)
9 All Door Unlock Relay energised for
200ms
Cabin Temperature Key in ignition High series only
Sensor* position
Circuit Open
Circuit short to
battery
Circuit short to
ground
Driver Sunload Key in ignition High series only
Sensor* position
Circuit Open
Circuit short to
battery
Circuit short to
ground
Passenger Sunload Key in ignition High series only
Sensor* position
Circuit Open
Circuit short to
battery
Circuit short to
ground
10 Heated Backlight Heated Backlight Key in ignition Look at dash board
Relay position to observe indicator
Open circuit*
Short to battery
11 Power Windows Power Window Hold button to
Relay observe window
Open circuit* operation
Short to battery
12 Dome Lamp No fade in/out
Twilight Sensor* Battery Saver active High series only
Circuit Open
Circuit short to
battery
Circuit short to
ground
13 Auto Headlamp Auto headlamp feed Headlamp switch in High series only
back "auto" position
CAN PCM data out Key in ignition
of range (speed)* position
CAN battery voltage Key in ignition
- signal out of range position
from cluster*
14 (end) Dome flashes
(300ms on) to
indicate self test
complete.
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BEM Diagnostic Trouble Code (DTC) index
DTC Description Precondition Action

C1943 Airbag Deployment Airbag Deployed CAN bit Airbag deployed. No
Indication Input Fault received. Status read action
during self tests.
B1213 Anti-Theft Number of Number of programmed Program more Keys
Programmed Keys Is keys is less than 2.
Below Minimum
B1250 Air Temperature Internal Out of range. Will be set if Check ICC wiring. If
Sensor Circuit Failure input is between 0.32V wiring OK then replace
and 0.47V Cabin Temperature
Sensor.
B1251 Air Temperature Internal Input floats > 4.56V Check resistance of CTS.
Sensor Circuit Open If O/C then change CTS.
If not O/c then check ICC
wiring.
B1253 Air Temperature Internal Input < 0.32V, External Check resistance of CTS.
Sensor Circuit Short To Fault If S/C then change CTS.
Ground If not S/c then check ICC
wiring.
B1259 Solar Radiation Sensor Circuit open or short to Check Driver’s Sunload
Circuit Open battery, Input greater then Sensor and Wiring.
4.78V, External Fault
B1261 Solar Radiation Sensor Input held at less than Check Driver’s Sunload
Circuit Short To Ground 0.17V, External Fault Sensor and Wiring.
B1300 Power Door Lock Circuit Door Lock Motor Error / Pinpoint tests G and N.
Failure Driver’s door lock
feedback did not change
after lock action, External
Fault
B1342 ECU Is Faulted EEPROM /TEMIC are ECU Failure - Replace
continuous only, but if set Module.
the DTC will be reported
as part of self test. ROM /
RAM DTC can be set
after BEM power reset
(continuous DTC) or
during self test. Internal
Fault
B1348 Heated Backlite Relay O/C or S/C to Ground, Check Heated Backlite
Circuit Open External Fault and wiring
B1349 Heated Backlite Relay S/C to Battery, External Check Heated Backlite
Short To Battery Fault and wiring
B1446 Wiper Park Sense Circuit Feedback does not Check Wiper motor,
Failure change / park circuit wiring and switch
failure, External Fault Confirm DTC with Self
Test
B1458 Wiper Washer Pump Front wash motor error, Check Washer motor,
Motor Relay Circuit External Fault wiring and switch
Failure
B1548 Power Window Master Power Window Relay Check Power window
Circuit Open driver O/C or S/C to relay and wiring
Ground, External Fault
G43561 en 01/2003 2003.0 BA Falcon


B1549 Power Window Master Power Window Relay Check Power window
Circuit Short To Battery driver S/C to Battery, relay and wiring
External Fault
B1600 PATS Ignition Key TILA RF receiver error Check power available on
Transponder Signal Is J1/4 & earth on J1/3.
Not Received Check continuity from
BEM J1/7 to TILA J6/1.
Check TILA.
B1601 PATS Received Incorrect Key ID unknown or Check programmed key
Key-Code From Ignition Incorrect challenge is used. Reprogram keys
Key Transponder if required.
B1602 PATS Received Invalid Faulty or fixed code Program correct
Format Of Key-Code transponder transponder Key
From Ignition Key
Transponder
B1693 Autolamp On Circuit Autoheadlamps Driver Twilight sensor Headlamp
Failure Circuit Failure, External switch must be in Auto
Fault. position. Check Wiring
and headlamp switch and
headlamp relay.
B1790 Autolamp Sensor Input Twilight sensor input Check operation of
Circuit Failure circuit failure battery saver. Check
Twilight sensor and wiring
B1791 Autolamp Sensor Input Twilight sensor input Check Twilight sensor
Circuit Open circuit open, External and wiring
Fault
B1982 Driver’s Door Unlock Driver’s door unlock is Pinpoint tests G and N.
Relay Circuit Failure not successful / Driver’s
door lock feedback did
not change after unlock
action
B2072 Seat Memory Module S/C to Battery, External Check Seat memory
Data Line Short to Battery Fault module and wiring J2/22
Check option is fitted
B2073 Seat Memory Module O/C or S/C to Ground, Check Seat memory
Data Line Open or Short External Fault module and wiring J2/22
to Ground Check option is fitted
B2074 Seat Memory Module S/C to Battery, External Check Seat memory
Enable Line Short to Fault module and wiring J2/23
Battery Check option is fitted
2075 B Seat Memory Module O/C or S/C to Ground, Check Seat memory
Enable Line Open or External Fault module and wiring J2/23
Short to Ground Check option is fitted
B2103 Antenna Not Connected TILA antenna not Check power available on
connected, External Fault J1/4 & earth on J1/3.
Check continuity from
BEM J1/7 to TILA J6/1.
Check TILA.
B2141 NVM Configuration No PCM ID Stored Conduct a parameter
Failure reset
B2431 Transponder Key programming failed Program new key. If this
Programming Failed fails try new transponder.
If this still fails try a new
TILA.
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B2477 Module Configuration Calibration factor is not Program CTS calibration
Failure configured factor
B2511 Horn Output Relay Circuit S/C to Battery, External Test wiring J2/9 and horn
Short to Battery Fault relay
B2682 PCM (PCM) Immobilisation Message Conduct a parameter
Communication Fault Invalid reset. If this fails check
the PCM.
B2849 Horn Output Relay Circuit O/C or S/C to Ground, Check Horn relay and
Open External Fault wiring J2/9
Continious DTC not valid.
On demand DTC is valid.
B2891 Front Wiper Switch Potentiometer is missing, Check wiper dwell pot
Potentiometer Circuit External Fault (O/C or and wiring J2/19 to J2/8
Failure S/C)
B2894 Decklid Release Circuit Boot is not ajar after boot Boot release solenoid
Failure release, External Fault error, Test boot ajar
switch and listen for
activation of solenoid. If
not heard then check
wiring and boot solenoid.
DTC not valid on utes.
B2929 Transmit Data Line Short S/C to Battery, External Check continuity from
to Battery Fault BEM J1/8 to TILA J6/9.
Check wiring and TILA.
B2930 Transmit Data Line Open O/C or S/C to Ground, Check continuity from
Circuit or Short to Ground External Fault BEM J1/8 to TILA J6/9.
Check wiring and TILA.
U1900 CAN Communication Bus CAN Network failure Check PID B902 for
Fault - Receive Error (Missing Messages) modules whose
messages where missed.
Check relevant module
and CAN wiring.
U2197 Invalid ’Vehicle Speed’ CAN bytes for vehicle BEM default speed data
data speed is read as $FF used is Zero. Test PCM.
from PCM
Symptom Chart

No Clock illumination BEM related Check for open circuit J1/1 to J4/12
No Graphics Illumination and J1/2 to J4/10
Feedthrough Check for 12v at J1/2 when park
No park lamp supply feedthrough lamps on
from park lamp relay Check other possible causes on
Incorrect BEM fitted symptom chart
Cluster fault Check correct level BEM fitted
Wiring fault
Clock fault
No TILA light Ring Illumination BEM related Check 12v at J1/4 and J6/3
Courtesy lamp driver Check BEM battery fuse
Battery BEM fuse blown Test continuity J6/10 to J6/3
Cluster fault Go to pinpoint test A
Wiring fault Check other possible causes on
TILA fault symptom chart
O/C globe
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No Demist Function BEM related Check relevant fuses
Relay driver failure Check DTC B1348/49. If present go to
DTC’s logged Pinpoint Test B. If not present check
Backlight fuse 40A blown ICC, wiring, Element, external relay.
BEM accessories fuse Blown
Radio 2 fuse (7.5A) blown
External Relay failure
Demist Element fault
Demist switch failure (ICC)
Audio fault
Wiring fault
No accessories feed to BEM
CAN line failure
BEM does not mobilise BEM related Connect WDS

PCM/BEM comms not working Turn Ignition On and Run On Demand
BEM/TILA comms not working Self Test.
More than one key in the TILA Record any DTC’s logged.
antenna field. Refer DTC chart for relevant pinpoint
Transponder does not validate. tests
Wrong type of transponder key eg – Note TILA Status
Ford Transit. Record any DTC’s logged.
Magnetic badge on key ring. Low frequency security scanners may
Vehicle parked close to magnetic interfere with TILA read process.
scanner. Check other possible causes on
PCM fault symptom chart.
Wiring fault (CAN)
TILA fault
Transponder key fault
Customer Cannot Teach Transponder BEM related Check programmed keys mobilise car.
Keys Customer Key teach mode not Pinpoint test C
enabled. BEM programmed to If pinpoint test C OK check other
disable customer key teach. probable causes on symptom chart.
Ignition not turned to accessories
position.
Low Battery Voltage.
More than one key in antenna field
Wiring fault
TILA fault
Transponder key fault
BEM/PCM Training Failure BEM Related Use WDS to check vehicle anti theft
BEM has not learnt Ignition Key. status PID THEFTS
BEM does not learn PCM key or Use WDS to check if ignition keys
loses Key (System Noise) have been trained (>1)
BEM validation failure (dealer PID N_KEYCODE If training fails retry
used Dealer Teach Mode causing parameter reset.
code erasure) If pinpoint test C OK check other
Low battery prevents Training. probable causes on symptom chart.
Power interrupted during training.
Wiring fault.
Water in PCM connector (No codes
Logged)
PCM fault
Wiring fault
Auto Headlamps do not turn on at low BEM related Check setting values PID ON_THOLD
light level Setting values Incorrect. and DTC’s B1693, B1790, B1791 with
Low series BEM fitted to Vehicle. WDS.
Open circuit wiring Sunload sensor to Control headlamp drivers using WDS
BEM. PID AUTOOUTST#.
Twilight sensor fault Check other possible causes on
Wiring fault symptom chart.
Headlamp switch fault
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No Automatic Delay of Headlamps BEM related Check setting values PID ON_THOLD
Faulty Headlamp Drivers and DTC’s B1693, B1790, B1791 with
Low Series BEM Fitted. WDS.
No Park input to Cluster or BEM Control headlamp drivers using WDS
Pin J2/12 or J1/10 remains high at PID AUTOOUTST#.
Ignition Off. Go to Pinpoint Test D
Incorrect Headlamp switch fitted. Check other possible causes.
Headlamp switch fault
Wiring fault
Wipers do not Park in Off position BEM Related Operate wipers and monitor wiper park
Feedback circuit faulty J3/1, J3/2 switch status using WDS and monitor
Wiring fault pin J3/1. If J3/1 does not follow status
Wiper motor fault of PID WFLUID Byte 1 Bit 0 then
Wiper switch fault change BEM else.
Check other possible causes on
symptom chart.
Wipers do not Operate in Intermittent BEM Related Do all tests in Wiper does not park, if
Mode. No accessories input to BEM ok proceed.
BEM wiper relay faulty Using WDS read wiper switch status
Wiring fault PID WP_STAT by selecting each
Wiper motor fault position with intermittent selected. Pin
Wiper switch fault J2/19 should vary between 0 - 2.5V as
intermittant position is changed. If
voltage varies and PID WP_STAT
does not reflect change then replace
BEM.
Else check other possible causes.
No Variable Speed Dependant Wipers BEM Related Functional test for missing CAN
No accessories input to BEM messages
BEM wiper relay faulty Check for existence of DTC U2917
No Speed data or invalid data from (invalid speed data) using WDS. If
PCM present check PCM else
Wiring faulty (CAN) Check other possible causes.
Intermittent Dwell Time cannot be BEM Related Use WDS to Monitor Wiper dwell
changed BEM potentiometer input faulty. positions 1 to 5 (PID WP_STAT) while
BEM wiper motor driver faulty changing position of dwell pot.
(relay or relay drive circuit) – If not OK then test dwell pot.
Wiper dwell pot switch faulty If WDS check OK then check Check
Wiper stalk switch faulty other possible causes
Wiring faulty
No Wash Function or timed wash or BEM Related Check washer level warning jewel on
wipe after wash BEM output driver faulty cluster. If showing then add water to
BEM wash input faulty wahser bottle.
Washer bottle empty Using WDS monitor status of washer
No accessories supply to BEM switch (PID WASH_SW) when
Faulty wash motor activating switch. If not OK check
Faulty wiring voltage level at pin J3/10. If PID status
Faulty washer switch and voltage levels do not match, then
change BEM. If signal does not
change then check wiring. If OK then
Using WDS activate and deactivate
washer motor output (PID
WASH_SW). If no operation of washer
motor, check wiring and motor. If
wiring and motor OK then change
BEM.
Check other possible causes.
Power Windows not Working BEM related Go to Pinpoint test E

Faulty BEM power window supply Check other possible causes.
output
Wiring faulty
Power window switch faulty
Power window motor faulty
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Power windows do not time out 45 BEM related Go to Pinpoint Test E
seconds after door opened BEM power window supply output Go to pinpoint test M
faulty Check other possible causes
BEM door ajar inputs faulty
Faulty door ajar switch.
Wiring fault
Doors will not lock, Horn beeps BEM related Check if key in ignition
Door Ajar input faulty Check if transponder in vicinity of
Door open ignition
Ignition key in ignition lock. Check cluster door ajar indicator if not
Transponder in vicinity of ignition accurate then
Faulty Door actuator Go to pinpoint test M
Wiring fault Go to doors will not lock/unlock
Water ingress into connectors of door Check other possible causes
circuits.
Doors will not Lock/unlock BEM related Check all doors are closed
BEM door lock driver circuit faulty Using WDS ensure BEM is not in taxi
BEM door ajar inputs faulty mode. PID TAXI_MODE Byte 1 Bit 7
BEM door lock status input faulty should =0. If not then change status of
PCM mistakenly reports a crash (lock bit.
only) Check for DTC B1300. Action DTC’s
Remote key not trained Go to Pinpoint Test C
Remote key battery Flat Following test should be called up from
Poor range due to aftermarket window DTC chart:
tint Check door lock output status with
High local RF field. WDS (PID D_LCKO#)
Faulty door feedback circuit Monitor status of door lock feedback
Ignition turned on (PID DLOCK_ST) while activating
Blown Door Fuse locks manually.
Remote receiver fault Go to pinpoint test M
Wiring fault Go to Pinpoint Test F
Door lock motor fault Check other possible causes
ICC switch fault
Door Locks Change State randomly BEM related Using WDS check for DTC B1300.
Door lock feedback circuit faulty Action DTC
Door lock output faulty Check earth connections for door
Wiring fault (Ground shift). Turning on actuators, main battery to body earth
high current loads such as headlamps G1.
can cause the feedback reference at Refer to earth path, Door actuator to
pin J2/24 to move upwards. G2 or G3
ICC faulty Check other possible causes
No Response from Remote Keys all BEM related: Resynchronise keys.
Buttons Comms line with Receiver not Replace remote key battery if required.
working Retrain all keys.
Ignition and/or Accessories not Go to Pinpoint Test F
low at key off Go to Pinpoint Test D
Remote key not trained. Relocate vehicle and test remote keys.
Two remotes operating at the same
time
Remote key lost sychronisation.
Remote key battery Flat.(<3.2V)
Poor range due to aftermarket window
tint.
High local RF field
Remote Receiver not operating.
G43561 en 01/2003 2003.0 BA Falcon


Boot will not open using Instrument BEM Related: Press decklid switch, Ignition On.
Panel Switch Input to BEM faulty Monitor decklid switch status, PID
BEM output faulty DECKLIDOS#
Vehicle speed above 8km/h. If PID does not change state then
Vehicle Locked and Battery Saver check J1/9 goes low when boot
Timed out release pressed
Wiring faults Press decklid switch, Ignition On.
Switch fault. Monitor decklid output status, PID
Solenoid fault DECKLIDOS#
If PID does not change state Activate
PID DECKLIDOS#
Listen for activation of solenoid. If not
OK then test J3/7 with a test light to
ground press boot release switch a
short pulse should be observed.
Test solenoid and wiring to boot
solenoid.
Check other possible causes
Battery Saver Circuit Not Functioning BEM related: Cycle ignition switch. Does battery
Remote key will not turn on dome Incorrect Personalised settings. saver turn on? If not proceed as
lamp. Battery saver timed out. follows.
Faulty Battery Saver Output Use PID BATSAVRLY# to turn on
NOTE: The following functions will not battery saver
operate: Dome lamps, Glove box lamps, Blown Courtesy Fuse.
Go To Pinpoint Test H.
Boot lamp, Sunload/Twilight sensor, Power Fault in wiring
Antenna, Antenna amplifier, TILA Light Check other possible causes
Ring.
Dome lamp not functioning BEM Related: Go to Pinpoint Test I

Personalized settings incorrect Pinpoint test H
No 12 V Input at J3/6 Pinpoint test M and monitor dome
Low Side Driver Failure(J3/12) lamp operation
Door ajar input faulty Check other possible causes
Remote Receiver did not receive
unlock signal
Ignition On
Blown Globe
Dome lamp will not go out BEM Related: Press dome lamp button on ICC, if
Shorted Low Side Driver dome lamps do not turn off then
Faulty Wiring Test for shorts on J3/12 to dome
Can message not being received from lamps, check wiring from BEM to Light
ICC ring for shorts to ground.
Short circuit on TILA Select PID ILLENTRLY#, and monitor
status while pressing dome lamp
switch. If not changing state then
check ICC and CAN wiring. If PID is
changing state then check wiring. If
wiring OK then control PID
ILLENTRLY#. IF wiring OK, CAN
comms OK and PID will still not turn
off dome lamp then change BEM.
No Hazard Acknowledgment of BEM Related: Confirm other remote functions are
Remote Key BEM/receiver comms not operating correctly
operating With ignition on check the CAN
BEM not sending CAN message communication between BEM and
BEM CAN global wake up line cluster by opening and closing a door
faulty to check if door ajar status is correctly
Wiring fault (CAN line or Can wake up shown on cluster. If status is not
line faulty) correctly shown then check CAN
Faulty cluster wiring. If status is correctly shown then
Faulty receiver proceed
Leave car in ignition off status for more
than 2 minutes, then press remote key.
Check pin J2/21 (CAN global wake up)
goes low for 2 minutes after remote
key is pressed
G43561 en 01/2003 2003.0 BA Falcon


Low Washer Fluid not detected BEM related Monitor Washer Fluid level PID
Faulty washer fluid level input WFLUID Remove the lid from the
circuit washer bottle so that the switch
CAN comms not working closes. Did Status of PID change?
Wiring O/C A low should be present on J1/20.
Faulty Level switch Check earthing of switch.
Cluster fault Check BEM to cluster CAN comms by
opening and closing a door with the
ignition on. Cluster should indicate
door ajar status
Check other possible causes.
BEM does not have Accessories input. If 12V is not available at the BEM the Check the 10A fuse is not blown
(CCT297) following functions will be affected: Check wiring
No wash function If fuse OK and wiring OK then change
No intermittent wipe BEM
No power windows
No rear demist
No ICC operation
Fuse blown
Wiring fault
BEM input faulty
BEM Accessories line remains high at BEM related Remove all non standard accessories
key off resulting in Internal short on BEM and see if problem persists
No remote entry External wiring problem If problem persists without the
No battery saver function This fault is often due to the fitment of accessories then check wiring. If wiring
No boot release time out other accessories holding the OK then change the BEM
Rear demist time out not cancelled accessories line high. Audio amplifiers
or mobile phones can have high
supply line capacitance that keeps the
voltage high after key off
No Ignition input to BEM in ignition or BEM related Tila fault
start position resulting in Ignition input on BEM faulty Check fuse
No Headlamp failure chime Wiring fault Check wiring
Blown fuse Check TILA
No global can make up Using WDS check PID IGN_SW
correctly reflects ignition switch
position. If it does not and wiring and
fuse and TILA are OK then change
BEM.
No Clock illumination BEM related Check continuity between pins J1/1

Feedthrough circuit/s faulty and J4/12
Faulty cluster Check continuity between pins J1/2
Faulty wiring and J4/10
If continuity checks above are not OK
then change BEM. If they are OK then
check other possible causes.
Cannot Teach Transponder Keys BEM related Confirm correct procedure has been
Customer Key teach mode not used to enter transponder key teach
enabled mode
BEM/TILA communication circuit Using already trained key check that
faulty key out/dome on function works. If this
Faulty TILA does not work there is a problem with
Faulty wiring TILA/BEM system and al possible
Faulty transponder causes should be checked. If TILA,
Low Battery Voltage wiring, and transponder are OK then
change BEM
Headlamps do not go on when light BEM related Check other possible causes
level is low (dark conditions) with Low series BEM in a High series Using WDS control using PID
Ignition on and Auto Selected car. AUTOOUTST# to turn headlamps on
Twilight level settings incorrect and off (with headlamp switch in auto
No connection between J1/6, J2/1 and position). If this does not work then
the headlamp switch change BEM. If this works then
Faulty Headlamp switch Check twilight level settings using
Low series Headlamp switch fitted in WDS and interrogating PID
high series car ON_THOLD & OFF_THOLD. Adjust
Faulty twilight sensor these thresholds using block write $0F
Faulty wiring if required
G43561 en 01/2003 2003.0 BA Falcon


No Wipe on take off BEM related Using WDS Check for $D900 DTC.
Speed signal not received on This, in conjunction with PID
CAN from PCM PCM_MSG will indicate if there have
Faulty PCM been issues with CAN comms to PCM
Faulty CAN line Check other possible causes
Wipers do not Park in Off position BEM related Use WDS to determine if park switch
Wiper interface circuit on BEM is in parked position. PID
faulty WPRPRKSTS
Ignition turned off before wipers Test continuity between J3/1 and J3/2,
parked wiper off. Tests internal relay contacts.
Faulty wiper motors Test continuity between J3/2 and 28 of
Faulty park switch wiper switch
Test continuity between J3/1 and wiper
park switch
Inspect wiper park switch
Check Adjustment
Wipers do not operate in intermittent BEM related Do all tests in Wipers do not park in
mode Faulty wiper interface circuitry Off position, if ok proceed
Faulty wiper dwell pot input circuit Using WDS read wiper switch status
Wiper motor drivers not working PID WP_STAT by selecting each
Faulty wiper motor position with intermittent selected
Faulty wiper dwell pot Test wiring between J1/19 and wiper
Faulty wiring switch. Goes low when intermittent
selected
Check Wiper switch grounding
No Timed Wash Function or Wipe after BEM related If washer motor runs but no timed
Wash Wash input circuit faulty feature, check wiring between J3/10
Wiring fault and wiper switch (CCt 941)
Wiper switch fault Check 12 V available at J2/12 and
J1/10 with ignition on
No Headlamp Fail Chime BEM related Check headlamp switch is in auto

Ignition input circuit faulty position
CAN communication to cluster Check BEM communications to cluster
not working by opening and closing a door when
BEM thinks its in auto mode ignition is on and confirming the cluster
No Ignition Input to BEM is correctly displaying door ajar status
Cluster faulty Check other possible causes
Wiring faulty Test 12V available at J1/10 when in
Headlamp switch faulty ignition position, and 0V when ignition
is off
BEM
G43561 en 01/2003 2003.0 BA Falcon


J1/1 19J (BL/RD) De-energised: 0-2.2
Graphics illumination feed Energised: 8.0-12.0
Level: H
J1/2 14KC (BR) De-energised: 0-2.2
Park lamp Fuse Energised: 8.0-12.0
Level: H & L
J1/3 25 (GR/VLT) De-energised:
J6/2 Transceiver ground Energised: 12-1.0
Level: H & L
J6/3 23 (RD/YLW) De-energised: Less than 1.0
Transceiver Supply Energised: Greater than 10.0
Level: H & L
J1/5 57CP (BLK) De-energised: 0
Auto Headlamp relay ground Energised: 0
Level: H
J1/7 24 (BL/ORG) De-energised: <5.2
J6/1 Transceiver RX Data Energised: >11
Level: H & L
J1/8 340 (BLK/LT GR) De-energised: Data
J6/9 Transceiver TX Data Energised: Data
Level: H & L
J1/9 170 (RD) De-energised: <5.2
Boot/Tailgate release switch Energised: >11
Level: H & L
J1/10 16HB 16C (RD/GR) De-energised: <2.2
J6/5 BEM Tila Energised: >8.0
Level: H & L
J1/11 627 (BLK/ORG) De-energised: <5.2
Rear right hand passenger door Energised: >11
ajar switch Level: H & L
J1/12 630 (BLK/RD) De-energised: <5.2
Rear left hand passenger door ajar Energised: >11
switch Level: H & L
J1/13 629 (WHT/RD) De-energised: <5.2
Front passenger door ajar switch Energised: >11
Level: H & L
J1/14 628 (WHT) De-energised: <5.2
Front drivers door ajar switch Energised: >11
Level: H & L
J1/15 Digital spare 1 Level: Optional
J1/16 341 (ORG) Level: H & L, Optional
Digital spare 2
J1/17 26 (WHT) De-energised: <5.2
Boot/Tailgate ajar switch Energised: >11
Level: H & L
J1/18 234D (WHT/BLU) De-energised: <5.2
Twilight sensor PWM Energised: >11
Level: H
J1/19 590C (GR/WHT) De-energised: <5.2
Front intermittent wiper switch Energised: >11
Level: H & L
J1/20 82 (PNK/YLW) De-energised: <5.2
Washer fluid level switch Energised: >11
Level: H
G43561 en 01/2003 2003.0 BA Falcon


J2/1 2903A (ORG/RD) De-energised: <1.5
Auto headlamp relay plug 2 Energised: >11
Level: H
J2/2 Output spare 2 Level: Optional
J2/3 Output spare 1 Level: Optional
J2/4 1324 (BLK/LT GR) Level: H & L, Optional
Output spare 3
J2/5 Not used
J2/6 234E (BL/WHT) Level: H
Solar twilight sensor return
J2/7 Analogue spare return Level: Optional
J2/8 589 (ORG) Level: H & L
Variable intermittent wipe Pot rtn
J2/9 1A (BL) De-energised: <2
Horn relay Energised: >11
Level: H & L
J2/10 686 (VLT) De-energised: <2
Heated backlight relay Energised: >11
Level: H & L
J2/11 513 (BR) De-energised: <2
Power window relay Energised: >11
Level: H & L
J2/12 297B, 37F (BLK/YLW, YLW) De-energised: <2.2
J6/12 Accessories Energised: >8
Level: H & L
J2/13 914N (BR/YLW) De-energised: <3.0 min 2.0
J8/6 CAN data link high Energised: >3.0 max 4.5
Level: H & L
J2/14 914P (BR/YLW) De-energised: <3.0 min 2.0
CAN data link high Energised: >3.0 max 4.5
Level: H & L
J2/15 915N (PNK/BL) De-energised: <1.75
CAN data link low Energised: >2 max 3.0
Level: H & L
J2/16 915P (PNK/BL) De-energised: <1.75
CAN data link low Energised: >2 max 3.0
Level: H & L
J2/17 788 (RD/WHT) Level: H
Solar sensor link output
J2/18 Analogue spare 1
J2/19 993 (BR/WHT) Level: H & L
Variable intermittent wipe Pot
J2/20 Analogue spare 2
J2/21 489B (PNK/BLK) De-energised: Data
CAN global wakeup request Energised: Data
Level: H & L
J2/22 268 (BLK/ORG) De-energised: <2.0
Seat memory data Energised: >11.0
Level: H
J2/23 267 (BR) De-energised: <2.0
Seat memory enable Energised: >11.0
Level: H
G43561 en 01/2003 2003.0 BA Falcon


J2/24 122 (YLW) De-energised: <5.2
Driver central door lock status Energised: >11.0
Level: H & L
J3/1 8A (BLK/ORG) 2De-energised: <1.5
Front wiper park switch Energised: >3.5
Level: H & L
J3/2 28 (BLK/ORG) De-energised:>3.8
Front wiper motor Energised: <0.3
Level: H & L
J3/3 54B (GR/YLW) Level: H & L
Battery saver supply
J3/4 Tailgate/boot release option De-energised: open
Energised: >11.7
Level: Optional
J3/5 Spare Level: Optional
J3/6 55B (BLK/PNK) Energised: 12.0
Courtesy lamp fuse Level: H & L
J3/7 84 (VLT) De-energised: open
Boot/Tailgate release solenoid Energised: >11.7
Level: H & L
J3/8 Spare Level: Optional
J3/9 1329 (YLW) De-energised: <0.3
Drivers door unlock motor Energised: >11.7
Level: H & L
J3/10 941B (GRY/BLK) De-energised: <5.2
Front wash motor switch Energised: >11.0
Level: H & L
J3/11 38BA (YLW/BLK) Level: H & L
BEM battery fuse
J3/12 53G/53D (BLK/BL) De-energised: <1.5
J6/10 Courtesy lamp transceiver return Energised: >11.0
Level: H & L
J4/1 C11 (GR/WHT) Level: H & L
J9/1 RF receiver supply
J4/2 C8 (RD/WHT) De-energised: <5.2
J9/4 RF receiver data Energised: >11.0
Level: H & L
J4/3 C9 (GRY) De-energised: <0.5
J9/3 RF receiver polling Energised: >11.7
Level: H & L
J4/4 C10 (BL/WHT) De-energised: 0
J9/2 RF receiver return Level: H & L
J4/5 C1 (YLW/BLK) Level: H
Analogue clock supply
J4/6 C2 (BLK/LT. GR) De-energised: 0
Analogue clock return Level: H
J4/7 C6 (GR) De-energised: <1.5
J10/3 Cabin temperature sensor fan Energised: >11.0
supply Level: H
J4/8 C4 (WHT) Level: H
J10/1 Cabin temperature sensor
thermistor
J4/9 C5 (BL) Level: H
J10/2 Cabin temperature sensor return
G43561 en 01/2003 2003.0 BA Falcon


J4/10 14 (BR) Level: H
Analogue clock supply
J4/11 C7 (YLW) De-energised: 0
J10/4 Cabin temperature sensor fan Level: H
return
J4/12 C3 (BLK) De-energised: 0
Analogue clock illumination return Level: H
J5/1 118A (RD/YLW) De-energised: <0.3
Central door unlock motor Energised: >11.7
Level: H & L
J5/2 117A (YLW/BLK) De-energised: <0.3
Central door lock motor Energised: >11.7
Level: H & L
J5/3 134 (WHT) Energised: 12.0
Central door locking fuse Level: H & L
J5/4 57CN (BLK) De-energised: 0
High current ground Level: H & L
TILA 16 pin connector

J6/1 (BLK/Lt GR)
TILA Receive
J6/2 (BLK)
TILA Ground
J6/3 (RD/YLW)
TILA Supply
J6/4 (YLW)
Battery ignition circuit
J6/5 (RD/GR)
Ignition circuit
J6/6 (BLK)
Ground
J6/7 (YLW)
Pedal circuit Battery +
J6/8 (LT BL/ORG)
Pedal circuit motor -
J6/9 (DK GR/VLT)
TILA Transmit
J6/10 (BLK/BL)
Illumination return
J6/11 (VLT/WHT)
Brake fail circuit
G43561 en 01/2003 2003.0 BA Falcon


J6/12 (WHT)
Accesory
J6/13 (RD/BL)
Start circuit
J6/14 NC
J6/15 (BLK)
Pedal circuit ground
J6/16 (LT BL/BLK)
Pedal circuit Motor +
TILA 8 pin connector

J7/1 (YLW)
Pedal Circuit battery +
J7/3 (BLK)
Pedal circuit ground
J7/6 (LT BL/BLK)
Pedal circuit motor +
J7/8 (LT BL/ORG)
Pedal circuit motor -
Pinpoint Tests
PINPOINT TEST A : COURTESY LAMP DRIVER TEST
A1
Using WDS operate courtesy lamp drivers and monitor pin J3/12. Yes
Return to sympton chart for next steps
Is pin low when drivers activated and high otherwise?
No
Go to A2
A2
Check wiring to pin J3/12. Is wiring OK? Yes
Replace BEM
No
Fix wiring
G43561 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : HEATED BACKLIGHT TEST
B1
Using WDS monitor (BACKL_SW) when pressing ICC backlite switch. Yes
Go to B2
Is input OK?
No
Check other probable causes on symptom chart.
B2
Turn on demist relay using WDS (HEAT_BCK) Yes

Check other probable causes on symptom chart.
Check voltage at pin J2/10 is 0V.
No
Turn demist relay off using WDS. Go to B3
Check voltage at pin J2/10 is 12V.
Are results OK?
B3
Check wiring to pin J2/10 Yes

Replace BEM
Is wiring OK?
No
Fix wiring
PINPOINT TEST C : IGNITION SWITCH VOLTAGE LEVELS
C1
Does Battery Accessory and Ignition and ground have Yes
appropriate voltage levels when key in relevant ignition position? Return to symptom chart
No
Check TILA and wiring
PINPOINT TEST D : IGNITION AND ACCESSORY LOW AT KEY OFF
D1
Does ignition and Accessories go low at Ignition Off? Yes
Return to symptom chart
No
Check TILA and wiring
PINPOINT TEST E : POWER WINDOW SUPPLY
E1
Activate and deactivate BEM power window supply (PID WIND_OS#) Yes
Go to symptom chart.
Is the measured output voltage J2/11 as expected? No

Go to E2
G43561 en 01/2003 2003.0 BA Falcon


E2
Is wiring to pin J2/11 OK? Yes
Change BEM
No
Fix wiring
PINPOINT TEST F : REMOTE RECEIVER OPERATION

F1
Connect WDS. Yes

Go to symptom chart
Monitor status of PID TNSMT_CMD while pressing different buttons
on remote key. No
Go to F2
Does PID status reflect last button pressed ?
F2
Take known good remote key and try and train it to the car Yes
Original remote key was faulty. Replace original
Does BEM acknowledge receipt of key press as part of training remote key.
procedure?
No
Go to F3
F3
Change receiver and take known good remote key and try and train it Yes
to the car Original receiver was faulty.
Does BEM acknowledge receipt of key press as part of training

No
Replace BEM and repeat step F2. If still
procedure?
unsuccessful then replace ICC (Internal ICC
wiring fault).
PINPOINT TEST G : DOOR LOCK INPUT
G1
Monitor voltage at pin J2/24 while locking and unlocking the drivers Yes
door. Return to symptom chart
Is voltage 0V when door unlocked and 12V when door locked? No

Check wiring and door lock feedback on motor.
PINPOINT TEST H : BATTERY SAVER CIRCUIT NOT FUNCTIONING
H1
Ensure glovebox globe is present and operational Yes

Battery saver circuit operating correctly. Return
Activate PID BATTSAVRLY# command with Glove Box Door open to symptom chart.
Does glove box lamp illuminate? No
Go to H2
G43561 en 01/2003 2003.0 BA Falcon


H2
Using WDS activate and deactivate battery saver and monitor pin Yes
J3/3. Return to symptom chart.
Is voltage output as expected? No

Go to H3
H3
Check wiring to pin J3/3. Is wiring OK? Yes
Replace BEM
No
Fix wiring
PINPOINT TEST I : DOME LAMP NOT FUNCTIONING
I1
Turn off ignition. Yes

Dome lamp operating correctly.
Monitor Personalizes settings TAXI_MODE, PANIC_ALR,
DTRIG_MOD, MDT_MOD, HAZ_WARN, HORN_WARN, BAT_SAV, No
COURTESY. Go to I2
Test 12V available on J3/3. Operate Dome switch on ICC.
Does Dome lamp operate?
I2
Select PID LR_AJAR, RR_AJAR Yes

Return to symptom chart
Did dome lamp turn on?
No
Ground J3/12, Go to I3
I3
Does dome lamp light? Yes
BEM fault
No
Wiring fault
PINPOINT TEST J : NO DEMIST FUNCTION
J1
Are DTC’s B1348 and B1349 present? Yes
Follow fault finding chart for these codes
No
Go to J2
G43561 en 01/2003 2003.0 BA Falcon


J2
Check radio fuse 7.5A is not blown. Yes

Return to symptom chart.
Check backlight fuse 40A is not blown.
No
Test heater element continuity. Check CAN communications.
Test element earth point.
Using PID BACKL_SW check status of heated backlight switch and
status of output driver when switch operated with ignition on (PID
HEAT_BCK#).
Is the backlight status available?
PINPOINT TEST K : NO WASH FUNCTION

K1
Ground J3/10. Yes

Fault is in the wiring or wiper switch.
Does washer motor run?
No
Go to K2
K2
Confirm 12V is supplied to washer motor? Yes
Go to K3
No
Check wiper fuse. If wiper fuse blown or
missing, then replace. If fuse OK then check
wiring.
K3
Using WDS control BEM washer motor output activate. PID Yes
WASHPUMP#. Return to symptom chart.
Monitor pin J3/10. Is pin 0V when output is activated and 12V No

otherwise? Check wiring. If wiring OK then change BEM.
PINPOINT TEST L : POWER WINDOWS NOT WORKING
L1
Connect WDS. Yes

Is the status of the power window relay with the ignition turned
on OK? No
Test for 12 v output from the power window
relay pin J2/11, check fuses.
G43561 en 01/2003 2003.0 BA Falcon

PINPOINT TEST M : DOOR AJAR INPUT TEST
M1
Check Door ajar status with WDS (PID LR_AJAR, RR_AJAR, Yes
LF_AJAR, RF_AJAR) while opening and shutting doors. Return to symptom chart.
Does PID reflect door ajar status? No

Go to M2
M2
Check voltage at following pins and compare to PIDs bits as follows: Yes
J1/14 - Drivers door - RF_AJAR
J1/11 - Rear right - RR_AJAR No
Go to M3
J1/12 - Rear left - LR_AJAR
J1/13 - Front left - LF_AJAR
Does PID status reflect voltage levels?
M3
Is wiring to relevant pins OK? Yes
Change BEM.
No
Fix wiring.
PINPOINT TEST N : DOOR LOCK OUTPUT TEST
N1
Ensure fuses and wiring are not faulty. Yes

Control door lock output status with WDS (PID D_LCKO#).
No
Does this reflect soldier button requested position? Go to N2
N2
Monitor voltage level at pins J5/2, J5/1 and J3/9 while locking and Yes
unlocking doors with WDS. Return to symptom chart
Unlock all doors: J5/2 = 12V, J5/1 = 0V, J3/9 =0V. Note that 12V No
will only be supplied for 800ms. If fuses and wiring and motors have been
Lock all doors:J5/2 = 12V, J5/1 = 0V, J3/9 =0V. Note that 12V checked to be OK then replace the BEM.
will only be supplied for 800ms.
Are voltage levels as expected?
G43561 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
6. To exit at any time turn the ignition off for longer

Remote Key Teaching than 10 seconds.
1. Have all remote keys to be taught to the system 7. Next perform a parameter reset to reteach the
available for this session. PCM ID to the BEM.
2. Turn the ignition switch to the accessories Customer DST Ignition Key Teach
position, within 5 seconds, press the demist
button 3 times, teach mode is acknowledged by NOTE: PCM ID is not disturbed in this teach mode.
the door locks changing state. i.e. lock to unlock
or unlock to lock. When teach mode is entered all 1. The customer must have 2 valid keys that are
recognised by the BEM.
remote key codes stored in memory will be
erased. 2. It is recommended that the customer sit in the
3. Once key teach mode has been entered, vehicle with the doors closed.
immediately press any button on the remote key. 3. Place the first key in the ignition and turn to
If the BEM learns the key, the doors locks will accessories position turn to off and remove key.
change state. 4. Within 5 seconds place the second key into the
4. Select the next remote key to be taught, again ignition and turn to the ignition position. At this
press any button, and wait for the doors locks to point the door locks will state to indicate learn
change state. Repeat this procedure until all keys mode is entered.
are taught (up to 8 keys may be taught). 5. To teach a new key insert the new key within 5
NOTE: High series seat memory data is only seconds and turn to the ignition position, if
designed to work on two remote keys. successful an acknowledgment will be received.
5. To exit mode, turn key to off or ignition on. The Lost Keys
door locks will cycle to indicate the mode has
been terminated. If the ignition key is moved from NOTE: It is recommended that the vehicle be taken to
the accessories position during key teach the the dealer if keys are lost. The lost keys can be
session will be terminated. erased from the BEM and new keys taught.
Receiver Resynchronization Customer Key Erasure

1. If a remote key is out of synchronization it may be NOTE: This procedure can only be used if more than
resynchronized by transmitting with a valid key to 2 keys have been programmed to the BEM.
the BEM then within 30 seconds transmit with the
key to be resynchronized. NOTE: The two keys used to enter teach mode will
not be erased.
Dealer DST Ignition Key Teach Mode 1. Enter Customer key teach mode and when
NOTE: This mode is used by dealers to teach DST acknowledgment is received.
keys to new P & BEM or for general DST key erasing 2. Place the second key used to enter teach mode in
and teaching. Entering Dealer key teach mode will the ignition lock and turn to the ignition on
also erase the PCM ID in the BEM. On completion of position, then off and remove, followed by the first
the key teach the PCM will be prompted to perform a key which must also be turned to the ignition on
parameter reset. It is recommended that the dealer be position then removed. The BEM will perform two
seated in the vehicle with the doors closed. acknowledgments.
1. Starting with the key in the ignition position, turn 3. All other keys are erased. Leaving the ignition off
the ignition to the off position. for longer than 10 seconds will exit the mode and
an acknowledgment will be received.
2. Within 2 minutes of turning the key to the off
position enter dealer key teach mode using the PCM Parameter Reset
WDS.
3. When the dealer key teach mode is entered the NOTE: Parameter reset is used whenever a BEM or
PCM ID is erased, an acknowledgment will be PCM is replaced or Dealer key teach is used. The
received. Place the first DST ignition key to be WDS Diagnostic tool is used to perform this function.
taught in the ignition switch and turn to ignition on, See also Changing a BEM.
an acknowledgement will be received if teach is
successful. Cabin Temperature Sensor Calibration
4. Turn the key to off and remove the DST key. Factor
5. Place the next key in the ignition and turn to on, 1. Whenever a cabin Temperature sensor, ICC or
when the second key is taught 2 BEM is replaced the CTS calibration factor needs
acknowledgments will be received and so on. Up to be taught to the BEM.
to 8 keys may be taught in this way.
G43562 en 01/2003 2003.0 BA Falcon

2. The CTS mounted on the ICC has a barcode

sticker attached to it which has the letters CTS
followed by the calibration factor. This calibration
number should be loaded to the BEM using a
WDS service tool. If the sticker is missing then
ring ’OASIS’ hotline.
3. If a BEM is being replaced, the CTS calibration
factor can be read from the original BEM by the
WDS. Select "Module Programming" and
"Programmable Parameters" - "Climate Control".
It can then be automatically down loaded into the
new BEM using "Module Installation" - "BEM" or
manually by entering "Module Programming" and
"Programmable Parameters" - "Climate Control"
and selecting the correct value.
Changing BEM
Whenever a BEM is to be replaced the following steps
need to be done. Read and record the following
values.
1. Cabin Temperature Sensor Calibration Factor
(high series vehicle)
2. Body Type
3. Battery saver/ interior lamp operation
(police/taxi/normal/etc)
4. Twilight settings (high series vehicle)
When the new BEM is installed using WDS and
"Module Installation" the above setting along with
stored remote pad values should be automatically
entered into the new BEM.
If the data is unable to be recovered from the existing
BEM then the data and values will need to be
manually entered.
In a separate operation WDS will be required to teach
a minimum of two ignition keys to the new BEM and a
parameter reset before the vehicle can be started.
G43570 en 01/2003 2003.0 BA Falcon

The BEM and Remote Receiver

The BEM and Remote Receiver are attached to the
ICC. Therefore, please refer to the ICC in Section
413-08 for removal and installation instructions.
G43571 en 01/2003 2003.0 BA Falcon

SECTION : 501-00 Body System - General

Information
VEHICLE APPLICATION :2003.0 BA Falcon
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-00-2
Body .......................................................................................................................................501-00-3
Body System ........................................................................................................................501-00-3
Insulation ..............................................................................................................................501-00-3
Body Sealer Type and Application .......................................................................................501-00-3
Body System ..........................................................................................................................501-00-4
Symptom Chart ....................................................................................................................501-00-4
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives

Item Specification
Butyl sealer, fluid C9AZ-19554B ESB-M4G162-A
Caulking strip D6AZ-19560-A ESB-M4G32-A
Rubber seal adhesive E8AZ-19552-A ESB-M2G14-A
Silicone grease C0AZ-19553-AA ESR-M13P4-A
G86726 en 01/2003 2003.0 BA Falcon

Body Exterior Vinyl Sealer

After a new panel has been prepared for painting and
Body System prime coat has been applied, areas such as the inner
The body shell structure consists of the following edge of the hem flange and door frame must be
features: sealed with a seam sealer.
front section side members have set deformation NOTE: A polyurethane adhesive such as Sikaflex 255
zones for collision. or equivalent is suitable and may be used.
transverse reinforcement at the bulkhead. Corrosion Protection Materials
all sheet metal surfaces prone to corrosion are
galvanized. Use locally purchesed weld through primers and
corrosion protection materials for all body work.
bolted, removable front fenders.
Insulation
Insulation is composed of urethane, PVC, foam and
recycled felt. Insulation is installed:
above and below the instrument panel,
at the cowl side panels,
over the front floor pan and rear floor pan areas,
over the luggage compartment floor.
Body Sealer Type and Application
Interweld Sealer
Hot applied heat expanding weldable sealer is now
used in all seam joints throughout the body structure.
This material is not suitable for in field use.
When fitting replacement panels, all mating surfaces
are to be cleaned of this sealant and the cleaned
surfaces painted with zinc rich primer (weld through
primer). The edges of seams should be closed by a
sealer, applied after the primer coat and before the
undercoat.
Expanding Sealers/Adhesives
There are a number of areas in the body structure
where an expanfing sealer is used to exclude dust
and moisture from inside the struture.
This material is formulated to foam up and expand
when heat is applied. When fitting a new panel or
section of a panel where an expanding sealer is
located and welding is to take place, all sealant must
be removed for at least 50mm each side of the area
to be welded prior to final fit up of the replacement
panel and the exposed surface primed with a zinc rich
primer.
Structural Composite Foam

This material is deposited in the areas shown in
section 5 during vehicle maintenance. It is formulated
to expand and solidify with the application of heat.
The material is not serviced for in field service use.
G86727 en 01/2003 2003.0 BA Falcon

Body System
system. the symptom and refer to the Symptom
or electrical damage.
4. If the concern is not visually evident, verify the
symptom and refer to the Symptom Chart.
Mechanical
Dust Leaks
Water Leaks
Symptom Chart

Dust Leaks Displaced sealer. Refer to the service procedure below.
Damaged body parts. Refer to the service procedure below.
Missing underbody grommets. Refer to the service procedure below.
Misaligned doors. Refer to the service procedure below.
Misaligned glass. Refer to the service procedure below.
Water Leaks Displaced sealer. Refer to the service procedure below.
Damaged body parts. Refer to the service procedure below.
Missing underbody grommets. Refer to the service procedure below.
Misaligned doors. Refer to the service procedure below.
Misaligned glass. Refer to the service procedure below.

Sealer locations should be considered when checking Spare tire
for dust or water leaks. The forward motion of the Roof opening panel.
vehicle causes any unsealed small opening in the
After removing the trim panel(s), the location of most
lower section of the body to permit air and dust to be
drawn into the body. Opening the ventilator air ducts leaks will be evident. The entrance of dust is usually
indicated by a point of dust or silt. Seal these leaks,
will equalise these pressures. Dust accumulates in the
then road test the vehicle on a dusty road to ensure
luggage compartment body opening and may move
into the luggage compartment. all leaks are sealed. A suitable Leak Detector can
locate dust leaks, wind and water leaks.
To eliminate dust leakage, determine the exact point
After the road test, check for indications of a dust
at which the dust enters. Under certain conditions,
water may also enter the body at any point where pattern around the door openings, cowl side trim
panel, lower part of the quater panel and in the
dust can enter.
luggage compartment.
To determine the exact location of a dust leak, it may
be necessary to remove the following trim panels from Sometimes leaks can be located by putting bright
lights under the vehicle, with the above components
the vehicle:
removed, and checking the interior of the body joints
Scuff plate. Section 501-05 and weld lines. A light will show through where leaks
C - Pillar trim. Section 501-05 exist.
Rear seat backrest and frame, and rear seat
cushion and frame. Section 501-10
Luggage compartment floor covering
G86728 en 01/2003 2003.0 BA Falcon

501-02-1 Front End Body Panels 501-02-1
SECTION : 501-02 Front End Body Panels

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-02-2
Front End Body Panels .........................................................................................................501-02-3
GENERAL PROCEDURES
Hood Alignment ....................................................................................................................501-02-4
Fender Alignment ..................................................................................................................501-02-4
Air Deflector ..........................................................................................................................501-02-7
Fender Splash Shield ............................................................................................................501-02-7
Cowl Panel Grille ..................................................................................................................501-02-7
Fender ...................................................................................................................................501-02-8
Modestry Panel .....................................................................................................................501-02-8
Hood Prop .............................................................................................................................501-02-8
Hood/Hood Hinge .................................................................................................................501-02-9
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Cowl grille screws 3
Fender bolts 10
Fender splash shield bolts 12
Air deflector 4.5
Hood hinge to dash panel bolts 30
Hood hinge to hood bolts 30
Wiper pivot arm nuts —
G36750 en 01/2003 2003.0 BA Falcon

Front End Body Panels

The front end body panel components consist of the
following:
air deflectors
cowl grille
fenders
fender splash shields
hood
hood hinges
hood prop
G36751 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Hood Alignment Fender Alignment

1. The hood is provided with fore and aft adjustment. 1. Loosen the fender retaining bolts.
These directions refer to the position of the hood
when it is fully lowered. Slots in the hinge provide
fore and aft adjustment.
1. Raise the hood.
2. Adjust the hood bumpers by screwing them in
or out of the panel to prevent over slam and
hood movement.
NOTE: The fenders are set relative to the hood latch

mounting point on the upper cross member during
body assembly. There is no hood latch adjustment
vertically or right to left. If vehicle damage results in a
need to reset the hood margins then the fenders
should be adjusted relative to the hood.
G36752 en 01/2003 2003.0 BA Falcon

Fender to Bumper
2. Adjust the fender to obtain hood/door margins as

shown below (Alignment Diagrams).
Fender to Bumper
Fender Margins
Item Description Fender to Lower Body Panel

1 Fender to Hood
2 Fender to Bumper
3 Fender to Bumper
4 Fender to Lower Body Panel
5 Side Repeater Lamp to Fender
Fender to Hood
G36752 en 01/2003 2003.0 BA Falcon

Side Repeater Lamp to Fender
3. Tighten the fender bolts to the specified torque.

4. Verfy alignment and repeat procedure if
necessary.
G36752 en 01/2003 2003.0 BA Falcon

Air Deflector 3. Remove the fender splash shield. Remove the

retaining scrivets (10 x 6mm), screws and firtree
Removal clips.
1. Remove the 10 attaching screws and 2 plastic NOTE: There are a total of 2 screws attaching the
push-in rivets. front lower section of the splashshield.
NOTE: Adjust torque specifications at the front of
the document.
Item Description
1 Lower Radiator Deflector Assembly
2 Screw Item Description
3 Scrivet 1 Fender Splash Shield
4 Front Bumper Assembly 2 Firtree clip 6.5x25mm (2 off)
2. Slide the deflector rearwards. 3 Scrivets - 6mm (10 off)
Installation 4 Screw - 5mm (1 off)
1. To install, reverse the removal procedure. 5 Screw - 5mm (2 off)
Installation
Fender Splash Shield
Removal
Cowl Panel Grille
information, refer to Section 100-02. Removal
2. Remove the wheel and tire. For additional 1. Remove the wiper front pivot arms. For additional
information, refer to Section 204-04. information refer to, Section 501-16.
2. Remove the 5 retaining scrivets.
G36756 en 01/2003 2003.0 BA Falcon

3. Remove the LH cowl grille. 6. Remove 4 remaining bolts as shown. For

Item Description
Item Description
1 Scrivet
1 Bolt
2 LH Cowl Grill Assembly
2 Front Fender
4. Remove the RH cowl grille.
NOTE: Front fender bolt is removed during headlight
removal process.
Installation
Modestry Panel
Removal
1. Remove the grille. For additional information, refer
to Section 501-08.
2. Remove the 2 retaining scrivets and release the
retaining legs from the metal bracket below the
modestry panel.
Item Description
1 Scrivet
2 RH Cowl Grill Assembly
Installation
Fender
Removal
1. Remove wheels. For additional information, refer
to Section 200-04.
2. Remove splashshield. For additional information,
3. Remove the modesty panel.
Installation
3. Remove side indicator lamp. For additional
information, refer to Section 417-01. 1. To install, reverse the removal procedure.
4. Remove front bumper. For additional information, Hood Prop
5. Remove headlamp. For additional information, Removal
refer to Section 417-01. 1. Raise hood and support it.
2. Pry the prop the retaining clips from the ball
retainers using small screw driver.
G36756 en 01/2003 2003.0 BA Falcon

3. Remove prop from vehicle.
Item Description
Installation
1. Install spring clips to ball retainers. 1 Hinge
2 Bolt
2. Snap ball retainers onto ball studs. Check
operation. Installation
Hood/Hood Hinge 1. Reverse the removal procedure. Care must taken
when aligning hinge to hood prop/s to tighten
Removal attaching the bolts.
1. Open hood and suport hood in the open position.
2. Fit fender covers.
3. Remove the hood props.
4. Scribe around hinge and remove hinge retaining
bolts, remove hood from vehicle.
Item Description
1 Hinge
2 Bolt
3 Hood
G36760 en 01/2003 2003.0 BA Falcon

501-03-1 Body Closures 501-03-1
SECTION : 501-03 Body Closures

CONTENTS PAGE
Door Windlace ......................................................................................................................501-03-2
Weatherstrip Front and Rear Doors ......................................................................................501-03-3
Decklid Weatherstrip .............................................................................................................501-03-4
Liftgate Weatherstrip .............................................................................................................501-03-4
Roof Side Rail - Sedan .........................................................................................................501-03-4
Roof Side Rail — Wagon ......................................................................................................501-03-6
Dash Panel Upper Seal ........................................................................................................501-03-6
Hood Inner Seal ....................................................................................................................501-03-6
Front Door Beltline Outer ......................................................................................................501-03-7
Rear Door Beltline Outer ......................................................................................................501-03-7
Rear Door Beltline Inner .......................................................................................................501-03-7
Rear Door Beltline Inner .......................................................................................................501-03-7
B Pillar Aplique ......................................................................................................................501-03-8
Rocker Margin Seal ..............................................................................................................501-03-8
Weatherstrip Door Outer — Ute ...........................................................................................501-03-8
Exterior — Ute ......................................................................................................................501-03-8
Front Door Glass Run ...........................................................................................................501-03-9
Rear Door Glass Run ...........................................................................................................501-03-9
01/2003 2003.0 BA Falcon

501-03-2 Body Closures 501-03-2
Door Windlace
1. The door opening weatherstrip is a roll on fit,
attaching to the body pinch weld flange. Refer to
illustration for assembly start and finish point
locations.
Installation Repeat B pillar corner process on A pillar corner

1. Fit windlace starting at bottom of B pillar pushing finish fitting windlace down A pillar.
down B pilar until windlace will not go down any Check and smooth out any bumps in windlace
further. Then roll up B pillar fitting over flange as fitment using crimping tool to crimp windlace in B
you go. pillar corner.
Roll around B pillar corner making sure windlace
fits up tight into corner but does not sit up high on
style line.
Continue rolling along header.
G80840 en 01/2003 2003.0 BA Falcon

501-03-3 Body Closures 501-03-3
Weatherstrip Front and Rear Doors Rear Door

Removal
Front Door
NOTE: The weatherstrips are attached to the doors

via a retaining channel above beltline and by push fit
fasteners below beltline.
Above Beltline
1. Remove at corner cup, pull w/strip to remove from
door retainer recess.
Below Beltline
1. Grasp the weatherstrip beside fastener and pull,
stretch and lift the weatherstrip to detach it from
the end of the fastener. Slide the weatherstrip in
the opposite direction to disengage from the other
end of the fastener.
2. Using a pair of pliers firmly grasp the fastener and
pull from the door panel. Fasteners must be
renewed after removal.
Installation
Above Beltline
1. Affix top corner clip and first clip on A-and B-pillar.
2. Sit lower edge of weatherstrip base in to retainer
and then, push upper edge of base into retainer.
Below Beltline
1. Assemble the fasteners to the weatherstrip and
install to the door panel. Ensure the fasteners are
fully seated.
G80840 en 01/2003 2003.0 BA Falcon

501-03-4 Body Closures 501-03-4
Decklid Weatherstrip Liftgate Weatherstrip

Removal Removal
1. Remove Decklid Weatherstrip as shown in figure. 1. Remove liftgate weatherstrip as shown in figure.
Installation
NOTE: Vulcanised joint to be on centre line.
Yellow dot signifies centre line near latch.
A rubber moller may be used to assist installation.
Roof Side Rail - Sedan

Removal
1. Remove flange from fitting along complete length,
except…
2. At sequence Z, unclip flange.
3. At sequence Y, remove adhesive from ditch
moulding on underside edge of top of
weatherstrip.
Installation
1. Reverse removal procedure
NOTE: The weatherstrip must be positioned with
the trim panel lip on the inboard side of the body
flange and covering the trim panel. Vulcanised
joint to be on centre line near latch. Fully insert
the weatherstrip onto the flange.
A rubber moller may be used to assist installation.
G80840 en 01/2003 2003.0 BA Falcon

501-03-5 Body Closures 501-03-5
Installation
G80844 en 01/2003 2003.0 BA Falcon

501-03-6 Body Closures 501-03-6
2. At sequence Z, unclip flange.

Roof Side Rail — Wagon
3. At sequence Y, align weatherstrip to corner.
Removal
1. Remove flange from fitting along complete length,
except…
1. Reverse removal procedure. 1. Reverse removal procedure.
Dash Panel Upper Seal NOTE: Trim panel to be facing towards front of
vehicle.
Removal
1. Remove dash panel weatherstrip as shown in Hood Inner Seal
figure. Removal
1. Remove hood inner weatherstrip as shown in
figure.
G80844 en 01/2003 2003.0 BA Falcon

501-03-7 Body Closures 501-03-7
Installation Front Door Beltline Inner

NOTE: "Yellow" ID dot on right end of seal. Removal
1. Remove front door beltline inner weatherstrip as
Front Door Beltline Outer shown in figure.
Removal
1. Remove front door beltline outer weatherstrip as
shown in figure.
Installation
NOTE: Part must be fully seated onto flange.
Installation Rear Door Beltline Inner

NOTE: Item 1 must click into door panel to ensure Removal
clips are fully seated. 1. Remove rear door beltline inner weatherstrip as
shown in figure.
Rear Door Beltline Outer
Removal
1. Remove rear door beltline outer weatherstrip as
shown in figure.
Installation
NOTE: Part must be fully seated onto flange.
Weatherstrip angle cut to rear.
Installation
NOTE: Item 1 must click into door panel to ensure
clips are fully seated.
G80849 en 01/2003 2003.0 BA Falcon

501-03-8 Body Closures 501-03-8
B Pillar Aplique Weatherstrip Door Outer — Ute

Removal Removal
1. Applique to be pulled off at clip. 1. Remove door outer weatherstrip as shown in
figure.
2. Remove remaining tape.

3. Use thinners to remove remaining tape off
vehicle.
Installation
1. Applique to be clipped in at front.
2. Applique to be pushed forward on door steel.
3. Tape pushed down to adhere to sheet steel.
Rocker Margin Seal

Removal
1. Remove rocker margin seal weatherstrip as
shown in figure.
Installation
Exterior — Ute
Removal
1. Remove exterior weatherstrip as shown in figure.
Installation
Installation
G80849 en 01/2003 2003.0 BA Falcon

501-03-9 Body Closures 501-03-9
Front Door Glass Run Rear Door Glass Run

Removal Removal
NOTE: To aid installation, lubricate the corner NOTE: To aid installation, lubricate the corner
mouldings lightly with water based lubricant (eg tyre mouldings lightly with water based lubricant (eg tyre
lube, KY). Do not use petroleum based lubricants. lube, KY). Do not use petroleum-based lubricants.
NOTE: The B pillar corner is the alignment datum for NOTE: For the rear door, the division bar corner is the
the front door Glass Run Weatherstrip. alignment datum.
1. Fit the B pillar corner moulding first and the 1. Fit the division bar corner first. Use the top bar
adjacent 100mm of the top bar. Use the adjacent extrusions to position the lightly lubricated corner
extrusions to position the corner mould. mould.
2. Refer to Fig. 9. Assemble the B pillar extrusion 2. Work forward along the top bar towards the B
with an even gap all the way down for later fitment pillar corner. Fit the B pillar corner again using the
of the B pillar applique. adjacent extrusions to position the corner mould.
3. Fit the A pillar corner. Again use the extrusion to 3. Refer Fig. 9. Assemble the B pillar extrusion with
position the lubricated corner. an even gap all the way down for later fitment of
4. Assemble the remainder of the top bar extrusion. the B pillar applique.
5. Assemble the A pillar extrusion. 4. Fit the division bar extrusion.
NOTE: Assembly of the top bar section to the NOTE: Assembly of the top bar section to the
door upper requires the outer lip to be pushed in door upper requires the outer lip to be pushed in
first before the inner lip can be pushed home. first before the inner lip can be pushed home.
(This also applies to the vertical A pillar and B (This also applies to the vertical A pillar and B
pillar extrusions). pillar extrusions).
G80853 en 01/2003 2003.0 BA Falcon

501-04-1 Pickup Bed and Platform Body 501-04-1
SECTION : 501-04 Pickup Bed and Platform Body

CONTENTS PAGE
GENERAL PROCEDURES
Hoisting the vehicle ................................................................................................................501-04-2
Pickup Box .............................................................................................................................501-04-3
Aluminium Tray ......................................................................................................................501-04-5
01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Hoisting the vehicle

Hoisting Area - Ute Rear
Item Description
1 Hoisting area pad
2 Hoist arm
CAUTION: When Hoisting the vehicle the

unitized body-frame construction requires special
precautions and procedures when the vehicle is
jacked up or hoisted. In some cases, special hoist
adapters must be used as recommended by
specific hoist manufacturers. Refer to the Owner’s
Manuals when using the jack supplied with the
car.
CAUTION: Drive-on Type Hoist

To prevent possible damages to the underbody,
do not drive the vehicle on to any type hoist
without first checking for possible interference
between the upright flanges of the hoist rails and
the underbody. Should there be interference, the
hoist flanges should be modified as necessary
and/or the approach ramps built up to provide the
needed clearance.
CAUTION: Adapters
Front and rear adapters to hoist plates must be
carefully positioned in contact with the side rail to
ensure safe, accurate lifting.
CAUTION: Trolley Jack

When a trolley jack is used it is to be located in
the same position as for hoist lifting.
G34530 en 01/2003 2003.0 BA Falcon

Pickup Box 10. Remove eight bolts (Item 1 ) retaining the box to
the chassis through floor cross members.
Removal
1. Remove tonneau cover.
2. Remove twelve M6 Bolts retaining bedliner load
tiedown brackets (Only 6 LH side ones shown).
11. Attach overhead lifting device by the means of

four equally spaced hooks located under the top
rail section at the position shown. Two on R/H
side of box and two on L/H of box.
3. Remove four screws retaining bedliner along the WARNING: The inner angle section
rearsection in tailgate opening. adjacent to the wheelarch must not be used to
lift the box.
NOTE: Ensure the chains / slings on the
overhead lifting device are near vertical when
viewed from the rear to minimize "pull-in" on the
bodysides.
4. Pull in both walls & bow floor section of bedliner

up to release locking tabs at wheel arch.
5. Remove bedliner from vehicle.
6. Remove two bolts that retain taillights ( LH and
RH ).
7. Remove taillights and allow globe holders to drop 12. Remove scrivets retaining the plastic inner wheel
back inside cavity. arch mud deflector to chassis (LH and RH.).
8. Carefully remove the fir-tree clips retaining the
wiring for each taillight.
9. Disconnect reversing lamp/number plate
illumination connector.
G34531 en 01/2003 2003.0 BA Falcon

13. Raise the box, carefully manoeuvreing around the

fuel filler neck. Store the box on trestles locating
on cross beams under the floor.
Installation
WARNING: Corflex bolts must be
re-started by hand. Attempting to restart a
corflex bolt with a rattle gun can result in
stripped threads.
CAUTION: Ensure rubber insulators have
been replaced on the vertical pins if dislodged
during removal.
G34531 en 01/2003 2003.0 BA Falcon

Aluminium Tray
Removal
Item Description
1 Floor Assy. RR Flatbed
2 Bolt rear chasis mount
3 Bolt mid tray
4 Bolt front tray
1. Remove the four bolts retaining the front tray mounting brackets to the tray.
NOTE: To remove the actual tray mounting bracket from the x-member, the fuel tank must be removed to
access the lower bolt on the LH bracket.
2. Remove four bolts retaining the middle traymounting bracket to the chassis rail on both sides.
3. Remove the four bolts attaching the rearmounting brackets to the chassis rail on both sides.
4. Attach lifting device, ensuring the tray is lifted with
equal loading of all four corner points.
Installation
WARNING: Corflex bolts must be
re-started by hand. Attempting to restart a
corflex bolt with a rattle gun can result in
stripped threads.
G34532 en 01/2003 2003.0 BA Falcon

501-05-1 Interior Trim and Ornamentation 501-05-1
SECTION : 501-05 Interior Trim and Ornamentation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-05-2
Interior Trim and Ornamentation ............................................................................................501-05-3
Interior Trim ..........................................................................................................................501-05-3
Luggage compartment Interior Trim System ........................................................................501-05-3
A — Pillar Trim Panel ............................................................................................................501-05-4
B — Pillar Upper & Lower Trim Panel ...................................................................................501-05-4
C — Pillar Trim Panel ............................................................................................................501-05-4
D — Pillar Trim Panel — Wagon ...........................................................................................501-05-4
Front Door Trim Panel ...........................................................................................................501-05-4
Rear Door Lo Series Trim Panel ............................................................................................501-05-5
Rear Quarter Trim Panel — Wagon ......................................................................................501-05-6
Quarter Trim Panel — Ute .....................................................................................................501-05-6
Loadspace Trim Panel — Ute ................................................................................................501-05-7
Liftgate Upper Trim ................................................................................................................501-05-7
Liftgate Lower Trim ................................................................................................................501-05-7
Parcel Shelf ............................................................................................................................501-05-7
Sunvisor .................................................................................................................................501-05-8
Headliner — Wagon ...............................................................................................................501-05-8
Headliner — Sedan ................................................................................................................501-05-8
Headliner — Ute ....................................................................................................................501-05-9
Luggage Compartment Cover Lower Back ............................................................................501-05-9
Luggage Compartment Quarter Trims .................................................................................501-05-10
Luggage Compartment Load Floor Carpet ..........................................................................501-05-10
Spare Wheel Board ..............................................................................................................501-05-10
Package Tray Insulator ........................................................................................................501-05-11
Decklid Trim ........................................................................................................................501-05-11
Front Door Watershield ........................................................................................................501-05-12
Rear Door Watershield ........................................................................................................501-05-12
Front Inner Scuff Plate (RH) ................................................................................................501-05-12
Front Inner Scuff Plate (LH) .................................................................................................501-05-13
Rear Inner Scuff Plate ..........................................................................................................501-05-13
Rear Outer Scuff Plate .........................................................................................................501-05-13
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
B-Pillar trim panel screws 1.5-1.9
Sunvisor screws 1.7
Sunvisor check block 1.7
Liftgate lower panel nut and washer 3
assembly
D-Pillar panel screw 1.5
G11849 en 01/2003 2003.0 BA Falcon

Interior Trim and Ornamentation

Interior Trim
The interior trim consists of the following components:
A-pillar lower trim panels
B-pillar trim panels
C-pillar trim panels
D-pillar trim panels
front door sail panels
front door scuff plate trim panels
front door trim panels
headliner
liftgate scuff plate trim panel
liftgate trim panel
rear door sail panels
rear door scuff plate trim panels
rear door trim panels
front quarter trim panels
sun visors
window control switch panel cover
Luggage compartment Interior Trim
System
The luggage compartment consists of the following
trim components:
Cover lower back
Quarter trims
Load floor carpet
Spare wheel board
Package tray insulator
Decklid trim (Hi series only)
G11850 en 01/2003 2003.0 BA Falcon

A — Pillar Trim Panel C — Pillar Trim Panel

Removal Removal
1. Follow removal instructions as shown in figure. 1. Follow removal instructions shown in figure.

1 Moulding assy w/shield garn 1 Quarter trim panel - upper
2 Panel body side LH 2 Quarter panel outer
B — Pillar Upper & Lower Trim Panel D — Pillar Trim Panel — Wagon
Removal Removal
1. Follow removal instructions shown in figure. 1. Follow removal instructions shown in figure.

1 Panel - Centre body pillar I/S fin 1 Rear pillar trim
2 Cover - Front seat belt adjuster 2 Screw
3 Screw #8 18x0.5 Round washer head Installation
Installation 1. Reverse removal procedure.
Front Door Trim Panel
Removal
1. Insert small flat head screw driver at point shown.
G11851 en 01/2003 2003.0 BA Falcon

2. Lever out and remove grab handle cap, taking 7. Remove screws from grab handle.
care not to mark surface of door trim grab handle.
8. Disengage door trim retention clips by pulling door

3. Remove Interior Latch Release. For additional trim away from sheet metal (in direction of arrow),
information, refer to Door Latch Interior Release in starting at lower edge.
this section. NOTE: Pull along edge of trim; do not use the
4. Remove 2 lower screw covering caps and screws. grab handle.
5. Remove Rear upper screw fixing.
6. Remove Front upper screw fixing.
Item Description
1 Front door trim
Item Description 2 Screw
1 Front door trim 9. When trim is loose, lift up and over lock rod
2 Interior latch release (indicated by circle).
3 Screw 10. Disconnect electrical connectors if required and
remove door trim panel assembly.
Installation
Rear Door Lo Series Trim Panel

Removal
NOTE: Rear door trim with pull cup / window winder.
For rear door trim with power windows, refer to Front
Door Trim notes for removal and installation.
1. Remove pull cup screw.
2. Remove pull cup.
3. Remove Window Winder.
G11871 en 01/2003 2003.0 BA Falcon

4. Remove Door Latch Interior Release handle. Rear Quarter Trim Panel — Wagon
Removal
1. Follow removal instructions shown in figure.
Item Description
1 Screw
2 Ash tray
Item Description
3 Rear door trim - Lo Series
1 Quarter panel trim
5. Remove 2 lower screw fixings.
2 Sunvisor check block
6. Remove forward upper screw fixing.
3 Luggage compartment carpet
7. Remove rear upper screw fixing.
4 Wheel arch
5 Screw
Installation
Quarter Trim Panel — Ute

Removal
1. Remove the right and left hand side quarter trim
panel as shown.
Item Description
1 Rear door trim - Lo series
2 Screw
8. Disengage door trim retention clips by pulling door
trim away from sheet metal. Start at lower edge,
working around the edge of the door trim.
9. Disconnect electrical connectors if required and
remove door trim panel assembly.
Installation
1. Reverse removal procedure. Item Description
1 Trim panel
2 Locator plug
Installation
G11871 en 01/2003 2003.0 BA Falcon

Loadspace Trim Panel — Ute Liftgate Lower Trim

Removal Removal
1. Follow removal instructions shown in figure. 1. Follow removal instructions shown in figure.

1 Clip fir tree 1 Liftgate lower trim
2 Cover Assy Back panel trim 2 Pull strap
3 Child restraint anchorage 3 Scrivet
Installation 4 Nut and washer Assy. M6
1. Reverse removal procedure. 5 Clip
Installation
Liftgate Upper Trim
Removal
1. Follow removal instructions shown in figure.
Parcel Shelf
Removal
1. Carefully remove the barbed clips. (4 x No. 1 and
1 x No. 2)
2. Lift the Package tray trim from the parcel shelf
sheet metal.
Item Description
1 Liftgate upper trim LH
2 Liftgate upper trim RH
3 Push on clip (Type A)
4 Push on clip (Type B)
Item Description
Installation
1 Barbed clip no. 1
2 Barbed clip no. 2
Installation
G11857 en 01/2003 2003.0 BA Falcon

Sunvisor 8. Remove headlining via liftgate opening.
Removal
1. Remove sunvisor as shown in figure.
Item Description
1 Headlining
2 Barbed clip
Item Description
1 Sunvisor
Installation
2 Screw
3 Screw
NOTE: Care should be taken when handling
Installation headlining not to be bend unnecessarily.
Headliner — Sedan
Headliner — Wagon
Removal
Removal 1. Remove grab handles and hook.
1. Remove grab handles and hook. 2. Remove sunvisors and check blocks.
2. Remove sunvisors and check blocks. 3. Remove A,B,C and pillar interior trim parts.
3. Remove A,B,C and D pillar interior trim parts. 4. Remove dome light lens and body and disconnect
4. Remove dome light lens and body and disconnect wiring.
wiring.
5. Remove rear courtesy light lens and body and
disconnect wiring.
6. Remove upper sections of door and liftgate
opening weatherstrip.
7. Remove barbed clips.
Item Description
1 Headlining
2 Barbed clip
NOTE: Avoid folding or creasing the headlining during
removal.
G11857 en 01/2003 2003.0 BA Falcon

Installation 2. Undo spare wheel board tie down and remove

1. Reverse removal procedure. spare wheel cover.(Refer removal of spare wheel
cover in this section.)
Headliner — Ute
Removal
1. Remove A,B,C pillar interior trim parts.
2. Remove sunvisors and check blocks.
3. Remove grab handles and hook.
4. Locate interior light wiring connector at base of
"A" pillar trim and disconnect.
5. Remove barbed clips.
6. Remove headlining via door opening.
3. Remove 3 fir tree clips from front of cover lower

back.
Item Description
1 Panel assy. roof trim
Installation
NOTE: Care should be taken when handling Item Description
headlining not to bend unnecessarily. 1 Fir tree clip
Luggage Compartment Cover Lower 4. Remove cover lower back with an upwards
Back motion.
NOTE: Be careful not to damage hooks located
Removal on both the LH and RH extremities.
1. Lift carpet.
Installation
G11864 en 01/2003 2003.0 BA Falcon

Luggage Compartment Quarter Trims 2. Fold carpet from underneath seat backs into the
luggage compartment.
Removal 3. Remove carpet.
1. Remove 2 fir tree clips on luggage compartment
side.
NOTE: On high series vehicles that have luggage
net fitted, luggage net hook will be removed
instead of a fir tree.
Installation
Spare Wheel Board

Removal
Item Description 1. Fold carpet back.
1 Quarter trim
2 Fir tree clip
3 Fir tree clip
4 Plug
2. Lower seat back in cabin. (Refer to Section
501-10.)
3. Loosen package tray trim at front edge.
4. Remove 2 fir tree clips located behind seat back.
2. Undo spare wheel tie down.
Installation
Luggage Compartment Load Floor

Carpet
Removal Item Description
1. Lower seat back in cabin. (Refer to Section 1 Strap
501-10.) 2 Cover
G11864 en 01/2003 2003.0 BA Falcon

Item Description Installation

3 Spare wheel 1. Reverse removal procedure.
3. Remove spare wheel board. Decklid Trim
Installation
Short Wheel Base
Package Tray Insulator 1. Remove 14 fir tree clips.
Removal 2. Slide trim off decklid latch.
1. Remove both LH and RH quarter trims.(Refer
removal of quarter trim in this section.)
2. Remove package tray trim. (Refer to removal of
Parcel Shelf in this section.)
3. Remove 2 fir tree clips located on front edge of
package tray insulator behind seat backs.
Item Description
1 Decklid trim - SWB
2 Fir tree clips
Long Wheel Base
1. Remove 13 fir tree clips.
Item Description 2. Remove pulldown handle.
1 Package tray insulator
2 Fir tree clip
4. Remove clips on rear edge of package tray
insulator.
Item Description
1 Decklid trim - LWB
2 Fir tree clips
3 Pull down handle
Item Description 3. Slide decklid trim off decklid latch.
1 Package tray insulator Installation
2 Plastic snap clip 1. Reverse removal procedure.
5. Bend part through the middle and slide through
pass through into luggage compartment.
G11869 en 01/2003 2003.0 BA Falcon

Front Door Watershield Front Inner Scuff Plate (RH)

Removal Removal
1. Remove watershield as shown in figure. 1. Remove plug from front of plate (dash panel side).
Item Description 2. Remove plug from door side.

1 Pull through hole in watershield
2 Front door trim watershield
Installation
Rear Door Watershield

Removal
1. Remove watershield as shown in figure.
3. Pull scuff plate towards centre of vehicle.
Installation
Installation
G11869 en 01/2003 2003.0 BA Falcon

Front Inner Scuff Plate (LH) Rear Outer Scuff Plate

Removal Removal
1. Remove front inner scuff plate (LH) as shown in 1. Remove outer scuff plate as shown in figure.
figure .
Installation Item Description

1. Reverse removal procedure. 1 Screw
2 Front Outer Scuff Plate
Rear Inner Scuff Plate 3 Screw Grommet
Removal 4 Rear Outer Scuff Plate
1. Remove rear inner scuff plate as shown in figure. Installation
Installation
G11876 en 01/2003 2003.0 BA Falcon

501-08-1 Exterior Trim and Ornamentation 501-08-1
SECTION : 501-08 Exterior Trim and

Ornamentation
CONTENTS PAGE
Exterior Trim and Ornamentation .........................................................................................501-08-2
Radiator Grille .......................................................................................................................501-08-3
Licence Plate Housing ..........................................................................................................501-08-3
Rear Decklid Moulding — High Series, SWB Sedan ............................................................501-08-4
Rear Decklid Moulding — Low Series, SWB Sedan ............................................................501-08-4
Rear Liftgate Moulding — Wagon .........................................................................................501-08-5
Rear Decklid Moulding — Wagon .........................................................................................501-08-5
Window Moulding ..................................................................................................................501-08-5
Door Moulding — All Vehicles ..............................................................................................501-08-6
Rocker Panel Moulding — SWB & LWB ..............................................................................501-08-7
Body Side Protection Moulding .............................................................................................501-08-7
Roof Ditch Moulding ..............................................................................................................501-08-8
Decklid Spoiler ......................................................................................................................501-08-8
01/2003 2003.0 BA Falcon

Exterior Trim and Ornamentation

Component Location
Item Description
1 Radiator Grille
2 Hood Moulding
3 Door Moulding
4 Window Moulding
5 Roof Ditch Moulding
6 Decklid Spoiler
7 Licence Plate Moulding
8 Rocker Pane Moulding
9 Door Moulding
G86721 en 01/2003 2003.0 BA Falcon

Radiator Grille Licence Plate Housing

Removal Removal
1. Raise the Hood. 1. Gently use a screwdriver to depress the clip tab
2. Remove the two scrivets along the top rear edge on the side of the lamp housing to remove it from
of the grille. the applique.
3. Lift the grille up and away. NOTE: The lamp will still be attached to the
applique by the bulb holder and wiring.
Hi Series
Item Description
1 Scrivet - 8mm
2 Grille - SWB/UTE Item Description
1 Number Plate Lamp
Lo Series
Item Description
1 Scrivet - 8mm
2 Grille - LWB Item Description
1 Number Plate Lamp
Installation
1. To install, reverse the removal procedure. 2. Turn the bulb holder approximately 1/8 of a turn
anti-clockwise until it is free of the lamp housing.
Installation
NOTE: Tabs prevent the bulb holder from being
inserted into the lamp housing at the incorrect
orientation. Do not apply force.
G86722 en 01/2003 2003.0 BA Falcon

Rear Decklid Moulding — High Series, Rear Decklid Moulding — Low Series,
SWB Sedan SWB Sedan
Removal Removal
1. Remove 6 off nuts from inside decklid. 1. Remove 4 off nuts from inside decklid.

1 Nut - M5 1 Nut - M5
2. Carefully release the two lower inboard retainers 2 Ornament Assy Lugg Comp Door
from within the decklid using a screwdriver to 2. Carefully remove the moulding.
depress the locking tabs and remove the
moulding. 3. Pull out wiring grommet and unplug wiring
connector for license plate lamps.
3. Pull out the wiring grommet and unplug the wiring
Installation
connector for license plate lamps.
Installation 1. Feed in license plate lamp wire into decklid and
insert lamp wire grommet.
1. Feed in license plate lamp wire into decklid and
2. Plug in connector.
insert lamp wire grommet.
2. Plug in connector. 3. Line up 4 off studs with decklid and insert (Insure
seals are fitted to appliqué).
3. Line up top 4 off studs with decklid and rotate
4. Insert screws and torque.
moulding so as to insert lower two outboard studs
and two inboard retainers, and press home
(Insure seals are fitted to moulding including
retainers).
G86722 en 01/2003 2003.0 BA Falcon

Rear Liftgate Moulding — Wagon Window Moulding

Removal Removal
1. Remove the liftgate interior trim.
2. Remove the four mounting screws.
Item Description
1 Moulding - Liftgate
2 Nut - M5x0.8
3. Unplug the wiring connector.
Installation
Rear Decklid Moulding — Wagon

Removal
1. Remove 6 off nuts from inside decklid.
2. Carefully remove the moulding.

Installation
1. Line up 6 off studs with decklid and insert (Insure
seals are fitted to moulding).
G86727 en 01/2003 2003.0 BA Falcon

Door Moulding — All Vehicles

Removal
1. Remove the applique moulding by pulling the clip.
Sedan
Item Description
1 Rivet
2 Moulding
3 Clip
2. Use an adhesive cleaner to remove all tape
Item Description residue on the vehicle.
1 Applique Installation
2 Wheatherstrip 1. Remove the backing tape from the applique.
3 Foam Tape
Ute
Item Description
1 Applique - B Pillar Rear Door
Item Description 2 Applique - B Pillar Front Door
1 Wheatherstrip 3 Rivet
2 Door Inner 2. Insert the applique into position and clip it at the
3 Applique top.
4 Rivet 3. Push the applique forward onto the door frame.
4. Press firmly on the surface of the applique to
ensure tape contact over the full length.
G86727 en 01/2003 2003.0 BA Falcon

Rocker Panel Moulding — SWB & LWB 4. Remove all rocker moulding seal clips from the
top slots.
Removal
1. Remove the three clips along the underside of the
rocker panel moulding.
5. Remove rocker panel moulding.

Installation
1. Locate rocker moulding lower fixing channel onto
Item Description rocker panel weld seam.
1 Location of Metal Clip 2. Roll rocker panel in vertical position to locate
rocker seal clips into corresponding top slots.
2 Rocker Moulding
3. Fully insert all rocker moulding clips starting from
2. Dislodge the metal clip. the first front clip.
4. Ensure all clips are fully located home.
5. Fully insert the three fir tree clips on the
underside, to the floor in corresponding holes.
6. Insert 2 front splash shield to rocker scrivets.
Body Side Protection Moulding
Removal
NOTE: The procedures below covers the removal and
Installation of the double sided tape as used on
Falcon BSPMs and other Falcon applications.
1. Carefully cut the end of the tape on the BSPM
vertically to split the foam.
3. Remove the 2 scrivets attaching front splash 2. Peel the BSPM off the door, taking care not to
shield to the rocker. damage it if the BSPM is to be reused (not
recommended).
3. Use an adhesive cleaner to remove tape residue
on the vehicle. Saturate the remaining tape and
use a squeegee to remove. All the adhesive
residue must be cleaned off the vehicle.
4. Give the vehicle a final wipe with a 70% isopropyl
alcohol and water mixture (rubbing alcohol).
5. Dry with a clean cloth.
Installation
1. Wipe metal surface with clean rag and isopropyl
alcohol solution (50/50 min. solution).
NOTE: Ensure ambient temperature is at a
minimum of 16 deg Celsius and is dry.
2. Remove the backing tape without contaminating
the adhesive surface.
G86731 en 01/2003 2003.0 BA Falcon

3. Press the BSPM firmly onto body starting from the

front of the panel and apply minimum of 100N
pressure over the full length of BSPM.
Repeat to ensure adequate wet-out of the double
sided tape.
NOTE: Moulding should have a constant gap to
the door feature line and be consistent to the
other door. Moulding should not be riding up on
the door or fender feature line.
Item Description
1 Moulding Asy Body Side Half Car Set
2 Moulding Asy Front Door
3 Moulding Asy Rear Door
4 Moulding Asy Body Side Rear
Roof Ditch Moulding

Removal
Item Description
1. Remove the existing roof ditch moulding.
2 Moulding Asy Front Door
3 Moulding Asy Rear Door
2. Use an adhesive cleaner to remove tape residue

from the channel.
Installation
1. Remove the backing tape from the new moulding.
Item Description
2. Align corner of moulding tail with the rear corner
of roof.
2 Moulding Asy Door
3. Place body of moulding in channel.
3 Moulding Asy Cabin Side
4. Ensure uniform pressure is applied to molding
4 Moulding Asy Style Side Box using a roller.
Decklid Spoiler
Removal
1. Disconnect the wiring loom from the license plate
lamp via the rear of inside left hand side decklid
panel.
G86731 en 01/2003 2003.0 BA Falcon

2. Remove the screws from each spoiler foot via the

inside edges of decklid.
Item Description
1 Nut
2 Rear Spoiler
3. Lift the spoiler assembly off the decklid, pulling
the wiring loom through the hole.
Item Description
1 Rear Spoiler
2 Nut
Installation
G86733 en 01/2003 2003.0 BA Falcon

501-09-1 Rear View Mirrors 501-09-1
SECTION : 501-09 Rear View Mirrors

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-09-2
Rear View Mirrors ..................................................................................................................501-09-3
Rear View Mirrors ..................................................................................................................501-09-4
Symptom Chart ....................................................................................................................501-09-4
Pinpoint Tests ......................................................................................................................501-09-7
Power Mirror Switch ............................................................................................................501-09-12
Exterior Mirror Glass ...........................................................................................................501-09-13
Exterior Mirror & Round Plug in Door Trim ..........................................................................501-09-14
Interior Rear View Mirror .....................................................................................................501-09-14
Ambient Temperature Sensor ..............................................................................................501-09-14
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Exterior rear view mirror screws (Part 3-5
No:V810181)
G90850 en 01/2003 2003.0 BA Falcon

Rear View Mirrors

The rear view mirrors consist of the following
components:
exterior rear view mirrors (standard electric
operation or memory operation)
exterior mirror control switch
door switch control module (memory mirrors only)
interior rear view mirror
integral ambient temperature sensor in LH
exterior mirror only
The exterior rear view mirrors are adjusted by the
exterior mirror control switch or via the memory
seat/mirror function buttons.
G90851 en 01/2003 2003.0 BA Falcon

Rear View Mirrors 2. Visually inspect for obvious signs of mechanical

and electrical damage.
Refer to Wiring Diagram Section for schematic and Visual Inspection Chart
connector information.
Special Tool(s) Exterior rear view Central junction box
73III Automotive Meter mirror(s) (CJB) Fuse: RADIO
105-R0057 or equivalent No.2 7.5A
Circuitry
Exterior rear view
mirror motor(s)
Exterior mirror control
switch
Inspection and Verification concern is found, correct the cause (if possible)
1. Verify the customer concern by operating the 4. If the concern is not visually evident, determine
system, using appropriate standard mirror or the symptom and proceed to the Fault Diagnosis
memory mirror flowchart. Tables.
Symptom Chart
NOTE: Refer to fault diagnostic tables (Standard
mirror & Memory mirror).
Standard Mirror Fault Diagnostic Flow Chart

Switch vehicle electrics on via ignition.
Operate both LH & RH mirrors via door mirror control
switch.
1) Are both mirrors No Both mirrors non-functional. Check fuse for mirror
operational ? system at fusebox GO to Step 2.
No One mirror non-functional. Remove mirror & check for
+12V & GND at door connector using multimeter whilst
operating mirror switch (Refer to pinpoint tests A3 &
B1) Go to Step 6.
Yes No system mulfunction
2) Is fuse intact ? No Replace fuse and retest. Go to Step 3.
Yes Remove mirror switch and check for +12V and GND at
connector using multimeter. Refer pinpoint test A1 and
A2. Go to Step 4.
3) Is system functioning No Remove mirror switch and check for +12V and GND at
correctly ? connector using multimeter. Refer pinpoint test A1 and
A2. Go to Step 4.
4) Is +12V and GND No Possible wiring malfunction. Check for continuity from
available at switch ? fuse/GND to corresponding pins at switch connector
Repair discontinuous wiring. Recheck operation of
mirrors via switch. Go to Step 5.
Yes Replace faulty switch. Recheck operation of mirrors via
switch. Go to Step 5.
5) Is system functioning No Replace door mirror and retest. Go to Step 7.
correctly ?
G90852 en 01/2003 2003.0 BA Falcon

6) Is +12V and GND No Replace mirror control switch and retest. Go to Step 7.
available at door/mirror
connector ?
Yes Replace door mirror and retest. Go to Step 7.
7) Does new mirror or Yes No system mulfunction
switch function correctly ?
Memory Exterior Mirror Fault Diagnostic Flow Chart
NOTE: Various memory positions for seats and mirrors must be selected and stored in seat module prior to
commencement of checklist, as long as the system is (partially) operating.
Switch vehicle electrics on via ignition.

Operate both LH & RH mirrors via door mirror control
switch.
1) Are both mirrors No Both mirrors non-functional. Check fuses for mirrors
operational ? and seat control module. Press seat/mirror memory
buttons and check for seat and mirror movement. GO
to Step 6.
No One mirror only works. Press seat/mirror memory
buttons and check for seat and mirror movement. Go to
Step 3.
Yes Both mirrors functional. Press seat/mirror buttons and
check for seat and mirror movement. Go to Step 2.
2) Do both mirrors and No Refer to Seat module diagnostics and replace module if
seats operate ? necessary and retest.
3) Do both mirrors No Remove suspect mirror and check for +12V and ground
operate? at door/mirror connector. (Refer pinpoint test D1 & D2).
Go to Step 4.
Yes Possible faulty door switch module. Replace module
1R23 17E704 AA. Go to Step 8.
4) Is +12V and GND No Trace power and ground supply from door connector to
available at connector ? source and repair.
Yes Replace faulty mirror and retest. Go to Step 5.
5) Does replaced mirror No Refer to Seat module diagnostics and replace module if
function ? necessary and retest.
6) Do seats and mirrors No Refer to Seat module diagnostics and replace module if
move ? necessary and retest.
Yes Possible faulty door mirror switch. Replace switch. Go
to Step 7.
7) Do mirrors operate with No Possible faulty door switch module. Replace module
new switch ? 1R23 17E704 AA. Go to Step 8.
8) Do mirrors work with No Refer to Seat module diagnostics and replace module if
new module ? necessary and retest.
G90852 en 01/2003 2003.0 BA Falcon

C86

1 Circuit 540A (R) 0 voltage, less than 5 ohms between power
mirror switch and right front mirror motor
2 Circuit 541B (L) 0 voltage, less than 5 ohms between power
Mirror x direction control mirror switch and right front mirror motor
3 Circuit 544A (V) 0 voltage, less than 5 ohms between power
Mirror y direction control mirror switch and right front mirror motor
C88

1 Circuit 299 (V-R) 0 voltage, less than 5 ohms between the power
Power mirror switch power input mirror switch and ignition switch
2 Circuit 57F (B) 0 voltage, less than 5 ohms between and
Power mirror switch ground chassis ground
3 Circuit 540B (R) 0 voltage, less than 5 ohms between power
mirror switch and front mirror motors
4 Circuit 541A (L) 0 voltage, less than 5 ohms between power
Right mirror x direction control mirror switch and right front mirror motors
5 Circuit 541B (L) 0 voltage, less than 5 ohms between power
Left mirror x direction control mirror switch and left front mirror motors
6 Circuit 544A (V) 0 voltage, less than 5 ohms between power
Right mirror y direction control mirror switch and right front mirror motors
7 Circuit 544B (V) 0 voltage, less than 5 ohms between power
Left mirror y direction control mirror switch and left front mirror motors
G90852 en 01/2003 2003.0 BA Falcon

C94

mirror switch and left front mirror motor
2 Circuit 541 (L) 0 voltage, less than 5 ohms between power
Mirror x direction control mirror switch and left front mirror motor
3 Circuit 544 (V) 0 voltage, less than 5 ohms between power
Mirror y direction control mirror switch and left front mirror motor
C377

mirror switch and left front mirror motor
2 Circuit 541 (L) 0 voltage, less than 5 ohms between power
Mirror x direction control mirror switch and left front mirror motor
3 Circuit 544 (V) 0 voltage, less than 5 ohms between power
Mirror y direction control mirror switch and left front mirror motor
Pinpoint Tests
STANDARD MIRROR (NON MEMORY)
PINPOINT TEST A : THE MIRRORS ARE INOPERATIVE
A1 CHECK CIRCUIT 299 (V/R) FOR VOLTAGE
Disconnect Exterior Mirror Control Switch. Yes

Go to A2.
Key in ON position.
Measure voltage between exterior mirror control switch Connector No
C88, Circuit 299 (V/R), harness side and ground. REPAIR the circuit. TEST the system for normal
operation.
G90852 en 01/2003 2003.0 BA Falcon


A2 CHECK CIRCUIT 57 B/F (B) FOR AN OPEN
Measure the resistance between exterior mirror control switch Yes

Connector C88, Circuit 57(B/F), harness side and ground. Go to A3.
operation.
A3 CHECK CIRCUIT 540 (R) FOR OPEN
Disconnect Inoperative Exterior Rear View Mirror/s C520. Yes

INSTALL a new exterior mirror control switch.
Measure the resistance between inoperative rear view mirror TEST the system for normal operation.
Connector (C86/C94/C377) and mirror control switch Connector C88,
Circuit 540 (R). No
Is the resistance less than 5 ohms? REPAIR the circuit. TEST the system for normal
operation.
PINPOINT TEST B : A SINGLE MIRROR IS INOPERATIVE
B1 CHECK CIRCUITS 541 (L) AND 544 (V) FOR VOLTAGE
Disconnect Inoperative Exterior Rear View Mirror Connector. Yes

Go to A3.
Key in ON position.
Select the inoperative mirror on the exterior mirror control switch. No
Go to B2.
Measure the voltage between the inoperative exterior rear view mirror
connector, harness side and ground while operating the exterior
mirror control switch to the specified direction.
Driver mirror Passenger mirror Mirror control

direction
C86 circuit 541 C94/C377 circuit UP
541
C86 circuit 544 C94/C377 circuit RIGHT
544
Are the voltages greater than 10 volts?
B2 CHECK FOR AN OPEN CIRCUIT

Disconnect Exterior Mirror Control Switch C88. TEST the system for normal operation.
Measure the resistance between the inoperative exterior rear view
mirror connector, harness side and exterior mirror control switch No
connector, harness side. REPAIR the suspect circuit. TEST the system
Circuit
Driver
541 A (L)
544 A (V)
Passenger
544 B (V)
541 B (L)
Are all of the resistances less than 5 ohms?
G90852 en 01/2003 2003.0 BA Falcon


B3 CHECK CIRCUIT 540 (R) FOR OPEN
Disconnect Inoperative Exterior Rear View Mirror/s. Yes

INSTALL a new exterior rear view mirror. Refer
Measure the resistance between the inoperative exterior rear view to Exterior Mirror in this section. TEST the
mirror connector, circuit 540 (R), harness side and exterior mirror system for normal operation.
control switch C88, circuit 540 (R), harness side.
operation.
G90852 en 01/2003 2003.0 BA Falcon

PINPOINT TEST C : A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
C1 CHECK FOR THE CORRECT INPUT TO THE EXTERIOR REAR

VIEW MIRROR
Disconnect Inoperative Exterior Rear View Mirror. Yes

INSTALL a new exterior rear view mirror. Refer
Key in ON position. to Exterior Mirror in this section. TEST the
Select the inoperative exterior rear view mirror on the exterior mirror system for normal operation.
control switch.
No
Measure the voltage or resistance between the suspect exterior rear Go to C2.
view mirror connector, harness side and ground while operating the
exterior mirror control switch to the specified position. Refer to the
following chart:
Exterior Circuit Mirror Measurement

mirror control
Connector position
Driver
C86 540 A Down Greater than
10 volts
C86 540 A Up Less than 50
ohms
C86 540 A Right Greater than
10 volts
C86 540 A Left Less than 50
ohms
Driver and Passenger
C86/C94/C377 541 A/B Up Greater than
10 volts
C86/C94/C377 541 A/B Down Less than 50
ohms
C86/C94/C377 541 A/B Left Greater than
10 volts
C86/C94/C377 541 A/B Right Less than 50
ohms
Passenger
C94/C377 540 B Down Greater than
10 volts
C94/C377 540 B Up Less than 50
ohms
C94/C377 544 B Right Greater than
10 volts
C94/C377 544 B Left Less than 50
ohms
Are the measurements as indicated?
G90852 en 01/2003 2003.0 BA Falcon


C2 CHECK THE EXTERIOR REAR VIEW MIRROR CIRCUITS
FOR A SHORT TO GROUND
Disconnect Exterior Mirror Control Switch C88. TEST the system for normal operation.
Measure the resistance between the exterior rear view mirror
connector, harness side and ground. Refer to the following chart: No
REPAIR the suspect circuit. TEST the system
Exterior mirror pin Circuit
Driver
C86 540 A
C86 541 A
C86 544 A
Passenger
C94/C377 540 B
C94/C377 541 B
C94/C377 544 B
Are all of the resistances greater than 10,000 ohms?
MEMORY MIRROR
PINPOINT TEST D : THE MIRRORS ARE INOPERATIVE
D1 CHECK CIRCUIT 541 A/B (R) FOR VOLTAGE

Disconnect Exterior Mirror Connector. Yes
Go to D2.
Key in ON position.
Measure voltage between exterior mirror Connector C377/C86, Circuit No
541 A/B, harness side and ground. Trace power supply from mirror connector to
source and repair. (Refer to Seat Module
Is the voltage greater than 10 volts? Diagnostics + Repair).
D2 CHECK CIRCUIT 544 A/B (R) FOR AN OPEN

Disconnect Exterior Mirror Control Switch. Yes
Replace faulty mirror and retest.
Key in ON position.
Measure the resistance between exterior mirror Connectors No
C86/C377, harness side and ground. Trace ground supply from mirror connector to
source and repair. (Refer to Seat Module
Is the resistance less than 50 ohms? Diagnostics + Repair).
PINPOINT TEST E : TEMPERATURE SENSOR — AMBIENT (part of LH exterior mirror assembly)

NOTE: For diagnosis and testing of the ambient temperature sensor which is an integral part of the LH
exterior mirror assembly, refer to the section 412-04, Pinpoint test A.
G90852 en 01/2003 2003.0 BA Falcon

Power Mirror Switch 6. Gently pull the wiring harness connector from its
socket. (It may be necessary to use the
Removal screwdriver as a lever, to allow the switch socket
1. Remove the door trim as per Section 501-5. enough gap to clear the barbed lock tag of the
harness connector). Be extremely careful when
WARNING: Do not attempt to remove the removing the harness connector from the socket
mirror switch before the trim has been by making sure the two halves of the switch do
removed. not break away and separate.
2. Once the door trim is removed from the door, Installation
support the trim by taking care to make sure that 1. Reassemble the door trim to the door making sure
it is not pulling against the power mirror switch the wiring harness for the mirror switch is fed
and the wiring harness through the hole for the mirror switch.
3. Remove the mirror switch from the door trim by 2. When the trim has been reassembled to the door,
pushing firmly and evenly on the flat base of the fit the mirror switch last.
switch until it pops out from the trim. Gently push 3. Connect the protruding wiring harness and
the two mirror retaining clips inwards so that the connector to the switch socket.
ends are clear of the hole and push the switch out
from the cut out. 4. Carefully feed the mirror switch into the door trim
and match the switch locator with the locating slot
1. If door switch is difficult to remove then insert in the trim.
a fine, flat blade screwdriver where the
retaining clips are and gently push up on the 5. Push down firmly on the outside of the mirror
mirror switch. switch until it pops into place. DO NOT PUSH
DOWN ON THE SWITCH ADJUSTER KNOB.
4. Pull the switch through the trim hole so there is

enough room to be ableto access the rear of the WARNING: Warranty claims for power mirror
switch and harness connector and socket. switches returned with a broken switch base as a
5. Insert a fine, flat blade screwdriver into the reult of incorrect removal will not be accepted as
harness connector near the barbed lock tag and a warrantable defect.
support the lower switch body. Supplier assessment for functional faults in the
manufacture of the switch is not when the switch
is broken at the base.
Warranty Status - Reimbursable within the
provisions of the Warranty and Policy Manual.
Damage to the switch through not using the
correct removal procedure is not warrantable.
G90853 en 01/2003 2003.0 BA Falcon

Exterior Mirror Glass 4. Cover glass surface with cloth and apply even
pressure to engage all clips. Manually adjust the
Removal glass angle outward and confirm that the wire
1. Remove broken glass and backing plate. spring is positioned correctly in guide track.
2. Remove spring wire taped to rear surface of 5. Check mirror glass operation. If glass vibrates
backing plate. Re-install spring wire into spring when adjusted, or if inward movement is
housing on rear surface of backing plate. restricted, repeat steps 1 to 4 to ensure correct
wire spring position and that clips are fully
engaged.
Installation
1. Reverse the removal instruction.
Exterior Mirror & Round Plug in Door

Trim
Removal
1. Remove interior triangular trim panel to access
rear of mirror assembly.
2. Remove mirror retaining screws and remove
mirror assembly.
CAUTION: Do not drop screws into door.
3. Position spring into guide track and align backing
plate clips with slots on the mirror adaptor plate.
G90856 en 01/2003 2003.0 BA Falcon

3. Disconnect electrical connector from mirror

assembly. (Small screwdriver required for
temperature sensor 6 pin connector (C377) LH
mirror only.
Installation
1. Reverse the removal instruction.
Interior Rear View Mirror

NOTE: The interior rear view mirror is adhered to the
windscreen and should not be removed due to the
possibility of cracking the windscreen.
Ambient Temperature Sensor

The Ambient Temperature Sensor is integral in the left
hand exterior mirror. The sensor is not a serviceable
item, and if faulty, the complete LH external mirror
assembly should be replaced.
G90856 en 01/2003 2003.0 BA Falcon

501-10-1 Seating 501-10-1
SECTION : 501-10 Seating

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-10-2
Seating ..................................................................................................................................501-10-3
Seats ....................................................................................................................................501-10-3
Seats .....................................................................................................................................501-10-4
Symptom Chart ....................................................................................................................501-10-4
Pinpoint Tests ....................................................................................................................501-10-12
Front Seat Assembly ...........................................................................................................501-10-18
Rear Seat Cushion ..............................................................................................................501-10-19
Rear Seat Bolster ................................................................................................................501-10-19
Rear Seat Back ...................................................................................................................501-10-19
Front Head Restraint ...........................................................................................................501-10-21
Back Cover .........................................................................................................................501-10-21
Headrest Guides .................................................................................................................501-10-22
Lumbar Knob ......................................................................................................................501-10-22
Inner Side Cover .................................................................................................................501-10-23
Recliner Knob and Outer Side Cover ..................................................................................501-10-23
Front Seat Back ..................................................................................................................501-10-24
Airbag ..................................................................................................................................501-10-26
Front Seat Back Trim Cover ...............................................................................................501-10-27
Pre-tensioner ......................................................................................................................501-10-28
Seat Operating Switch ........................................................................................................501-10-29
Memory Module ..................................................................................................................501-10-29
Front Seat Cushion (2-way) ................................................................................................501-10-30
Front Seat Cushion (4-way & 6-way non-memory) ............................................................501-10-30
Front Seat Cushion (6-way memory) ..................................................................................501-10-31
01/2003 2003.0 BA Falcon

501-10-2 Seating 501-10-2
SPECIFICATIONS
Description Specification(mm)
Front seat track travel Fore/aft 264
Front seat front height travel 55
Front seat rear height travel 55
Headrest height travel 50
Description Nm
Cushion to tracks 28 ± 4
Front seat back to cushion 32 ± 5
Pre-tensioner bolt 33 ± 3
SIAB nut to FSB frame 5.4 ± 0.9
Front seat to floor bolt 35 ± 5
G73253 en 01/2003 2003.0 BA Falcon

501-10-3 Seating 501-10-3
Seating
Seats
The front seats are of a steel frame construction and
have a sprung suspension mat in the seat cushion
and a sprung mat with an adjustable lumbar section in
the seat back (where applicable).
Seat adjustments improve occupant comfort and the
key features are summarized below:
Pull up towel bar at front of seat cushion to
facilitate fore/aft manual travel adjustment
Raise/Lower switch knob at side of seat cushion
to raise/lower seat height (independent front &
rear)
Slide fore/aft switch knob at side of seat cushion
for fore/aft electrical travel 6-way power seat
Rotate knob at side of seat for recline adjustment
Rotate knob at side of seat for lumbar adjustment
Push handle at side of seat for dump forward of
seat back (utility only)
Vertically adjustable head rest.
When specified, a side impact bag is packaged in the
seat back to maximize occupant protection.
G73254 en 01/2003 2003.0 BA Falcon

501-10-4 Seating 501-10-4
Seats Visual Inspection Chart

Inspection and Verification Seat tracks obstructed Fuse(s)
1. Verify the customer concern by operating the or damaged Wiring harness
system. Seat base track Loose or corroded
alignment connector(s)
Mechanical linkage(s) Motor(s)
or electrical damage. obstructed or Multifunction switch
3. If an obvious cause for an observed or reported damaged Damaged
concern is found, correct the cause (if possible) Seat frame alignment connector(s)
before proceeding to the next step. Internal operating Memory button(s)
4. If the concern is not visually evident, verify the cables obstructed, LED
Symptom Chart. damaged or broken
Symptom Chart

The power seat is inoperative Connector(s) Go to PinPoint Test A.
Circuit
The power seat moves but is noisy Seat base assembly Go to PinPoint Test B.
Motor(s)
The power seat moves but is loose Seat track(s) Go to PinPoint Test C.
Seat base assembly
The power seat does not make full Fastening hardware Check Diagnostics then Go to PinPoint
travel Seat base assembly Test D.
Circuit
The pedal does not remember stored Circuit Go to PinPoint Test E
positions Potentiometer
The power seat does not move Motor(s) Check diagnostics then Go to PinPoint
horizontally/vertically Connector(s) Test F.
Switch pack
The power seat does not recline (10 Connector(s) Check diagnostics then Go to PinPoint
way seat only) Switch pack Test G.
Motor
The power lumbar is inoperative (10 Motor Check diagnostics then Go to PinPoint
way seat only) Connector(s) Test H.
Circuit
Switch pack
Seat lumbar assembly
Memory recall is inoperative Connector(s) Check diagnostics then Go to PinPoint

Memory buttons Test I.
Priority recall is inoperative Connector(s) Check diagnostics then Go to PinPoint

Circuit Test I.
Mirror dip is inoperative Connector(s) Check diagnostics then Go to PinPoint

Circuit Test K.
NOTE: Put the seat into Diagnostic mode:
Checking Diagnostic Trouble Codes

Entering Diagnostics
Step Do Seat does
1 Ignition on No change from previous state
2 Using the Ford service tool, select to enter Seat will flash out DTC
plant mode
G73255 en 01/2003 2003.0 BA Falcon

501-10-5 Seating 501-10-5
Diagnostic Flash Code Phases

Phase Seat does
1 Flash out high value (count number of times light turns off).
2 Green light ON for about 1 second.
3 Flash out low value(count number of times light turns off).
4 Green light ON for about 3 seconds.
5 Pressing memory button ‘2’ will go to the next DTC.
Return to phase 1 and start again
NOTE: Check codes against table.
Diagnostic Test Codes

Flash Codes
First
group Second group Code Action
1 1 6 way seat Ensure seat is 6 way.
1 2 10 way seat Ensure seat is 10 way.
1 3 No Priority Data Go to J1.
1 4 No Priority Frame Synchronisation Go to J1.
1 5 No Ignition Go to K1.
1 6 No Reverse Go to K1.
2 1 No Fore lift motor sensor Go to I1.
2 2 No Aft lift motor sensor Go to I1.
2 3 No Track motor sensor Go to D3&I1.
2 5 No Recliner motor sensor Go to I1.
2 6 No lumbar motor sensor Go to I1.
3 1 Button stuck (Memory) Replace button/board which ever is at
fault.
3 2 Button stuck (Position, including Replace switch pack.
lumbar)
3 3 Button stuck (Pedals) Replace button.
3 4 LH mirror not responding or faulty Replace Mirror.
3 5 RH mirror not responding or faulty Replace Mirror.
3 6 Mirror button pack not responding or Replace Mirror botton pack.
faulty
6 3 Internal error Replace Module.
6 6 End of errors No Action
NOTE: After finishing repeat to ensure DTC is current
fault code.
G73255 en 01/2003 2003.0 BA Falcon

501-10-6 Seating 501-10-6

Seat Power

1 Circuit 1 (Black) ~0V
Ground
2 Circuit 2 (Red) >10V
Power
3 Circuit 3 (Green/Pink)
Polack
4 Circuit 4 (pink/Orange)
Polack
Vehicle Inputs

1 Circuit 1 (Green)
AI reserved
2 Circuit 2 (Black/Blue) >10V if ignition on
Ignition
3 Circuit 3 (Black/Red) >10V if in Reverse
Reverse
4 Circuit 4 (Black/White) ~0V
Mirror Ground
5 Circuit 5 (Green/Black) >0V when seat LED on
Mirror Power
6 Circuit 6 (Black/Yellow) ~0V
Electronics Ground
7 Circuit 7 Not Connected
8 Circuit 8 (Red/Orange) Refer to DTC
Priority Data
G73255 en 01/2003 2003.0 BA Falcon

501-10-7 Seating 501-10-7

9 Circuit 9 (White/Pink) Refer to DTC
Priority FS
10 Circuit 10 (Yellow/Grey) Refer to DTC
Mirror Data
Pedal Memory

1 Circuit 1 (Blue/Yellow) 12V if selected
Pedal Fwd
2 Circuit 2 (Black/Brown) 12V if selected
Pedal Bwd
3 Circuit 3 (Yellow) 0 to 4.5KΩ
Pedal Pot
4 Circuit 4 (Red/Black) 0 to 4.5KΩ
Pedal Pot
5 Circuit 5 (Grey/Black) 12V or 0V
Pedal Motor
6 Circuit 6 (Black/White) 0V to 12V
Pedal Motor
Module Power Connector A

1 Circuit 1 (Red) >10V
Power
2 Circuit 2 (Green/Yellow) 0 or 12V
Rear Lift Motor
3 Circuit 3 (Brown/Green) 0 or 12V
Rear Lift Motor
4 Circuit 4 (Blue/Red) 0 or 12V
Front Lift Motor
5 Circuit 5 (Green/Pink) 0 or 12V
Track Motor
G73255 en 01/2003 2003.0 BA Falcon

501-10-8 Seating 501-10-8

7 Circuit 7 (Black) 0V
Ground
8 Circuit 8 (Black/Yellow) 0V
Electronics GND
9 Circuit 9 (Grey) 0 or 12V
Track Motor
10 Circuit 10 (Black/White) 0 or 12V
Pedal Motor
11 Circuit 11 (Black/Blue) 0 or 12V
Front Lift Motor
12 Circuit 12 (Grey/Black) 0 or 12V
Pedal Motor
Module Power Connector B

1 Circuit 1 (Brown) 0 to 10KΩ
Front Lift Pot
2 Circuit 2 (Green/Violet) 0 to 10KΩ
Rear Lift Pot
3 Circuit 3 (Black/Orange) 0 to 10KΩ
Track Pot
4 Circuit 4 (Blue/Green) 0 to 10KΩ
Track Pot
5 Circuit 5 (Red/Orange) Refer to DTC
Priority Data
6 Circuit 6 (white/Pink) Refer to DTC
Priority FS
7 Circuit 7 (Black/Red) >10V
Reverse
9 Circuit 9 (Black/White) 0V
Mirror Ground
10 Circuit 10 (Blue) 0V
Memory Scan
11 Circuit 11 (Brown/Black) 0V
Position Scan
13 Circuit 13 (Red/Black) 0 to 10KΩ
Pedal Pot
14 Circuit 14 (Yellow) 0 to 10KΩ
Pedal Pot
G73255 en 01/2003 2003.0 BA Falcon

501-10-9 Seating 501-10-9

15 Circuit 15 (Brown/Blue) Refer to cct1
Front Lift Pot
16 Circuit 16 (Green/Red) Refer to cct2
Rear Lift Pot
Lift Motor Connectors

1 Circuit 1 (Blue/Red) 0 or 12V
Front Lift Motor
2 Circuit 2 (Black/Blue) 0 or 12V
Front Lift Motor
3 Circuit 3 (Green/Yellow) 0 or 12V
Rear Lift Motor
4 Circuit 4 (Brown/Green) 0 or 12V
Rear Lift Motor
Track Motor Connector

1 Circuit 1 (Grey) 0 or 12V
Track Motor
2 Circuit 2 (Green/Pink) 0 or 12V
Track Motor
G73255 en 01/2003 2003.0 BA Falcon

501-10-10 Seating 501-10-10
Motor Potentiometer Connectors

1 Circuit 1 (Black/Orange) 0 to 10kΩ
Track Pot
2 Circuit 2 (Blue/Green) 0 to 10kΩ
Track Pot
3 Circuit 3 (Brown) 0 to 10kΩ
Front Lift Pot
4 Circuit 4 (Brown/Blue) 0 to 10kΩ
Front Lift Pot
7 Circuit 7 (Green/Violet) 0 to 10kΩ
Rear Lift Pot
8 Circuit 8 (Green/Red) 0 to 10kΩ
Rear Lift Pot
Lumbar & Recliner Connector

1 Circuit 1 (Violet/Green) 0 to 12V
Backrest Motor
2 Circuit 2 (Pink/Orange) 0 to 12V
Backrest Motor
3 Circuit 3 (Blue/Whiten) 0 to 12V
Lumbar Motor
4 Circuit 4 (Green/Brown) 0 to 10kΩ
Backrest Pot
5 Circuit 5 (Orange/Brown) 0 to 10kΩ
Backrest Pot
6 Circuit 6 (Blue/Violet) 0 to 10kΩ
Lumbar Pot
G73255 en 01/2003 2003.0 BA Falcon

501-10-11 Seating 501-10-11

7 Circuit 7 (Violet/Blue) 0 to 10kΩ
Lumbar Pot
8 Circuit 8 (White/Blue) 0 to 12V
Lumbar Motor
Lumbar & Recliner Module Connector

1 Circuit 1 (Pink/Orange) 0 or 12V
Backrest Motor
2 Circuit 2 (White/Blue) 0 or 12V
Lumbar Motor
3 Circuit 3 (Violet/Blue) 0 to 20kΩ
Lumbar Pot
4 Circuit 4 (Green/Brown) 0 to 10kΩ
Backrest
5 Circuit 5 (White/Brown) 0V
Lumbar Scan
6 Circuit 6 (Orange/Brown) Refer to cct4
Backrest Pot
7 Circuit 7 (Blue/White) 0 or 12V
Lumbar Motor
8 Circuit 8 (Violet/Green) 0 or 12V
Backrest Motor
9 Circuit 9 (Blue/Orange) Refer to cct 3
Lumbar Pot
10 Circuit 10 (Blue/Orange) open cct or 0V
Lumbar Down
12 Circuit 12 (Orange/Blue) open cct or 0V
Lumbar Up
G73255 en 01/2003 2003.0 BA Falcon

501-10-12 Seating 501-10-12
Pinpoint Tests
PINPOINT TEST A : THE POWER SEAT IS INOPERATIVE

A1 CHECK FOR POWER AT SEAT
Measure the voltage between the power pins on connectors CON-1 Yes
pins 1 and 2, CON-1 pin 1 and CON-2 pin 6. Go to A2
Replace the fuse if CON-1 problem. Check BEM
if CON-2 problem.
A2 CHECK CONNECTION AND CIRCUIT CONTINUITY

Measure voltage between the power and grounds on the module Yes
connector, CON-4 pins 1 and 8 also 1 and 7. Replace the harness. Refer to removal and
installation instructions in this chapter.
Is the voltage within 0.5 of a volt of that measured in A1?
No
Replace seat module. Refer to removal and
PINPOINT TEST B : THE POWER SEAT MOVES BUT IS NOISY
B1 VISUAL INSPECTION FOR OBSTRUCTION IN SEAT

TRACKS
Inspect upper and lower seat track area for any foreign matter such Yes
as biros, coins, etc. Remove any obstructions from the seat tracks
that could affect seat movement.
Was foreign matter or debris found in the seat tracks?
No
Go to B2
B2 VISUAL INSPECTION FOR POWER SEAT MOVEMENT

OBSTRUCTION
Check under the seat for anything that could affect seat movement, Yes
such as accessory floor mats, etc. Remove all obstructions.
Was an obstruction found? No
Apply Grease, “SHELL ALVANIA RL2” onto the
sliding areas of the seat tracks.
NOTE: Care should be taken not to apply
excess grease to the tracks as excessive grease
could transfer to the carpet.
PINPOINT TEST C : THE POWER SEAT MOVES BUT IS LOOSE
C1 SEAT LOWER TRACK TO FLOOR

Check tightness of the bolts used to retain the seat tracks to the Yes
vehicle floor. Go to C2
Were the bolts tight? No
Tighten the seat mounting bolts to 35 ± 5 NM.
G73255 en 01/2003 2003.0 BA Falcon

501-10-13 Seating 501-10-13

C2 SEAT UPPER TRACK TO SEAT
Check the tightness of the nuts used to retain the seat tracks to the Yes
seat cushion frame. Go to C3
Were the nuts tight? No
Tighted the nuts to 28 ± 4 NM.
C3 SEAT TRACK CONDITION

Carry out a visual inspection using a torch of the seat track assembly Yes
for any physical damage. Remove the seat assembly and replace the seat
track assembly. Refer to removal and installation
Is damage evident? instructions in this chapter .
No
Go to C4
C4 SEAT TRACK BALL BEARING CHECK

Using an assistant, grasp the seat backrest and move backwards and Yes
forwards by hand to check for excessive movement. Replace the track assembly. Refer to removal
While the assistant is moving the seat backrest, use a torch to view and installation instructions in this chapter.
the seat tracks look for excessive movement between the upper and
lower rail.
No
Go to C5
NOTE: Carry out this test in 3 positions of the seat, fully forward -
mid - fully back.
Did your see or feel excessive track movement in any of the 3
positions?
C5 SEAT ASSEMBLY GENERAL MOVEMENT - PART 1

Grasp the seat backrest and move backwards and forwards by hand Yes
to check for excessive movement. Remove the Two (2) plastic side covers and
tighten the bolts retaining the seat recliner to the
Is the recliner mechanism loose at the cushion frame? cushion frame. 32 ± 5 Nm.
No
Go to C6
C6 SEAT ASSEMBLY GENERAL MOVEMENT - PART 2

Using an assistant, grasp the seat backrest and move backwards and Yes
forwards by hand to check for excessive movement. Replace the fatigue affected assembly.
While the assistant is moving the seat backrest, using a torch to view
the under side of the seat to establish at what point the seat No
movement is happening. The seat, frame and tracks appear to be Okay.
Once the movement point is established check for signs of metal
fatigue.
Did you find any signs of metal fatigue?
PINPOINT TEST D : THE POWER SEAT DOES NOT MAKE FULL TRAVEL

D1 UNDER SEAT OBSTRUCTION
Check under the seat for an obstruction, such as floor mats, umbrella, Yes
first aid kit etc. Remove the obstruction and recheck seat
movement.
Did you find an obstruction that could cause the seat not to
travel the full movement? No
Go to D2
G73255 en 01/2003 2003.0 BA Falcon

501-10-14 Seating 501-10-14

D2 SEAT TRACK OBSTRUCTION
Check in the seat tracks for an obstruction, such as a pen, pencil, Yes
coins etc. Remove the obstruction and recheck seat
movement.
Did you find an obstruction that could cause the seat tracks not
to travel the full movement? No
Go to D3
D3 CHECK CIRCUIT CONTINUITY

Check for resistance between pot connector and module connector Yes
for the effected motor. If DTC 23 is active, replace Motor Sensor. If no
Track - measure between CON-8 pin 1 and pin 2, also CON-5 DTC replace seat module.
pin 3 and pin 4.
No
Front Lift - measure between CON-8 pin 3 and pin 4, also Replace Harness. Refer to removal and
CON-5 pin 1 and pin 15. installation instructions in this chapter.
Rear Lift - measure between CON-8 pin 7 and pin 8, also CON-5
pin 2 and pin 16
Is the difference between readings less than 5 ohms?
PINPOINT TEST E : THE PEDAL DOES NOT REMEMBER STORED POSITIONS
E1 MEASURE POTENTIOMETER CHANGE AT TWO

DIFFERENT PEDAL POSITIONS
Remove connector CON-3 and measure the potentiometer resistance Yes
at CON-3 between pin 3 and pin 4. Reconnect CON-3 and move the Replace APM. Section 206-06
pedal then remove connector CON-3 and re-measure.
No
Is the difference in resistance less than 20 ohm’s? Replace Module. Refer to removal and
PINPOINT TEST F : THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY
F1 CONTINUITY MOTOR TO MODULE

Measure the harness resistance between the motor and the module. Yes
Track - measure between CON-7 pin 1 and CON-4 pin 9, also Go to F2
CON-7 pin 2 and CON-4 pin 5.
No
Front Lift - measure between CON-6 pin 1 and CON-4 pin 4, Replace Harness. Refer to removal and
also CON-7 pin 2 and CON-4 pin 11. installation instructions in this chapter.
Rear Lift - measure between CON-7 pin 3 and CON-4 pin 2, also
CON-7 pin 4 and CON-4 pin 3.
F2 MEASURE MOTOR OUTPUT VOLTAGES

Disconnect each motor while measuring voltage push appropriate Yes
switch. Replace seat motor. Refer to removal and
Track - measure between CON-7 pin 1 and pin 2. installation instructions in this chapter.
Front Lift - measure between CON-6 pin 1 and pin 2. No
Rear Lift - measure between CON-7 pin 3 and pin 4. Go to F3
Is the voltage more than 10 volts?
G73255 en 01/2003 2003.0 BA Falcon

501-10-15 Seating 501-10-15

F3 CHECK SWITCH FUNCTION
Connect a working switch pack to the harness and try to move the Yes
seat horizontally and vertically. Replace Switch pack. Refer to removal and
Did the seat move the effected motor?
No
Replace Seat module. Refer to removal and
PINPOINT TEST G : THE POWER SEAT DOES NOT RECLINE

G1 MOVEMENT CHECK FOR GOOD SWITCH PACK
Replace the switch pack with a known good switch and test if seat still Yes
doesn’t recline. Replace Switch pack. Refer to removal and
Did the recliner move?
No
Go to G2
G2 VOLTAGE CHECK FOR MOTOR

Measuring voltage on the motor pins in the backrest connector while Yes
pushing the appropriate switch. Measure between CON-9 pin 1 and 2. Replace seat motor. Refer to removal and
No
Go to G3
G3 CONTINUITY BACKREST CONNECTOR TO MODULE

Measure the harness resistance between: Yes
CON-9 pin 1 to CON-10 pin 8. Replace Seat module. Refer to removal and
CON-9 pin 2 to CON-10 pin 1.
Is the resistance less than 5 ohm’s? No
Replace Harness. Refer to removal and
PINPOINT TEST H : THE POWER LUMBAR IS INOPERATIVE
H1 CONTINUITY CHECK SWITCH AND BACKREST

CONNECTOR TO MODULE
Measure continuity between CON-10 pin 5 and CON-10 pin 12 and Yes
CON-10 pin 10 while operating the lumbar. Go to H2
Is the resistance less than 5 ohm’s between pin 5 and one of the No
other pins while Lumbar is being operated and open CCT when Replace Switch pack. Refer to removal and
not being operated? installation instructions in this chapter.
H2 VOLTAGE CHECK FOR MOTOR

Measuring voltage on the motor pins in the lumbar connector while Yes
pushing the appropriate switch.CON-9 pins 3 and 8. Replace motor. Refer to removal and installation
instructions in this chapter .
No
Go to H3
G73255 en 01/2003 2003.0 BA Falcon

501-10-16 Seating 501-10-16

H3 MEMORY BUTTON MOVEMENT CHECK
CON-9 pin 3 and CON-10 pin 7 Replace Harness. Refer to removal and
CON-9 pin 8 and CON-10 pin 2
Did the lumbar move? No
Replace Seat Module. Refer to removal and
PINPOINT TEST I : MEMORY RECALL IS INOPERATIVE

I1 CONTINUITY FROM POTENTIOMETER FEEDBACK TO
MODULE
Measure the harness resistance between the Potentiometer and the Yes
module. If any DTC from 21 to 26 is set replace the pot
Track - CON-5 pin 3 and 4. otherwise. Go to I2.
Front Lift - CON-5 pin 1 and 15. No
Rear Lift - CON-5 pin 2 and 16. Replace Harness. Refer to removal and
Recliner - CON-10 pin 4 and 6. installation instructions in this chapter.
Lumbar - CON-10 pin 3 and 9.

Is the resistance in the range specified by the connector
measurement chart?
I2 CHECK BUTTON BOARD

Push all 3 memory buttons one at a time. Yes
Replace seat Module. Refer to removal and
Did chime sound and seat NOT move? installation instructions in this chapter.
No
Replace Button Board. Refer to removal and
PINPOINT TEST J : PRIORITY RECALL INOPERATIVE
J1 CONTINUITY FROM BODY INTERFACE TO MODULE

CON-2 pin 8 and CON-5 pin 5. If DTC 13 or 14 is set problem is with the BEM (
Section 419-10) else replace seat module. Refer
CON-2 pin 9 and CON-5 pin 6. to removal and installation instructions in this
Is the resistance less than 5 ohms? chapter.
No
Replace Harness. Refer to removal and
G73255 en 01/2003 2003.0 BA Falcon

501-10-17 Seating 501-10-17
PINPOINT TEST K : MIRROR DIP IS INOPERATIVE
K1 CHECK FOR IGNITION FUNCTION

Perform a seat recall and activate ignition before recall is complete. Yes
Go to K3
Did the seat stop short of the recall position?
No
Go to K2
K2 CHECK FOR IGNITION AT THE SEAT CONNECTOR

Measure the harness voltage at CON-2 pin 2. Yes
If DTC 15 is set problem is with the Harness
Is the Voltage >10V? else replace seat module.
No
Refer to section 501-10.
K3 CHECK FOR REVERSE FUNCTION

With Ignition on and PRNDL in Reverse activate the Mirror Dip button, Yes
hold the button for 2 seconds to ensure chime will happen even if the Go to K5
function is currently enabled.
No
Did the seat chime? Go to K4
K4 CHECK FOR REVERSE AT THE SEAT CONNECTOR

Measure the harness voltage at CON-2 pin 3. Yes
If DTC 16 is set problem is with the Harness
Is the Voltage >10V? else replace seat module.
No
Refer to PCM section 303-14.
K5 CHECK FOR MIRROR OPERATION

Program different mirror locations into the memory buttons and then Yes
recall each memory position. Replace Harness. Refer to removal and
Did the mirrors move to the correct location?
No
Refer to the Exterior Mirror section 501-09.
G73255 en 01/2003 2003.0 BA Falcon

501-10-18 Seating 501-10-18
Front Seat Assembly 4. Unplug all electrical connectors from outboard

underside of seat.
Removal
1. Set seat back angle to vertical position and set
height adjustment to full up position.
disconnecting any supplemental restraint
system electrical connector. Failure to follow
this warning could cause premature
deployment and may result in personal injury.
NOTE: Number of connectors depend on seat

option and may include seat belt pre-tensioner,
side airbag, memory and power connectors on
outboard side of seat (Refer to Section 501-20a).
3. Remove front and rear plastic track cover by

releasing metal spring.
5. Remove four seat mounting bolts.
6. Carefully remove the seat from the vehicle.

Installation
1. To install front seat, reverse the removal
procedure.
G73256 en 01/2003 2003.0 BA Falcon

501-10-19 Seating 501-10-19
Rear Seat Cushion 2. Press spring clip down to release.

Removal
1. To remove rear seat cushion push each side back
and up to release floor clips.
3. Pull bolster forward to remove, disengage plastic

hook at bottom.
Installation
1. Ensure that rear metal loop is engaged in sheet
metal as shown and push each side down to
engage floor clip.
Installation
Rear Seat Back
Removal
1. Remove seat bolster. Refer to Rear Seat Bolster
Rear Seat Bolster in this section.
Removal 2. Delatch seat back and fold forward.
1. Insert screw driver down back of bolster.
G73259 en 01/2003 2003.0 BA Falcon

501-10-20 Seating 501-10-20
3. Place narrow screw driver between white cam Installation

and bearing. 1. Ensure white cam is in disengaged position and
seat back is lying flat.
4. Disengage cam from bearing by levering

outboard. 2. Place cam in holder and raise seat back to
engage.
5. Lift seat back up vertically.

3. Check that cam has engaged properly.
6. Remove Rear Seat Back.
G73259 en 01/2003 2003.0 BA Falcon

501-10-21 Seating 501-10-21
Front Head Restraint Back Cover

Disassembly and Assembly Disassembly
1. Press locking button next to headrest guide and 1. Remove two screws located at bottom edge of
lift in direction shown. back cover.
2. Slide cover down until hooks located at the top

Item Description are released.
1 Press locking button
2 Lift headrest
2. Detach trim cover retaining strip by removing the
2 retaining screws.
3. Carefully disengage side clips and lift the back

cover away.
3. Peel back the trim cover up and away to remove

from head restraint pad.
CAUTION: Failure to follow procedure
can result in damage to the side retention clip.
Assembly
1. Insert the top retaining/locating tabs and slide
cover upwards.
2. Locate and snap in the side clips.
G73261 en 01/2003 2003.0 BA Falcon

501-10-22 Seating 501-10-22
3. Replace the 2 lower edge screws.

Lumbar Knob
CAUTION: Failure to follow procedure
can result in damage to the side retention clip. Disassembly and Assembly
1. Use a flat tool and remove lumbar knob cover.
Headrest Guides
1. Remove headrest (Refer to Headrest in this
section).
2. Remove back cover (Refer to Back Cover in this
section).
3. Undo top J-clip retainer.
2. Remove screw.
4. Insert your hand between the back rest foam pad

and the frame. With your fingers squeeze the
head rest guide ends and push upwards.
3. Place hands or fingers behind escutcheon/knob.
G73261 en 01/2003 2003.0 BA Falcon

501-10-23 Seating 501-10-23
4. Pull to remove knob and escutcheon together.

Recliner Knob and Outer Side Cover
1. Remove 2 mounting screws from the outer side
cover.
CAUTION: Failure to do so may cause
cover to crack around cover mounting boss.
Inner Side Cover

1. Undo screw from inner side cover.
2. Place hands behind side cover.
2. Remove inner side cover.
3. Pull side cover away from seat base to remove

the reclining knob and side cover together.
4. Where applicable, disconnect plugs from switch

and/or memory buttons.
G73265 en 01/2003 2003.0 BA Falcon

501-10-24 Seating 501-10-24
Front Seat Back 9. Unclip yellow plug from connector cradle (where
side air bag is fitted).
1. Remove seat out of vehicle (Refer to Seats in this
section).
2. Remove head rest (Refer to Headrest in this
section).
3. Remove plastic back cover (Refer to Back Cover
in this section).
4. Remove back cover (Refer to Back Cover in this 10. Remove three fir tree clips (where side air bag is
section). fitted).
5. Remove lumbar knob (Refer to Lumbar Knob in
this section).
6. Remove recliner knob and outer side cover (Refer
to Recliner Knob and Outer Side Cover in this
section).
7. Remove inner side cover (Refer to Inner Side
Cover in this section).
8. Unclip connector cradle cover (where side air bag
is fitted).
WARNING: Never probe the connectors
on the air bag module. Doing so can result in
air bag deployment, which can result in
personal injury.
G73267 en 01/2003 2003.0 BA Falcon

501-10-25 Seating 501-10-25
11. Undo four M10 bolts as shown. 15. Unzip side airbag cover (where fitted) and remove
Outside it with the foam assembly.
WARNING: Never probe the connectors
on the air bag module. Doing so can result in
air bag deployment, which can result in
personal injury.
WARNING: After deployment, the air bag
surface can contain deposits of sodium
hydroxide, a product of the gas generant
combustion that is irritating to the skin. Wash
your hands with soap and water afterward.
Inside
12. Place seat back face down on clean work bench.

13. Remove head rest guides (Refer to Headrest in
this section).
14. Undo the 4 rear J clip retainer.
16. Remove dummy block where fitted.
G73267 en 01/2003 2003.0 BA Falcon

501-10-26 Seating 501-10-26
or side supplemental restraint system (SRS)

Airbag components and before repairing, installing new,
Disassembly adjusting or striking components near the front or
side air bag sensors, such as doors, instrument
1. See front seat (Refer to Seats in this section). panel, console, door latches, strikers, seats and
WARNING: Wait at least one minute after hood latches.
disconnecting the battery ground cable before Please refer to the appropriate workshop manual
disconnecting any supplemantal restraint to determine the location of the front air bag
system electrical connector. Failure to follow sensors.
this warning could cause premature The side air bag sensors are located at or near the
deployment and may result in personal injury. base of the B-pillar.
2. Remove plastic outboard side cover (Refer to disconnect the battery ground cable and wait at
Outer Side Cover in this section). least one minute. Be sure to disconnect auxiliary
3. Remove seat back from seat (Refer to Front Seat batteries and power supplies (if equipped).
Back in this section).
4. Remove trim cover and foam pad from seat back WARNING: The restraint system diagnostic
assembly (Refer to Front Seat Back in this tool is for restraint system repair only. Remove
section). from vehicle prior to road use. Failure to remove
could result in injury and possible violation of
5. Read warnings below and then remove two M5
vehicle safety standards.
nuts from airbag module.
WARNING: Never power up a seat inside or
WARNING: Always wear safety glasses when
repairing an air bag supplemental restraint system out of the vehicle except using the in-car
connector dedicated to power supply.
(SRS) vehicle and when handling an air bag
module. This will reduce the risk of injury in the NOTE: If a seat equipped with a seat mounted side
event of an accidental deployment. air bag system is being repaired, the air bag system
must be deactivated per the deactivation procedure
WARNING: Carry a live side air bag module contained in Section 501-20b of the appropriate
with the air bag and tear seam pointed away from workshop manual.
your body. This will reduce the risk of injury in the NOTE: Restraint system diagnostic tools must be
event of an accidental deployment. installed under the seats in the side air bag to floor
connector.
WARNING: Do not set a live side air bag
module down on the cover tear seam. This will NOTE: Diagnostics or repairs are not to be carried out
reduce the risk of injury in the event of an on a side air bag system or a safety belt pretensioner
accidental deployment. (if equipped) with the seat in the vehicle.
Prior to attempting to diagnose/repair the side air bag
WARNING: After deployment, the air bag system or a safety belt pretensioner (if equipped) the
surface can contain deposits of sodium seat must be removed from the vehicle and the
hydroxide, a product of the gas generant restraint system diagnostic tool must be installed in
combustion that is irritating to the skin. Wash side air bag connector at the floor connector. The
your hands with soap and water afterward. restraint system diagnostic tool must be removed prior
to operating the vehicle.
WARNING: Never probe the connectors on
NOTE: After diagnosing/repairing a seat system the
the air bag module. Doing so can result in air bag
restraint system diagnostic tool must be removed
deployment, which can result in personal injury.
before operating the vehicle.
equipped with an air bag supplemental restraint
system (SRS) is involved in a collision, inspect
the sensor mounting bracket and wiring pigtail for
deformation. Install and correctly position the new
sensor or any other damaged supplemental
not the air bag is deployed.
To avoid accidental deployment and possible
personal injury, the backup power supply must be
depleted before repairing or installing a new front
G73272 en 01/2003 2003.0 BA Falcon

501-10-27 Seating 501-10-27
6. Carefully remove airbag. 2. Carefully remove cover from foam by placing one
finger on the blue hook cover retaining strip and
peeling cover from the foam pad, making sure not
to pull the blue hook retaing strip the foam pad.
WARNING: After deployment, the air bag
surface can contain deposits of sodium
hydroxide, a product of the gas generant
combustion that is irritating to the skin. Wash
your hands with soap and water afterward.
CAUTION: Failure to do so may result in
retaining strip not being held in place
securely.
Item Description
1 Nut
2 Side Airbag
Assembly
1. Assemble Airbag module to seat frame ensuring
front plastic retaining features are located over
metal bracket tabs.
2. Install the two M5 nyloc nuts.
3. Check and fit dummy module to inboard side of
seat, if required. 3. Pull cover and loop (white seam on trim cover)
4. Fit foam and trim to frame. carefully so the blue hook assembly is not pulled
5. Pull SIAB covering material (“chute”) through and out of foam.
around SIAB module.
6. Close zip around seat frame.
CAUTION: Ensure that the zip is closed
properly.
CAUTION: Trim cover hook and loop
must be securely engaged and the trim cover
must be aligned in its proper orientation.
7. Reverse installation procedures 5,4,3,2 and 1.
NOTE: A repair is made by installing new
components only. If a new part is installed and the
new part does not correct the condition, install the
original part and carry out the diagnostic
procedure again.
4. Repeat for each section of hook and loop strip.
NOTE: If a side air bag deployment took place,
new seatback pad, trim cover, and side air bag Assembly
module must be installed. A new seatback frame 1. Make sure that you are installing the correct front
should be installed if necessary. seat back cover onto the foam seat back. A side
airbag cover can be identified by a tag with the
Front Seat Back Trim Cover words "AIRBAG" sewn into the seam on the
outboard side of each seat cover.In addition on
Disassembly the inside of the cover where the "AIRBAG" tag is
1. Follow instructions for front seat back attached a white airbag chute and trim cover ID
disassembly (Refer to Front Seat back in this bar code will be sewn into the seam.
section).
CAUTION: Do not fit a non airbag front
seat back cover to a seat that has a side
airbag fitted. Doing so may result in a side
G73268 en 01/2003 2003.0 BA Falcon

501-10-28 Seating 501-10-28
airbag deployment failure, which may cause 4. Unclip cover from connector cradle.
severe or fatal injuiry to the occupant.
NOTE: If a side airbag deployment took place,
new seatback pad, trim cover, and side airbag
module must be installed. A new seatback frame
should be installed if necessary.
NOTE: Do not fit an airbag front seat back cover
to a seat that does not have a side airbag fitted.
2. Push the cover loop (white seam on trim cover)
onto the blue hook in the foam seat back. The
cover loop must be engage along the entire
lenght of the seat back blue hook.
CAUTION: Failure to secure the cover
loop with the seat blue hook may result in a
side airbag deployment failure, which may 5. Unplug grey plug from connector cradle.
cause severe or fatal injury to the occupant.
6. Remove three fir tree clips.

Pre-tensioner
1. Where applicable, raise seat electrically to full
upright position.
2. Remove seat from vehicle (Refer to Seats in this
section).
3. Turn seat upside down to begin work on under
seat.
G73268 en 01/2003 2003.0 BA Falcon

501-10-29 Seating 501-10-29
7. Undo pre-tensioner mounting bolt. 3. Disconnect wiring plug(s).
8. Remove pretensioner wiring loom connector 4. Remove switch assembly from side cover housing
through space on top of seat track. using a flat bladed instrument to dislodge the
switch assembly.
Memory Module
1. Remove Seat from vehicle (Refer to Seats in this
section).
2. Unclip underseat wiring loom retention protecting
cover.
9. Remove pretensioner assembly.
Seat Operating Switch

1. Remove outer side trims.
3. Unplug the white memory module plugs.
2. Remove outer side cover (Refer to Outer Side

Cover in this section).
G73271 en 01/2003 2003.0 BA Falcon

501-10-30 Seating 501-10-30
4. Undo two retaining mounting screws. 4. Turn seat over and undo four cushion retaining
nuts.
5. Remove memory module.

5. Remove front seat cushion from track.
CAUTION: Take care during removal
6. Undo three black J clips (rear and sides).
process not to break off top mounting boss.
Front Seat Cushion (2-way)

section).
2. Remove pre-tensioner cable fir tree clips.
NOTE: Leave pretensioner fitted to track. 7. Undo front white J clip.
NOTE: White clip is glued to seat.
3. Remove front seat back (Refer to Front Seat Back

in this section). 8. Remove cover from foam as per seat back foam
disassembly instructions.
Front Seat Cushion (4-way & 6-way

non-memory)
1. Perform steps 1,2,3 from 2-way front seat cushion
disassembly.
G73271 en 01/2003 2003.0 BA Falcon

501-10-31 Seating 501-10-31
2. Remove three fir tree clips.
3. Perform steps 4,5,6,7,8,9 of front seat cushion

(2-way) disassembly.
Front Seat Cushion (6-way memory)

section).
2. Unclip wiring loom retention nappy.
3. Remove pre-tensioner cable fir tree clips.
4. Remove front seat back (Refer to Front Seat Back
in this section).
5. Unclip wiring loom clip from cushion frame using
long nose pliers.
6. Undo two memory module mounting screws.
7. Undo the memory module.
8. Per step 3 above on 4-way seat (Refer to Front
Seat Back in this section).
CAUTION: Be careful not to break off top
lug during removal process.
G73275 en 01/2003 2003.0 BA Falcon

501-11-1 Glass, Frames and Mechanisms 501-11-1
SECTION : 501-11 Glass, Frames and Mechanisms

CONTENTS PAGE
Glass, Frames and Mechanisms ..........................................................................................501-11-2
Glass, Frames and Mechanisms ..........................................................................................501-11-3
Window Control Switch .........................................................................................................501-11-4
Front Door Window Glass .....................................................................................................501-11-4
Rear Door Window Glass — Moveable ................................................................................501-11-5
Rear Door Quarter Window Glass — Sedan ........................................................................501-11-5
Rear Quarter Glass — Wagon ..............................................................................................501-11-6
Rear Door Quarter Glass — LWB ........................................................................................501-11-7
Rear Door Quarter Glass — Ute ...........................................................................................501-11-7
Front Door Window Regulator ..............................................................................................501-11-8
Rear Door Window Regulator ...............................................................................................501-11-8
Fixed (Stationary) Glass Replacement .................................................................................501-11-9
Front Windshield Glass .........................................................................................................501-11-9
Rear Windshield Glass — Sedan .......................................................................................501-11-12
Liftgate Glass — Wagon .....................................................................................................501-11-13
Rear Windshield Glass — Ute ............................................................................................501-11-13
01/2003 2003.0 BA Falcon

Glass, Frames and Mechanisms

Vehicles may be fitted with front power operated
windows (rear windows manually operated) or both
front and rear power operated windows.
Front only Power Windows
The switches located on the front door trims are used
to raise/lower the front windows. Depress and hold
the up/down switch locations to raise and lower the
window.
Front and Rear Power Windows

The five switches, located on the front driver door
trim, control the four windows. Switches are also
provided on the other three door trims for operation of
that window only. The child lock switch on the front
driver door can be used to disable the rear switches.
Auto down - the driver’s window switch can be
pressed and held for approximately 1 second to
automatically fully lower the driver’s window.
All electric windows operate with the ignition switch in
the ‘ON’ or ‘accessory’ positions. When the key is
returned to the ‘OFF’ position, power window
operation is available for one hour (or 45 seconds if a
door is opened).
F56430 en 01/2003 2003.0 BA Falcon

Glass, Frames and Mechanisms 2. Connect voltmeter or test light between lower
circuit breaker terminal and ground to ensure
Before making any of the following trouble checks, electrical supply at this point.
make sure that the battery is fully charged, and turn 3. Check operation of accessory relay in relay block
the ignition switch to the accessory position. by turning the ignition switch on and off and
observe the relay operation by sound or feel. If
Circuit relay is not operating, fit a new relay. Check for
For wiring circuit checks refer to the wiring diagram in current at the switches.
Section 000-00.
A Single Power Window is inoperative
All Power Windows are inoperative
4. Activate the switch and listen for the motor
1. Remove 30 amp circuit breaker in fuse panel and running free. If the motor runs and the window
check for continuity through contacts. does not move, the glass coupling or gear teeth
have failed.
5. If the motor does not run, disconnect the wires at
the motor in order to check for voltage attach feed
wire while actuating the window switch. If there is
no voltage at the motorfeed terminals, check for
voltage at the switch feed wire. If there is voltage
at the switch, replace the switch.
Window inoperative in one direction
6. Check the operation with the individual and
master switches. If only one switch is inoperative,
replace the faulty switch.
7. If the window will not function correctly from either
switch, check for defective wiring between the
switch and the motor. If the wiring leads are open,
replace the wiring.
8. If the window operates normally in one direction,
the motor is not defective.
Power window operates sluggishly

9. Check the regulator and window runs for binding.
Adjust the runs, repair and lubricate the regulator.
Lubricate the runs with silicone lubricant.
10. Check for frayed insulation where the window
wires may partially ground. Check for loose
connections which will cause high resistance.
11. Check motor current draw during operation (place
an ammeter in series with the ground lead of the
battery). Motor current draw should not exceed 12
amps during normal operation and should exceed
20 amps at stall. If the current is above 12 amps
during operations of the window, readjust the
glass mechanism. If the stall current is below 20
amperes at stall, look for poor electrical
connections.
12. Motor current draw when disconnected from the
regulator plate should not exceed 5 amps.
F56431 en 01/2003 2003.0 BA Falcon

Window Control Switch 3. Remove the power window switch from the door
trim & disconnect the wiring.
Removal
1. Remove door trim (For additional information refer
to Section 501-05).
2. Remove switch panel by depressing locking tabs
at rear of door trim and pushing through to front of
trim.
Item Description
1 Window control switch
2 Door trim
4. Remove the door trim retaining screws and
remove door trim.
5. Remove the door watershield.
6. Raise the door glass until the glass to regulator
Item Description retaining clips are accessible. Hold the glass at
1 Window control switch the top edge and use a blade screwdriver to
2 Door trim deflect and disengage the vertical legs of both
retaining clips.
NOTE: If the regulator is jammed preventing
access to the retaining clips it may be necessary
to cut the cable on the regulator in order to lower
the glass.
Item Description
2 Door trim
Installation
1. Reverse the removal procedure. Item Description
1 Front Power Window Regulator
Front Door Window Glass 2 Front Door Inner Panel
Removal 3 Glass and Clip Assembly Nut
1. Remove the remote mirror interior trim. 4 Nut
2. Remove the interior door handle bezel and 5 Bolt
window regulator handle. 7. Raise the glass in the door and disengage from
the glass run. Tilt the glass forward and withdraw
from the outside of the door.
F56432 en 01/2003 2003.0 BA Falcon

Installation 5. Raise the door glass until the glass to regulator

1. Insert the glass into the door, forward edge retaining clips are accessible. Hold the glass at
downwards from the outside. Lower glass into the the top edge and use a blade screwdriver to
door and tilt back to normal position to engage in deflect and disengage the vertical legs of both
door glass runs. retaining clips.
2. Align the glass to regulator. Push glass NOTE: If the regulator is jammed preventing
downwards to ensure engagement of retaining access to the retaining clips it may be necessary
clips. to cut the cable on the regulator in order to lower
the glass.
3. Temporarily connect the switch to the wiring to
ensure glass moves freely in glass runs.
4. Install door watershield.
5. Position door trim panel and install retaining
screws.
6. Install interior door handle bezel and window
regulator handle.
NOTE: With the glass fully raised, position the
window regulator handle pointing rearwards (i.e. 3
o’clock for RHS and 9 o’clock for LHS).
7. Install power window switch whilst connecting
wiring to back of switch.
Install remote mirror interior trim panel.
Rear Door Window Glass — Moveable

Item Description
Removal 1 Rear Door Inner Panel
1. Remove interior door handle bezel. Remove 2 Glass and Clip Assembly
window regulator handle. 3 Nut
2. Remove the door trim retaining screws and 4 Bolt
remove door trim.
5 Rear Power Window regulator
3. Remove the power window switch from the door
trim and disconnect the wiring. 6. Withdraw the moveable door glass from the
outside of the door frame.
NOTE: It may be found beneficial to lower the
window regulator after disengaging the glass to
regulator retaining clips.
Installation
1. Insert the glass into the door from the outside, tilt
the glass forward and lower it into the glass run.
2. Raise the window regulator and align the glass to
regulator. Push glass downward and ensure
engagement of retaining clips. Check that glass
operates freely in glass run.
3. Refit the door watershield.
4. Install door trim panel and retaining screws.
Item Description 5. Install the interior door handle bezel and window
regulator handle.
NOTE: With the glass fully raised, position the
2 Door trim window regulator handle pointing rearwards (i.e. 3
4. Remove the door watershield. o’clock for RHS and 9 o’clock for LHS).
6. Install power window switch whilst connecting
wiring to back of switch.
F56434 en 01/2003 2003.0 BA Falcon

Rear Door Quarter Window Glass — 3. Remove the rear quarter glass lower moulding.
Sedan
Removal
CAUTION: Gloves and protective eyewear
should be worn at all times.
1. Prepare to remove the rear door quarter glass by
applying masking tape to the body in line with the
glass edges. This will help to protect the vehicle
paintwork should the cutting tool used in removal
slip or cut through the urethane.
2. Remove antenna terminal (left hand side only).
Item Description
1 Door Outer Panel
2 Door Inner Panel
3 Seal Assembly
4. Open the liftgate and remove the quarter glass
rear moulding.
5. Grasp the rear glass upper moulding by hand and
carefully pull the moulding upwards to detach it
from the glass.
6. Make antenna terminal connection (left hand
glass only).
Item Description
7. Prepare to remove the quarter glass by applying
1 Rear Door Quarter Window Glass masking tape to the body in line with the glass
2 Door Inner Panel edges. This will help to protect the paintwork
3 Screw should the cutting tool used in removal slip or cut
through the urethane suddenly.
4 Rivet
3. Cut the urethane around the perimeter of the CAUTION: When cutting near the corners
glass using a sharp, long-bladed knife. Remove of the glass, cut inwards from the corners to
glass and weatherstrip assembly. avoid bodywork damage.
Installation
1. Prepare surfaces and apply primer and sealer as
described in the windshield long or short
installation procedures.
2. Attach glass and weatherstrip assembly to door
by first locating the lugs on the lower part of the
moulding into the guides on the beltline.
3. Use duct tape or G-clamps to hold assembly to
door during curing period. (approx. 1.5 hours).
Rear Quarter Glass — Wagon

Removal
should be worn at all times. Item Description
1. Remove interior ‘C’ pillar trim. For additional 1 Seal
2. Remove two retaining nuts and remove exterior
‘C’ pillar trim.
F56434 en 01/2003 2003.0 BA Falcon

8. Cut the urethane around the perimeter of the 3. Prise the glass from the panel by cutting the
glass using a dual handle knife. Continue until all butyl-coated PVC foam sealer.
urethane is cut. Thick areas of urethane not cut
by the dual handle knife can be cut with a utility
knife.
9. Attach suction cups to the quarter glass and lift it
clear of the aperture.
NOTE: Ensure that no urethane contacts silver
paint grid lines.
Item Description
1 Rear Door Quarter Glass
2 Stud
3 Nut
4. Remove up butyl/foam from painted sheetmetal.
Installation
Item Description 1. Remove the plastic release liner from the
1 Quarter Panel butyl-coated PVC foam of the 6th Lite. Check that
2 Quarter Glass Assembly the butyl covers the full length to be sealed.
3 Urethane Sealer 2. Apply and tighten nuts to the five studs.
3. Reinstall interior C-pillar trim.
Installation
NOTE: For installation refer to the windshield long or Rear Door Quarter Glass — Ute
short installation procedures.
Removal
1. Install the rear quarter glass lower moulding.
2. Install the ‘C’ pillar trim panel. CAUTION: Gloves and protective eyewear
Rear Door Quarter Glass — LWB 1. Remove interior C-pillar trim. For additional
Removal
2. Remove antenna terminal.
CAUTION: Gloves and protective eyewear 3. Remove the two nuts from the studs.
1. Remove interior C-pillar trim. For additional
2. Remove the five nuts from the studs.
F56438 en 01/2003 2003.0 BA Falcon

4. Prise the glass from the panel by cutting the Item Description
butyl-coated PVC foam sealer. 3 Glass and Clip Assembly Nut
4 Nut
5 Bolt
2. Raise the glass by hand and support the glass in
the fully raised position.
3. Remove the three nuts and three bolts attaching
the regulator to the inner panel.
4. The regulator assembly is a non-serviceable item
and must be replaced if faulty.
Installation
1. Position the regulator into the door and install the
retaining nuts and bolts.
2. Repeat steps 2-8 of Removal and Installation in
section Front Door Window Glass.
Item Description
1 Glass Primer Urethane Rear Door Window Regulator
2 Panel Assembly
Removal
3 Glass and Weatherstrip Assembly
4 Lock Nut section Rear Door Window Glass - Moveable.
5. Remove up butyl/foam from painted sheetmetal.
paint grid lines.
Installation
1. Remove the plastic release liner from the
butyl-coated PVC foam on the 6th Lite. Check that
the butyl covers the full length to be sealed.
2. Apply and tighten nuts to the two studs.
3. Connect antenna terminal.
4. Reinstall interior C-pillar trim.
Front Door Window Regulator
Removal
Item Description
section Front Door Window Glass. 1 Rear Door Inner Panel
2 Glass and Clip Assembly
3 Nut
4 Bolt
5 Rear Power Window regulator
2. Raise the glass by hand and support the glass in
the fully raised position.
3. Remove the bolts and nuts attaching the regulator
to the door inner panel and withdraw the regulator
assembly. The regulator assembly is a non
serviceable unit and must be replaced as an
assembly.
Installation
1. Position the regulator assembly into the door and
Item Description install the retaining bolts and nuts.
1 Front Power Window Regulator 2. Repeat steps 2-6 of Removal and Installation in
section Rear Door Window Glass - Moveable.
2 Front Door Inner Panel
F56438 en 01/2003 2003.0 BA Falcon

Fixed (Stationary) Glass Replacement 1. Place covers on vehicle fenders, seats and
instrument panel. Remove interior mirror.
Special Tool(s) 2. Remove the wiper arm and blade assemblies. For
additional information refer to Section 501-08.
BTB Glass Removal tool
WK 10 HD 3. Raise the engine hood and remove the cowl top
vent grille panel. For additional information refer
to Section 501-08.
4. Prepare to remove the windshield glass by
glass edges. This will protect the vehicle
CAUTION: Do not slam vehicle doors within slip or cut through the urethane.
24 hours of fixed glass replacement unless 5. Cut paas moulding lip away level with edge of
vehicle windows are open 150mm. minimum. glass.
Vehicles should not be driven until urethane
sealant has cured for a minimum of 6 hours.
NOTE: The stationary glass, which is bonded to the
body aperture flanges by urethane sealant, forms part
of the body structure. The replacement of any
stationary glass requires that urethane sealant be
used to maintain the integrity of the structure.
Stationary glass is fitted to:
Windshield (laminated with a tinted band).
Rear window glass - Sedan.
Liftgate glass - Wagon.
Rear door quarter glass - Sedan and Wagon.
Rear quarter glass - Wagon.
Two alternative methods may be used in the
replacement of stationary glass, depending on
certain criteria.
Short method
The short method is used where the original
urethane adhesive is retained on the body
opening flanges after the glass is removed
and serves as a base for the replacement
glass. The operator should remove the glass
ensuring the maximum amount of urethane is
retained on the body flanges. This method
may be used to replace cracked windscreens
or glass which is still intact.
Long method
In the long method, the urethane adhesive is
completely removed from the body aperture Item Description
flanges and replaced with new adhesive. This 1 Primer
method used where the adhesive cannot NOTE: Width of primer at top edges of
serve as a base for the replacement glass or windshield
body and paint repairs are required. All
2 Primer Overlap Area
remaining urethane adhesive must be
removed from the body aperture flanges. 3 Paas Moulding
NOTE: Width of primer along bottom edge
Front Windshield Glass of windshield
Removal 4 NOTE: Width of primer at side edge of
windshield
CAUTION: Gloves and protective eyewear 5 Primer Overlap Area
F56444 en 01/2003 2003.0 BA Falcon

6. Clean glass thoroughly to allow visibility of the Short Method

cutting operation, and trim excess sealant
1. Trim the urethane sealant bed on the windshield
material from the edge of glass using a suitable
aperture flange until it is relatively smooth, and
blade.
remove any loose urethane pieces. Exposed body
7. Use BTB glass removal air tool (Part no:WK 10 surfaces should be cleaned with X55 solvent (or
HD). Spray into the flange from outside, & as equivalent) and primed with urethane primer.
close as possible to the urethane from inside. Use
a combination of Baby shampoo & water as this
will not stain IP etc. This aids the cutting tool to
slide through the urethane. Cut the Sides & Top
externally using 90° external blade.
Then using the long flat blade from inside the
vehicle cut away the Bottom & Free top corners.
Take care not to demage sheet metal & the IP
Top as it is not replacable.
8. When cutting operation is completed (be sure
there are no areas where sealant is still attached
to glass, as one such hold-up will cause breakage
of the windscreen on removal) attach suction cups
to glass and lift clear of aperture.
WARNING: Be careful not to damage IP
top surface (not replaceable).
Installation
NOTE: Determine which installation method is
appropriate under the circumstances. Refer to the
criteria for each method given earlier on this page.
Item Description
1 Glass asy. windshield
2 Paas moulding
3 Urethane sealant
2. Apply urethane sealant to exposed areas to
achieve an even sealant bed.
3. Clean periphery of glass with urethane cleaner
(ESB M5B 280 A or equivalent). Wipe cleaner off
immediately.
4. Apply urethane glass primer to the glass surface
ensuring no light is visible through the primer.
Allow the primer to cure.
NOTE: Thoroughly shake and stir the urethane
glass primer to ensure uniform pigment mixing
prior to application.
5. Apply a 13-15 High X 9-11 Wide triangular bead
of urethane sealant to the primed surface of the
glass for the entire perimeter. Ensure it is
positioned within the sealant areas shown.
F56444 en 01/2003 2003.0 BA Falcon

6. Attach suction cups to the windshield glass and lift 11. Assemble the interior rear view mirror to the
into position on primed body flange. bracket and tighten the mirror retaining grub
NOTE: Glass must be centred in windshield screws.
opening so the side clearances vary by not more Installation
than 3mm. Long Method
1. Clean all hardened Urethane from the flange.
Remove all dirt, dust etc. and clean flanges with
X55 solvent or equivalent to remove grease etc.
Wear light cotton gloves to avoid finger prints and
apply cleaner with a lint free cloth.
2. Using a clean brush, apply urethane body primer
to the flanges ensuring that no paint is visible
through the primer. Overlap primer in bottom LH
and RH corners. Primer application is sufficient
when appearance is glossy and free of streaks.
Allow 30 minutes for primer to cure.
NOTE: Do not touch primed surfaces or allow
surfaces to be contaminated prior to glass fitment.
3. Clean all dirt, dust etc. from windshield glass inner
surface.
4. Using a lint free cloth wipe the outer 25mm. of
inside windshield perimeter with urethane glass
cleaner.
NOTE: Remove glass cleaner immediately after
application because it flash dries.
5. Using a clean brush, apply urethane glass primer
to the glass surface with no light visible through
the primer. Allow to dry for 5 minutes.
NOTE: Thoroughly shake and stir the urethane
glass primer to ensure uniform pigment mixing
prior to application.
6. Apply a bead of urethane sealant around the
perimeter of the glass on the primed surface. The
Item Description sealant bead should be approximately 13-15. high
1 Rear door fixed glass with a base width of 9-11mm. and triangular in
shape.
2 Screw
7. Attach suction cups to the windshield glass and lift
3 Bolt into position on primed body flange. Use the
4 Rear door locating pins to position the glass.
5 Rivet NOTE: If any primer and/or urethane adheres to
the body or trim, other than where required, it
7. Secure the windshield by pressing upward until
must be removed immediately or the surface may
the upper moulding is firmly contacting the roof
be damaged if removed when dry.
rebate.
NOTE: If any primer and/or urethane adheres to 8. Position the wiper arm and blade assemblies and
the body or trim, other than where required, it install the retaining nuts.
must be removed immediately or the surface may 9. Install the cowl top grille panel support brackets.
be damaged if removed when dry. 10. Position the cowl top grille panel and install
8. Position the cowl top grille panel and install attaching screws.
attaching screws. 11. Attach the interior rear view mirror bracket to the
9. Position the wiper arm and blade assemblies and windshield in position as shown in Figure using
install the retaining nuts. the Motorcraft Adhesive Kit or equivalent.
10. Attach the interior rear view mirror bracket to the 12. Assemble the interior rear view mirror to the
windshield in position as shown in Fig. 20 using bracket and tighten the mirror retaining grub
the Motorcraft Adhesive Kit or equivalent. screw.
F56444 en 01/2003 2003.0 BA Falcon

13. Clean windshield, remove covers from fenders,

seats and instrument panel.
Rear Windshield Glass — Sedan

Special Tool(s)
BTB Glass Removal Air Tool
WK 10HD
NOTE: The rear windshield glass is bonded to the

moulding and the two cannot be separated.
The moulding will be damaged during the removal
process and therefore the glass and mouldings
assembly cannot be re-used. Remove Roof Ditch
Mouldings to avoid damage.
Removal
1. Place covers on the rear parcel shelf, seats and
rear quarter panels.
2. Remove the heated rear glass wiring connectors.
3. Remove rear interior trim panels surrounding rear
windscreen. For additional information refer to
Section 501-08. Item Description
4. Prepare to remove the rear glass by applying 1 Rear Windshield
masking tape to the body in line with the glass 2 Paas Moulding
edges. This will help to protect the vehicle
3 Urethane Sealant
slip or cut through the urethane. 5. Use a lubricant such as Baby shampoo & water
applied inside the flange to aid air tool to slide
CAUTION: When cutting the urethane when cutting urethane. Use glass removal air tool
near the corners of the glass, cut inwards to cut all four sides around the perimeter of the
from the corners to avoid vehicle bodywork glass, externally using external blades. Free top
damage when cutting from inside. Be carefull corners using long flat blade & cut from inside the
not to demage sheet metal. vehicle.
6. Attach suction cups to the rear glass and lift it
Installation
For installation procedures refer to the windshield long
or short installation procedures. And also follow these
steps:
1. Urethane bead 9-11 wide and 12-14 high.
2. Make electrical connection from rear glass.
Fly-Lead to aerial amplifier module box on left
hand side.
3. Make electrical connection from earth lead to
glass terminal left hand side.
4. Because it will effect on glass antenna
performance.
paint grid lines.
F56444 en 01/2003 2003.0 BA Falcon

Liftgate Glass — Wagon 4. Cut around the perimeter of the glass using a dual
handle knife. Continue until all urethane is cut.
Removal Thick areas of urethane not cut by the dual
handle knife can be cut with a utility knife.
1. Remove liftgate wiper arm and blade.
NOTE: The PCV perimeter moulding is bonded to
the glass and must be replaced as part of the
liftgate rear glass assembly.
3. Prepare to remove the liftgate rear glass by
glass edges. This will help to protect the vehicle
CAUTION: When cutting near the corners
of the glass, cut inwards from the corners to
avoid bodywork damage.
Item Description
Item Description 1 Liftgate outer panel
1 Rear Windshield 2 Liftgate inner panel
2 Glass Prier - Urethane 3 Nut
3 Glass Cleaner - Urethane 4 Urethane Sealer
5. Attach suction cups to the liftgate glass and lift it
Installation
NOTE: For installation, refer to the windshield long or
short installation procedures, followed by assembly of
four retaining nuts.
1. Reconnect the liftgate rear heated glass wiring
connectors.
2. Refit the liftgate wiper arm and blade.
Rear Windshield Glass — Ute
Removal
NOTE: The rear windshield glass is bonded to the
moulding and the two cannot be separated.
F56447 en 01/2003 2003.0 BA Falcon

NOTE: The moulding will be damaged during the

removal process and therefore the glass and
mouldings assembly cannot be re-used.

1. Place covers on the rear parcel shelf, seats and
rear quarter panels.
3. Remove rear interior trim panels surrounding rear
windscreen. For additional information refer to
Section 501-08.
4. Prepare to remove the rear glass by applying
masking tape to the body in line with the glass
edges. This will help to protect the vehicle
CAUTION: When cutting the urethane
near the corners of the glass, cut inwards
from the corners to avoid vehicle bodywork
damage.
5. Cut the urethane around the perimeter of the
glass, on the inside of the vehicle, using a sharp
long-bladed knife.
6. Attach suction cups to the rear glass and lift it
Installation
NOTE: For installation procedures refer to the
windshield long or short installation procedures.
1. Reconnect the heater rear glass wiring
connectors.
paint grid lines.
F56447 en 01/2003 2003.0 BA Falcon

501-12-1 Instrument Panel and Console 501-12-1
SECTION : 501-12 Instrument Panel and Console

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-12-2
Instrument Panel ....................................................................................................................501-12-3
Instrument Panel ....................................................................................................................501-12-4
Floor Console & Duct Assembly ............................................................................................501-12-6
Overhead Console .................................................................................................................501-12-8
Sun Load Sensor ...................................................................................................................501-12-8
Vent Outlet Registers .............................................................................................................501-12-8
Demist Nozzles ......................................................................................................................501-12-8
Glove Compartment (with damper mechanism) ....................................................................501-12-8
Glove Compartment (without damper mechanism) ...............................................................501-12-9
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Lower Centre Finish Panel Assembly 1.2-1.8
Screw
Instrument Panel Centre Tunnel 25.5-34.5
Retaining Bolt
Instrument Panel Footwell Brace 25.5-34.5
Retaining Bolt
Instrument Panel Cowl Top Bolt 8.9-12.1
Instrument Panel Outside Retaining 25.5-34.5
Bolt
Instrument Panel Inside Retaining Bolt 25.5-34.5
Console Retaining Screw 3.1-4.3
PRNDL Retaining Screw 1.2-1.8
Console Transmission Retaining Screw 1.2-1.8
Console Gearshift Retaining Screw 1.2-1.8
G432160 en 01/2003 2003.0 BA Falcon

Instrument Panel
The following components are contained within the
instrument panel:
climate control HVAC (Heating, Ventilation and Air
Conditioning) unit
glove compartment
instrument cluster
instrument panel side finish panels
passenger airbag module
Instrument panel duct (incorporating Demist, Face
centre and side ducts)
Vent outlet registers
Sunload sensor
Interior command centre
G432166 en 01/2003 2003.0 BA Falcon

Instrument Panel 10. Detach the lever-lock wiring connectors at lower

cowl side wiring block retainers (common both
Removal sides. RH side shown).
1. Set seat back angle to vertical position and set
height adjustment to full up position.

disconnecting any supplemental restraint system
electrical connector. Failure to follow this warning
could cause premature deployment and may
result in personal injury.
3. Remove both front seat. Refer to Section 501-10
Seating.
4. Remove park brake handle. Refer to Section
206-05 Parking Brake and Actuation.
11. Detach wiring block retainers from body.
5. Remove Floor console as described later in this
section.
WARNING: The restraints control module
6. Remove A-pillar trim. Refer to Section 501-05 (RCM) orientation is critical for proper airbag
Interior Trim and Ornamentation. supplemental restraint system (SRS) operation. If
7. Remove instrument panel end cap mouldings (LH a vehicle equipped with an SRS system has been
and RH sides). involved in a collision in which the center tunnel
area has been damaged, inspect the mounting
and bracket for deformation. If damaged, the RCM
must be replaced whether or not the airbags have
deployed. In addition, make sure the area of the
RCM mounting is restored to its original
condition.

critical for proper system operation. If a vehicle
equipped with an airbag supplemental restraint
the sensor mounting bracket and wiring pigtail for
deformation. Replace and properly position the
sensor or any other damaged supplemental
8. Remove the fuse panel cover. not the airbag is deployed.
9. Disconnect the engine hood release cable from
the fuse box by pushing down at the rear and WARNING: To avoid accidental deployment
sliding it forward. and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side airbag supplemental
restraint system (SRS) components and before
servicing, replacing, adjusting or striking
components near the front or side airbag sensors,
such as doors, instrument panel, console, door
latches, strikers, seats and hood latches.
disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary
batteries and power supplies (if equipped).
CAUTION: Electronic modules are sensitive

to static electrical charges. If exposed to these
charges, damage can result.
G432162 en 01/2003 2003.0 BA Falcon

12. Disconnect the large restraints control module 17. Remove instrument panel centre tunnel retaining
(RCM) electrical connector. bolt.
1. Pinch the thumb tab and pivot the connector
position assurance lever all the way back until
it stops.
2. Pull out and disconnect the RCM electrical
connector.
18. Remove instrument panel foot well brace retaining

bolt.
Item Description
1 Small RCM connector cover
2 Small RCM connector
3 RCM
4 Large RCM connector
13. Disconnect the small RCM electrical connector.
1. Pull out and remove the electrical connector
locking wedge.
2. Push down to release the retaining tab.
19. Remove the sunload sensor blank.
3. While releasing the retaining tab, pull out and
20. Loosen Instrument panel cowl top bolt at least
disconnect the small RCM electrical
8-10 turns while pushing down firmly on the bolt
connector.
head. This spreads the two instrument panel
14. Remove steering column. Refer to Section 211-04 tangs so that they can be slid over the mating
Steering Column. cowl tang during the disassembly process.
15. ( Column Shift Only) Remove Centre Lower Finish
Panel Assembly.
16. Remove the Interior Command Centre. Refer to

Section 413-08 Interior Command Centre
G432162 en 01/2003 2003.0 BA Falcon

21. Undo outside instrument panel retaining bolts 8. Attach sun load sensor trim panel or blank.
below upper front door hinge. Do not remove. 9. Attach cowl scuff trims.
10. Attach fuse door.
11. Attach seat belts.
12. Refit console system.
13. Fit hand brake.
14. Fit front seat.
15. Fit seat side lower garnish and scuff plate.
16. Reconnect battery.
Floor Console & Duct Assembly

Removal
1. Remove front seating. For additional information,
22. Remove instrument panel side retaining bolts. 2. Remove parking brake. For additional information,
3. Move gear shift to D (Automatic) or 4th (manual).
Remove securig screw and handle/knob.
23. Place Gearshift in ’D’ position to provide

clearance for instrument panel removal.
24. Remove instrument panel assembly through right
hand side of vehicle.
Installation
NOTE: Prior to installing the instrument panel
assembly, its critical that the instrument panel cowl
top bolt is loosened at least 8-10 turns while pushing
down firmly on the bolt head. This process spreads
the two instrument panel tangs so that they can slide
over the mating cowl tang during assembly.
1. Position instrument panel assembly into vehicle
and secure side, outer, upper cowl, lower tunnel
and front floor retaining bolts.
2. Fit wiring retainer blocks to cowl sides.
3. Attach wiring connectors at cowl sides and crash
sensor.
4. Attach hood release cable.
5. Refit steering column.
Item Description
6. Attach A-pillar trim.
1 Selector handle
7. Attach end caps.
2 Screw
G432162 en 01/2003 2003.0 BA Falcon

4. Remove PRND dial or manual gear shift cover by 7. Remove tissue holder assembly.
lifting the cover evenly at the points illustrated
below.
8. Remove console gearshift retaining screws ( 3

screws for Automatic, 2 screws for Manual ).
5. Remove console wing trims by removing retaining
screws.
9. Remove side screw fixings.

6. Remove console retaining screws at instrument
panel interface.
G432163 en 01/2003 2003.0 BA Falcon

10. Detach retaining clips from inside console bin Installation

using flat head screwdriver.
Sun Load Sensor

For removal and installation of sunload sensor, refer
to section 412-04.
Vent Outlet Registers

For removal and installation of climate control vent
outlet registers, refer to section 412-02.
Demist Nozzles
Each of the two demist nozzles can be removed from
the instrument panel assembly separately.
11. Lift console at rear and disconnect wiring lead To remove, use a long fine tool (preferably with a
(where fitted). hooked end).
12. Remove console and duct assembly. Push the tool through the slot in each of the 4 spring
loaded clips at the rear of the nozzle (closest to the
Installation
driver/passenger) and lever /the spring clip forwards
1. Reverse removal procedure. and upwards from under the edge of the instrument
panel while gently prying the nozzle upwards.
Overhead Console
When all four rear spring clips are disengaged, the
Removal nozzle can be slid rearwards and upwards to
1. Carefully remove the Headliner. Refer to Section disengage the four fixed clips (closest to the
501-05. windscreen).
2. Disconnect all the wiring to the Interior Dome To assemble, the demist nozzle can be pushed
Lamp, Reading Lamps/Mobile Office Lamps. directly downwards in to the instrument panel until all
Refer to Section 417-02. four front fixed clips and four rear spring clips are
engaged.
3. Carefully remove the headliner from the vehicle.
(Care should be taken when handling headlining Glove Compartment (with damper
not to bend or crease unnecessarily). mechanism)
WARNING: Take care when handling Removal
headlining as skin irritation may result from
contact with fiberglass fibers. 1. Release and pull the damper pivot clip at the top
of the glove compartment by reaching up from the
4. Remove the 4 screws (Screw 4.2 x 1.4, 1x13 pan foot well to the left-hand side (passenger’s
washer head tap) connecting the backing plate
A-pillar). Release the damper pivot clip by
that is glued to the headliner and Overhead
depressing the central tab.
Console.
NOTE: Do not fully remove the damper pivot clip
to avoid difficulty in re-inserting it into the hole.
Pull it out only far enough to clear the damper
pivot ring.
G432163 en 01/2003 2003.0 BA Falcon

2. Fully extend the damper and push toward the

runner channel.
Item Description
1 Damper
2 Damper pivot clip Item Description
1 Damper pivot clip
2 Damper pivot runner
3 Damper
3. Close the glove compartment. The glove
compartment stop should engage and the damper
pivot should be positioned to allow the damper
pivot clip to slide in.
4. Push the damper pivot clip in to secure the
damper into position.
Glove Compartment (without damper
mechanism)
Removal
1. Open the glove compartment and release the stop
by pushing the stop downwards.
2. Pull the glove compartment out of the lower
hinges.
Installation
1. Clip the glove compartment into the lower hinges.
2. Close the glove compartment. The glove
compartment stop should engage.
2. Open the glove compartment and release the stop

by pushing the stop downwards.
3. Pull the glove compartment out of the lower
hinges.
NOTE: Avoid removing the damper from the glove
compartment moulding as damage to the damper
may result.
Installation
1. Clip the glove compartment into the lower hinges.
G432170 en 01/2003 2003.0 BA Falcon

501-14-1 Handles, Locks, Latches and Entry Systems 501-14-1
SECTION : 501-14 Handles, Locks, Latches and

Entry Systems
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-14-2
Latches .................................................................................................................................501-14-3
GENERAL PROCEDURES
Wagon Liftgate Latch ............................................................................................................501-14-4
Hood Latch ............................................................................................................................501-14-5
Front Door Latch ...................................................................................................................501-14-5
Rear Door Latch ....................................................................................................................501-14-5
Door Latch Striker .................................................................................................................501-14-6
Liftgate Latch and Actuator ...................................................................................................501-14-6
Liftgate Latch Striker .............................................................................................................501-14-7
Hood Latch Release Cable ...................................................................................................501-14-7
Decklid Latch and Emergency Release Cable .....................................................................501-14-7
Decklid Latch Striker .............................................................................................................501-14-8
Exterior Front Door Handle ...................................................................................................501-14-8
Exterior Rear Door Handle ...................................................................................................501-14-8
Interior Door Handle ..............................................................................................................501-14-9
Ignition Lock ..........................................................................................................................501-14-9
Interior Lock Button ................................................................................................................501-14-9
Grab Handles — Ute ..........................................................................................................501-14-10
Grab Handles — Sedan ......................................................................................................501-14-10
Fuel Filler ............................................................................................................................501-14-10
Fuel Filler Door Release Switch .........................................................................................501-14-11
Door and Liftgate Locks ......................................................................................................501-14-12
Ignition Lock ........................................................................................................................501-14-14
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Door Latch striker screws 8.9 - 12.1
Front door latch screw 5
Exterior rear door handle screws 5
Rear door latch screw 5
Exterior front door handle screws 5
Exterior front door handle lock 5
retaining screw
Decklid latch nuts 10
Decklid striker bolts 23
Wagon liftgate latch screws 15
Wagon liftgate actuator nuts 9
Wagon liftgate striker bolts 24
Hood latch bolts 23
Fuel filler 1.7
G31870 en 01/2003 2003.0 BA Falcon

Latches
The decklid consists of the following components:
Decklid latch
Decklid striker
Decklid emergency release cable
The wagon liftgate consists of the following
components:
Liftgate latch and actuator
Liftgate striker
The hood consists of the following components:
Hood Latch
Hood latch release handle and cable
The fuel filler consists of the following components:
Solenoid Assembly
G31871 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Wagon Liftgate Latch

NOTE: This latch consists of a primary latch position
designed to hold the liftgate firmly into the
weatherstrip section to preclude water leaks and/or
wind noise.
1. Ensure that the primary latch has been activated
when the liftgate is fully closed.
2. Adjust the liftgate latch striker pin as required to
establish a door-to-weatherstrip seal.
3. The striker can be adjusted fore/aft and sideways
by loosening the retaining bolts.
G31872 en 01/2003 2003.0 BA Falcon

Hood Latch 3. Remove door trim panel retaining screws (4).

Remove grab handle screws (2). Pull door trim
Removal away from sheetmetal.
1. Open bonnet. 4. Remove the door watershield and Hip Bolster.
2. Remove attaching screws and remove latch 5. Disengage latch rod from outer door handle and
assembly from vehicle. the door locking rod from the lock barrel lever.
Item Description
Item Description
1 Screw
1 Front door latch and actuator assembly
2 Bonnet Latch assembly
2 Screw
3. Disconnect latch operating cable.
6. Disconnect interior handle cable from latch.
7. Remove the door latch retaining screws (Torx
head), remove the latch from the door.
Installation
1. With the latch actuating rods attached assemble
the latch into the door panel. Install the retaining
screws.
2. Connect interior handle cable to latch.
3. Connect the outer door handle and lock barrel
rods.
4. Make sure soldier button rod is fitted to latch
handle. Make sure soldier button is fitted to rod.
5. Refit the door watershield and Hip Bolster.
Item Description 6. Install the door trim panel and refit the retaining
screws.
1 Latch operating cable
7. Install the interior door handle bezel and grab
2 Retaining clips handle cap.
3 Bonnet latch assembly
Rear Door Latch
Installation
1. Remove interior door handle. Remove window
Front Door Latch regulator handle (where fitted).
Removal 2. Remove grab handle cap (where fitted).
1. Remove the interior door handle bezel. 3. Remove door trim retaining screws, pull the door
trim panel from the door channel and remove.
2. Remove grab handle cap.
4. Remove water shield.
G31875 en 01/2003 2003.0 BA Falcon

5. Disconnect exterior door handle rod from latch Door Latch Striker
and handle.
Removal
1. Remove striker as shown in figure.
Item Description
1 Rear door latch and actuator assembly
2 Screw Item Description
1 Striker Assy. (1 per door)
6. Remove nuts retaining outer door handle, detach
handle from door panel and disconnect door latch 2 Screw - M8x18 Csk Tx (x2 per door)
rod. Installation
7. Remove latch retaining screws (Torx head). 1. Reverse removal procedure.
Disconnect interior handle cable from latch and
remove latch from door. Liftgate Latch and Actuator
Installation
Removal
1. Position latch into door panel, connect interior
handle cable. Install retaining screws. 1. Remove the liftgate interior trim panel.(Refer to
Section 501-05.)
2. Connect latch rod to outer door handle, position
handle to door panel and install retaining nuts. 2. Disconnect the wiring plug.
3. Refit door watershield.
4. Refit interior door trim panel and retaining screws.
5. Install interior door handle bezel, window
regulator handle and grab handle cap (where
fitted).
Item Description
1 Actuator assembly
2 Lock barrel connecting rod
3 Lock barrel
4 Actuator to latch connecting rod
5 Latch assembly
6 Nut
3. Remove the liftgate actuator mechanism retaining
nuts and disconnect the lock barrel connecting
rod.
G31875 en 01/2003 2003.0 BA Falcon

4. Remove the actuator assembly while Hood Latch Release Cable

disconnecting the latch rod.
5. Remove the latch assembly retaining screws and Removal
remove the latch with connecting rod and 1. Remove hood latch.
courtesy lamp wiring lead attached. 2. Disconnect hood release handle from instrument
panel.
Item Description
1 Latch assembly Item Description
2 Screw 1 Hood release handle
3 Courtesy lamp wiring 3. Pop out grommet on cowl side attached to cable.
4 Connecting rod Installation
5 Liftgate body 1. Reverse removal procedure.
Installation
Decklid Latch and Emergency Release
Cable
Liftgate Latch Striker
Removal
Removal 1. Remove decklid trim if fitted.(Refer to Section
1. Remove load floor carpet. (Refer to Section 501-05.)
501-05.) 2. Remove decklid latch nuts.
2. Remove liftgate latch striker bolts.
Item Description
Item Description 1 Decklid latch assembly
1 Liftgate striker 2 Nut
2 Bolt 3 Decklid body
Installation
G31878 en 01/2003 2003.0 BA Falcon

3. Disconnect emergency release cable. Exterior Front Door Handle

Removal
1. Remove the interior door handle bezel and
window regulator handle.
2. Remove door trim. For additional information,
refer to Door Trim section.
3. Remove the door trim retaining screws, lift the
door trim panel from the door channel and
remove.
4. Remove the door watershield sufficiently to gain
access to door handle.
5. Remove the two bolts retaining the outer door
handle.
6. Unclip the latch rod, remove the door handle from
Item Description the door panel and remove door handle.
1 Emergency release cable
2 Actuating cable end
3 Emergency release pull tab
Installation
Decklid Latch Striker

Removal
1. Remove cover lower back.(Refer to Section
501-05.)
2. Remove decklid latch striker bolts.
Item Description
1 Front outer door handle
2 Lock retaining screw
3 Lock retainer
4 Screw - M6
Installation
Exterior Rear Door Handle

Removal
1. Remove interior door handle bezel. Remove
Item Description window regulator handle.
1 Decklid striker 2. Remove door trim. For additional information,
2 Bolt refer to Door Trim section.
Installation 3. Remove door trim retaining screws, lift the door
1. Reverse removal procedure. trim panel from the door channel and remove.
4. Remove the door watershield sufficiently to gain
access to door handle.
G31878 en 01/2003 2003.0 BA Falcon

5. Remove bolt retaining outer door handle, detach 4. Disengage handle assembly from door inner
handle from door panel and unclip door latch rod. sheet metal by sliding rearwards and withdrawing
through trim.
Installation
Ignition Lock
Removal
1. Insert the ignition key and turn it to the ’1’
position.
2. Depress the pin in the steering column lock
housing and withdraw the lock assembly.
3. Insert the ignition key and turn it to the ’1’
position.
4. Align the lock in the column housing, depress the
Item Description pin and push the lock into the housing until the pin
1 Exterior rear door handle snaps into its locating hole.
2 Bolt
Installation
Interior Door Handle

Removal
1. Remove plug.
2. Remove screw attaching handle assembly to door
inner sheet metal.
Item Description
1 Solenoid assembly
2 Solenoid retaining screw
Installation
Interior Lock Button
Removal
NOTE: Lock button is not serviceable. Should a new
Item Description lock rod be required, a new lock button should be
fitted.
1 Interior door handle
2 Actuating cable Installation
3 Screw 1. Door trim must be removed to gain access to lock
rod.
4 Button plug
3. Disconnect cable attaching handle to latch.
G31886 en 01/2003 2003.0 BA Falcon

2. Push lock rod button firmly onto lock rod. Ensure Grab Handles — Sedan
locating rib faces out.
Removal
1. Remove grab handles as shown in figure.
Item Description
1 Lock button
Item Description
3. Replace door trim, guiding lock button through
1 Grab handle
hole in door trim.
4. Ensure button is flush with trim in locked position. 2 Screw
5. Check for satisfactory operation of the lock. Installation
Grab Handles — Ute
Fuel Filler
Removal
1. Remove grab handles as shown in figure. Removal
1. Open Luggage compartment.
2. Remove quarter trim.
3. Remove the two solenoid-retaining screws via the
fuel door.
Item Description
1 Grab handle
2 Screw
Installation
Item Description
1 Fuel filler flap
2 Solenoid retaining screw
4. Remove solenoid and cable assembly.
Installation
G31886 en 01/2003 2003.0 BA Falcon

Fuel Filler Door Release Switch

Removal
1. Use a flat plastic spatula similar to a credit card to
gently remove switch assembly from crash pad.
Clipping points are on the sides of the bezel.
NOTE: Using a screw driver or similar may cause
damage to the instrument panel.
2. Disconnect electrical connector from rear of

switch.
3. To disassemble the switch assembly:
Gently depress locking tabs and push switch
out from bezel.
Installation
G31887 en 01/2003 2003.0 BA Falcon

Door and Liftgate Locks

Door Lock
Disassembly
1. Drive out the roll pin securing the lever to the
magazine. Remove the lever and spring.
Item Description
1 Spacer
2 Wave washer
3 Tumbler
Liftgate Lock
Item Description
1 Spacer
2 Wave washer
3 Tumbler
NOTE: The same service procedures apply to both
locks. If the key code is unknown, it can be read
through the lock drain slot as follows:
Position the lock with the drain slot upwards and the Item Description
operating lever to the right. Starting at the left, read 1 Shutter
the code from each tumbler by counting the number of
notches on the edge of each tumbler. 2. Remove the circlip retaining the magazine.
3. Withdraw the magazine and tumblers.
1 notch = 1
2 notches = 2 Assembly
3 notches = 3 1. Open the overhaul kit and select the tumblers
0 notches = 4 required (in our example 1, 4, 3, 4, 2, 3) 4
spacers and 1 tumbler pack spring (wave
As can be seen, in our example the key code is washer).
143423.
G31891 en 01/2003 2003.0 BA Falcon

2. Select the correct handed magazine for the lock 7. Holding the magazine upright between finger and
being overhauled. An R or L is stamped on the thumb of one hand, lower the lock housing over
end of each magazine indicating the “hand” of the the magazine, ensuring that the roller does not fall
magazine. out and that it locates in the housing correctly.
Left hand door = L magazine
Right hand door = R magazine
NOTE: A right hand magazine is used for the
liftgate application.
8. Keeping the magazine in place in the housing,

check that the lock operates correctly. Holding the
lock face towards you (drain slot facing down):
A Left hand lock will have 0° freeplay to lock
(turn key to left), 45° freeplay before
NOTE: The roller slot is the narrower of the two slots. unlocking (turn key to right).
NOTE: Use a pencil to insert tumblers. A Right hand lock will have 0° freeplay to lock
(turn key to right), 45° freeplay before
3. Insert the tumbler into the magazine so that the unlocking (turn key to left).
roller cutout in the tumbler is on the same side as
the roller slot in the magazine.
The first tumbler inserted should be the last
number of the key code, in our example a ‘3’.
Follow this with a spacer, again ensuring that the
roller cutout aligns with the roller slot.
9. Up-end the assembly so that it rests on its front

face. Secure the magazine in the housing by
fitting the circlip.
4. The remaining tumblers are inserted in the

following order: ‘2’ + spacer, ‘4’ + spacer, ‘3’ +
spacer, ‘4’ + pack spring and finally the last
tumbler ‘1’. This is our key code example 143423.
5. Using multi-purpose grease, pack the centre of
the magazine and lubricate the magazine casing.
6. Lubricate and then insert the roller into the slot in
the magazine.
G31891 en 01/2003 2003.0 BA Falcon

10. Refit the lever return spring onto the housing by Disassembly
crossing the legs of the spring about the post on 1. Remove the large circlip (A) from the end of the
the housing. magazine.
11. Refit the lever ensuring that the spring sits
correctly about the lever and install the roll pin.
2. Remove the small circlip (B) and withdraw the

magazine assembly from the housing.
3. If the key code is unknown, remove the end cap
Ignition Lock from the magazine by spreading the castellations
and working from left to right, lay out the tumblers
in a line as they are removed.
4. Identify the tumblers (by reading the notches on
the edge of each tumbler) and write down the key
code.
NOTE: The housing is serviced as an assembly.
Individual components of the housing are not
serviced.
1 notch = 1
2 notches = 2
3 notches = 3
0 notches = 4
Assembly
Item Description 1. Open the overhaul kit and select the tumblers
1 Spacer required.
2 Wave washer NOTE: When rebuilding the lock, the first tumbler
to be inserted will be the last one removed: using
3 Shutter
our example, a ‘3’.
4 Tumbler
G31891 en 01/2003 2003.0 BA Falcon

2. Insert the first tumbler into the magazine ensuring

that the roller cutout is on the same side as the
roller slot in the magazine. Follow this with a
spacer, ensuring that the roller cutout aligns with
the roller slot. The first tumbler inserted (using our
example) should be a ‘3’.
Item Description
A Make sure roller slot and tumbler cut out
are on the same side.
3. Again, following our example, the remaining
tumblers are inserted in the following order:
2 + spacer, 4 + spacer, 3 + spacer,
4 + pack spring (wave washer) and finally the
last tumbler ‘1’.
This completes our key code example
143423.
4. Apply powdered graphite to the centre of the
magazine and to the magazine casing. At this
stage check that the roller descends/rises when
the key is inserted and turned, and that there is 0°
free play to lock and 45° free play before
unlocking.
5. Fit the end cap to the magazine, clamp it in a soft
jawed vice and using an automatic centre punch,
deform the castellations to secure the assembly.
6. Lubricate and insert the semi-circular shutter into
the magazine by holding the thin tapered end of
the shutter between the finger and thumb and
passing the thicker end under the two side tabs,
so that the thicker end of the shutter sits over the
centre of the lock.
7. Lubricate the roller and insert it into the roller slot.
8. Assemble the magazine into the housing by
aligning the roller to the roller recess in the
housing and sliding it in. Secure the magazine in
the housing by fitting the smaller circlip.
9. Refit the large circlip to the magazine so that its
open end is opposite the small raised tang on the
magazine.
G31892 en 01/2003 2003.0 BA Falcon

501-16-1 Wipers And Washers 501-16-1
SECTION : 501-16 Wipers And Washers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-16-2
Wipers and Washers — Front ..............................................................................................501-16-3
Wipers and Washers — Rear ...............................................................................................501-16-3
Wipers And Washers ............................................................................................................501-16-4
Rear Window Wiper Washer ................................................................................................501-16-4
GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm Adjustment .............................................................501-16-6
Rear Window Wiper Blade and Pivot Arm Adjustment .........................................................501-16-6
Washer Hose Repair .............................................................................................................501-16-6
Windscreen wiper motor test ................................................................................................501-16-6
Windscreen Wiper Blade Insert ............................................................................................501-16-7
Windscreen Wiper Arm and Blade ........................................................................................501-16-7
Windscreen Wiper Motor and Linkage Assembly .................................................................501-16-7
Wiper Motor from W/S Wiper Linkage Assembly .................................................................501-16-8
Washer Pump .......................................................................................................................501-16-8
Low Level Sensor .................................................................................................................501-16-8
Windshield Washer Reservoir — Sedan ..............................................................................501-16-9
Windshield Washer reservoir Sedan — High Series ............................................................501-16-9
Windshield Washer Reservoir Wagon ................................................................................501-16-10
Liftgate Wiper Assembly .....................................................................................................501-16-11
Washer Hose ......................................................................................................................501-16-11
Windshield Wiper/Washer Switch and/or Rear Window Wiper Switch ...............................501-16-11
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Front
Driver W/S wiper arm 510mm
length
Passenger W/S wiper 600mm
arm length
Driver W/S wiper blade 550mm
length *
Passenger W/S wiper 550mm
blade length *
Rear
Rear liftgate wiper arm 290mm
length
Rear liftgate wiper blade 400mm
length
* Driver and passenger blades are common
Description Nm
W/S wiper pivot shaft nut (Driver and 19-24
passenger) (F + G)
W/S wiper motor bolts (H.J.K) 9-15
W/S wiper motor crank nut (L) 16-20
W/S wiper motor linkage bolts and nuts 5.2-7.2
(ABCDE)
Rear wiper motor bracket bolts 8.8-11.5
Rear wiper motor pivot shaft nut 5.4-6.8
Rear wiper motor tower nut (Large) 1.3-1.8
Windshield washer reservoir bolts and 5-7
nut
G43530 en 01/2003 2003.0 BA Falcon

Wipers and Washers — Front

The W/S wipers and washer system consists of the
following:
W/S wiper blade (x2)
W/S wiper arm - Driver
Rear window wiper motor

Rear window wiper/washer switch
Control through the Body Electronic Module
(BEM)
Rear washer reservoir
Rear window washer pump
W/S wiper arm - Passenger Rear window washer hose
Rear window washer check valve
Rear window washer nozzle jet
W/S wiper motor

W/S wiper linkage
W/S wiper/washer switch
Control through Body Electronic Module (BEM)
W/S washer reservoir
W/S washer pump
W/S washer nozzle jet (x2)
Wipers and Washers — Rear

The rear W/S wiper and washer system consists of
the following:
Rear window wiper blade
Rear window wiper arm
G43532 en 01/2003 2003.0 BA Falcon

Wipers And Washers INT position, the windshield wipers and washers will
run as long as the knob is depressed (up to 10
Refer to Wiring Diagrams Section 501-16 for seconds). When the knob is released, the washer will
schematic and connector information. stop immediately, but the windshield wipers will
continue to run for two to three sweeps, then return to
Special Tool(s) their previous set operation. Washer engagement
73III Automotive Meter does not affect windshield wiper operation when the
105-R0057 or equivalent wiper/washer switch is in the LOW or HIGH position,
but the washer will be deactivated if the knob is held
for longer than 10 seconds.
Rear Window Wiper Washer
The body electronic module (BEM) allows operation of
the rear window wiper functions when the ignition
Worldwide Diagnostic System switch is in the ON or ACC position only. The BEM
(WDS) controls the cycling of the rear window wiper motor
418-F224 through a single relay (rear window wiper relay).
New Generation STAR (NGS) There are four modes of operation: off mode, interval
Tester mode, on mode and wash mode.
418-F052 or equivalent
diagnostic tool NOTE: The BEM does not control the rear window
washer, only the rear window wiper.
SABRE Electrical System
Tester In the off mode, there is no liftgate wiper motor activity
010-00736 or equivalent and the liftgate wiper motor will be in the PARK
position.
Principles of Operation
The wiper system has four different operating modes:
off mode, low-speed mode, high-speed mode, and
speed sensitive interval mode.
In the off mode, there is no windshield wiper motor
activity, and the windshield wiper motor is in the
PARK position.
In the ON mode, the windshield wiper motor is set to
a low-speed setting. The wiper/washer switch
provides voltage to the windshield wiper motor
through the low-speed circuit. The windshield wiper
motor provides ground through a dedicated ground
circuit.
In the high-speed mode, the windshield wiper motor is
set to a high-speed setting. The wiper/washer switch
provides voltage to the windshield wiper motor
through the high-speed circuit. The windshield wiper
motor provides ground through a dedicated ground
circuit.
In the interval mode, the windshield wiper motor is set
to a low-speed setting. The windshield wiper interval
relay is activated at the beginning of each wipe and
deactivated when the windshield wiper motor park
switch reaches the run position. The interval relay is
part of the wiper/washer electrical system.
When the wiper/washer switch is in the interval
position, the windshield wipers will make a single
sweep followed by a pause. The interval frequency
can be varied by rotating the control. The frequency
will auto adjust to vehicle speed.
To engage the windshield washer, pull the knob of
(WDS) the wiper/washer switch toward the steering
wheel. When the wiper/washer switch is in the OFF or
G43533 en 01/2003 2003.0 BA Falcon


C-159 RH High Beam Headlamp

1 (BR) Common switch 0V (GRND)
3 (GR) Supply/park switch +12V
4 (RD) Low speed 0V (GRND)
5 (BLK) Earth 0V
6 (BL) High speed 0V (GRND)
G43533 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm 2. To check each wiper motor function, apply power
to the appropriate plug terminals as described in
Adjustment the following table. Refer to Connector Circuit
NOTE: LHD shown, RHD similar. Reference - Wiper Motor Plug for terminal
location.
1. Cycle and park the windshield wipers.
3. The parking function requires the connections to
2. Verify that the RH and LH wiper blades are be made as per the low speed function. Once the
located at the specified position. motor is running at low speed applying ground
(0V) at the brown lead terminal with engage the
park function. The motor will remain in park
position until either the ground or power is
removed.
Function Wire Color Voltage Supply(V)

High Speed Green +12 V
Blue 0V (GRND)
Low Speed Green +12 V
Red 0V (GRND)
Park Green +12 V
Red 0V (GRND)
Brown 0V (GRND) - Park
3. If not within specification, remove the windshield
wiper pivot arms and reposition to the proper
locations; refer to Wiper Pivot Arm - Front in this
section.
Rear Window Wiper Blade and Pivot

Arm Adjustment
1. Cycle and park the rear window wiper.
2. Verify that the rear window wiper blade is located
at the horizontal position.
3. If not within specification, remove the rear window
wiper pivot arm and reposition to the correct
location; refer to Wiper Pivot Arm - Front in this
section.
Washer Hose Repair

1. Locate and verify the leaking washer hose.
2. Cut the hose cleanly and remove the damaged
portion of the washer hose.
3. Install a windshield washer hose adapter between
the cut ends of the hose.
NOTE: In diffucult cases, replacement of total
hose may be required.
Windscreen wiper motor test

1. Using an equivalent vehicle power supply (12V
DC), locate and disconnect the wiper motor loom
plug from the vehicle electrical system.
NOTE: The plug can be accessed in the engine
bay. No removal of windscreen wiper or vehicle
components is required.
G43534 en 01/2003 2003.0 BA Falcon

Windscreen Wiper Blade Insert 4. Cycle wiper motor to correct park position.
Removal
1. Lift (by the tip) the wiper arm away from the
screen as far as it will go; it will be held in that
position by spring tension.
2. Press to disengage the spring clip on the blade
and pull the wiper blade assembly off the wiper
arm.
3. Using a small screwdriver, lift the retention lug
and slide the cap off the refill. Discard all old refill
components.
5. Position the arm on the spindle.

6. Tighten the attaching nut finger tight and rotate
the arm to the correct position.
7. Tighten the attaching nut to specified torque.
8. Replace the plastic cover.
Windscreen Wiper Motor and Linkage

Assembly
Removal
1. Park the windscreen wiper system.
Installation 2. Remove wiper arms from pivots - note positions.
1. The replacement refill is supplied with one end 3. Remove black plastic shield which covers the
cap and a small retaining clip fitted. Remove the heater plenum and disconnect washer hoses to
small clip. give access to wiper motor and linkage assembly.
2. Carefully slide the end without the cap into the 4. Remove the 3 bolts which hold the passenger
metal support ensuring that the refill passes pivot end of the assembly to the body.
through each metal claw.
5. Remove the 2 nuts which retain the driver’s side
3. Assemble new end cap supplied with the refill pivot to the body. Push pivot into the plenum.
onto the end of the refill ensuring that the
retention lug on the end cap is securely located
behind the two upturned ends of the metal rails.
NOTE: Do not reuse any old end caps.
4. Refit the blade onto the arm ensuring the plastic
locking clip snaps into the hole in the arm hook.
Windscreen Wiper Arm and Blade

Removal
1. Lift the plastic cover from the spindle end of the
wiper arm.
2. Remove the nut attaching the arm to the pivot
spindle.
3. Prise the arm from the serrated tapered seat on 6. Disconnect the wiring from the wiper motor.
the spindle. 7. Carefully withdraw the motor and linkage
assembly towards the passenger side through the
hole in the cowl area.
8. Remove components as necessary from the
linkage.
Installation
1. Ensure the linkage is in park position.
G43540 en 01/2003 2003.0 BA Falcon

2. Slide the motor and linkage assembly through the 3. Remove washer pump
hole where the passenger pivot mounts, locate 1. Disconnect the electrical connector.
the driver’s side pivot and hand start the nuts on
2. Disconnect the washer hose from the
the securing studs.
washer-pump.
3. Locate the 3 mounting screws at the passenger
3. Remove the washer-pump.
pivot mounting points.
4. Tighten the 3 screws and the 2 nuts.
5. Connect the wiring to the motor.
6. Operate the motor to ensure park position.
7. Replace cover shield.
8. Replace wiper arm and arm nut covers.
Wiper Motor from W/S Wiper Linkage

Assembly
1. Remove link end from motor crank ball pin.
2. Clamp motor and linkage assembly in vice via
motor crank.
NOTE: This is to ensure motor crank does not 4. Install washer pump
rotate during step 3.
CAUTION: Do not operate the windshield
3. Loosen motor crank nut and remove motor crank. washer pump prior to filling the windshield
(Note motor crank position) reservoir.
4. Loosen and remove (3) motor mounting bolts. 1. Dip washer-pump inlet into water and
5. Remove motor from linkage. immediately insert washer-pump into washer
reservoir grommet.
6. To install, reverse removal procedure.
2. Dip washer hose in water and immediately
Washer Pump push washer hose (10mm) onto washer-pump
outlet.
Removal and Installation 3. Reconnect the electrical connector to
1. Remove the left front wheel (Refer to Section washer-pump.
204-04). Fill the windshield washer reservoir with clean
2. Remove the left front stone guard (Refer to water and Motorcraft R1-47 screen wash
Section 501-08). solution or equivalent.
NOTE: To prevent spilling windshield washer Low Level Sensor
fluid, drain the windshield washer reservoir before
removal. Removal and Installation
1. Remove the left front wheel (Refer to Section
204-04).
2. Remove the left front stone guard (Refer to
Section 501-08).
NOTE: To prevent spilling windshield washer
fluid, drain the windshield washer reservoir before
removal.
G43540 en 01/2003 2003.0 BA Falcon

3. Remove low level sensor 5. Install windshield washer reservoir

2. Ease the low level sensor out of the washer pump prior to filling the windshield
windshield washer reservoir. reservoir.
1. Locate windshield washer reservoir on stud
and place nut onto stud.
NOTE: Do not tighten.
2. Fit self tapping bolts (2 places) and tighten to
5-7Nm.
3. Tighten nut to 5-7Nm.
4. Dip washer hose in water and immediately
push washer hose (10mm) onto washer pump
outlet.
5. Reconnect the electrical connector to
washer-pump.
6. Fit washer cap to reservoir.
4. Install low level sensor
washer pump prior to filling the windshield
reservoir.
1. Dip low level sensor (sensor rubber seal
portion) into water and immediately insert
washer-pump into windshield washer
reservoir.
2. Reconnect the electrical connector to low
level sensor. Fill the windshield washer
reservoir with clean water and Motorcraft
R1-47 screen wash solution or equivalent.
Windshield Washer Reservoir — Fill the windshield washer reservoir with clean
Sedan water and Motorcraft R1-47 screen wash
solution or equivalent.
1. Remove the left front wheel (Refer to Section Windshield Washer reservoir Sedan —
204-04). High Series
2. Remove the left front stone guard (Refer to Removal and Installation
Section 501-08).
1. Remove the left front wheel (Refer to Section
3. Drain washer fluid from reservoir prior to removing 204-04).
washer reservoir.
2. Remove the left front stone guard (Refer to
4. Remove windshield washer reservoir Section 501-08).
1. Disconnect the electrical connector from 3. Drain washer fluid from reservoir prior to removing
washer-pump. washer reservoir.
2. Remove washer cap from reservoir so that 4. Remove windshield washer reservoir.
washer cap does not become obstructive at
windshield washer reservoir removal stage. 1. Disconnect the electrical connector from
washer-pump.
3. Disconnect the washer hose from the washer
pump. 2. Disconnect the electrical connector from low
level sensor.
4. Remove the two bolts & nut.
3. Remove washer cap from reservoir so that
5. Lower windshield washer reservoir and washer cap does not become obstructive at
remove from vehicle. windshield washer reservoir removal stage.
4. Disconnect the washer hose from the washer
pump.
G43545 en 01/2003 2003.0 BA Falcon

5. Remove the two bolts & nut. 4. Remove windshield washer reservoir.
6. Lower windshield washer reservoir and 1. Disconnect the electrical connectors from
remove from vehicle. washer-pumps.
2. Remove washer cap from reservoir so that
washer cap does not become obstructive at
windshield washer reservoir removal stage.
3. Disconnect the washer hoses from the
washer pumps.
4. Remove the two bolts & nut.
5. Lower windshield washer reservoir and
remove from vehicle.
5. Install windshield washer reservoir

washer pump prior to filling the windshield
reservoir.
1. Locate windshield washer reservoir on stud
and place nut onto stud.
NOTE: Do not tighten.
2. Fit self tapping bolts (2 places) and tighten to 5. Install windshield washer reservoir
5-7Nm.
3. Tighten nut to 5-7Nm. CAUTION: Do not operate the windshield
4. Dip washer hose in water and immediately washer pump prior to filling the windshield
push washer hose (10mm) onto washer pump reservoir.
outlet. 1. Locate windshield washer reservoir on stud
5. Reconnect the electrical connector to and place nut onto stud.
washer-pump. NOTE: Do not tighten.
6. Reconnect the electrical connector to low 2. Fit self tapping bolts (2 places) and tighten to
level sensor. 5-7Nm.
7. Fit washer cap to reservoir. 3. Tighten nut to 5-7Nm.
Fill the windshield washer reservoir with clean 4. Dip washer hose in water and immediately
water and Motorcraft R1-47 screen wash push washer hose (10mm) onto washer pump
solution or equivalent. outlet.
Windshield Washer Reservoir Wagon NOTE: Ensure correct washer hose is fitted to
correct washer-pump.
Removal and Installation 5. Reconnect the electrical connector to
1. Remove the left front wheel (Refer to Section washer-pump.
204-04). NOTE: Ensure correct electrical connector is
2. Remove the left front stone guard (Refer to fitted to correct washer-pump.
Section 501-08). 6. Reconnect the electrical connector to low
3. Drain washer fluid from reservoir prior to removing level sensor.
washer reservoir.
7. Fit washer cap to reservoir.
Fill the windshield washer reservoir with clean
water and Motorcraft R1-47 screen wash
solution or equivalent.
G43545 en 01/2003 2003.0 BA Falcon

Liftgate Wiper Assembly Washer Hose

Removal Removal
1. Remove trim panel from the inner surface of 1. Follow hose locations as shown in figures and
liftgate. unclip or pull off as necessary.
2. Remove wiper arm and remove the plastic shield
off the large mounting nut.
3. Remove the large mounting nut, spacer and
shield.
4. Remove the two nuts on the inner panel which
mounts the wiper motor.
5. Remove the wiring harness.
6. Remove the wiper assembly.
Installation
1. Reverse order of removal procedure.
Windshield Wiper/Washer Switch
and/or Rear Window Wiper Switch
The above switches are a component of the steering
column multifunction switch. To remove or install the
above switches the entire steering column
Installation multifunction switch must be removed/installed.
1. Fit seal to wiper motor output shaft. Please refer to Section 211-05 for information
regarding installation and removal of steering column
2. Position wiper motor into vehicle and secure using
the two nuts through the inner panel (do not multifunction switch.
tighten).
3. Fit the seal, spacer and tighten the large mounting
nut.
4. Fit the cover shield over the large nut.
5. Tighten the two screws on the inner panel.
6. Attach wiring loom and operate wiper motor to
ensure it is in the park position.
7. Fit wiper arm and position appropriately.
8. Reinstall trim panel.
G43551 en 01/2003 2003.0 BA Falcon

501-17-1 Sunroof 501-17-1
SECTION : 501-17 Sunroof

CONTENTS PAGE
Roof Opening Panel ..............................................................................................................501-17-2
Operating Instruction ............................................................................................................501-17-4
Wiring Routing ......................................................................................................................501-17-6
Sunroof .................................................................................................................................501-17-7
Symptom Chart ....................................................................................................................501-17-8
Pinpoint Tests ......................................................................................................................501-17-9
GENERAL PROCEDURES
Sunshade Check .................................................................................................................501-17-12
Glass Panel Adjustment ......................................................................................................501-17-12
Glass Panel Seal Adjustment .............................................................................................501-17-12
Ventilation Tray Adjustment ................................................................................................501-17-13
Wind Deflector Adjustment .................................................................................................501-17-13
Mechanism Covers Adjustment ..........................................................................................501-17-13
Motor ...................................................................................................................................501-17-14
Sunroof Control Unit (SCU) ................................................................................................501-17-14
Drive Cables .......................................................................................................................501-17-14
Drive Cables Timing ............................................................................................................501-17-15
Glass Panel Seal ................................................................................................................501-17-16
Retraction Mechanism ........................................................................................................501-17-16
Guide Rail Mechanism ........................................................................................................501-17-16
Blocking Catch ....................................................................................................................501-17-17
Drain Channel .....................................................................................................................501-17-17
01/2003 2003.0 BA Falcon

501-17-2 Sunroof 501-17-2
Roof Opening Panel
G39860 en 01/2003 2003.0 BA Falcon

501-17-3 Sunroof 501-17-3
Item Description
1 Glass Panel
2 Rubber Seal
3 Drain Channel
4 Wind Deflector
5 Sunshade
6 Covers set LH/RH
7 Sunshade Handle
9 Mounting Set Mechanism
13 Service Set Locater LH/RH
14 Service Set Mechanism LH/RH
15 Nut Wind Deflector
19a Wire Harness SCU-UI
19 Wire Harness SCU & Rocker Switch (not
on drawing)
21 Switch
22 Fuse and Fuse Holder
24 Frame Rubber
25 Service Set Drive Cables
26 Service Set Blocking Catch LH/RH
27 Panel Mounting Set
33 Service Set Retraction Mechanism LH/RH
35 Set Drain Tubes (6 metre)
36 Trim Ring
37 Set Exterior Covers
40 Mounting Set Drain Channel
42 Set Guides Sunshade + Springs
46 Service Set Motor
49 Mounting Set Motor
51 Repair Set SCU 54
54 Set Side Support Brackets
58 Foam
60 Set Side Trimming LH/RH
61 Glue Set For Stratos 700 Unit
The STRATOS 700 Glass Panel sunroof is capable of
tilting, venting and sliding. The roofs are glass and
incorporate an internal sunshade. They are electrically
operated by a switch installed in the header panel.
G39860 en 01/2003 2003.0 BA Falcon

501-17-4 Sunroof 501-17-4
Item Description automatically closes the sunroof from any position

when the ignition key is removed.
1 Kit - Panel Roof Slide
When closed in this manner, the sunroof has
2 Bracket - Rear Cassette Support (x2) automatic jamming protection.
3 Rivet 6.4 x 2.8-4.8 (x10)
4 Bracket - Front Cassette Support (x2) Operating Instruction
5 Bracket - Interior Dome Lamp Opening - tilt positions
6 Retainer Roof Headlining (x2) The sunroof is controlled by its operating switch.
7 Rivet - 4.8mm Diameter (x4)
8 Filler - Headlining Front Outer (x6)
9 Filler - Roof Headlining Rear (x2)
10 Hose - Flex PVC Diameter 10mm Front
(x5 meters)
11 Hose - 10mm Rear (x2 Meters)
12 Grommet Rear Drain (x4)
13 Bracket - Dome Lamp Mounting
14 Screw - AB Tap 4.2x12.5 Dome Bracket
(x4)
The sunroof is installed in a special steel frame which
provides mounting points for the operating
mechanism, drain tubes, frame support brackets,
drive unit, electrical harness and a wind deflector. With the ignition on and the sunroof in the closed
A safety feature is incorporated into the system which position, press the switch. The sunroof will open
ensures that the sunroof automatically opens in the to the maximum tilt position open. By quickly pressing
event the sunroof encounters an obstruction while it is the switch, the sunroof will move down slightly to
being closed. the second highest tilt position A. The next quick
A further feature is the interconnection between the press of the switch will move it down to position B
sunroof and the vehicle’s ignition system which and so on until the sunroof is closed.
G39860 en 01/2003 2003.0 BA Falcon

501-17-5 Sunroof 501-17-5
Auto-close
When you turn off the ignition, the sunroof will beep to
indicate that auto-close will be activated. After 3
seconds, the sunroof will automatically start to close
which will be indicated by 2 beeps.
Once the sunroof has started to automatically close,
you can stop it from closing fully by briefly pressing
the or switch. If you don’t want the sunroof to
close from its current open position, press the or
switch during the 3 second interval and it will not
start to close.
You can still close the sunroof when the ignition is off.
Always ensure there are no obstructions to ensure the
Alternatively, press and hold the switch until the sunroof closes completely when leaving the vehicle.
sunroof tilts to the desired open position. When the
switch is released or the sunroof reaches the highest Sunroof Position Memory
tilt position, the opening function will stop. You can Two preset positions can be stored for the sliding
press and hold the switch until the sunroof has range of the sunroof. To program:
lowered to the desired position. If the switch is 1. Place the panel in the desired position.
released or the sunroof reaches the closed position,
the closing function will stop. 2. Press and hold the 1 switch until you hear a beep
(approx. 3 seconds).
Opening - sliding open 3. Place the panel in the second desired position.
With the ignition on, press the switch. The sunroof 4. Press and hold the 2 switch until you hear a beep
will start to slide open. To stop the movement before it (approx. 3 seconds).
opens fully, quickly press the or switch. To To select either programmed position, press the 1 or 2
close the sunroof, quickly press the switch. switch. By briefly pressing the switch, the sunroof
can be opened completely.
Alternatively, press and hold the switch until the
sunroof slides to the desired open position. When the Cleaning
switch is released or the sunroof reaches the fully
open position, the opening function will stop. You can Keep the sunroof gutter areas and drain openings free
of dirt, dust, leaves etc. Use an air hose twice a year
press and hold the switch until the sunroof has
to clean gutter areas and drain tubes. Clean the glass
closed to the desired position. If the switch is released
panel using only a mild non-scratching detergent and
or the sunroof reaches the closed position, the closing
a moist chamois leather.
function will stop.
Closing - from open or tilt position
Quickly press the C button to close the panel from
any position.
One-touch control
The sunroof can be operated by one-touch control.
With the ignition on, if the or switch is
momentarily pressed (for a maximum of 0.3 seconds)
for the required movement (either open or closed) it
will travel to the fully open or fully closed position.
Movement can be stopped at any intermediate
position by again pressing either switch.
Safety operation
If the sunroof is closed by either one-touch control or
auto-close, jamming protection is provided. The
sunroof will automatically re-open if it encounters an
obstruction while closing. After reaching the fully open
position, the sliding (closing) movement automatically
recommences. The sunroof will continuously try to
close until the obstruction has been removed.
G39861 en 01/2003 2003.0 BA Falcon

501-17-6 Sunroof 501-17-6
Wiring Routing
G39861 en 01/2003 2003.0 BA Falcon

501-17-7 Sunroof 501-17-7
Sunroof Motor
Disconnect the motor wire (green/black) from the
Inspection and Verification sunroof control unit. Dismount the motor. Use a
Wire Harness Sunroof Control Unit to Battery double wire of sufficient length, connect directly to
battery and inspect the motor for proper operation in
Check if the power supply on the red and red/black both directions. This is accomplished by reversing the
wires are OK? Inspect for broken/damaged wires. connection of the double wire. The motor has an
Inspect for proper connection to the sunroof control inbuilt thermal cut-out device that automatically
unit. The wire harness connector is numbered to aid switches the motor off during periods of overload.
in proper installation: After a cooling down period the motor will function
Connector Power on wire if Power on wire if properly.
ignition is off ignition is on Sunroof Control Unit
Wire number 1 12 V 12 V
Testing is covered in the electric trouble shooting
(red)
guide. The following failures could be the a result of a
Wire number 2 Ground Ground broken Sunroof Control Unit.
(green)
Auto close function defective.
Wire number 3 0 V 12 V
Soft touch operation defective
(red/black)
Comfort position can not be programmed
Wire Harness Sunroof Control Unit to Control 4 step down option defective
Panel One way closing defective
Inspect for proper power supply to the STRATOS 700 Before exchanging the Sunroof Control unit, the SCU
control panel, accomplished by using a voltage meter needs to be calibrated. Proceed with the trouble
on the connector pins. Measurements with battery shooting table if the problem is not solved by the
voltage of 13 V: calibration.
Connector Power on wire if Power on wire if Calibration of the SCU
ignition is off ignition is on
The first time the S.C.U. is connected to the power
Wire 1 (red) 10.9 V 13 V
supply, the maximum tilt position must be defined.
Wire 2 10.9 V 13 V Proceed as follows:
Wire 3 0V 0V 1. Turn on the ignition.
Wire 4 0V 0V 2. Open the panel to the maximum tilt position till it
Wire 5 0V 0V reaches the mechanical block (continuous control
Wire 6 0V 0.6 V the switch). The maximum tilt position is now
stored in the Control Unit and all electrical
features are available.
3. To complete the calibration, the panel must be
moved to the complete opened position by soft
touch operation.
Testing Electrical Components

Ensure that during the test of electrical components the TVS unit is connected to a 12 to 14V power source. If
the unit is installed, the battery needs to be connected and operable. During testing the ignition/accessory
switch should be on. This test can be accomplished with a test light/votage meter. Cable harness and motor
inspection requires the removal of the headlining.
Fuse
Visually inspect the fuse for damage.
G39862 en 01/2003 2003.0 BA Falcon

501-17-8 Sunroof 501-17-8
Symptom Chart

While cycling the panel from tilt to Replace blocking catch. Blocking catch is broken.
close it begins sliding rearward.
While cycling fully open panel forward, Replace blocking catch. Blocking catch is broken.
it begins tilting under roofskin.
Panel is misaligned side to side. Retime drive cables. Timing to drive cables incorrect.
Panel sliding too slowly (with 13.5V Weak battery. Charge or replace.
power supply panel should not take
more than 7 sec. to cycle from full
retraction to closure).
Misaligned panel creating drag or Retime drive cables.
friction.
Weak motor. Test as indicated in Replace motor.
electrical trouble shooting section.
Dirty mechanism. Clean and grease mechanism or

replace if necessary.
Blocking of mechanism, glass panel Sunroof control unit adjusted Synchronize sunroof control unit.
stopping prematurely. improperly, panel stopping prior to
cycle.
Obstacle in mechanism or guide track. Find object and remove.

Rattles: One or two rear panel nuts not Tighten panel nuts. Refer Final
Rear of panel rattling in any position. tightened properly. Assembly and Adjustments section.
Sliding cap (plastic) on long lever not Inspect for proper alignment or
in place or functioning improperly. replace.
Drain channel rattles. Inspect for insulator tape between Add insulator tape.
drain channel and mechanism.
Squeaking sunshade. Plastic to metal movement between Grease contact spots.

sunshade and slides.
Sunshade handle rattling on trim Curvature of front sunshade incorrect. Correct curvature, manual adjustment.
finisher.
Rattling in motor area. Cover plate on motor has loose Tighten coverplate screws.
screws.
Wind noise: Replace blocking catch. Correct glass panel adjustment. Refer
Panel closed, excessive wind noise. Final Assembly and Adjustment
section.
Blocking catch broken. Glass panel seal not tight to trim ring.
Panel vented emitting whistling sound. Vinyl headlining material wrapped Place insulating tape along either
around sunshade too thin, creating outboard edge of sunshade to close
large wind channel between rail and channel.
side of sunshade.
Water leakage: Blocked drain tubes. Inspect drain tubes c!ean opening,
Water coming through panel opening blow out tubes.
area.
Misaligned or kinked drain tubes. Correct routing of drain tubes.

Housing frame distorted, seal to rail Correct frame curvature if necessary
disconnected. reseal rail to frame.
Rear rail bracket has broken seal. Reseal at rear rail seal point. Refer
Trimming Repair section.
Headlining wet in front. Frame seam has improper seal. Reseal at seam.
G39862 en 01/2003 2003.0 BA Falcon

501-17-9 Sunroof 501-17-9

Sunshade fails to open when glass Retraction mechanism broken. Replace retraction mechanism.
panel is opened to tilt position.
Operating of the sunroof is possible, Voltage-drop of power supply Check power-supply Reset
no auto-close, no Soft-touch. (changing battery or bad battery). programmable preset positions.
Clicking noises of CSU, panel not Voltage to low. Check power-supply/battery.
sliding.
CSU clicking in open position, roof Voltage-drop or power-supply. Cut off power-supply briefly (pull fuse),
does not close with continuous reset programmable positions.
pressing of button.
Pinpoint Tests
PINPOINT TEST A : SUNROOF NOT OPERATING CORRECTLY
A1 PANEL OPERATION
Turn the ignition switch on. Yes
Go to A2
Does the panel move when holding switch pressed?
No
Go to A9
A2 PANEL DIRECTION
Does the panel move in both directions? Yes
Go to A3
No
Go to A14
A3 PANEL TILTING
Is panel tilting and sliding possible? Yes
Go to A4
No
Go to A20
A4 SOFT TOUCH OPERATION

Is soft touch operational? Yes
Go to A5
No
Re-program preset stops and retest sunroof.
A5 AUTO-CLOSE FUNCTION
Is the auto close function working? Yes
Go to A6
No
Go to A11
A6 COMFORT POSITION
Is the comfort position working? Yes
Go to A6
No
Replace Sunroof control unit and retest.
G39862 en 01/2003 2003.0 BA Falcon

501-17-10 Sunroof 501-17-10

A7 ONE-WAY CLOSING
Is the one-way closing function working? Yes
Go to A8
No
A8 MOTOR OPERATION
Does the motor stop, SCU click in and position to max slide and Yes
max position? Sunroof O.K.
No
A9 SCU OPERATION
Does the SCU make a ’click’ sound? Yes
Go to A10
No
Go to A12
A10 MOTOR
Is the motor running properly? Yes
Solve mechanical failure and retest.
No
Go to A20
A11 POWER ON RED/BLACK WIRE

Is the power over red/black wire when the ignition is switched? Yes
No
Improve red/black connection and retest.
A12 WIRE VOLTAGE CHECK

On the SCU, does the red, red/black and green wires measure Yes
12V? Go to A13
No
Go to A15
A13 RED/BLACK WIRE VOLTAGE

Is the red/black power line 12V when body is grounded? Yes
Go to A14
No
Go to A16
A14 SWITCH CHECK

Does the switch appear to be O.K? Yes
Go to A17
No
Replace the switch and retest.
G39862 en 01/2003 2003.0 BA Falcon

501-17-11 Sunroof 501-17-11

A15 SCU POWER LINE VOLTAGE
Does the SCU power line measure 12V when the body is Yes
grounded? Improve ground wire connection and retest.
No
Go to A18
A16 FUSE 15A CHECK (MOBILE OFFICE)

Is fuse 15A O.K? Yes
Go to A19
No
Replace fuse 10A and retest.
A17 WIRE HARNESS CHECK

Is the wire harness O.K.? Yes
No
Replace wire harness and retest.
A18 FUSE 30A CHECK (SEAT)

Is fuse 30A O.K? Yes
Go to A19
No
Replace fuse 20A and retest.
A19 WIRE HARNESS CHECK

Does the wire harness appear to be O.K.? Yes
Improve power line connection and retest.
No
Replace wire harness and retest.
A20 POWER ON RED WIRE

Is there sufficient power supply over the red wire when operating Yes
the switch? Replace the motor and retest.
No
Improve red wire connection and retest.
G39862 en 01/2003 2003.0 BA Falcon

501-17-12 Sunroof 501-17-12
GENERAL PROCEDURES
Sunshade Check 6. Adjust the glass panel to the front. Check with for
example a business card the tension of the seal
1. Slide mechanism full backwards. against the trim ring at the rear.
2. Push sunshade retraction mechanism, on both 7. Tighten both center screws.
sides, completely forwards with a small 8. Adjust height at the front and tighten front screws.
screwdriver.
9. Adjust height at the rear by loosening torx screws
of the adjustment curve, adjust the glass level
with roof-skin and tighten screws (see figure 12).
Torque for all M5 screws is 3.5 Nm.
3. Check sunshade for curvature, headlining, for dirt,

damage, etc.
4. Push slide blocks on one side into locked position.
5. Place sunshade in position between slide rails, 10. Check functioning of mechanism and
unlock slide blocks. adjustments. Repeat operation 6 till 9 to readjust
6. Check for proper functioning. the glass panel if necessary.
Glass Panel Adjustment Glass Panel Seal Adjustment
1. Slide mechanism to tilt position. The proper positioning of the panel should result in
2. Inspect rubber seal and glass panel for damage. the seal firmly contacting either the EPDM trim ring or
flanged metal of the sunroof opening. If the panel fits
3. Place the height adjustment curve, (which is at
properly but gaps remain between seal and trim ring it
the rear of the glass panel), over the mechanism.
can be corrected as follows:
Place vertical front lips on panel between the RH
and LH mechanisms. 1. Adjust panel properly against the rear of the trim
profile (Refer to Final Assembly and Adjustment
4. Lift the mechanism mounting bracket from the
Section).
inside and install the 2 front and 2 center screws,
leaving the 4 screws untightened. 2. With a grease pencil mark the boundaries of
insufficient contact on the panel (at the front).
5. Put glass panel in closed position.
3. Remove panel.
G39863 en 01/2003 2003.0 BA Falcon

501-17-13 Sunroof 501-17-13
4. In the areas marked, a spacer will be inserted 9. Check functioning and adjustments.
inside the rubber seal. Use a vinyl tube with outer
diameter of 3 mm (0.12 in) for spacer material. Wind Deflector Adjustment
1. Slide panel backwards.
2. Bring deflector in position.
3. Adjust deflector to 4mm between trim profile and
deflector.
4. Tighten two capnuts (2 Nm).
5. Check operation of deflector.
Mechanism Covers Adjustment

1. Before mounting mechanism covers, check
functioning of completed roof on sunshade,
mechanism, wind deflector and adjustments of
glass panel. Correct if necessary.
2. Put mechanism in tilt position.
3. Place cover top part over 3 pins on side
adjustment brackets and lower part in rail under
drain channel.
5. Glue the spacer material to the seal with super

glue.
6. Remount panel and adjust. 4. Check functioning.
Ventilation Tray Adjustment

1. Slide the steel panel to tilt position.
2. Slide the ventilation tray completely to the rear
(release the 2 springs from the drain channel if
necessary).
3. Place the ventilation tray in the rail, starting with
the front guides, and slide it to the front. When the
ventilation tray slides completely to the front it can
occur that the guides come loose from the rail.
4. Place the left and right tumble mechanism over
the middle support pin of the steel panel.
5. Tumble the hook of the tumble mechanism into
the slot in the ventilation tray and fasten the
mechanism with a parker.
6. Place the panel in closed position.
7. Make sure the ventilation tray is parallel to the
trim tray. The rear corners of the ventilation tray
can be bend slightly if necessary.
8. The springs of the trim tray are automatically
locked to the drain channel during sliding open.
G39868 en 01/2003 2003.0 BA Falcon

501-17-14 Sunroof 501-17-14
Motor 3. Remove rear of headliner to access motor cover.

4. Remove motor cover, motor now drops down.
5. Disconnect the motor wire from the sunroof
1. Remove or drop rear of headliner to access motor control unit.
cover. 6. Remove the S.C.U. with screw, drop the front,
2. Remove cover, motor now drops down. slide back.
3. Disconnect the motor wire from the sunroof 7. Remove the gearwheel housing by removing the
control unit. two screws.
4. Connect new motor to sunroof control unit. 8. Remove gearwheel by inserting screw-driver,
5. Inspect motor for proper operations in both push forward, it drops down.
direc-tions.
6. Remount motor and motor cover.
7. Inspect the unit for proper electrical and
mechanical functioning.
8. Re-install headliner.
Sunroof Control Unit (SCU)

1. Remove or drop rear of headliner to access motor
cover.
2. Remove cover, motor now drops down.
3. Disconnect the motor wire from the S.C.U and
remove the motor.
9. Place a screwdriver in the mechanism as
4. Disconnect the wire harness from the S.C.U. indicated. Push this mechanism rearward into the
5. Remove the S.C.U. with screw, drop the front, slide position. Continue pushing backwards by
slide back. placing hand on front of mechanism, 3 locator
6. Place the new sunroof control unit by dropping the screws become accessible.
front of the S.C.U. low enough for cable clearance
slide forward, engage lip of cable plate in S.C.U.
slot. Straighten S.C.U. horizontally and tighten
screw.
7. Reconnect both wire connectors to the S.C.U. and
remount motor and cover.
8. Calibrate the SCU: The first time the S.C.U. is
connected to the power supply, the maximum tilt
position must be defined. Proceed as follows:
Turn on the ignition. Open the panel to the
maximum tilt position till it reaches the mechanical
block (continuous control the switch). The
maximum tilt position is now stored in the Control
Unit and all electrical features are available. To
complete the calibration, the panel must be 10. Remove the locator being careful to remember
moved to the complete opened position by soft the positioning of screws and the blocking catch.
touch operation. 11. Pull mechanism all the way forward.
9. Check proper functioning of sunroof. 12. Push the mechanism into tilt position. Be sure you
10. Mount headliner. do not inadvertently dislodge the mechanism.
11. Remount the LH mechanism cover. Keep the front of the mechanism down.
13. Remove the front screw and slide the retraction
Drive Cables mechanism forward. Do not take out.
Removal and Installation 14. Slide mechanism in tilt position further forward.
1. Remove covers, panel, drain channel, wind 15. You can now see the cable. Lift out cable and pull
deflector and sunshade or trim tray and ventilation forward out of the guide rail track.
tray and adjustment bracket.
2. Place mechanism in closed position.
G39869 en 01/2003 2003.0 BA Falcon

501-17-15 Sunroof 501-17-15
16. Inspect for proper length of new cable, grease 24. Mount the new gearwheel. Being sure to center it
and slide into rail. Make sure the oval shaped evenly between the walls of the hole in the motor
copper head of the cable seats firmly and bracket.
diagonally across the guide channel. NOTE: The core or center of the gear has splines
(teeth). The splines do not extend completely to
one side of the gears inner core. This is the down
(bottom) side for mounting
25. Mount the new gearwheel housing.
26. Mount the sunroof control unit. Dropping the front
of the S.C.U. low enough for cable clearance slide
forward, engage lip of cable plate in S.C.U. slot.
Straighten S.C.U. horizontally and tighten screw.
27. Connect the motor to the sunroof control unit (wire
one way connector).
28. Remount motor and cover, replace screws.
29. Calibrate the SCU as described in the Electrical
Trouble Shooting Section.
17. To check that cable is positioned properly grasp 30. Inspect the sunroof for proper electrical and
long lever in tilt position with one hand, the mechanical functioning.
pivoting adjustment bracket in the other hand and 31. Remount headliner.
slide backwards, it should slide into place (if
blocked turn cable slightly to reseat copper oval 32. Remount sunshade or ventilation tray and trim
head properly). tray, drain channel, panel, wind deflector and
mechanism covers.
18. Push mechanism into slide position as in point 9.
33. Final inspection of unit.
19. Slide whole mechanism rearwards to allow
remoun-ting of locator. Drive Cables Timing
20. Slide the retraction rearwards, remount screw and
locator. Removal and Installation
21. Repeat points 10 through 22 to replace other 1. Fully tilt panel.
cable. 2. Remove LH/RH mechanism covers.
22. Slide both LH/RH mechanisms to the front 3. Fully close panel.
position. 4. Drop rear of headliner to access motor cover
23. Push LH/RH mechanisms to closed position. plate.
Insert a pin in each 2.5 mm brass hole. (pointed 5. Remove motor cover, motor now drops down.
object). Slide mechanism forward until pin stops
the mechanisms movement at the desired 6. Disconnect sunroof control unit wires and remove
location. the motor.
7. Dismount sunroof control unit with screw, drop the
front and slide back.
8. Remove the gearwheel housing by removing the
two screws.
G39872 en 01/2003 2003.0 BA Falcon

501-17-16 Sunroof 501-17-16
9. Remove gearwheel by inserting screwdriver, push 2. Remove seal from panel.

forward, it drops down. 3. Remove all foreign debris from around glass
frame.
4. Install new seal, beginning at center front of glass
panel retaining channel.
5. Utilizing your thumbs, insert seal with enough
pressure to be sure of flushness (tight to panel).
6. Trim the glass seal length. when cutting excess
leave approximately 6 mm extra then work it into
retaining channel.
7. Remount the panel.
8. Mount the LH / RH mechanism cover.
Retraction Mechanism
Item Description 1. Retract panel completely.
1 SCU spots on gear wheel view finders 2. Remove the wind deflector.
2 SCU spots on gear wheel view finders 3. Remove the two screws and take the retraction
10. Push mechanisms LH/RH to closed position. mechanism forwards out of rail.
Access each 2.5 mm brass hole with a pin 4. Install new retraction mechanism in rail.
(pointed object). Slide mechanism forward until 5. Remount the wind deflector.
pin stops the mechanisms movement at the
6. Inspect for proper functioning.
desired location.
11. Mount the new gearwheel. Being sure to center it Guide Rail Mechanism
evenly between the walls of the hole in the motor
bracket. Note that the core or center of the gear Removal and Installation
has splines (teeth). The splines do not extend 1. Remove LH/RH mechanism covers, panel, drain
completely to one side of the gears inner core. channel, wind deflector and sunshade.
This is the down (bottom) side for mounting. 2. Fully retract mechanism.
12. Mount the new gearwheel housing. 3. Remove the locator, retraction mechanism and
13. Mount the sunroof control unit. Dropping the front rail screw.
of the S.C.U. low enough for cable clearance slide 4. Remove wind deflector mounting nuts.
forward, engage lip of cable plate in S.C.U. slot.
Straighten S.C.U. horizontally and tighten screw. 5. Slide rail sideways to unlock, then lift front up.
14. Connect the motor to the sunroof control unit. 6. With rail front up, remove retraction mechanism.
(wire one way connector). 7. Fully close mechanism.
15. Remount motor and cover, replace screws. 8. Lift and pull rail slowly forward over mechanism,
16. Calibrate the SCU as described in the Electrical as soon as the front of drive cable appears at end
Trouble Shooting Section. of guide, lift out cable, now pull mechanism
carefully forward and lift out. Inspect the new
17. Inspect the sunroof for proper electrical and replacement mechanism for cleanliness and
mechanical functioning. completeness.
18. Remount headliner. 9. Slide the new mechanism rearward out of rail for
19. Remount the LH mechanism cover. cable installation access.
20. Final inspection of unit. 10. Install cable, then push mechanism forward on rail
(maintain access to rear rail area).
Glass Panel Seal
1. Dismount LH / RH mechanism covers, glass
panel and exterior covers.
G39872 en 01/2003 2003.0 BA Falcon

501-17-17 Sunroof 501-17-17
11. Apply a bend of liquid butyl as indicated. 11. Remount panel, LH/RH mechanism covers. (Refer
Final Assembly and Adjustments section).
Drain Channel
1. Slide mechanism to tilt position.
2. Slide sunshade to half open position.
3. Mount drain channel on mechanism with screws
and washers (torque 0.8 Nm). High side at the
rear.
4. Check function of mechanism.
12. Slide rail rearward over mechanism and drive

cable while holding the front of the mechanism in
place. As soon as the rail is fully extended
rearward, drop the front to frame and push rail
rearward into rail stop. Line up the screw holes for
proper positioning.
13. Retract mechanism totally.
14. Lift front of rail to reinstall retraction mechanism.
15. Drop rail down, push inboard until it "locks" in
place.
16. Remount all new rail screws starting at front for
proper positioning. Use original positioning of
screws by size.
17. Replace wind deflector mounting nuts loosely.
18. Tilt mechanism completely.
19. Inspect for proper mechanical functioning of
mechanism.
20. Remount sunshade, drain channel, panel and
wind deflector.
21. Inspect functioning of sunroof, reinstall LH/RH
mechanism covers.
Blocking Catch
1. Remove LH/RH mechanism covers and panel.
(Refer Final Assembly and Adjustments section).
2. Fully retract mechanism.
3. Remove locator,
4. Fully tilt mechanism.
5. Romove blocking catch by lifting out.
6. Locate and clean out broken blocking catch
debris.
7. Install new blocking catch in mechanism, insert
circular eye stud into mechanism making sure
second smaller stud falls cleanly into mechanism
slot.
8. Fully retract mechanism.
9. Remount locator.
10. Inspect for proper mechanical functioning.
G39877 en 01/2003 2003.0 BA Falcon

501-19-1 Bumpers 501-19-1
SECTION : 501-19 Bumpers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-19-2
Bumpers ................................................................................................................................501-19-3
Front Bumper ........................................................................................................................501-19-4
Rear Bumper — Sedan ........................................................................................................501-19-5
Rear Bumper — Wagon .......................................................................................................501-19-6
Rear Bumper — Ute .............................................................................................................501-19-7
01/2003 2003.0 BA Falcon

501-19-2 Bumpers 501-19-2
SPECIFICATIONS
Description Nm
Upper Front Bumper Screw 10
Rear bumper Retaining Nut (Sedan) 3
Rear bumper Retaining Nut (Wagon) 3
Rear bumper Retaining Nut (Ute) 35
Rear bumper Retaining Bolt (Ute) 35
G32450 en 01/2003 2003.0 BA Falcon

501-19-3 Bumpers 501-19-3
Bumpers
The bumper system consists of the following
components:
Front bumper
Rear bumper
G32451 en 01/2003 2003.0 BA Falcon

501-19-4 Bumpers 501-19-4
Front Bumper 3. Disconnect the electrical connector to each lamp.
Removal
1. Remove the fender splash shield. Remove the
retaining scrivets (9 x 6mm), screws and firtree
clips.
NOTE: There are a total of 2 screws attaching the
front lower section of the splashshield.
NOTE: Adjust torque specifications at the front of
the document.
Item Description
1 Wiring Harness
2 Bumper Assy
4. Remove the two plastic push-in rivets from the
radiator grille and lift grille to remove.
Item Description
1 Fender Splash Shield
2 Firtree clip 6.5x25mm (2 off)
3 Scrivets - 6mm (9 off)
4 Screw - 5mm (1 off)
5 Screw - 5mm (2 off)
2. Remove the "lower air deflector" by removing the
eight attaching screws and two plastic push-in
rivets and sliding the air deflector rearwards.
Item Description
1 Rivet push in
2 Grille
Item Description
1 Air deflector
2 Screw
3 Rivet push in
4 Splash shield
G32452 en 01/2003 2003.0 BA Falcon

501-19-5 Bumpers 501-19-5
5. Remove the two screws from the bumper rabbit Rear Bumper — Sedan
ears.
Removal
1. Remove the rear splash shield by removing 2
plastic push in rivets, one rivet and a screw.
Item Description
1 Screws
2 Upper crossmembers
Item Description
3 Bumper
1 Rivet Aliminium
6. To detach the bumper from the bumper mounting
2 Screw
brackets, hold the bumper by the wheel arch
opening and push up, at the same time slowly pull 3 Rivet - Push in plastic
outboard until the tip of the bumper is clear of the 4 Splash Shield
fender. At this point push up, at the same time
slowly pull outboard until the bumper "clicks" clear 2. Remove plastic push in rivet in wheel arch.
of the bracket. 3. Remove three scrivets from the fording plate.
7. The bumper absorbes can be removed by NOTE: Fording plate should be below the wheel
removing the three screws for each side. tub tabs.
Item Description 4. Disconnect the electrical connector (if applicable).

1 Front Absorbers 5. Remove boot trim scuff plate and foldback side
carpets to expose the four mounting nuts.
2 Screw and washer assy
Installation
1. Reverse the procedure for Removal.
G32452 en 01/2003 2003.0 BA Falcon

501-19-6 Bumpers 501-19-6
6. Remove four mounting nuts from inside the boot. Rear Bumper — Wagon
Removal
1. Undo fording plate by drilling out the heads of the
two rivets at the bumper lower edge.
Item Description
1 M5 Nuts
2 Bumper Assy
3 Body
Item Description
7. To detach the bumper from the bumper mounting 1 Nut & Washer Assy
brackets, hold the bumper by the wheel arch
2 Nylon retainer - Oval
opening and push up, at the same time slowly pull
outboard until the bumper "clicks" clear of the 3 Nylon retainer - Round
bracket. 4 Rivet
5 Scrivet
2. Drill out tow plug rivets if fitted.
3. Remove splash shield “removable rivets”.
Installation
1. Reverse the procedure for removal.
Item Description
1 Bolt M6
2 Front cross member
3 Bumper front cover
G32452 en 01/2003 2003.0 BA Falcon

501-19-7 Bumpers 501-19-7
4. Remove the nut from inside the wheel arch on 5. Remove bolt.
each side.
Item Description
Item Description 1 Nut
1 Nut & Washer Assy 2 Bolt
2 Nylon retainer - Oval 3 Valence Panel
3 Nylon retainer - Round
6. Remove bumper assembly.
4 Rivet
5 Scrivet
Installation
5. Remove scrivets (4) attaching front top edge of 1. Reverse the procedure for Removal.
bumper.
6. Pull out bumper and stud at the wheel arch and
quarter panel. The push-in studs mid way along
the side of the bumper will pull out with a small
amount of force.
7. Slide bumper rearwards.
8. To remove the splash shields from the vehicle,
drill out the two rivet heads if required.
Installation
1. Reverse the procedure for Removal.
Rear Bumper — Ute

Removal
1. Remove tail lamps.
2. Remove stone deflector flap.
3. Remove 2 nuts at each end.
4. Remove licence plate.
G32455 en 01/2003 2003.0 BA Falcon

501-20a-1 Occupant Restraints — Active 501-20a-1
SECTION : 501-20a Occupant Restraints — Active

CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................501-20a-2
Occupant Restraint System ................................................................................................501-20a-3
Safety Belt Buckle Pretensioner and Switch .....................................................................501-20a-3
Energy Management Retractor ..........................................................................................501-20a-4
Web Grabber Retractor ......................................................................................................501-20a-4
Child Restraint System .......................................................................................................501-20a-4
Occupant Restraint System ................................................................................................501-20a-6
Inspection and Verification .................................................................................................501-20a-6
Symptom Chart ..................................................................................................................501-20a-6
Component Tests ...............................................................................................................501-20a-6
GENERAL PROCEDURES
Occupant Restraints — Active ............................................................................................501-20a-7
Belt Minder Deactivation/Activation ....................................................................................501-20a-7
Front Safety Belt Retractor .................................................................................................501-20a-8
Rear Outer Safety Belt Retractor ........................................................................................501-20a-8
Rear Centre Safety Belt Retractor — Sedan ....................................................................501-20a-10
Rear Centre Safety Belt Buckle/Minibuckle — Wagon .....................................................501-20a-11
Rear Centre Safety Belt Rectractor — Wagon .................................................................501-20a-11
Rear Centre Safety Belt Buckles ......................................................................................501-20a-12
Safety Belt Buckle and Pretensioner ................................................................................501-20a-13
Front Centre Seat Safety Belt Retractor — Ute ................................................................501-20a-13
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Safety belt retractor bolt (all) 33
Safety belt buckle and pretensioner 33
bolt
Safety belt lower anchor bolt (all) 33
Safety belt shoulder height adjuster 20
bolt
Safety belt sash guide bolt 33
Child safety seat tether anchor bolt 16
Rear safety belt buckle and rear centre 33
safety belt lower anchor nut
Rear centre safety belt buckle nut 33
G32450 en 01/2003 2003.0 BA Falcon

Occupant Restraint System Safety Belt Buckle Pretensioner and

Switch
WARNING: All safety belt components The front seat safety belt buckles incorporate
include retractors, buckles, shoulder height pretensioners and safety belt buckle switches, which
adjusters, child safety tether bracket, safety belt both are connected to the restraints control module
bezels and attaching hardware must be replaced (RCM) secured to the floor under the instrument
after they have been subjected to loading by panel.
occupants in a collision. Seat belt assemblies not If a fault is detected within the buckle system, the
in use during a collision should also be inspected RCM will illuminate the air bag warning light in the
and replaced if either damage or improper instrument cluster. Refer to Section 501-20B.
operation is noted.
The safety belt buckle pretensioners will deploy at the
same time with the front air bags in the event of a
WARNING: Each seating position in the
severe frontal collision. During a frontal collision, a
vehicle has a specific safety belt assembly, which
mechanism in the safety belt buckle system is
consists of one buckle and one tongue. The safety
triggered, which causes the buckle to move downward
belt assembly is designed to be used as a pair
and pull excess webbing from the lap and sash safety
and is not to be used across seating positions.
belts.
The active restraint system consists of the following:
The safety belt buckle pretensioner is not triggered in
Front outboard seat safety belt energy the event of a minor frontal, side or rear collision.
management retractors and shoulder height
The safety belt buckle pretensioner is not triggered in
adjusters, attached to the body under the B pillar
the event of a frontal collision, if the safety belt tongue
trim.
is not latched in the buckle.
Front outboard bucket seat safety belt buckles,
After the ignition is switched on and the front driver
attached to the inboard side of the seat.
seat safety belt buckle is not latched in, the warning
On the commercial vehicle fitted with an auto indicator in the instrument cluster will be on for 8
column gear shift, the front centre seat safety belt seconds or until the safety belt buckle is latched in.
buckle is attached to the left hand side of the rear
centre seat mounting foot. Belt Minder
On the commercial vehicle fitted with an auto This feature provides additional reminders to the
column gear shift, the front centre seat safety belt driver that the driver’s seat belt is unbuckled by
retractor is attached to the rear body panel behind intermittently sounding a chime and illuminating the
the trim panel. seat belt warning lamp in the instrument cluster.
Rear seat safety belt retractors for the outboard IF.... THEN....
and centre seats, attached to the parcel shelf
below the parcel shelf trim panel. The driver’s seatbelt is The seatbelt warning light
not buckled when the illuminates for
Rear centre and left hand side safety buckles, ignition is ON approximately 8 seconds
attached to the floor pan under the seat cushion. or until the seatbelt is
Rear centre and right hand side safety buckle, buckled
attached to the floor pan under the seat cushion. The driver’s seat belt is The Belt Minder feature
The child safety seat tether anchor, attached to not buckled and the is activated - the seatbelt
the parcel shelf. vehicle is moving more warning light flashes and
The seat safety belt system utilises three-point lap than 5km/h after the the warning chime
and sash safety belt in all seating positions. ignition is switched on. sounds 5 times every 30
The retractors in all seating positions feature ELR. seconds, repeating for
During any period of sudden deceleration, or under approximately 5 minutes
torsion load when cornering at speed, a weight within or until the seat belt is
the safety belt retractor moves a locking pawl against buckled.
the teeth on the retractor wheel, which then locks the The driver’s seat belt is The Belt Minder feature
retractor preventing any further release of webbing. buckled while the seat will stop activating.
As soon as the load applied onto the retractor through belt indicator light is
the safety belt webbing is removed the locking pawl illuminated and the seat
releases the retractor reel and normal movement is belt warning chime is
returned to the retractor. sounding.
The driver’s seat belt is The Belt Minder feature
buckled before the will not activate.
ignition switch is turned
to the ON position.
G32451 en 01/2003 2003.0 BA Falcon

One time disable

Anytime the seat belt is buckled and then unbuckled
during an ignition ON cycle, Belt Minder will be
disabled for that ignition cycle only.
Energy Management Retractor
The front driver and passenger (if a passenger air bag
is fitted) seat safety belt retractors, attached to the
base of the B pillar, have an energy management
feature designed to provide a controlled amount of
webbing pay-out in severe frontal crashes. Once
activated, the spindle in the retractor deforms so that
the belt forces transferred to the occupant’s chest do
not rise above a predetermined load.
Web Grabber Retractor Item Description
1 Anchor Fitting
The front passenger (if a passenger air bag is not
fitted) seat safety belt retractor attached to the base of 2 Attachment Clip
the B pillar is a Web grabber retractor. 3 Upper Tether Strap
4 Lock Washer
Child Restraint System
5 Spacer
WARNING: Rear-facing child restraint seat WARNING: Child restraint anchorages and
must not be placed in the front seat where a fittings are designed to withstand only those
passenger air bag is fitted. loads imposed by correctly fitted child restraints.
Infants and small children should be restrained at all Under no circumstances are they to be used for
times in an approved child restraint suited to the adult seat belts or harnesses or for attaching
vehicle and which conforms to AS1754-1991. Be sure other items or equipment to the vehicle.
to read the instructions provided by the restraint Incorrectly fitted child restraints may swing, twist,
manufacturer, or consult an approved Restraint Fitting tip or come away causing death or injury.
Station. Anchorage points for the installation of child restraint
Your automobile club or local vehicle registration anchor fittings are provided in the specific locations.
authority can provide location details of fitting stations.
Sedan
Use the child restraint seat only for the purpose it was
intended. Observe the manufacturer’s maximum load
or weight specifications. Do not carry other articles in
the child seat.
A child restraint anchor fitting is installed in the
rear centre anchorage position.
Illustrations of the restraint attachment clip and anchor
fitting are only applicable to child restraint attachment
clips conforming to AS1754-1991. If your child
restraint does not have an approved latched-hook
attachment clip, you should consult an approved
Restraint Fitting Station.
Item Description
1 Plug
2 Bracket Mount
G32451 en 01/2003 2003.0 BA Falcon

Wagon plug originally fitted in the hole or seal the hole

with a suitable plug or suitable bolt.
Item Description
1 Bracket
2 Screw
To gain access to the anchorage points it is
necessary to remove the small plug from the
anchorage to install the appropriate bolt, lock washer,
anchor fitting and spacer.
Ute
Ensure the anchor fitting is correctly oriented towards

the front of the vehicle, when the bolt is tightened.
The components supplied with child restraints
conforming to AS1754-1991 must be selected to suit
the anchorage point(s) in the vehicle.
Additional anchorage components may be obtained
from child restraint manufacturers or suppliers. Please
read and follow all the instructions supplied with the
child restraint. If you have any doubts, contact the
child restraint manufacturer or consult an approved
Restraint Fitting Station.
Child restraint anchorage points are manufactured
into the vehicle. Consult the car owner’s manual for
the location of the anchorage points.
WARNING: If the child restraint attachment

bolt is removed from the floor of your vehicle the
hole must be effectively sealed to prevent exhaust
gases entering the vehicle interior. Reinstall the
G32452 en 01/2003 2003.0 BA Falcon

Occupant Restraint System Visual Inspection Chart

Inspection and Verification Webbing Pretensioner wire
1. Verify the customer concern by operating the Safety belt retractor Warning indicator bulb
safety belts and tongue assembly on cluster
Safety belt buckle and
pretensioner
and electrical damage. Refer to the Visual Safety belt shoulder
Inspection Chart.
height adjuster
3. If the concern is not evident, verify the system
and proceed to the Symptom Chart.
Symptom Chart

Normal mode - occupant restraint Webbing CARRY OUT the Component Test in
system inoperative Safety belt retractor this section.
Safety belt warning indicator bulb is Safety belt switch Bulb Refer to DTC (Diagnostic Trouble
inoperative Circuitry Code) table in Section 501-20B.
RCM
Component Tests 1. Select for this test a quiet or private stretch of
road. Make sure that the road is clear and that full
Poor Retraction visibility is maintained at all times.
If a safety belt does not retract correctly, check that 2. Both driver and passenger should adopt a normal,
the trim bezels are correctly installed and not rubbing comfortable seating position. Both occupants
against the safety belt webbing. Where necessary, should wear the safety belts and the safety belt
check that the safety belt webbing is not rubbing at webbing must be correctly adjusted, with no slack.
one end of the retractor cover slot and, if so, correct 3. Proceed at a speed of 10 km/h (6 mph). Do not
by loosening the retaining bolt, aligning the retractor exceed 10 km/h (6 mph) for this test.
to centralize the safety belt webbing and retighten the
4. Apply the foot brake sharply to stop the vehicle. If
bolt.
both shoulder straps lock up, the safety belt
Functional Test retractor assemblies are functioning properly.
5. Conduct the test twice in each front and rear
WARNING: It is important that during this test passenger seat position.
the driver and passenger allows the safety belts to 6. Any safety belt retractor, which does not restrain
provide the restraint and do not attempt to the wearer during this test, must not be reused. A
anticipate the sudden deceleration. The steering new complete safety belt must be installed.
wheel should not be used as a brace. However,
both drive and passenger should prepare Static Test
themselves for the possibility that the safety belt With the vehicle stationary and on level ground take
will not lock. The passenger should hold their firm hold of the safety belt webbing (on the tongue
hands in front of them, just clear of the instrument side of the safety belt upper anchor) and pull out
panel or front seat backrest, depending on which quickly. The retractor should lock within 0.25 meter
safety belt is being tested. Failure to follow these (10 inches), preventing further webbing payout. Any
instructions may result in personal injury. safety belt retractor from which it is possible to extract
further webbing, must not be used. A new complete
safety belt must be installed.
G32453 en 01/2003 2003.0 BA Falcon

GENERAL PROCEDURES
Occupant Restraints — Active 3. Buckle the seat belt.

4. Press and hold the hazard button.
Safety Belt Cleaning
5. Unbuckle then buckle the seat belt.
WARNING: Do not bleach or re-dye the 6. Release the hazard switch. This will disable Belt
webbing, as the webbing may weaken. Minder if it is currently enabled, or enable Belt
Minder if it is currently disabled.
Clean the safety belt webbing only with a mild soap
solution recommended for cleaning upholstery or Confirmation of disabling Belt Minder is
carpets. Follow the instruction provided with soap. provided when the seat belt warning light
flashes 5 times.
Safety Belt Procedure After a Collision
Confirmation of enabling Belt Minder is
provided by constant illumination of the seat
WARNING: All safety belt assemblies belt warning light for 5 seconds.
including retractors, buckles, front seat belt
buckle support assemblies, shoulder belt height
adjusters, if so equipped, child safety seat tether
attachments, and attaching hardware should be
inspected after any collision. All belt assemblies
should be replaced unless a qualified technician
finds the assemblies show no damage and
operate correctly. Belt assemblies not in use
during a collision should also be inspected and
replaced if either damage or improper operation is
noted.
NOTE: Safety belt assemblies should be periodically
inspected to make sure they have not become
damaged and that they remain in correct operating
condition, particularly if they have been subjected to
severe stress. Before installing the new safety belt
assembly, the safety belt attaching areas must be
inspected for damage and distortion. If the attaching
points are damaged and distorted, the sheet metal
must be reworked back to its original shape and
structural integrity.
Install the new safety belt(s) using the appropriate
instructions. Perform the Functional Test.
Belt Minder Deactivation/Activation

CAUTION: The Belt Minder feature can be
deactivated/activated by performing the following
procedure. Before following the procedure, make
sure that:
the parking brake is on
the gearshift is in P (Park) (automatic
transmission) or the neutral position (manual
transmission)
the ignition switch is in the OFF position
all vehicle doors are closed
the driver’s seat belt is unbuckled
the parklights/headlights are OFF
WARNING: To reduce the risk of injury, do

not deactivate/activate the Belt Minder feature
while driving the vehicle.
1. Turn the ignition switch to the ON position. (DO
NOT START THE ENGINE)
2. Wait until the seat belt warning light turns off.
G32454a en 01/2003 2003.0 BA Falcon

Front Safety Belt Retractor 4. Remove the safety belt shoulder height adjuster.
Using M10 socket, remove the bolt.
Special Tool(s) Remove the safety belt shoulder height
Torx Bit T-50 adjuster.
Removal
1. Remove the safety belt anchor.
Remove plastic bolt cap
Using the special tool, remove the bolt
Remove the safety belt anchor
Item Description
1 Screw & Washer M8x20 Hex Flng
2 Belt & Rectractor Asy Frt
Installation
NOTE: Make sure to tighten all bolts to
Item Description
specification.
1 Belt & Retractor Asy Frt
NOTE: Make sure the safety belt webbing is not
2 Bolt 7/16 20 twisted prior to installation.
3 Screw Cap
NOTE: Make sure to align and install the safety
4 Spacer (UTE Only) belt retractor locating ear into the B-pillar sheet
2. Remove the B pillar trim panel. Refer to Section metal before installing the bolt.
501-05 NOTE: Make sure the trim spreader bracket is
3. Remove the front safety belt retractor. fitted to the B pillar sheet metal before installing
the height adjuster.
Remove the front safety belt retractor 2. Check the active restraint system for correct
operation.
Rear Outer Safety Belt Retractor
Removal
1. Remove the rear seat cushion. Refer to Section
501-10.
Item Description
1 Belt & Retractor Asy Frt
2 Screw M10x1.5
G32455 en 01/2003 2003.0 BA Falcon

2. Remove the safety belt anchor.

Item Description
1 Bolt Corflex (Pt of item 3)
2 Belt & Retractor Asy Rr
Item Description 3 C Pillar Trim
1 Belt & Rectractor Asy Rr 4 Safety belt trim (Pt of item 2)
2 Bolt Corflex (Pt of item 1) 5 Bolt 7/16 20
3. Remove the safety belt trim 4. Remove the child safety seat tether anchor
(Sedan only)
Prise off the safety belt trim from the package
tray trim (Sedan only) Using a 5mm hexagon key, remove the bolt
Remove the safety belt trim from C pillar Remove the child safety seat tether anchor on
(Wagon only) the package tray trim
Remove firtree clips
Item Description
1 Safety belt trim (Pt of item 3) Item Description
2 Bolt Corflex (Pt of item 3) 1 Plug
3 Belt & Rectractor Asy Rr 2 Bracket - Child Seat Back Mount
4 Pkg Tray Trim 5. Remove the package tray trim. Refer to Section
501-05.
Remove the pillar trim (Wagon only). Refer to
Section 501-05.
G32456 en 01/2003 2003.0 BA Falcon

6. Remove the rear safety belt retractor. 3. Remove the safety belt trim
Feed the safety belt webbing through the Prise off the safety belt trim from the package
package trim opening tray trim
Using the special tool, remove the bolt (s)
Remove the rear safety belt retractor
Installation
specification.
twisted prior to installation.
NOTE: Make sure to align and install the safety
belt retractor locating tab into the package tray
panel before installing the bolt.
2. Check the active restraint system for correct
operation. 4. Remove the child safety seat tether anchor
(Sedan only)
Rear Centre Safety Belt Retractor —
Using a 5mm hexagon key, remove the bolt
Sedan
Remove the child safety seat tether anchor on
Removal the package tray trim
1. Remove the rear seat cushion. Refer to Section Remove firtree clips
501-10.
2. Remove the safety belt buckle and rear center
anchor.
Remove the nut
Item Description
1 Plug
2 Bracket - Child Seat Back Mount
5. Remove the package tray trim. Refer to Section
501-05.
Item Description
1 Belt & Retrractor Asy Rr Ctr
2 Nut M12
G32456 en 01/2003 2003.0 BA Falcon

6. Remove the rear centre safety belt retractor. 3. To install, reverse the removal procedure.
Feed the safety belt webbing through the NOTE: Make sure to tighten all nuts to
package trim opening specification.
Using the special tool, remove the bolt NOTE: Make sure the safety belt webbing is not
Remove the rear center safety belt retractor twisted prior to installation.
NOTE: Make sure the safety belt buckles are
accessible after repositioning the seat.
Item Description
1 Bolt Corflex (Pt of item 2)
2 Belt & Retractor Asy Rr Ctr Item Description
1 Rear centre safety belt buckle/mini buckle
Installation
2 Nut M12
NOTE: Make sure to tighten all nuts and bolts to Rear Centre Safety Belt Rectractor —
specification.
Wagon
twisted prior to installation. Removal and Installation
NOTE: Make sure to align and install the safety 1. Unbuckle mini buckle.
belt retractor locating tab into the package tray 1. Insert a paper clip end into a hole on the
panel before installing the bolt. under side of the mini buckle.
operation.
Rear Centre Safety Belt

Buckle/Minibuckle — Wagon
Removal
501-10.
2. Remove the safety belt buckle and rear center
anchor.
Remove the nut
Remove the rear center safety belt
buckle/minibuckle
G32459 en 01/2003 2003.0 BA Falcon

2. Remove the safety belt guide. 2. Remove the safety belt buckles.
Prise off the safety belt guide from the seat Remove the nut.
back. Sedan
3. Disassemble the rear 60/40 split seat back. Refer

Wagon
to Section 501-10.
Remove seat back trim and pad.
4. Remove the safety belt retractor.
Remove the nut
Remove the rear safety belt retractor
Item Description
1 Rear centre safety belt buckles
2 Nut M12
Remove the rear center safety belt buckles
Installation
Item Description
1 Belt & Retractor Asy Rr
NOTE: Make sure to tighten all nuts to
2 Nut 7/16 20 Unf Hex Flg specification.
5. To install, reverse the removal procedure. NOTE: Make sure the safety belt webbing is not
NOTE: Make sure to tighten all nuts and bolts to twisted prior to installation.
specification. NOTE: Make sure the safety belt buckles are
NOTE: Make sure the safety belt webbing is not accessible after repositioning the seat.
operation.
Rear Centre Safety Belt Buckles
Removal
501-10.
G32459 en 01/2003 2003.0 BA Falcon

Safety Belt Buckle and Pretensioner Front Centre Seat Safety Belt
Removal
Retractor — Ute
1. Disconnect the battery ground cable. Removal
1. Remove the outboard seat bucket assembly from
WARNING: Wait at least two minutes after
disconnecting the battery ground cable,
Section 501-10.
before disconnecting any supplemental
restraint system electrical connectors. Failure 2. Remove the safety belt anchor
to follow this warning could cause premature Using the special tool, remove the bolt.
deployment and may result in personal injury. Remove the safety belt anchor from the front
2. Wait two minutes. center seat leg.
3. Remove the front seat. For additional information,
CAUTION: Note the position and routing
of the wiring harness to aid assembly. An
incorrectly routed harness may lead to the
wires becoming damaged on the seat
mechanism. Detach the seat wiring harness
from the underside of the seat.
4. Detach the safety belt pretensioner wiring harness
from the conduit.
Item Description
1 Belt & Retrector Asy Frt Ctr
2 Bolt Corflex (part of item 1)
3. Remove the safety belt trim
Prise off the safety belt trim from the back
panel trim.
4. Remove the back panel trim. For additional
5. Remove the safety belt pretensioner

Remove the safety belt buckle and
pretensioner
Installation
NOTE: Make sure to tighten all nuts and bolts to
specification.
NOTE: Make sure to align and install the
anti-rotational slot of the safety belt buckle and
pretensioner to the pin on the seat track before
installing the bolt.
2. Deploy the safety belt buckle pretensioner
assembly. For additional information, refer to
Section 501-20b.
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5. Remove the centre safety belt retractor

Using the special tool, remove the bolts.
Remove the center safety belt retractor
assembly by lifting it up.
Item Description
1 Bezel (part of item 5)
2 Belt Asy (part of item 5)
3 Cur Asy Bk Pnl Trim
4 Screw M10x1.5
5 Belt & Retrector Asy Frt Ctr
6 Corflex Bolt (part of item 5)
Installation
specification.
operation.
G32460 en 01/2003 2003.0 BA Falcon

501-20b-1 Occupant Restraints — Passive 501-20b-1
SECTION : 501-20b Occupant Restraints —

Passive
CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................501-20b-3
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ....................501-20b-4
Side Airbag Bridge Resistor ..............................................................................................501-20b-8
Driver Airbag Module ........................................................................................................501-20b-8
Clockspring .......................................................................................................................501-20b-8
Passenger Airbag Module .................................................................................................501-20b-8
Passenger Airbag Bridge Resistor .....................................................................................501-20b-8
Safety Belt Pretensioners .................................................................................................501-20b-8
Safety Belt Buckle Switches .............................................................................................501-20b-8
Seat Track Position Sensor ..............................................................................................501-20b-8
Restraints Control Module (RCM) .....................................................................................501-20b-8
Electrical System ..............................................................................................................501-20b-9
Sensors .............................................................................................................................501-20b-9
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ..................501-20b-10
Restraint System Diagnostic Tool Warning .....................................................................501-20b-10
Diagnosing Customer Concerns Without Hard DTCs ......................................................501-20b-10
Diagnosing Customer Concerns with Hard DTCs ...........................................................501-20b-10
Prove Out Procedure .......................................................................................................501-20b-12
Glossary ...........................................................................................................................501-20b-12
Airbag Reconnect Checklist .............................................................................................501-20b-13
Diagnostic Instructions — Airbag and Safety Belt Pretensioner Supplemental Restraint System
(SRS) ................................................................................................................................501-20b-13
Diagnostic Test Modes ....................................................................................................501-20b-13
Bit-Mapped Diagnostic Trouble Codes (DTCs) ................................................................501-20b-14
PID/Data Monitor and Record ..........................................................................................501-20b-14
Active Commands ...........................................................................................................501-20b-14
Inspection and Verification ...............................................................................................501-20b-17
Symptom Chart ................................................................................................................501-20b-17
Connector Circuit Reference ............................................................................................501-20b-17
Pinpoint Tests — Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
...........................................................................................................................................501-20b-23
Restraint System Diagnostic Tool Warning .....................................................................501-20b-23
Pinpoint Test A: The Airbag Warning Indicator Is Illuminated Continuously - RCM Disconnected
or Inoperative, Loss of Battery Feed, or Loss of Signal Ground .....................................501-20b-24
Pinpoint Test B: DTC B1869 — Lamp Airbag Warning Indicator Circuit Open or Short to
Ground .............................................................................................................................501-20b-26
Pinpoint Test C: DTC B1870 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-30
Pinpoint Test D: DTC B1891 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-33
Pinpoint Test E: LFC 53/DTC B1892 — Airbag Tone Warning Indicator Circuit Shorted to Ground
or Open ............................................................................................................................501-20b-37
01/2003 2003.0 BA Falcon

(Continued)
Pinpoint Test F: LFC 14/DTC B1921 — Airbag Diagnostic Monitor Ground Circuit
Open ................................................................................................................................501-20b-40
Pinpoint Test G: LFC 33 and 34/DTC B2292 - Restraint System Safety Belt Pretensioner
Status ...............................................................................................................................501-20b-45
Pinpoint Test H: LFC 19 and 21 /DTC B2293 - Restraint System Airbag Status ............501-20b-51
Pinpoint Test I: LFC 22 and 23 / DTC B2295 — Restraint System Side Airbag Module
Status ...............................................................................................................................501-20b-62
Pinpoint Test J: LFC 42, 43, 44 and DTC B2296 — Restraint System Impact Sensor
Status ...............................................................................................................................501-20b-70
Pinpoint Test K: LFC 51/DTC B2691 - Driver Safety Belt Buckle Switch Circuit Fault ...501-20b-83
Pinpoint Test L: LFC 51/DTC B2434 - Driver Safety Belt Buckle Switch Circuit Short to
Ground .............................................................................................................................501-20b-87
Pinpoint Test M: LFC 51/DTC B2435 - Driver Safety Belt Buckle Switch Current Out of
Range ...............................................................................................................................501-20b-91
Pinpoint Test N: LFC 52/DTC B2692 - Passenger Safety Belt Buckle Switch Circuit
Fault .................................................................................................................................501-20b-95
Pinpoint Test O: LFC 52/DTC B2438 - Passenger Safety Belt Buckle Switch Circuit Short to
Ground .............................................................................................................................501-20b-99
Pinpoint Test P: LFC 52/DTC B2439 - Passenger Safety Belt Buckle Switch Resistance Out of
Range .............................................................................................................................501-20b-103
Pinpoint Test Q: LFC 15/DTC C1414 - Incorrect Vehicle ID .........................................501-20b-107
Pinpoint Test R: LFC 49/DTC C1947 - Seat Track Position Sensor Circuit Short to
Ground ...........................................................................................................................501-20b-109
Pinpoint Test S: LFC 49/DTC C1948 - Seat Track Position Sensor Circuit Resistance Out of
Range .............................................................................................................................501-20b-114
Pinpoint Test T: LFC 49/DTC C1982 - Seat Track Position Sensor Circuit Fault .........501-20b-118
Pinpoint Test U: No Communication With The Restraints Control Module (RCM) ........501-20b-122
GENERAL PROCEDURES
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment ......501-20b-125
Airbag Disposal — Deployed Airbag ..............................................................................501-20b-125
Airbag Disposal — Undeployed, Inoperative ..................................................................501-20b-125
Airbag Disposal — Driver, Undeployed, Scrapped Vehicle ............................................501-20b-126
Airbag Disposal — Passenger, Undeployed, Scrapped Vehicle ....................................501-20b-127
Airbag Disposal — Side Airbag, Undeployed, Scrapped Vehicle ...................................501-20b-128
Safety Belt Pretensioner Disposal — Deployed .............................................................501-20b-129
Safety Belt Pretensioner Disposal — Undeployed, Inoperative .....................................501-20b-129
Safety Belt Pretensioner Disposal — Undeployed, Scrapped Vehicle ...........................501-20b-129
Supplemental Restraint System (SRS) Deactivation and Reactivation ..........................501-20b-130
Weld Nut Repair — Missing Weld Nut ............................................................................501-20b-134
Weld Nut Repair — Stripped Weld Nut ..........................................................................501-20b-135
Front Impact Severity Sensor .........................................................................................501-20b-136
Side Impact Sensor — First Row, B — Pillar .................................................................501-20b-138
Restraints Control Module (RCM) ...................................................................................501-20b-140
Driver Airbag Module ......................................................................................................501-20b-143
Passenger Airbag Module ...............................................................................................501-20b-148
Clockspring .....................................................................................................................501-20b-150
Side Airbag Bridge Resistor ............................................................................................501-20b-155
Seat Position Sensor ......................................................................................................501-20b-156
Side Airbag Module ..........................................................................................................501-20b-157
01/2003 2003.0 BA Falcon

SPECIFICATIONS
Description Nm
Front impact severity sensor 12 ± 1.8
Side impact sensor bolts (B pillar) 12 ± 1.8
Restraints control module-to-floor bolts 12 ± 1.8
Driver air bag module bolts 5±1
Passenger air bag module bolts 9.5*
* Refer to the passenger air bag module removal and
installation procedure for the torque specification and
sequence.
G12340 en 01/2003 2003.0 BA Falcon

Airbag and Safety Belt Pretensioner

Supplemental Restraint System (SRS)
The airbag supplemental restraint system (SRS) is
designed to provide increased collision protection for
front seat and second row outboard occupants in
addition to that provided by the three-point safety belt
system. Safety belt use is necessary to obtain the
best occupant protection and to receive the full
advantage of the SRS.
The Supplemental Restraint System contains dual
stage deployment (advanced restraint system) driver
and front passenger airbag modules. These vehicles
can also be equipped with optional side airbags that
deploy from the seats upon a side impact. In addition,
a front impact severity sensor is mounted to the lower
radiator support, a seat position sensor is mounted to
the driver seat and a usage detection switch is added
to the front driver and passenger outboard buckles.
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Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components
G12341 en 01/2003 2003.0 BA Falcon

Item Description
1 Clockspring
2 Driver airbag module
3 Safety belt buckle and pretensioner
4 Side airbag module
5 Passenger airbag module
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Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components
G12341 en 01/2003 2003.0 BA Falcon

Item Description is equipped on Commercial vehicles without

passenger airbag module.
1 Front impact severity sensor
must not be removed during deactivation.
2 First row, B-pillar side impact sensor
is located in the passenger airbag cover
3 Driver seat position sensor assembly.
4 First row, B-pillar side impact sensor
5 Restraints control module (RCM) Safety Belt Pretensioners
As part of the SRS the safety belt buckles are
Side Airbag Bridge Resistor equipped with pretensioners. The safety belt buckle
pretensioners remove excess slack from the safety
CAUTION: Do not deactivate the side airbag belt webbing. The pretensioners are activated by the
module circuit by removing the bridge resistor restraints control module (RCM) when the module
from the electrical connector. detects a crash event force exceeding a programmed
If the side airbag bridge resistor is removed, an open limit.
circuit fault will be generated by the restraints control Safety Belt Buckle Switches
module (RCM).
If a restraint system diagnostic tool is installed at the Both driver and front outboard passenger safety belt
side airbag electrical connector, a low resistance fault buckles are equipped with a switch. The safety belt
will be generated. buckle switch indicates to the restraints control
module (RCM) whether the driver and front outboard
The side airbag bridge resistor: passenger safety belt buckles are connected or
is equipped on vehicles without side airbag disconnected.
modules.
must not be removed during deactivation.
Seat Track Position Sensor
is located on the seat. The seat track position sensor is a hall-effect sensor
located on the driver seat track. The seat track
Driver Airbag Module position sensor informs the restraints control module
(RCM) of the driver seat position. The RCM uses this
The driver airbag module:
information in determining the deployment rate of the
is installed new as an assembly. dual-stage driver airbag module.
is mounted in the center of the steering wheel.
Restraints Control Module (RCM)
Clockspring
The clockspring: WARNING: The restraints control module
(RCM) orientation is critical for correct system
is mounted on the steering column, behind the
operation. If a vehicle equipped with an airbag
steering wheel.
supplemental restraint system (SRS) has been
continuously transfers electrical signals from the involved in a collision in which the center tunnel
driver airbag module to the restraints control area has been damaged, inspect the mounting
module (RCM). and bracket for deformation. If damaged, the RCM
must be replaced whether or not the airbags have
Passenger Airbag Module deployed. In addition, make sure the area of the
The passenger airbag module: RCM mounting is restored to its original
is installed new as an assembly. condition.
is mounted in the passenger side of the The restraints control module carries out the following
instrument panel. functions:
deploys the airbag(s) in the event of a deployable
Passenger Airbag Bridge Resistor crash.
activates the safety belt buckle pretensioners to
CAUTION: Do not deactivate this passenger remove slack from the safety belt.
airbag module circuit by removing the bridge monitors the SRS for faults.
resistor from the electrical connector.
If the passenger airbag bridge resistor is illuminates the airbag indicator if a fault is
removed, an open circuit fault will be generated detected.
by the RCM. flashes the airbag indicator to indicate the lamp
If a restraint system diagnostic tool is installed at fault code (LFC) detected.
the PAB electrical connector, a low resistance communicates through the data link connector
fault will be generated. (DLC) the current or historical Diagnostic Trouble
The PAB bridge sensor: Codes (DTCs).
G12341 en 01/2003 2003.0 BA Falcon

signals the instrument cluster module to activate a and bracket for deformation. If damaged, the RCM
chime to remind the driver to buckle up. must be replaced whether or not the airbags have
signals the instrument cluster module to activate a deployed. In addition, make sure the area of the
chime if the airbag indicator is not available and RCM mounting is restored to its original
another SRS fault exists. condition.
The RCM monitors the SRS for possible faults. If a
fault is detected while the ignition switch is in the ON
position, the RCM will illuminate the airbag indicator
equipped with an airbag supplemental restraint
located in the instrument cluster.
When the ignition is cycled (turned off and then on), the sensor mounting bracket and wiring pigtail for
the airbag indicator will prove out by lighting for six deformation. Replace and correctly position the
seconds. After the prove out, the airbag indicator will sensor or any other damaged supplemental
then flash the two-digit LFC. If a SRS fault exists, the restraint system (SRS) components whether or
airbag indicator will flash the LFC five times, then it not the airbag is deployed.
will remain illuminated for the rest of the key cycle.
The SRS uses up to five sensors. Within the RCM is
The RCM will also communicate the current and
one safing sensors which is not separately serviced.
historical DTCs through the DLC, to the scan tool. If
The RCM has one safing sensor for front impact. The
the airbag indicator does not function, and the system
RCM is mounted to the center tunnel beneath the
detects a fault condition, the RCM will signal the
console. All vehicles will have a front impact severity
instrument cluster module to activate an audible
sensor and it is located in the front-center of the
chime. The chime is a series of five sets of five tone
vehicle, mounted under the lower radiator support. If
bursts. If the chime is heard, the SRS and the airbag
the vehicle is equipped with side airbags, there are
indicator require repair.
two additional side impact sensors. The two additional
LFCs are prioritized. If two or more faults occur at the sensors are located on each B-pillar. Mounting
same time, the fault having the highest priority will be orientation is critical for correct operation of all impact
displayed. After that fault has been corrected, the next sensors.
highest priority fault will be displayed.
The RCM includes a backup power supply. This
feature provides sufficient backup power to deploy the
airbags in the event that the ignition circuit is lost or
damaged during impact. The backup power supply
will deplete its stored energy approximately one
minute after the battery ground cable is disconnected.
Electrical System
The electrical system that supports the airbag SRS:
is powered from the battery through the ignition
circuit.
provides the electrical path from the restraints
control module (RCM) to the SRS components.
provides the electrical path from the RCM to the
airbag indicator.
belt minder indicator.
data link connector (DLC).
generic electronic module (GEM) or instrument
cluster module.
Sensors
WARNING: The restraints control module

(RCM) orientation is critical for correct system
operation. If a vehicle equipped with an airbag
supplemental restraint system (SRS) has been
involved in a collision in which the center tunnel
area has been damaged, inspect the mounting
G12341 en 01/2003 2003.0 BA Falcon


Restraint System Diagnostic Tool
Supplemental Restraint System (SRS)
Warning
Refer to Wiring Diagram Section 000-00 for schematic
and connector information. WARNING: Restraint system diagnostic tools
are for service only. Remove from vehicle prior to
Special Tool(s) road use. Failure to remove could result in
FLUKE 73III Automotive Meter personal injury and possible violation of vehicle
105-R0057 or equivalent safety standards.
Diagnosing Customer Concerns Without
Hard DTCs
If a lamp fault code (LFC) is reported by the customer
but is not present when the vehicle comes in for
service, follow the Diagnostic Instruction procedures
Diagnostic Tool, Restraint DAB
in this section to identify the intermittent DTC.
System, (2 Req’d)
418-F395 (014-R1079) Once the DTC is known, read the Normal Operation
418-F403, (1 Req’d) section of the pinpoint test for the DTC involved.
Follow the deactivation procedure in this section.
Determine the location of components involved in
creating the DTC.
Carry out a thorough visual inspection of:
components.
connectors.
splices and wiring harnesses.
insulation on conductors.
Refer to the Possible Causes section of the pinpoint
Diagnostic Tool, Restraint PAB test for the DTC involved, which lists the common
System, (1 Req’d) concerns that relate to the DTC. Concerns are listed
418-F403 according to priority.
Diagnosing Customer Concerns with
Hard DTCs
Most Supplemental Restraint System (SRS)
diagnostic procedures will require deactivation and
Diagnostic Tool, Restraint P/T reactivation of the system. Deactivation and
System, (2 Req’d) reactivation require the disconnection of most SRS
418-F403 components and the installation of restraint system
diagnostic tools. This reduces the risk of inadvertent
deployment of SRS components while diagnostic
procedures are being carried out.
Restraint system diagnostic tools are required for the
Diagnostic Tool, Restraint SAB diagnosis and testing of the SRS. It is not acceptable
System to short-circuit the airbag module connections with a
418-F088 (105-R0012) jumper wire. If a jumper wire is used to short-circuit
2 Req’d the airbag module connections, a lamp fault code
(LFC) will be displayed.
Deactivation Procedure
Worldwide Diagnostic System WARNING: If the supplemental restraint

(WDS) system (SRS) is being serviced, the system must
418-FS317, be deactivated and restraint system diagnostic
or equivalent scan tool tools must be installed. Refer to Airbag and Safety
Belt Pretensioner Supplemental Restraint System
(SRS) in this section.
The airbag restraint system diagnostic tools must
G12343 en 01/2003 2003.0 BA Falcon

be removed and the airbag modules reconnected 3. Attach restraint system diagnostic tools 418-F395
when the system is reactivated to avoid (2 required) to the clockspring side of the driver
non-deployment in a collision, resulting in airbag module electrical connectors.
possible personal injury. 4. Remove the outboard passenger side air register.
NOTE: Do not deactivate the passenger airbag
WARNING: Never probe the connectors on module circuit by removing the passenger airbag
the airbag module. Doing so can result in airbag bridge resistor from the passenger airbag bridge
deployment, which can result in personal injury. resistor electrical connector.
WARNING: The safety belt buckle If the passenger airbag bridge resistor is
pretensioner is a pyrotechnic device. Never probe removed, an open circuit fault will be generated
a pretensioner electrical connector. Doing so by the RCM.
could result in pretensioner or airbag deployment If a restraint system diagnostic tool is installed at
and could result in personal injury. the PAB electrical connector, a low resistance
fault will be generated by the RCM.
WARNING: Never probe the connectors on For commercial vehicle w/o PAB, do not
the side airbag module. Doing so can result in disconnect the PAB bridge resistor.
side airbag deployment.
5. For vehicles with airbags only:
WARNING: To avoid accidental deployment 1. Disconnect the passenger airbag module
and possible personal injury, the RCM backup electrical connector.
power supply must be depleted before repairing 6. Attach restraint system diagnostic tool 418-F403
or replacing any front or side airbag SRS to the harness side of the passenger airbag
components and before servicing, replacing, module electrical connector.
adjusting or striking components near the front or NOTE: Do not deactivate the side airbag module
side airbag sensors, such as doors, instrument circuit by removing the side airbag bridge resistor
panel, console, door latches, strikers, seats and from the side airbag bridge resistor electrical
hood latches. connector.
disconnect the battery ground cable and wait at If the side airbag bridge resistor is removed, an open
least one minute. Be sure to disconnect auxiliary circuit fault will be generated by the RCM.
batteries and power supplies (if equipped). If a restraint system diagnostic tool is installed at the
The side impact sensors (if equipped) are located side airbag electrical connector, a low resistance fault
in the B-pillars below the latch. will be generated by the RCM.
NOTE: Diagnostics or repairs are not to be performed For vehicles without side airbags, do not disconnect
on a seat equipped with a seat side airbag with the the side airbag bridge resistor.
seat in the vehicle. Prior to attempting to diagnose or 7. For vehicles with side airbags only:
repair a seat concern when equipped with a seat side
airbag, the seat must be removed from the vehicle 1. Disconnect the passenger side airbag
and the restraint system diagnostic tools must be electrical connector, located on the seat track.
installed in the seat side airbag electrical connectors. 2. Attach a restraint system diagnostic tool
418-F088 (105-R0012) to the vehicle harness
NOTE: After diagnosing or repairing an SRS, the side of the passenger side airbag electrical
restraint system diagnostic tools must be connector.
removed before operating the vehicle over the
road. 8. Disconnect the safety belt buckle pretensioner
electrical connector, located on the seat track.
NOTE: After diagnosing or repairing a seat system, 9. Attach Restraint System Diagnostic Tool
the restraint system diagnostic tools must be 418-F403 to the passenger front seat safety belt
removed before operating the vehicle over the buckle pretensioner vehicle harness side.
road.
10. For vehicles with airbags only:
NOTE: The SRS must be fully operational and free of 1. Disconnect the driver side airbag electrical
faults before releasing the vehicle to the customer. connector, located on the seat track.
1. Disconnect the battery ground cable (14301) and 2. Attach a restraint system diagnostic tool
wait for one minute. For additional information, 418-F088 (105-R0012) to the vehicle harness
refer to Section 414-01. side of the driver side airbag electrical
2. Remove the driver airbag module. For additional connector.
information, refer to Driver Airbag Module in this 11. Disconnect the safety belt buckle pretensioner
section. electrical connector, located on the seat track.
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12. Attach Restraint System Diagnostic Tool will either:

418-F403 to the driver front seat safety belt fail to light.
buckle pretensioner vehicle harness side.
remain lit continuously.
13. Reconnect the battery ground cable. For
additional information, refer to Section 414-01. flash.
The flashing might not occur until approximately 30
14. Prove out the system.
seconds after the ignition switch has been turned from
Reactivation Procedure the OFF to the RUN position. This is the time required
for the restraints control module (RCM) to complete
WARNING: To reduce the risk of serious the testing of the SRS. If the airbag indicator is
personal injury, read and follow all warnings, inoperative and an SRS fault exists, a chime will
cautions, and notes at the beginning of the sound in a pattern of five sets of five beeps. If this
deactivation procedure. occurs, the airbag indicator will need to be repaired
before diagnosis can continue.
1. Disconnect the battery ground cable and wait one
minute. For additional information, refer to Section Glossary
414-01.
Secondary Airbag Warning
2. Disconnect the restraint system diagnostic tool
and connect the driver front seat safety belt The secondary airbag warning is an audible fault
buckle pretensioner electrical connector. format that consists of five sets of five tone bursts,
3. For vehicles with side airbags only: with each set of five tone bursts separated by a five
second quiet period. One tone burst cycle will consist
1. Remove the restraint system diagnostic tool of one second ON and one second OFF. This series
from the driver side side airbag electrical of five activations is repeated every 30 minutes.
connector.
2. Connect the driver side side airbag electrical Airbag/Pretensioner Restraint System
connector. Diagnostic Tools
4. Disconnect the restraint system diagnostic tool Airbag/pretensioner restraint system diagnostic tools
and connect the passenger front seat safety belt are used to simulate the equivalent resistance of an
buckle pretensioner floor electrical connector. airbag module or safety belt pretensioner during
5. For vehicles with side airbags only: certain diagnostic procedures.
1. Remove the restraint system diagnostic tool Disconnect the Component
from the passenger side airbag electrical
connector. Disconnect the component means disconnect the
component vehicle harness connector. It does not
2. Connect the passenger side airbag electrical
mean remove the component. Do not reconnect a
connector.
disconnected component unless instructed to do so.
6. For vehicles with side airbags only:
1. Remove the restraint system diagnostic tool Deactivate the System
from the passenger airbag module electrical Deactivate the system means to carry out a
connector. deactivation procedure. For additional information,
7. Connect the passenger airbag module electrical refer to Deactivation Procedure in this section.
connector.
Prove Out the System
8. Remove the restraint system diagnostic tools from
the driver airbag module electrical connectors. Prove out the system means to turn the ignition switch
from the OFF to the RUN position and visually monitor
9. Install the driver airbag module. For additional
the airbag indicator with the airbag modules and
information, refer to Driver Airbag Module in this
safety belt pretensioners or restraint system
section.
diagnostic tools installed. For additional information,
10. Reconnect the battery ground cable. For refer to Prove Out Procedure in this section.
11. Prove out the system.
Prove Out Procedure
Turn the ignition switch from the OFF to the RUN
position and visually monitor the airbag indicator with
all SRS components connected or restraint system
diagnostic tools installed. The airbag indicator will light
continuously for approximately six seconds and then
turn off. If an SRS fault is present, the airbag indicator
G12343 en 01/2003 2003.0 BA Falcon

Reactivate the System 2. Run the On-Demand Self Test to determine what
DTCs are currently being sensed by the RCM.
Reactivate the system means to carry out the Refer to On-Demand Self Test in this section.
reactivation procedure. For additional information,
refer to Reactivation Procedure in this section. 3. If the stored DTCs are different than the current
DTCs, always repair the current DTCs first.
Reconnect the System 4. If memory displays different continuous DTCs
Reconnect the system means to reconnect all system than the On-Demand Self Test, carry out in the
components. For additional information, refer to following order:
Airbag System Reconnect Checklist in this section. On-Demand Self Test
Install a New Component Memory (Retrieve/Clear Continuous DTCs)
A DTC can indicate several concerns. The DTCs are
Install a new component means to remove the to assist in system diagnosis and are not to be
existing component and install a new authorized part considered definitive. Always refer to the pinpoint test
obtained from Ford Customer Service Division. corresponding to the DTC to determine where the
Verify the System concern lies and to repair the concern correctly.
The SRS diagnostics can be divided into three
Verify the system means to prove out the system with sections:
restraint system diagnostic tools installed in place of
the SRS components. diagnostic test modes
PID/data monitor and record
Airbag Reconnect Checklist
active command modes
The checklist below should be completed following
diagnosis or repair of any airbag system concern: Diagnostic Test Modes
All restraint system diagnostic tools removed? Two menu options are available under the diagnostic
All in-seat harness connectors connected? test modes:
All airbag modules connected? Retrieve/Clear Continuous DTCs
Safety belt pretensioner connectors connected? On-Demand Self Test
Restraints control module (RCM) connected? Retrieve/Clear Continuous DTCs
All sensors (front and side impact sensors) During vehicle operation the restraints control module
connected? (RCM) will detect and store both intermittent and hard
Battery connected? failure DTCs in nonvolatile memory. The DTC strategy
employed by the RCM incorporates a time-out
Diagnostic Instructions — Airbag and scheme for determining when a concern exists in the
Safety Belt Pretensioner Supplemental system. This requires a concern to exist for up to one
minute in the system before the RCM will detect it.
Restraint System (SRS) For the RCM to determine that a concern no longer
exists, the concern must be absent for up to one
Special Tool(s) minute. The actual detection time-outs vary with each
Worldwide Diagnostic System DTC. The DTCs can be retrieved with a scan tool
(WDS) using the retrieve/clear continuous DTCs option. Any
418-FS317, DTCs stored in the RCM will be displayed on the scan
or equivelant scan tool tool along with a brief description of the DTC. If no
DTCs are present, the scan tool will display a
SYSTEM PASSED message. This option can also be
used to clear DTCs from the RCM memory, as long
as the concern no longer exists. Once 128 key cycles
The symptom chart can be used to help locate have been recorded since the concern was last
supplemental restraint system (SRS) concerns if no detected, the DTC will automatically be removed from
diagnostic trouble codes (DTCs) are retrieved and the memory.
listed symptoms are observed. Whether or not the To retrieve or clear DTCs, follow these steps:
listed symptoms are observed, always carry out the
following: 1. Connect the scan tool to the data link connector
(DLC).
1. Retrieve all DTCs stored in the restraints control
module (RCM) memory. For additional 2. Turn the ignition switch to the RUN position.
information, refer to Retrieve/Clear Continuous 3. Follow the manufacturer’s instructions for the
DTCs in this section. scan tool being used.
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4. All continuous DTCs will be displayed on the that DTC, including the status or state that exists
screen. (on-demand DTC) or existed (continuous DTC).
NOTE: Before proceeding with the clearing To view and flag bit-mapped DTCs, follow these
operation, make note of the DTCs displayed. steps:
Once cleared, DTCs cannot be retrieved. 1. Connect the scan tool to the data link connector
5. Clear the DTCs. After clearing the DTCs, cycle (DLC).
the key OFF, then ON. 2. Turn the ignition switch to the ON position.
Continuous DTCs that have been cleared will 3. Follow the manufacturer’s instructions for the
not re-occur as “Continuous” in the same key scan tool being used.
cycle. Only new DTCs which were not 4. Carry out an On-Demand Self Test or retrieve
present before clearing can occur as continuous DTCs.
“Continuous” after clearing.
5. Select the DTC and the “FLAG” option on the
On-Demand Self Test scan tool.
The On-Demand Self Test option is used to verify that 6. The scan tool will display PIDs for the DTC.
no electrical concerns exist with the airbag SRS. Record all flagged faults.
Upon entering the self test, the restraints control
module (RCM) will make an electrical check of each
PID/Data Monitor and Record
electrical component in the system. If a concern is The PID/Data Monitor and Record option allows the
detected, a DTC is displayed on the scan tool with a scan tool operator to read the state of several
brief description of the DTC. Concerns detected parameter IDs (PIDs) to aid in diagnosing the system.
during the self test are not stored in memory, unless PIDs are real time measurements of parameters such
the same concern was also detected during normal as voltages, resistances, etc., calculated by the
vehicle operation. The self test should always be run restraints control module (RCM) and sent to the scan
after any repair to verify that the repair was tool for display. Many of the PIDs supported by the
successful. RCM are calculated periodically and are, therefore,
To run the On-Demand Self Test, follow these steps: not true real time readings.
1. Connect the scan tool to the data link connector To retrieve PIDs, follow these steps:
(DLC). 1. Connect the scan tool to the data link connector
2. Turn the ignition switch to the RUN position. (DLC).
3. Follow the manufacturer’s instructions for the 2. Turn the ignition switch to the ON position.
scan tool being used. 3. Follow the manufacturer’s instructions for the
4. The RCM will run the On-Demand Self Test and scan tool being used.
display on-demand DTCs (reflecting hard system 4. Record all PIDs that are to be retrieved and
concerns) on the scan tool. initiate PID retrieval. PIDs are updated
continuously on the display.
Bit-Mapped Diagnostic Trouble Codes
(DTCs) Active Commands
Many of the continuous and on-demand DTCs that Instrument Cluster Module
can be present in the RCM are bit-mapped DTCs that
These commands allow the technician to verify the
utilize PIDs (flagged faults). Bit-mapped DTCs are
operation of instrument cluster module components
conceptually different from the previous style of DTCs.
and sub-systems.
Previously, DTCs identified a specific concern for a
given component and pointed to a particular Restraints Control Module (RCM)
diagnostic path. In the diagnostic path, PIDs are
sometimes used to determine the root cause. These commands allow the technician to verify
Bit-mapped DTCs do not identify the specific concern. operation of the supplemental restraint system (SRS)
A bit-mapped DTC identifies the component(s) in indicator lamps.
which the concern exists. The next level (PIDs or Lamp Fault Codes
flagged faults) identifies the specific concern.
A scan tool must be used to view the PIDs (flagged When the restraints control module (RCM) detects a
faults) of a bit-mapped DTC. Once a scan tool has system fault, it will cause the airbag indicator to flash
retrieved a bit-mapped DTC, the scan tool will provide a coded sequence; a lamp fault code (LFC). The code
the option to “FLAG” that DTC. When the option to is two digits. The first digit is flashed with a 0.5
“FLAG” the DTC is available, it must be carried out to second interval between pulses. There is a 2 second
identify the specific concern that is present. When the pause before the second digit is flashed which also
option to “FLAG” the DTC has been carried out, the has a 0.5 second interval between pulses. There is a
scan tool will then display the PIDs (flagged faults) for 5 second pause between each display of an LFC.
G12344 en 01/2003 2003.0 BA Falcon

Each LFC is flashed five times after which the airbag

indictor will remain lit for the remainder of the key-on
cycle. If there are multiple LFCs, each LFC will flash
in order of priority.
Diagnostic Trouble Codes (DTCs)
While the lamp fault codes (LFCs) are an indication of
a general concern in the passive restraints system,
the diagnostic trouble codes (DTCs) are more
specific. The DTCs can be retrieved from the
restraints control module (RCM) with a scan tool via
the data link connector (DLC).
Restraints Control Module (RCM) Diagnostic Trouble Code (DTC) Table
DTC * LFC * Description Action To Take
— Continuous The Airbag Indicator is GO to Pinpoint Test A.
Illuminated Continuously, RCM
Disconnected or Inoperative,
Loss of Battery Feed, or Loss
of Signal Ground
B1231 13 Crash Data Memory Full Install a new RCM and
impact sensors. REFER to
Inspection and Repair After a
Supplemental Restraint
System (SRS) Deployment.
B1317 Continuous Battery Voltage High CHECK battery voltage; to
be below 16 volts. REFER to
Section 414-00.
B1318 Continuous Battery Voltage Low CHECK battery voltage; to
be above 9.0 volts. REFER
to Section 414-00.
B1342 12 RCM Is Faulted Install a new RCM.
B1869 NONE Lamp Airbag Warning Indicator GO to Pinpoint Test B.
Continuous lamp Circuit Open or Short to
Secondary airbag Ground
warning sounds if
another fault is
present
B1870 NONE Airbag Warning Indicator GO to Pinpoint Test C.
Secondary airbag Circuit Short to Battery
warning sounds if
another fault is
present
B1891 53 Airbag Tone Warning Indicator GO to Pinpoint Test D.
Circuit Short to Battery
B1892 53 Airbag Tone Warning Indicator GO to Pinpoint Test E.
Circuit Open or Shorted to
Ground
B1921 14 Airbag Diagnostic Monitor GO to Pinpoint Test F.
Ground Circuit Open
B2292 33 Restraint System - Safety Belt GO to Pinpoint Test G.
Pretensioner Status (Driver
Pretensioner Circuit Fault)
B2292 34 Restraint System - Safety Belt GO to Pinpoint Test G.
Pretensioner Status
(Passenger Pretensioner
Circuit Fault)
G12344 en 01/2003 2003.0 BA Falcon

DTC * LFC * Description Action To Take

B2293 19 Restraint System - Airbag GO to Pinpoint Test H.
Status (Driver Front Airbag
Circuit Fault)
B2293 21 Restraint System - Airbag GO to Pinpoint Test H.
Status (Passenger Front Airbag
Circuit Fault)
B2295 22 Restraint System - Side Airbag GO to Pinpoint Test I.
Module Status (Driver Side
Side Airbag Circuit Fault)
B2295 23 Restraint System - Side Airbag GO to Pinpoint Test I.
Module Status (Passenger
Driver Side Side Airbag Circuit
Fault)
2296 42 Restraint System - Impact GO to Pinpoint Test J.
Sensor Status (Front Impact
Severity Sensor Circuit Fault)
B2296 43 Restraint System - Impact GO to Pinpoint Test J.
Sensor Status (Driver Side
Front Row Impact Sensor
Circuit Fault)
B2296 44 Restraint System - Impact GO to Pinpoint Test J.
Sensor Status (Passenger Side
Front Row Impact Sensor
Circuit Fault)
B2691 51 Driver Safety Belt Buckle GO to Pinpoint Test K.
Switch Circuit Fault
B2434 51 Driver Safety Belt Buckle GO to Pinpoint Test L.
Switch Circuit Short To Ground
B2435 51 Driver Safety Belt Buckle GO to Pinpoint Test M.
Switch Circuit Resistance Out
Of Range
B2477 54 Module Configuration Failure Install new RCM.
(Not programmed or incorrect)
B2692 52 Passenger Safety Belt Buckle GO to Pinpoint Test N.
Switch Circuit Fault
B2438 52 Passenger Safety Belt Buckle GO to Pinpoint Test O.
Switch Circuit Short to Ground
B2439 52 Passenger Safety Belt Buckle GO to Pinpoint Test P.
Switch Circuit Resistance Out
of Range
C1414 15 Incorrect Vehicle ID GO to Pinpoint Test Q.
C1947 49 Seat Track Position Sensor GO to Pinpoint Test R.
Circuit Short to Ground
C1948 49 Seat Track Position Sensor GO to Pinpoint Test S.
Circuit Resistance Out of
Range
C1981 49 Seat Track Position Sensor GO to Pinpoint Test T.
Circuit Fault
— — No communication with the REFER to Symptom Chart in
restraints control module this section. & GO to
(RCM). Pinpoint Test U.
G12344 en 01/2003 2003.0 BA Falcon

* DTC: Diagnostic trouble code, retrieved using scan Visual Inspection Chart
tool. Mechanical Electrical
* LFC: Lamp fault code, flashed on airbag indicator. Damaged restraints Open fuse(s)
Inspection and Verification control module (RCM) Damaged wiring
bracket harness
1. Verify the customer concern by checking the Damaged front crash Loose or corroded
airbag indicator in the instrument cluster module. severity sensor or connectors
For additional information, refer to Prove Out the bracket Circuitry open/shorted
System in this section. Damaged side impact Damaged shorting
2. Visually inspect for obvious signs of mechanical sensor or bracket bars
and electrical damage using the following chart. 3. If the concern is not visually evident, use the scan
tool to retrieve diagnostic trouble codes (DTCs)
and carry out the on-demand self test.
4. If the on-demand self test is passed and no DTCs
are retrieved, Go to Symptom Chart.
5. If DTCs are retrieved, refer to the Restraints
Control Module (RCM) Diagnostic Trouble Code
(DTC) Table.
Symptom Chart

Airbag warning indicator is illuminated Fuse to RCM. Go to PinPoint Test M.
continuously Wiring, terminals, or connectors.
Faulty diagnostic connector.
RCM.
Airbag indicator flashing Airbag/pretensioner supplemental REFER to DTC Table.

restraint system (SRS) fault.
Audible tone — DTCs retrieved Airbag SRS system fault. REFER to DTC Table.
No communication with the restraints Scan tool. Go to PinPoint Test AG.
control module (RCM) Data link connector (DLC).
RCM.
Circuitry.

C189a
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Pin Number(s) Circuit Designation/Description

1 Circuit 614 (O/B)
Driver Airbag Feed Squib 1
2 Circuit 615 (GR/W) Driver Airbag Return Squib 1
3 Circuit 607 (BR) Pass.
Airbag Feed Squib 1
4 Circuit 616 (P/B) Pass.
Airbag Return Squib 1
5 Circuit 1516 (Y/W)
6 Circuit 1517 (GR/B)
Driver Airbag Return Squib 2
11 Circuit 70B (SB/W)
ISO 9141
12 Circuit 16PA (R/G)
Run / Start Ignition
13 Circuit 1518 (R/W)
Pass. Airbag Feed Squib 2
14 Circuit 1519 (LG/R)
Pass. Airbag Return Squib 2
15 Circuit 608 (B/Y)
Airbag Indicator Power Supply
16 Circuit 1203A (B/G)
Ground
17 Circuit 8109A (P/O)
TAS Deployment Signal
20 Circuit 1203C (B/G)
Vehicle ID 1 - Ground
22 Circuit 609 (O)
Audible Signal Indicator
c189b
G12344 en 01/2003 2003.0 BA Falcon


3 Circuit 1257 (W)
Driver Side Airbag Feed
4 Circuit 1258 (BR)
Driver Side Airbag Return
5 Circuit 1259 (W/Y)
Pass. Side Airbag Return
6 Circuit 1260 (BR/Y)
19 Circuit 617 (P)
Front Crash sensor Feed
20 Circuit 618 (V)
Front Crash Sensor Return
23 Circuit 8107 (BR/G)
Seat Track Sensor Feed
24 Circuit 8108 (B/O)
Seat Track Sensor Return
25 Circuit 85 (B/L)
Driver Buckle Switch Input
26 Circuit 1514 (R/B)
Pass. Buckle Switch Input
27 Circuit 1261 (W/B)
Driver Side Sensor Feed
28 Circuit 1262 (W/R)
Driver Side Sensor Return
29 Circuit 1263 (G/W)
Pass. Side Sensor Feed
30 Circuit 1264 (R)
Pass. Side Sensor Return
Driver Pretensioner Feed
32 Circuit 1080 (LG/B)
Driver Pretensioner Return
33 Circuit 1081 (Y/R)
Pass. Pretensioner Feed
34 Circuit 1082 (Y/B)
Pass. Pretensioner Return
C233
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1 Circuit 1203D (B)
Ground
2 Circuit 85 (B/L)
Driver Buckle (Hall Sensor) Switch Input
Driver Pretensioner Feed
4 Circuit 1080 (LG/B)
Driver Pretensioner Return
C234

1 Circuit 1203B (B)
Ground
2 Circuit 1514 (R/B)
Pass. Buckle (Hall Sensor) Switch Input
3 Circuit 1081 (Y/R)
Pass. Pretensioner Feed
4 Circuit 1082 (Y/B)
Pass. Pretensioner Return
C190

1 Circuit 614 (O/B)
2 Circuit 615 (GR/W)
3 Circuit 1516 (Y/W)
4 Circuit 1517 (GR/B)
G12344 en 01/2003 2003.0 BA Falcon

C146

1 Circuit 1518 (R/W)
3 Circuit 607 (BR)
4 Circuit 616 (P/B)
C342

1 Circuit 1258 (BR)
Driver Side Airbag Return
2 Circuit 1257 (W)
Driver Side Airbag Feed
C344
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1 Circuit 1260 (BR/Y)
2 Circuit 1259 (W/Y)
C340

1 Circuit 618 (V)
Front Crash Sensor Return
2 Circuit 617 (P)
Front Crash sensor Feed
C341

1 Circuit 1262 (W/R)
Driver Side Sensor Return
2 Circuit 1261 (W/B)
Driver Side Sensor Feed
C345
G12344 en 01/2003 2003.0 BA Falcon


1 Circuit 1264 (R)
Pass. Side Sensor Return
2 Circuit 1263 (G/W)
Pass. Side Sensor Feed
C72

1 Circuit 8108 (B/O)
Seat Track Sensor Return
2 Circuit 8107 (BR/G)
Seat Track Sensor Feed
Special Tool(s)
Pinpoint Tests — Airbag and Safety Diagnostic Tool, Restraint
Belt Pretensioner Supplemental System
Restraint System (SRS) 418-F088 (105-R0012)
Refer to Wiring Diagram Section 000-00 for schematic

and connector information.
Special Tool(s)
Worldwide Diagnostic System
FLUKE 73III Automotive Meter
(WDS)
418-FS317
or equivalent scan tool
Diagnostic Tool, Restraint Restraint System Diagnostic Tool

System Warning
418-F395 (014-R1079)
WARNING: Restraint system diagnostic tools
are for service only. Tools must be removed prior
to operating the vehicle over the road. Failure to
remove restraint system diagnostic tools could
Diagnostic Tool, Restraint result in injury and possible violation of vehicle
System safety standards.
418-F403
G12345 en 01/2003 2003.0 BA Falcon

Pinpoint Test A: The Airbag Warning

Indicator Is Illuminated Continuously -
RCM Disconnected or Inoperative, Loss
of Battery Feed, or Loss of Signal Ground
Normal Operation
NOTE: During normal operation, the airbag indicator
will illuminate continuously for 6 seconds after the
ignition switch is placed to the RUN or ON position
and after five cycles of a lamp fault code (LFC) if a
fault exists. Be sure to cycle the ignition switch and
look for a 6 second indicator prove-out without LFCs.
The restraints control module (RCM) will communicate
diagnostic trouble codes (DTCs) to the scan tool
through the diagnostics connector. If the scan tool
displays NO COMMUNICATION when retrieving
continuous DTCs, Go to PinPoint Test U to
troubleshoot the system.
Possible Causes
An airbag indicator that is illuminated continuously
can be caused by one of the following:
damaged ignition circuit.
The RCM disconnected from the vehicle harness.
A loss of RCM signal ground.
a faulted RCM.
damaged wiring, terminals, or connectors.
loss of RCM battery feed.
instrument cluster.
PINPOINT TEST A : THE AIR BAG WARNING INDICATOR IS ILLUMINATED CONTINUOUSLY - RCM
DISCONNECTED OR INOPERATIVE, LOSS OF BATTERY FEED, OR LOSS OF SIGNAL GROUND
A1 CHECK FOR CONTINUOUS OR ON-DEMAND SELF

TEST DTCs
Enter the following diagnostic mode on the diagnostic tool: Yes
Retrieve Continuous DTCs If continuous DTCs were retrieved, Go to A2. If
on-demand DTCs were retrieved, GO to the
Retrieve and record any continuous DTCs for use later in this pinpoint Restraints Control Module (RCM) Diagnostic
test. Trouble Code (DTC) Table in this section for
Enter the following diagnostic mode on the diagnostic tool: pinpoint test direction.
On-Demand Self Test. No
Go to A2.
Were any continuous or on-demand self test DTCs retrieved?
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A2 CHECK THE RCM CONNECTION
Yes
WARNING: If the supplemental restraint system (SRS) is Go to A3.
being serviced, the system must be deactivated and restraint system
diagnostic tools must be installed. Refer to Airbag and Safety Belt No
Pretensioner Supplemental Restraint System (SRS) in this section. CONNECT C189a and ENGAGE the locking
The airbag restraint system diagnostic tools must be removed and tabs. Go to A7.
the airbag modules reconnected when the system is reactivated to
avoid non-deployment in a collision, resulting in possible personal
injury.
WARNING: Never probe the connectors on the airbag

module. Doing so can result in airbag deployment, which can result in
personal injury.
WARNING: The safety belt buckle pretensioner is a

pyrotechnic device. Never probe a pretensioner electrical connector.
Doing so could result in pretensioner or airbag deployment and could
WARNING: Never probe the connectors on the side airbag

module. Doing so can result in side airbag deployment.
NOTE: Diagnostics or repairs are not to be performed on a seat

equipped with a seat side airbag with the seat in the vehicle. Prior to
attempting to diagnose or repair a seat concern when equipped with a seat
side airbag, the seat must be removed from the vehicle and the restraint
system diagnostic tools must be installed in the seat side airbag electrical
connectors. The restraint system diagnostic tools must be removed
prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS, the restraint system

diagnostic tools must be removed before operating the vehicle over
the road.
NOTE: After diagnosing or repairing a seat system, the restraint system

diagnostic tools must be removed before operating the vehicle over the
road.
NOTE: The SRS must be fully operational and free of faults before
releasing the vehicle to the customer.

Deactivate the system. Refer to Airbag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in the Diagnosis and Testing
portion of this section.
Connect RCM C189a.
Make sure RCM C189a is connected and fully seated.
Is RCM C189a fully connected and the connector locking tabs
engaged?
A3 CHECK CIRCUIT 16PA (R/G) FOR AN OPEN

Go to A4.
Measure the voltage between RCM C189a pin 12, circuit 16PA (R/G),
harness side and ground. No
Is the voltage between 9 and 16 volts? REPAIR circuit 16PA (R/G). Go to A7.
G12345 en 01/2003 2003.0 BA Falcon


A4 CHECK CIRCUIT 1203A (B/G) FOR AN OPEN
Go to A5.
Measure the resistance between RCM C189a pin 16, circuit 1203A
(B/G), harness side and ground. No
Is the resistance less than 1 ohm? Repair circuit 1203A (B/G). Go to A7.
A5 CHECK CIRCUIT 608 (B/Y) FOR A OPEN

Disconnect RCM C189a. Yes
Go to A6.
Disconnect Instrument Cluster C171a.
Measure the resistance between instrument cluster module C171a, No
circuit 608 (B/Y), harness side and RCM C189a pin 15, circuit 608 REPAIR circuit 608 (B/Y). Go to A7.
(B/Y), harness side.
A6 CHECK INDICATOR LAMP OPERATION (DRIVE LAMP

OFF)
Connect Instrument Cluster C171a. Yes
INSTALL a new RCM. REFER to Restraints
Key in ON position. Control Module (RCM) in this section.
Connect a fused jumper between the RCM C189a pin 15, circuit 608 Go to A7
(B/Y), harness side and ground.
No
Is the indicator lamp off ? REPAIR or INSTALL a new instrument cluster
module. REFER to Section 413-01.
Go to A7
A7 CHECK FOR ADDITIONAL DTCs

Refer to the continuous DTCs recorded during Step A1. Yes
Do not clear any DTCs until all DTCs have been
Were any continuous DTCs retrieved during Step A1? resolved. GO to the Restraints Control Module
(RCM) Diagnostic Trouble Code (DTC) Table in
this section for pinpoint test direction.
No
RECONNECT the system. REACTIVATE the
system. PROVE OUT the system. REFER to
Supplemental Restraint System (SRS) in this
section. CLEAR all DTCs.
Pinpoint Test B: DTC B1869 — Lamp

Airbag Warning Indicator Circuit Open or
Short to Ground
Normal Operation
If the restraints control module (RCM) detects an
open or short to ground on the airbag warning
indicator circuit, it will store diagnostic trouble code
(DTC) B1869 in memory.
Possible Causes
An open airbag indicator circuit can be caused by:
a faulted RCM.
a faulty indicator bulb.
an instrument cluster module internal concern.
G12345 en 01/2003 2003.0 BA Falcon

PINPOINT TEST B : DTC B1869 — LAMP AIR BAG WARNING INDICATOR CIRCUIT OPEN OR SHORT
TO GROUND
B1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve Continuous DTCs. If the airbag indicator lamp does illuminate, Go
to B2.
Retrieve and record any continuous DTCs for use later in this pinpoint If the airbag indicator does not illuminate, Go to
test. B4.
Enter the following diagnostic mode on the diagnostic tool: No
On-Demand Self Test. This is an intermittent fault. The fault condition is
not present at this time.
Was DTC B1869 retrieved during the on-demand self test? Go to B5
G12345 en 01/2003 2003.0 BA Falcon


B2 CHECK INDICATOR LAMP OPERATION (DRIVE LAMP
OFF)
Yes
WARNING: If the supplemental restraint system (SRS) is INSTALL a new RCM. REFER to Restraints
being serviced, the system must be deactivated and restraint system Control Module (RCM) in this section. Go to B6.
diagnostic tools must be installed. Refer to Airbag and Safety Belt
Pretensioner Supplemental Restraint System (SRS) in this section. No
The airbag restraint system diagnostic tools must be removed and Go to B3.
injury.

personal injury.




the road.

road.

Disconnect RCM C189a.
Key in ON position.
Connect a fused jumper between the RCM C189a pin 15, circuit 608
(B/Y), harness side and ground.
Is the indicator lamp off?
B3 CHECK CIRCUIT 608 (B/Y) FOR AN OPEN

Go to B6.
Disconnect Instrument Cluster Module C220a.
Disconnect RCM C189a. No
REPAIR circuit 608 (B/Y). Go to B6.
Measure the resistance between instrument cluster module C171a,
circuit 608 (B/Y), harness side and RCM C189a pin 15, circuit 608
(B/Y), harness side.
G12345 en 01/2003 2003.0 BA Falcon


B4 CHECK INDICATOR LAMP OPERATION (DRIVE LAMP
ON)
Disconnect RCM 189a. Control Module (RCM) in this section. Go to B6.
Key in ON position.
No
Is the indicator lamp on? REPAIR the circuit 608 (B/Y). Go to B6.
B5 CHECK FOR AN INTERMITTENT FAULT

Yes
WARNING: If the supplemental restraint system (SRS) is Go to B2.
Pretensioner Supplemental Restraint System (SRS) in this section. CHECK for causes of intermittent open or short
The airbag restraint system diagnostic tools must be removed and to ground on circuit 608 (B/Y). ATTEMPT to
the airbag modules reconnected when the system is reactivated to recreate the hard fault by flexing the wire
avoid non-deployment in a collision, resulting in possible personal harness and cycling the ignition key frequently.
injury. REPAIR any intermittent concerns found. Go to
B6.

personal injury.




the road.

road.

On-Demand Self Test
Was DTC B1869 retrieved during the on-demand self test?
G12345 en 01/2003 2003.0 BA Falcon


B6 CHECK FOR ADDITIONAL DTCs
Refer to the continuous DTCs recorded during Step B1. Yes
Were any continuous DTCs retrieved during Step B1? resolved. GO to the Restraints Control Module
No
Supplemental Restraint System (SRS)in this
Pinpoint Test C: DTC B1870 — Airbag

Warning Indicator Circuit Short to Battery
Normal Operation
If the restraints control module detects an open or
short to battery on the airbag warning indicator circuit,
it will store diagnostic trouble code (DTC) B1870 in
memory. If any other DTCs are detected with this
DTC active, the secondary airbag warning will be
activated.
Possible Causes
An airbag indicator circuit short to battery can be
caused by:
a faulted RCM.
PINPOINT TEST C : DTC B1870 — AIR BAG INDICATOR CIRCUIT SHORT TO BATTERY
C1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve Continuous DTCs Go to C2.
Retrieve and record any continuous DTCs for use later in this pinpoint No
test. This is an intermittent fault. The fault condition is
not present at this time. Go to C4.
On-Demand Self Test
G12345 en 01/2003 2003.0 BA Falcon


C2 CHECK CIRCUIT 608 (B/Y) FOR SHORT TO BATTERY
Yes
WARNING: If the supplemental restraint system (SRS) is Go to C3.
Pretensioner Supplemental Restraint System (SRS) in this section. REPAIR circuit 608 (B/Y). Go to C5.
The airbag restraint system diagnostic tools must be removed and
injury.

personal injury.




the road.

road.
NOTE: Any DTCs for airbag indicator faults associated with the
instrument cluster module will be logged by the RCM.

Disconnect Instrument Cluster Module C220a.
Key in ON position.
Measure the voltage between C171a, circuit 608 (B/Y), harness side
and ground.
Is the voltage less than 0.2 volt?
G12345 en 01/2003 2003.0 BA Falcon


C3 CHECK THE RCM
Connect RCM C189a. Control Module (RCM) in this section.
Enter the following diagnostic mode on the diagnostic tool: Go to C5
On-Demand Self Test No
REPAIR or INSTALL a new instrument cluster
module. Go to C5.
NOTE: DTC B1869 should be retrieved when carrying out the
on-demand self test due to an open on circuit 608 (B/Y), DTC B1870
should not be retrieved at this time.
Was DTC B 1870 retrieved during the on-demand self test?
C4 CHECK FOR AN INTERMITTENT FAULT

Yes
WARNING: If the supplemental restraint system (SRS) is Go to C2.
Pretensioner Supplemental Restraint System (SRS) in this section. CHECK for causes of intermittent short to
The airbag restraint system diagnostic tools must be removed and battery on circuit 608 (B/Y). ATTEMPT to
injury. ACTIVATE other systems in the same wire
bundle. REPAIR any intermittent concerns
found. Go to C5.
personal injury.




the road.

road.

On-Demand Self Test
G12345 en 01/2003 2003.0 BA Falcon


C5 CHECK FOR ADDITIONAL DTCs
Refer to the continuous DTCs recorded during Step C1. Yes
Were any continuous DTCs retrieved during Step C1? resolved. GO to the Restraints Control Module
No
Pinpoint Test D: DTC B1891 — Airbag

Warning Indicator Circuit Short to Battery
Normal Operation
The restraints control module (RCM) monitors its
connection to the instrument cluster module at C189a
pin 22. This connection is used to signal a chime if the
airbag indicator is inoperative and another SRS fault
exists. If the RCM detects a short to battery on the
connection to the instrument cluster module, it will
store diagnostic trouble code (DTC) B1891 in
memory.
Possible Causes
An airbag indicator circuit short to battery can be
caused by:
a damaged or inoperative instrument cluster
module.
a faulted RCM.
PINPOINT TEST D : DTC B1891 — AIR BAG TONE WARNING INDICATOR CIRCUIT SHORT TO
BATTERY
D1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve Continuous DTCs This is a hard fault. The fault condition is still
present. This fault cannot be cleared until it is
Retrieve and record any continuous DTCs for use later in this pinpoint corrected and the DTC is no longer retrieved
test. during the on-demand self test. Go to D2.
No
On-Demand Self Test This is an intermittent fault. The fault condition is
not present at this time.
Was DTC B1891 retrieved during the on-demand self test? Go to D4
G12345 en 01/2003 2003.0 BA Falcon


D2 CHECK THE AIR BAG TONE WARNING INDICATOR
CIRCUIT FOR A SHORT TO BATTERY
Yes
WARNING: If the supplemental restraint system (SRS) is Go to D3.
Pretensioner Supplemental Restraint System (SRS) in this section. REPAIR circuit 609 (O). Go to D5.
injury.

personal injury.




the road.

road.

Disconnect Instrument Cluster Module C171b.
Key in ON position.
Measure the voltage between RCM C189a pin 22, circuit 609 (O),
harness side and ground.
G12345 en 01/2003 2003.0 BA Falcon


D3 CHECK THE RCM
INSTALL a new RCM.
Connect RCM C189a. Go to D5
Key in ON position.
No
Enter the following diagnostic mode on the diagnostic tool: INSTALL a new instrument cluster module.
On-Demand Self Test Go to D5
NOTE: DTC B1892 should be retrieved when carrying out the

on-demand self test due to an open on circuit 609 (O), DTC B1891
should not be retrieved at this time.
G12345 en 01/2003 2003.0 BA Falcon


D4 CHECK FOR AN INTERMITTENT FAULT
Yes
WARNING: If the supplemental restraint system (SRS) is Go to D2.
Pretensioner Supplemental Restraint System (SRS) in this section. CHECK for causes of intermittent short to
The airbag restraint system diagnostic tools must be removed and ground or open on circuit 609 (O). ATTEMPT to
D5.

personal injury.




the road.

road.

On-Demand Self Test
D5 CHECK FOR ADDITIONAL DTCs

Refer to the continuous DTCs recorded during Step D1. Yes
Were any continuous DTCs retrieved during Step D1? resolved. GO to the Restraints Control Module
No
G12345 en 01/2003 2003.0 BA Falcon

Pinpoint Test E: LFC 53/DTC B1892 —

Airbag Tone Warning Indicator Circuit
Shorted to Ground or Open
Normal Operation
The restraints control module (RCM) monitors its
connection to the instrument cluster module at C189a
pin 22. This connection is used to signal a chime if the
airbag indicator is inoperative and another SRS fault
exists. If the RCM detects a short to ground or open
on the connection to the cluster, it will store diagnostic
trouble code (DTC) B1892 in memory and flash lamp
fault code (LFC) 53 (or a higher priority code if one
exists) on the airbag indicator.
Possible Causes
An airbag tone warning indicator circuit short to
ground or open can be caused by:
a damaged or inoperative instrument cluster
module.
a faulted RCM.
PINPOINT TEST E : LFC 53/DTC B1892 — AIR BAG TONE WARNING INDICATOR CIRCUIT SHORTED
TO GROUND OR OPEN
E1 CHECK FOR A HARD OR INTERMITTENT DTC

test. during the on-demand self test. Go to E2.
not present at this time. Go to E5.
G12345 en 01/2003 2003.0 BA Falcon


E2 CHECK THE AIR BAG TONE WARNING INDICATOR
CIRCUIT FOR GROUND SHORT
Yes
WARNING: If the supplemental restraint system (SRS) is Go to E3.
Pretensioner Supplemental Restraint System (SRS) in this section. REPAIR circuit 609 (O). Go to E6.
injury.

personal injury.




the road.

road.

Disconnect Instrument Cluster Module C171b.
Measure the resistance between RCM C189a pin 22, circuit 609 (O),
harness side and RCM C189a pin 16, circuit 1203A (B/G), harness
side.
Is the resistance greater than 1,000,000 ohms?

CIRCUIT FOR AN OPEN
Go to E4.
Measure the resistance between RCM C189a pin 22, circuit 609 (O),
harness side and instrument cluster module C171b, circuit 609 (O), No
harness side. REPAIR circuit 609 (O). Go to E6.
G12345 en 01/2003 2003.0 BA Falcon


Connect Instrument Cluster Module C171b. Yes
INSTALL a new RCM. Go to E6.
Key in ON position.
Measure the voltage at RCM C189a pin 22, circuit 609 (O). No
INSTALL a new instrument cluster module. Go
Is the voltage greater than 10 volts? to E6.
E5 CHECK FOR AN INTERMITTENT FAULT

Yes
WARNING: If the supplemental restraint system (SRS) is Go to E2.
Pretensioner Supplemental Restraint System (SRS) in this section. CHECK for causes of an intermittent short to
The airbag restraint system diagnostic tools must be removed and ground or open on circuit 609 (O). ATTEMPT to
E6.

personal injury.




the road.

road.

On-Demand Self Test
G12345 en 01/2003 2003.0 BA Falcon


E6 CHECK FOR ADDITIONAL DTCs
Refer to the continuous DTCs recorded during Step E1. Yes
Were any continuous DTCs retrieved during Step E1? resolved. GO to the Restraints Control Module
No
Pinpoint Test F: LFC 14/DTC B1921 —

Airbag Diagnostic Monitor Ground Circuit
Open
Normal Operation
WARNING: The tightening torque of the

restraints control module (RCM) retaining bolts is
critical for correct airbag supplemental restraint
system (SRS) operation. REFER to Restraints
Control Module (RCM) in this section for correct
torque values.
NOTE: A resistance difference as low as 10 ohms can
set the LFC.
The restraints control module (RCM) monitors the
resistance between the ground connections at the
mounting bracket and the reference ground at C189a
pin 16, circuit 1203A (B/G). If the RCM detects a
difference in resistance, it will store diagnostic trouble
code (DTC) B1921 in memory and flash lamp fault
code (LFC) 14 (or higher priority code if one exists) on
the airbag indicator.
Possible Causes
A resistance difference between the RCM bracket
ground and harness ground can be caused by:
the RCM or RCM bracket is not securely
mounted.
a faulted RCM.
G12345 en 01/2003 2003.0 BA Falcon

PINPOINT TEST F : LFC 14/DTC B1921 — AIR BAG DIAGNOSTIC MONITOR GROUND CIRCUIT OPEN
F1 CHECK FOR A HARD OR INTERMITTENT DTC

test. during the on-demand self test.
Enter the following diagnostic mode on the diagnostic tool: Go to F2
On-Demand Self Test No
This is an intermittent fault. The fault condition is
Was DTC B1921 retrieved during the on-demand self test? not present at this time.
Go to F5
G12345 en 01/2003 2003.0 BA Falcon


F2 INSPECT THE RCM MOUNTING, MOUNTING BRACKET
AND MOUNTING SURFACE
Yes
WARNING: If the supplemental restraint system (SRS) is CLEAN, TIGHTEN bolts or REPAIR the
being serviced, the system must be deactivated and restraint system mounting surface as necessary. REINSTALL the
diagnostic tools must be installed. Refer to Airbag and Safety Belt RCM and mounting bracket to the mounting
Pretensioner Supplemental Restraint System (SRS) in this section. surface.
The airbag restraint system diagnostic tools must be removed and Go to F6.
avoid non-deployment in a collision, resulting in possible personal No
injury. Go to F3.

personal injury.




the road.

road.

Inspect the RCM mounting and make sure that the retaining bolts are
fully seated and tightened correctly.
Remove the RCM. Refer to Restraints Control Module (RCM) in this
section.
Visually inspect the RCM, mounting bracket and mounting surface for
damage, corrosion or dirt.
Was a significant amount of corrosion or dirt found, the RCM
mounting bracket attached to the mounting surface incorrectly
or were the RCM bolts not fully seated and tightened correctly?
G12345 en 01/2003 2003.0 BA Falcon


F3 INSTALL THE RCM AND CARRY OUT THE ON-DEMAND
SELF TEST
Clean the RCM mounting surfaces and bolts. Yes
Go to F4.
Install the RCM. Refer to Restraints Control Module (RCM) in this
section. No
Enter the following diagnostic mode on the diagnostic tool: Fault corrected. Go to F6.
On-Demand Self Test
F4 CHECK GROUND CIRCUIT 1203A (B/G) FOR HIGH

RESISTANCE
INSTALL a new RCM. Go to F6.
Measure the resistance between RCM C189a pin 16, circuit 1203A
(B/G), harness side and the RCM case ground. No
Is the resistance less than 5 ohms? REPAIR circuit 1203A (B/G). Go to F6.
G12345 en 01/2003 2003.0 BA Falcon


F5 CHECK FOR AN INTERMITTENT FAULT
Yes
WARNING: If the supplemental restraint system (SRS) is Go to F2.
Pretensioner Supplemental Restraint System (SRS) in this section. CHECK for causes of intermittent high
The airbag restraint system diagnostic tools must be removed and resistance on circuit 1203A (B/G) or the chassis
the airbag modules reconnected when the system is reactivated to ground. ATTEMPT to recreate the hard fault by
avoid non-deployment in a collision, resulting in possible personal flexing the wire harness and cycling the ignition
injury. key frequently. REPAIR any intermittent
concerns found. Go to F6.

personal injury.




the road.

road.

On-Demand Self Test
F6 CHECK FOR ADDITIONAL DTCs

Refer to the continuous DTCs recorded during Step F1. Yes
Were any continuous DTCs retrieved during Step F1? resolved. GO to the Restraints Control Module
No
G12345 en 01/2003 2003.0 BA Falcon

Pinpoint Test G: LFC 33 and 34/DTC

B2292 - Restraint System Safety Belt
Pretensioner Status
Normal Operation
The restraints control module (RCM) checks all of the
safety belt pretensioners for faults. If the RCM detects
one of the following faults on any of the safety belt
pretensioner circuits, it will store diagnostic trouble
code (DTC) B2292 in memory and flash, depending
on the fault indicator, either lamp fault code (LFC) 33
or 34 (or higher priority code if one exists) on the
airbag indicator.
Fault Conditions
The RCM monitors for the following fault conditions:
low resistance.
circuit open.
circuit short to voltage.
circuit short to ground.
Possible Causes
A safety belt pretensioner status fault can be caused
by:
a faulty pretensioner.
a faulted RCM.
PINPOINT TEST G : LFC 33 AND 34/DTC B2292 - RESTRAINT SYSTEM SAFETY BELT PRETENSIONER
STATUS
G1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve/Flag Continuous DTCs This is a hard fault. The fault condition is still
Retrieve, flag and record any continuous DTCs for use later in this corrected and the DTC is no longer retrieved
pinpoint test. during the on-demand self test. Go to G2.
not present at this time. Go to G18.
Flag DTC B2292
Retrieve and record any flagged faults for use later in this pinpoint
test.
G12345 en 01/2003 2003.0 BA Falcon


G2 CHECK THE PRETENSIONER
Yes
WARNING: If the supplemental restraint system (SRS) is This is a hard fault. The fault condition is still
being serviced, the system must be deactivated and restraint system present. This fault cannot be cleared until it is
diagnostic tools must be installed. Refer to Airbag and Safety Belt corrected and the DTC is no longer retrieved
Pretensioner Supplemental Restraint System (SRS) in this section. during the on-demand self test.
The airbag restraint system diagnostic tools must be removed and Using the flagged faults recorded in the Step
the airbag modules reconnected when the system is reactivated to G1, GO to the appropriate pinpoint test step.
avoid non-deployment in a collision, resulting in possible personal If a flagged fault of “?” was recorded, multiple
injury. faults exist and the entire pinpoint test must be
carried out before installing a new RCM.
For driver safety belt pretensioner (DF—PRT)
WARNING: Never probe the connectors on the airbag with a low resistance (LOWRES) fault, Go to G3.
module. Doing so can result in airbag deployment, which can result in For DF—PRT with an open circuit (O—CIR)
personal injury. fault, Go to G4.
For DF—PRT with a short to battery (STB) fault,
Go to G6.
WARNING: The safety belt buckle pretensioner is a For DF—PRT with a short to ground (STG) fault,
pyrotechnic device. Never probe a pretensioner electrical connector. Go to G8.
Doing so could result in pretensioner or airbag deployment and could For passenger safety belt pretensioner
result in personal injury. (PF—PRT) with a low resistance (LOWRES)
fault, Go to G10.
For PF—PRT with an open circuit (O—CIR)
WARNING: Never probe the electrical connector on a side fault, Go to G11.
airbag module. Doing so can result in side airbag deployment. For PF—PRT with a short to battery (STB) fault,
Go to G13.
NOTE: Diagnostics or repairs are not to be performed on a seat For PF—PRT with a short to ground (STG) fault,
equipped with a seat side airbag with the seat in the vehicle. Prior to Go to G15.
side airbag, the seat must be removed from the vehicle and the restraint No
system diagnostic tools must be installed in the seat side airbag electrical INSTALL a new driver or passenger safety belt
connectors. The restraint system diagnostic tools must be removed pretensioner. Go to G19.

the road.

the road.

On-Demand Self Test
Was DTC 2292 retrieved during the on-demand self test?
G3 CHECK THE DRIVER SAFETY BELT PRETENSIONER

CIRCUIT 1079 (LG/RD) AND CIRCUIT 1080 (LG/BK) FOR
LOW RESISTANCE
Go to G17.
Disconnect Driver Safety Belt Pretensioner Restraint System
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1079 (LG/RD) and circuit 1080
(LG/BK).
Measure the resistance between RCM C189b pin 32, circuit 1080 Go to G19.
(LG/BK), and pin 31, circuit 1079 (LG/RD), harness side.
G12345 en 01/2003 2003.0 BA Falcon


G4 CHECK CIRCUIT 1079 (LG/RD) FOR AN OPEN
Go to G5.
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1079 (LG/RD). Go to G19.
Measure the resistance between RCM C189b pin 31, circuit 1079
(LG/RD), harness side and driver safety belt buckle pretensioner
C233, circuit 1079 (LG/RD), harness side.
Is the resistance less than 0.5 ohm?
G5 CHECK CIRCUIT 1080 (LG/RD) FOR AN OPEN

Go to G17.
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1080 (LG/BK). Go to G19.
(LG/BK), harness side and driver safety belt buckle pretensioner
C233, circuit 1080 (LG/BK), harness side.
G6 CHECK CIRCUIT 1079 (LG/RD) FOR A SHORT TO

VOLTAGE
Disconnect Driver Safety Belt Pretensioner Restraint System Yes
Diagnostic Tool. Go to G7.
Disconnect RCM C189b. No
Key in ON position. REPAIR circuit 1079 (LG/RD). Go to G19.
Measure the voltage between RCM C189b pin 31, circuit 1079
(LG/RD), harness side and ground.
G7 CHECK CIRCUIT 1080 (LG/BK) FOR A SHORT TO

VOLTAGE
Measure the voltage between RCM C189b pin 32, circuit 1080 Yes
(LG/BK), harness side and ground. Go to G17.
Is the voltage less than 0.2 volt? No
REPAIR circuit 1080 (LG/BK). Go to G19.
G8 CHECK CIRCUIT 1079 (LG/RD) FOR A SHORT TO

GROUND
Go to G9.
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1079 (LG/RD). Go to G19.
(LG/RD), harness side and ground.
G12345 en 01/2003 2003.0 BA Falcon


G9 CHECK CIRCUIT 1080 (LG/BK) FOR A SHORT TO
GROUND
Measure the resistance between RCM C189b pin 32, circuit 1080 Yes
(LG/BK), harness side and ground. Go to G17.
Is the resistance greater than 1,000,000 ohms? No
REPAIR circuit 1080 (LG/BK). Go to G19.
G10 CHECK THE PASSENGER SAFETY BELT

PRETENSIONER CIRCUIT 1081 (YE/RD) AND CIRCUIT
1082 (YE/BK) FOR LOW RESISTANCE
Go to G17.
Disconnect Passenger Safety Belt Pretensioner Restraint System
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1082 (YE/BK) and circuit 1081
(YE/RD). Go to G19.
(YE/BK), and pin 33, circuit 1081 (YE/RD), harness side.
G11 CHECK CIRCUIT 1081 (YE/RD) FOR AN OPEN

Go to G12.
Diagnostic Tool. No
Disconnect RCM C189b. REPAIR circuit 1081 (YE/RD). Go to G19.
(YE/RD), harness side and passenger safety belt buckle pretensioner
C234, circuit 1081 (YE/RD), harness side.
G12 CHECK CIRCUIT 1082 (YE/BK) FOR AN OPEN

(YE/BK), harness side and passenger safety belt buckle pretensioner Go to G17.
C234, circuit 1082 (YE/BK), harness side.
No
Is the resistance less than 0.5 ohm? REPAIR circuit 1082 (YE/BK). Go to G19.
G13 CHECK CIRCUIT 1081 (YE/RD) FOR A SHORT TO

VOLTAGE
Go to G14.
Diagnostic Tool. No
Key in ON position.
Measure the voltage between RCM C189b pin 33, circuit 1081
(YE/RD), harness side and ground.
G14 CHECK CIRCUIT 1082 (YE/BK) FOR A SHORT TO

VOLTAGE
Measure the voltage between RCM C189b pin 34, circuit 1082 Yes
(YE/BK), harness side and ground. Go to G17.
Is the voltage less than 0.2 volt? No
REPAIR circuit 1082 (YE/BK). Go to G19.
G12345 en 01/2003 2003.0 BA Falcon


G15 CHECK CIRCUIT 1081 (YE/RD) FOR A SHORT TO
GROUND
Go to G16.
Diagnostic Tool. No
(YE/RD), harness side and ground.
G16 CHECK CIRCUIT 1082 (YE/BK) FOR A SHORT TO

GROUND
(YE/BK), harness side and ground. Go to G17.
Is the resistance greater than 1,000,000 ohms? No
REPAIR circuit 1082 (YE/BK). Go to G19.
G17 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system diagnostic tools, sensor electrical Yes
connectors and the RCM electrical connector are connected before If a “?” was flagged by the scan tool, CARRY
carrying out the on-demand self test. If not, erroneous DTCs will be OUT the entire pinpoint test before installing a
recorded. new RCM.
Key in OFF position. Control Module (RCM). Go to G19.
Connect Restraint System Diagnostic Tools. No
Connect RCM C189b. Fault corrected. Go to G19.
Key in ON position.
On-Demand Self Test
Flag DTC B2292
Retrieve and record any flagged faults.
G12345 en 01/2003 2003.0 BA Falcon


G18 CHECK FOR AN INTERMITTENT FAULT
Yes
WARNING: If the supplemental restraint system (SRS) is CHECK for causes of the intermittent fault at or
being serviced, the system must be deactivated and restraint system near the affected safety belt pretensioner
diagnostic tools must be installed. Refer to Airbag and Safety Belt electrical connector. REPAIR any intermittent
Pretensioner Supplemental Restraint System (SRS) in this section. concern found.
The airbag restraint system diagnostic tools must be removed and If an intermittent concern was found and
the airbag modules reconnected when the system is reactivated to repaired, Go to G19.
avoid non-deployment in a collision, resulting in possible personal If an intermittent concern was not found and
injury. repaired, USE the flagged faults recorded and
GO to the appropriate pinpoint test step.
If a flagged fault of “?” was recorded, multiple
WARNING: Never probe the connectors on the airbag faults exist and the entire pinpoint test must be
module. Doing so can result in airbag deployment, which can result in carried out before installing a new RCM.
personal injury. For driver safety belt pretensioner (DF—PRT)
with a low resistance (LOWRES) fault, Go to G3.
For DF—PRT with an open circuit (O—CIR)
WARNING: The safety belt buckle pretensioner is a fault, Go to G4.
pyrotechnic device. Never probe a pretensioner electrical connector. For DF—PRT with a short to battery (STB) fault,
Doing so could result in pretensioner or airbag deployment and could Go to G6.
result in personal injury. For DF—PRT with a short to ground (STG) fault,
Go to G8.
For passenger safety belt pretensioner (PF/PRT)
WARNING: Never probe the electrical connector on a side with a low resistance (LOWRES) fault, Go to
airbag module. Doing so can result in side airbag deployment. G10.
For PF—PRT with an open circuit (O—CIR)
NOTE: Diagnostics or repairs are not to be performed on a seat fault, Go to G11.
equipped with a seat side airbag with the seat in the vehicle. Prior to For PF—PRT with a short to battery (STB) fault,
attempting to diagnose or repair a seat concern when equipped with a seat Go to G13.
side airbag, the seat must be removed from the vehicle and the restraint For PF—PRT with a short to ground (STG) fault,
system diagnostic tools must be installed in the seat side airbag electrical Go to G15.
prior to operating the vehicle over the road. No
CHECK for causes of the intermittent fault.
NOTE: After diagnosing or repairing an SRS, the restraint system ATTEMPT to recreate the hard fault by flexing
diagnostic tools must be removed before operating the vehicle over the wire harness and cycling the ignition key
the road. frequently. REPAIR any intermittent concerns
found. Go to G19.
the road.

On-Demand Self Test
Flag DTC B2292
If DTC B2292 is retrieved during the on-demand self test, retrieve and
record any flagged faults.
G12345 en 01/2003 2003.0 BA Falcon


G19 CHECK FOR ADDITIONAL DTCs
Refer to the continuous DTCs recorded during Step G1. Yes
Were any continuous DTCs retrieved during Step G1? resolved. GO to the Restraints Control Module
No
Supplemental Restraint System (SRS) in this
Pinpoint Test H: LFC 19 and 21 /DTC B2293 - Restraint System Airbag Status
Normal Operation
The restraints control module (RCM) checks all of the front airbag circuits for faults. If the RCM detects one of
the following faults on any of the front airbag circuits, it will store diagnostic trouble code (DTC) B2293 in
memory and, depending on the fault, flash either lamp fault code (LFC) 19 or 21 (or higher priority code if one
exists) on the airbag indicator.
Fault Conditions
low resistance.
circuit open.
Possible Causes
A driver airbag status fault can be caused by:
driver airbag sub-harness.
a faulty clockspring.
a faulty driver airbag module.
a faulted RCM.
A passenger airbag status fault can be caused by:
a faulty passenger airbag module.
faulted RCM.
G12345 en 01/2003 2003.0 BA Falcon

PINPOINT TEST H : LFC 19 AND 21/DTC B2293 - RESTRAINT SYSTEM AIR BAG STATUS
H1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve/Flag Continuous DTCs This is a hard fault. The fault condition is still
Retrieve, flag and record any continuous DTCs for use later in this corrected and the DTC is no longer retrieved
pinpoint test. during the on-demand self test. Go to H2.
No
Enter the following diagnostic mode on the diagnostic tool: not present at this time. Go to H38.
Flag DTC B2293
test.
G12345 en 01/2003 2003.0 BA Falcon


H2 CHECK THE DRIVER AND PASSENGER AIR BAG
MODULES
Yes
WARNING: If the supplemental restraint system (SRS) is This is a hard fault. The fault condition is still
being serviced, the system must be deactivated and restraint system present. This fault cannot be cleared until it is
diagnostic tools must be installed. Refer to Airbag and Safety Belt corrected and the DTC is no longer retrieved
Pretensioner Supplemental Restraint System (SRS) in this section. during the on-demand self test.
The airbag restraint system diagnostic tools must be removed and Using the flagged faults recorded in the Step H1,
the airbag modules reconnected when the system is reactivated to GO to the appropriate pinpoint test step.
avoid non-deployment in a collision, resulting in possible personal If a flagged fault of “?” was recorded, multiple
injury. faults exist and the entire pinpoint test must be
carried out before installing a new RCM.
For driver airbag module squib 1 (D—ABAG)
WARNING: Never probe the connectors on the airbag with a short to ground (STG) fault, Go to H3.
module. Doing so can result in airbag deployment, which can result in For driver airbag module squib 1 (D—ABAG)
personal injury. with a short to battery (STB) fault, Go to H5.
with an open circuit (O—CIR) fault, Go to H7.
WARNING: The safety belt buckle pretensioner is a For driver airbag module squib 1 (D—ABAG)
pyrotechnic device. Never probe a pretensioner electrical connector. with a low resistance (LOWRES) fault, Go to
Doing so could result in pretensioner or airbag deployment and could H11.
result in personal injury. For passenger airbag module squib 1
(P—ABAG) with a short to ground (STG) fault,
Go to H14.
WARNING: Never probe the electrical connector on a side For passenger airbag module squib 1
airbag module. Doing so can result in side airbag deployment. (P—ABAG) with a short to battery (STB) fault,
Go to H15.
NOTE: Diagnostics or repairs are not to be performed on a seat For passenger airbag module squib 1
equipped with a seat side airbag with the seat in the vehicle. Prior to (P—ABAG) with an open circuit (O—CIR) fault,
attempting to diagnose or repair a seat concern when equipped with a seat Go to H16.
side airbag, the seat must be removed from the vehicle and the restraint For passenger airbag module squib 1
system diagnostic tools must be installed in the seat side airbag electrical (P—ABAG) with a low resistance (LOWRES)
connectors. The restraint system diagnostic tools must be removed fault, Go to H18.
prior to operating the vehicle over the road. For driver airbag module squib 2 (D—ABAG2)
with a short to ground (STG) fault, Go to H20.
NOTE: After diagnosing or repairing an SRS, the restraint system For driver airbag module squib 2 (D—ABAG2)
diagnostic tools must be removed before operating the vehicle over with a short to battery (STB) fault, Go to H22.
the road. For driver airbag module squib 2 (D—ABAG2)
NOTE: After diagnosing or repairing a seat system, the restraint system For driver airbag module squib 2 (D—ABAG2)
with a low resistance (LOWRES) fault, Go to
the road.
H28.
NOTE: The SRS must be fully operational and free of faults before For passenger airbag module squib 2
releasing the vehicle to the customer. (P—ABAG2) with a short to ground (STG) fault,
Go to H31.
Key in OFF position. For passenger airbag module squib 2
(P—ABAG2) with a short to battery (STB) fault,
Deactivate the system. REFER to Airbag and Safety Belt Pretensioner Go to H32.
Supplemental Restraint System (SRS) in the Diagnosis and Testing For passenger airbag module squib 2
portion of this section. (P—ABAG2) with an open circuit (O—CIR) fault,
Key in ON position. Go to H33.
For passenger airbag module squib 2
Enter the following diagnostic mode on the diagnostic tool: (P—ABAG2) with a low resistance (LOWRES)
On-Demand Self Test fault, Go to H35.
Was DTC B2293 retrieved during the on-demand self test? No

If a flagged fault of “?” was recorded in Step
H1, multiple faults exist and the entire pinpoint
test must be carried out before installing a new
driver or passenger airbag module.
If a fault was flagged against driver airbag
module in Step H1, INSTALL a new driver
airbag module. REFER to Driver Airbag Module
in this section. Go to H39.
If a fault was flagged against passenger airbag
module in Step H1, INSTALL a new passenger
airbag module. REFER to Passenger Airbag
Module in this section. Go to H39.
G12345 en 01/2003 2003.0 BA Falcon


H3 CHECK CIRCUIT 614 (O/B) AND CIRCUIT 615 (GY/WH)
FOR A SHORT TO GROUND BETWEEN THE RCM AND
THE DRIVER AIR BAG MODULE
Go to H37.
Disconnect Driver Airbag Module Squib 1 Restraint System No
Diagnostic Tool. Go to H4.
Measure the resistance between RCM C189a pin 1, circuit 614 (O/B),
harness side and ground; and between RCM C189a pin 2, circuit 615
(GY/WH), harness side and ground.
Are the resistances greater than 1,000,000 ohms?

THE CLOCKSPRING
Disconnect Clockspring C190. Yes
INSTALL a new clockspring. REFER to
Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), Clockspring in this section. Go to H39.
(GY/WH), harness side and ground. No
Are the resistances greater than 1,000,000 ohms? Due to the shorting bar feature in the electrical
connector, the fault can exist in either circuit. Do
not remove or defeat the shorting bar.
REPAIR circuit 614 (O/B) or circuit 615
(GY/WH). Go to H39.

FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND
THE DRIVER AIR BAG MODULE
Go to H37.
Disconnect Driver Airbag Module Squib 1 Restraint System
Diagnostic Tool. No
Disconnect RCM C189a. Go to H6.
Key in ON position.
Measure the voltage between RCM C189a pin 1, circuit 614 (O/B),
(GY/WH), harness side and ground.
Are the voltages less than 0.2 volt?

FOR A SHORT TO VOLTAGE BETWEEN THE RCM AND
THE CLOCKSPRING
Disconnect Clockspring C190. Clockspring in this section. Go to H39.
Key in ON position.
No
Measure the voltage between RCM C189a pin 1, circuit 614 (O/B), Due to the shorting bar feature in the electrical
harness side and ground; and between RCM C189a pin 2, circuit 615 connector, the fault can exist in either circuit. Do
(GY/WH), harness side and ground. not remove or defeat the shorting bar.
REPAIR circuit 614 (O/B) or circuit 615
(GY/WH). Go to H39.
G12345 en 01/2003 2003.0 BA Falcon


FOR AN OPEN BETWEEN THE RCM AND THE DRIVER
AIR BAG MODULE
Go to H9.
Diagnostic Tool No
harness side and driver airbag module, circuit 614 (O/B), harness
side.
H8 CHECK CIRCUIT 614 (O/B) FOR AN OPEN BETWEEN

THE RCM AND THE CLOCKSPRING
Measure the resistance between RCM C189a pin 1, circuit 614 (O/B), Clockspring. Go to H39.
harness side and clockspring C190, circuit 614 (O/B), harness side.
Is the resistance less than 0.5 ohm? No
REPAIR circuit 614 (O/B). Go to H39.
H9 CHECK CIRCUIT 615 (GY/WH) FOR AN OPEN BETWEEN

THE RCM AND THE DRIVER AIR BAG MODULE
Measure the resistance between RCM C189a pin 2, circuit 615 Yes
(GY/WH), harness side and driver airbag module, circuit 615 Go to H37.
(GY/WH), harness side.
No
Is the resistance less than 0.5 ohm? Go to H10.
H10 CHECK CIRCUIT 615 (GY/WH) FOR AN OPEN BETWEEN

Measure the resistance between RCM C189a pin 2, circuit 615 Clockspring in this section. Go to H39.
(GY/WH), harness side and clockspring C190, circuit 615 (GY/WH),
harness side. No
Is the resistance less than 0.5 ohm? REPAIR circuit 615 (GY/WH). Go to H39.

FOR LOW RESISTANCE BETWEEN THE DRIVER AIR
BAG MODULE AND THE RCM
Go to H37.
Diagnostic Tool. No
Measure the resistance between driver airbag module, circuit 614 Go to H12.
(O/B) and circuit 615 (GY/WH), harness side.
Is the resistance greater than 10,000 ohms?
H12 MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT

614 (O/B) AND CIRCUIT 615 (GY/WH)
Go to H13.
and pin 2, circuit 615 (GY/WH), component side. No
Is the resistance greater than 10,000 ohms? Go to H37.
G12345 en 01/2003 2003.0 BA Falcon


FOR LOW RESISTANCE BETWEEN THE CLOCKSPRING
AND THE RCM
Connect RCM C189a. Yes
Disconnect Clockspring C190.
Clockspring in this section. Go to H39.
Measure the resistance between clockspring C190, circuit 614 (O/B)
and, circuit 615 (GY/WH), harness side. No
REPAIR circuit 614 (O/B) and circuit 615
Is the resistance greater than 10,000 ohms? (GY/WH). Go to H39.
H14 CHECK CIRCUIT 607 (BR) AND CIRCUIT 616 (PK/BK)

THE PASSENGER AIR BAG MODULE
Go to H37.
Disconnect Passenger Airbag Module Restraint System Diagnostic
Tool. No
Disconnect RCM C189a. Due to the shorting bar feature in the electrical
Measure the resistance between RCM C189a pin 3, circuit 607 (BR), not remove or defeat the shorting bar.
harness side and ground; and between RCM C189a pin 4, circuit 616 REPAIR circuit 607 (BR) or circuit 616 (PK/BK).
(PK/BK), harness side and ground. Go to H39.

FOR A SHORT TO BATTERY BETWEEN THE RCM AND
THE PASSENGER AIR BAG MODULE
Go to H37.
Tool. No
Disconnect RCM C189a. Due to the shorting bar feature in the electrical
Key in ON position. not remove or defeat the shorting bar.
Measure the voltage between RCM C189a pin 3, circuit 607 (BR), REPAIR circuit 607 (BR) or circuit 616 (PK/BK).
harness side and ground; and between RCM C189a pin 4, circuit 616 Go to H39.
(PK/BK), harness side and ground.
H16 CHECK CIRCUIT 607 (BR) FOR AN OPEN BETWEEN

THE RCM AND THE PASSENGER AIR BAG MODULE
Go to H17.
Tool. No
Disconnect RCM C189a. REPAIR circuit 607 (BR). Go to H39.
Measure the resistance between RCM C189a pin 3, circuit 607 (BR),
harness side and passenger airbag module C146, circuit 607 (BR),
harness side.
H17 CHECK CIRCUIT 616 (PK/BK) FOR AN OPEN BETWEEN

THE RCM AND THE PASSENGER AIR BAG MODULE
(PK/BK), harness side and passenger airbag module C146, circuit Go to H37.
616 (PK/BK), harness side.
No
Is the resistance less than 0.5 ohm? REPAIR circuit 616 (PK/BK). Go to H39.
G12345 en 01/2003 2003.0 BA Falcon


FOR LOW RESISTANCE BETWEEN THE PASSENGER
AIR BAG MODULE AND THE RCM
Go to H37.
Tool. No
Measure the resistance between passenger airbag module C146, Go to H19.
circuit 607 (BR), and pin 2, circuit 616 (PK/BK), harness side.

607 (BR) AND CIRCUIT 616 (PK/BK)
REPAIR circuit 607 (BR) and circuit 616 (PK/BK)
Measure the resistance between RCM C189a pin 3, circuit 607 (BR),
Go to H22.
and pin 4, circuit 616 (PK/BK), component side.
Is the resistance greater than 10,000 ohms? No
Go to H37.
H20 CHECK CIRCUIT 1516 (YE/WH) AND CIRCUIT 1517

(GR/B) FOR A SHORT TO GROUND BETWEEN THE
RCM AND THE DRIVER AIR BAG MODULE
Go to H37.
Diagnostic Tool. No
Measure the resistance between RCM C189a pin 5, circuit 1516 Go to H21.
(YE/WH), harness side and ground; and between RCM C189a pin 6,
circuit 1517 (GR/B), harness side and ground.

(GR/B) FOR A SHORT TO GROUND BETWEEN THE
RCM AND THE CLOCKSPRING
circuit 1517 (GR/B), harness side and ground. No
Are the resistances greater than 1,000,000 ohms? Due to the shorting bar feature in the electrical
not remove or defeat the shorting bar.
REPAIR circuit 1516 (YE/WH) or circuit 1517
(GR/B). Go to H39.

(GR/B) FOR A SHORT TO VOLTAGE BETWEEN THE
Disconnect Driver Airbag Module Squib 2 Restraint System Yes
Diagnostic Tool. Go to H37.
Key in ON position. Go to H23.
Measure the voltage between RCM C189a pin 5, circuit 1516
circuit 1517 (GR/B), harness side and ground.
G12345 en 01/2003 2003.0 BA Falcon


(GR/B) FOR A SHORT TO VOLTAGE BETWEEN THE
RCM AND THE CLOCKSPRING
Key in ON position.
No
Measure the voltage between RCM C189a pin 5, circuit 1516 Due to the shorting bar feature in the electrical
(YE/WH), harness side and ground; and between RCM C189a pin 6, connector, the fault can exist in either circuit. Do
circuit 1517 (GR/B), harness side and ground. not remove or defeat the shorting bar.
REPAIR circuit 1516 (YE/WH) or circuit 1517
(GR/B). Go to H39.
H24 CHECK CIRCUIT 1516 (YE/WH) FOR AN OPEN

BETWEEN THE RCM AND THE DRIVER AIR BAG
MODULE
Go to H26.
Diagnostic Tool. No
Measure the resistance between RCM C189a pin 5, circuit 1516
(YE/WH), harness side and the driver airbag module squib 2, circuit
1516 (YE/WH), harness side.
H25 CHECK CIRCUIT 1516 (YE/WH) FOR AN OPEN

BETWEEN THE RCM AND THE CLOCKSPRING
(YE/WH), harness side and clockspring C190, circuit 1516 (YE/WH),
harness side. No
Is the resistance less than 0.5 ohm? REPAIR circuit 1516 (YE/WH). Go to H39.
H26 CHECK CIRCUIT 1517 (GR/B) FOR AN OPEN BETWEEN

THE RCM AND THE DRIVER AIR BAG MODULE
(GR/B), harness side and driver airbag module squib 2, circuit 1517 Go to H37.
(GR/B), harness side.
No
Is the resistance less than 0.5 ohm? Go to H27.
H27 CHECK CIRCUIT 1517 (GR/B) FOR AN OPEN BETWEEN

(GR/B), harness side and clockspring C190, circuit 1517 (GR/B),
harness side. No
Is the resistance less than 0.5 ohm? REPAIR circuit 1517 (GR/B). Go to H39.
G12345 en 01/2003 2003.0 BA Falcon


H28 CHECK FOR LOW RESISTANCE ON CIRCUIT 1516
(YE/WH) AND CIRCUIT 1517 (GR/B) BETWEEN THE
Go to H37.
Diagnostic Tool. No
Measure the resistance between driver airbag module squib 2, circuit Go to H29.
1516 (YE/WH), harness side and circuit 1517 (GR/B), harness side.

1516 (YE/WH) AND CIRCUIT 1517 (RD/OG)
Go to H30.
(YE/WH), component side and pin 6, circuit 1517 (RD/OG), No
component side. Go to H37.

(YE/WH) AND CIRCUIT 1517 (GR/B) BETWEEN THE
DRIVER AIR BAG MODULE AND THE CLOCKSPRING
Connect RCM C189a. Yes
Measure the resistance between clockspring C190, circuit 1516
(YE/WH), harness side and pin 1, circuit 1517 (GR/B), harness side. No
REPAIR circuit 1516 (YE/WH) and circuit 1517
Is the resistance greater than 10,000 ohms? (GR/B). Go to H39.
H31 CHECK CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519

(LG/RD) FOR A SHORT TO GROUND BETWEEN THE
RCM AND THE PASSENGER AIR BAG MODULE
Disconnect Passenger Airbag Module Restraint System Diagnostic Yes
Tool. Go to H37.
Measure the resistance between RCM C189a pin 13, circuit 1518 Due to the shorting bar feature in the electrical
(RD/WH), harness side and ground; and between RCM C189a pin 14, connector, the fault can exist in either circuit.
circuit 1519 (LG/RD), harness side and ground. REPAIR circuit 1518 (RD/WH) or circuit 1519
(LG/RD). Go to H39.
H32 CHECK CIRCUIT 1518 (RD/WH) AND CIRCUIT 1519

(LG/RD) FOR A SHORT TO VOLTAGE BETWEEN THE
Disconnect Passenger Airbag Module Restraint System Diagnostic Yes
Tool. Go to H37.
Key in ON position. Due to the shorting bar feature in the electrical
connector, the fault can exist in either circuit.
Measure the voltage between RCM C189a pin 13, circuit 1518 REPAIR circuit 1518 (RD/WH) or circuit 1519
(RD/WH), harness side and ground; and between RCM C189a pin 14, (LG/RD). Go to H39.
circuit 1519 (LG/RD), harness side and ground.
G12345 en 01/2003 2003.0 BA Falcon


H33 CHECK CIRCUIT 1518 (RD/WH) FOR AN OPEN
BETWEEN THE RCM AND THE PASSENGER AIR BAG
MODULE
Go to H34.
Tool. No
Disconnect RCM C189a. REPAIR circuit 1518 (RD/WH). Go to H39.
(RD/WH), harness side and passenger airbag module C146, circuit
1518 (RD/WH), harness side.
H34 CHECK CIRCUIT 1519 (LG/RD) FOR AN OPEN

BETWEEN THE RCM AND THE PASSENGER AIR BAG
MODULE
(LG/RD), harness side and passenger airbag module C146, circuit Go to H37.
1519 (LG/RD), harness side.
No
Is the resistance less than 0.5 ohm? REPAIR circuit 1519 (LG/RD). Go to H39.

(RD/WH) AND CIRCUIT 1519 (LG/RD) BETWEEN THE
Go to H37.
Tool. No
Measure the resistance between passenger airbag module C146, Go to H36.
circuit 1518 (RD/WH), harness side and, circuit 1519 (LG/RD),
harness side.

1518 (RD/WH) AND CIRCUIT 1519 (LG/RD)
REPAIR circuit 1518 (RD/WH) and circuit 1519
Measure the resistance between RCM C189a pin 13, circuit 1518 (LG/RD). Go to H39.
(RD/WH), component side and pin 14, circuit 1519 (LG/RD),
component side. No
Is the resistance greater than 10,000 ohms? Go to H37.
H37 CONFIRM THE RCM FAULT
NOTE: Make sure all restraint system diagnostic tools, sensor electrical Yes
connectors and the RCM electrical connector are connected before If a “?” was flagged by the scan tool, CARRY
carrying out the on-demand self-test. If not, erroneous DTCs will be OUT the entire pinpoint test before installing a
recorded. new RCM.
Key in OFF position. Control Module (RCM) in this section. Go to
H39.
Connect Restraint System Diagnostic Tools.
Connect RCM C189a.
No
Fault corrected. Go to H39.
On-Demand Self Test
Retrieve and record any flagged faults.
G12345 en 01/2003 2003.0 BA Falcon


H38 CHECK FOR AN INTERMITTENT FAULT
Yes
WARNING: If the supplemental restraint system (SRS) is CHECK for causes of the intermittent fault at or
being serviced, the system must be deactivated and restraint system near the affected airbag module connector.
diagnostic tools must be installed. Refer to Airbag and Safety Belt REPAIR any intermittent concerns found.
Pretensioner Supplemental Restraint System (SRS) in this section. If an intermittent concern was found and
The airbag restraint system diagnostic tools must be removed and repaired, Go to H39.
the airbag modules reconnected when the system is reactivated to If an intermittent concern was not found and
avoid non-deployment in a collision, resulting in possible personal repaired, USE the flagged faults recorded and
injury. GO to the appropriate pinpoint test step.
If a flagged fault of “?” was recorded in Step
H1, multiple faults exist and the entire pinpoint
WARNING: Never probe the connectors on the airbag test must be carried out before installing a new
module. Doing so can result in airbag deployment, which can result in RCM.
personal injury. For driver airbag module squib 1 (D—ABAG)
with a short to ground (STG) fault, Go to H3.
WARNING: The safety belt buckle pretensioner is a with a short to battery (STB) fault, Go to H5.
pyrotechnic device. Never probe a pretensioner electrical connector. For driver airbag module squib 1 (D—ABAG)
Doing so could result in pretensioner or airbag deployment and could with an open circuit (O—CIR) fault, Go to H7.
result in personal injury. For driver airbag module squib 1 (D—ABAG)
with a low resistance (LOWRES) fault, Go to
H11.
WARNING: Never probe the electrical connector on a side For passenger airbag module squib 1
airbag module. Doing so can result in side airbag deployment. (P—ABAG) with a short to ground (STG) fault,
Go to H14.
NOTE: Diagnostics or repairs are not to be performed on a seat For passenger airbag module squib 1
equipped with a seat side airbag with the seat in the vehicle. Prior to (P—ABAG) with a short to battery (STB) fault,
attempting to diagnose or repair a seat concern when equipped with a seat Go to H15.
side airbag, the seat must be removed from the vehicle and the restraint For passenger airbag module squib 1
system diagnostic tools must be installed in the seat side airbag electrical (P—ABAG) with an open circuit (O—CIR) fault,
connectors. The restraint system diagnostic tools must be removed Go to H16.
prior to operating the vehicle over the road. For passenger airbag module squib 1
(P—ABAG) with a low resistance (LOWRES)
NOTE: After diagnosing or repairing an SRS, the restraint system fault, Go to H18.
diagnostic tools must be removed before operating the vehicle over For driver airbag module squib 2 (D—ABAG2)
the road. with a short to ground (STG) fault, Go to H20.
For driver airbag module squib 2 (D—ABAG2)
NOTE: After diagnosing or repairing a seat system, the restraint system with a short to battery (STB) fault, Go to H22.
For driver airbag module squib 2 (D—ABAG2)
the road.
NOTE: The SRS must be fully operational and free of faults before For driver airbag module squib 2 (D—ABAG2)
releasing the vehicle to the customer. with a low resistance (LOWRES) fault, Go to
H28.
Key in OFF position. For passenger airbag module squib 2
(P—ABAG2) with a short to ground (STG) fault,
Deactivate the system. Refer to Airbag and Safety Belt Pretensioner Go to H31.
Supplemental Restraint System (SRS) in the Diagnosis and Testing For passenger airbag module squib 2
portion of this section. (P—ABAG2) with a short to battery (STB) fault,
Enter the following diagnostic mode on the diagnostic tool: Go to H32.
On-Demand Self Test (P—ABAG2) with an open circuit (O—CIR) fault,
Enter the following diagnostic mode on the diagnostic tool: Go to H33.
Flag DTC B2293 (P—ABAG2) with a low resistance (LOWRES)
If the DTC B2293 is retrieved during the on-demand self test, retrieve fault, Go to H35.
and record any flagged faults.
No
Was the DTC B2293 retrieved during the on-demand self test? CHECK for causes of the intermittent fault.
ATTEMPT to recreate the hard fault by flexing
the wire harness and cycling the ignition key
frequently. REPAIR any intermittent concerns
found. Go to H39.
G12345 en 01/2003 2003.0 BA Falcon


H39 CHECK FOR ADDITIONAL DTCs
Refer to the continuous DTCs recorded during Step H1. Yes
Were any continuous DTCs retrieved during Step H1? resolved. GO to the Restraints Control Module
No
Supplemental Restraint System (SRS). CLEAR
all DTCs.
Pinpoint Test I: LFC 22 and 23 / DTC B2295 — Restraint System Side Airbag Module
Status
Normal Operation
The restraints control module (RCM) checks all side airbag module circuits for faults. If the RCM detects one
of the following faults on any of the side airbag module circuits, it will store diagnostic trouble code (DTC)
B2295 in memory and flash, depending on the fault, either lamp fault code (LFC) 22 or 23 (or higher priority
code if one exists) on the airbag indicator.
Fault Conditions
low resistance.
circuit open.
Possible Causes
A side airbag module status fault can be caused by:
a faulty side airbag module.
faulted RCM.
PINPOINT TEST I : LFC 22 AND 23/DTC B2295 - RESTRAINT SYSTEM SIDE AIRBAG MODULE STATUS
I1 CHECK FOR A HARD OR INTERMITTENT DTC

Retrieve Continuous DTCs Vehicles with side airbag modules:
This is a hard fault, the fault condition is still
Retrieve, flag and record any continuous DTCs for use later in this present. This fault cannot be cleared until it is
pinpoint test. corrected and the DTC is no longer retrieved
Enter the following diagnostic mode on the diagnostic tool: during the on-demand self test. Go to I3.
Vehicles without side airbag modules:
On-Demand Self Test
This is a hard fault, the fault condition is still
Enter the following diagnostic mode on the diagnostic tool: present. This fault cannot be cleared until it is
Flag B2295 corrected and the DTC is no longer retrieved
during the on-demand self test. Go to I2.
test. No
This is an intermittent fault. The fault condition is
Was DTC B2295 retrieved during the on-demand self test? not present at this time. Go to I17.
G12345 en 01/2003 2003.0 BA Falcon


I2 CHECK THE SIDE AIRBAG MODULE BRIDGE
RESISTOR
Yes
WARNING: If the supplemental restraint system (SRS) is Using the flagged faults recorded in Step I1, GO
being serviced, the system must be deactivated and restraint system to the appropriate pinpoint test step.
diagnostic tools must be installed. Refer to Airbag and Safety Belt If a flagged fault of “?” was recorded in Step I1,
Pretensioner Supplemental Restraint System (SRS) in this section. multiple faults exist and the entire pinpoint test
The airbag restraint system diagnostic tools must be removed and must be carried out before installing a new
the airbag modules reconnected when the system is reactivated to RCM.
avoid non-deployment in a collision, resulting in possible personal For driver side airbag module (DFCURTN) with
injury. a short to battery (STB) fault, Go to I4.
For driver side airbag module (DFCURTN) with
a short to ground (STG) fault, Go to I5.
WARNING: Never probe the connectors on the airbag For driver side airbag module (DFCURTN) with
module. Doing so can result in airbag deployment, which can result in an open circuit (O—CIR) fault, Go to I6.
personal injury. For driver side airbag module (DFCURTN) with
a low resistance (LOWRES) fault, Go to I8.
WARNING: The safety belt buckle pretensioner is a No

pyrotechnic device. Never probe a pretensioner electrical connector. Fault Corrected. Go to I18.
WARNING: Never probe the electrical connector on a side

airbag module. Doing so can result in side airbag deployment.


the road.

the road.

Disconnect RH Side Airbag Bridge Resistor.
Install a known good side airbag bridge resistor.
On-Demand Self Test
Flag DTC B2295
G12345 en 01/2003 2003.0 BA Falcon


I3 CHECK THE DRIVER AND PASSENGER SIDE AIRBAG
MODULES
Yes
WARNING: If the supplemental restraint system (SRS) is Using the flagged faults recorded in Step I1, GO
being serviced, the system must be deactivated and restraint system to the appropriate pinpoint test step.
diagnostic tools must be installed. Refer to Airbag and Safety Belt If a flagged fault of “?” was recorded in Step I1,
Pretensioner Supplemental Restraint System (SRS) in this section. multiple faults exist and the entire pinpoint test
The airbag restraint system diagnostic tools must be removed and must be carried out before installing a new
the airbag modules reconnected when the system is reactivated to RCM.
avoid non-deployment in a collision, resulting in possible personal For driver side airbag module (DFCURTN) with
injury. a short to battery (STB) fault, Go to I4.
For driver side airbag module (DFCURTN) with
a short to ground (STG) fault, Go to I5.
WARNING: Never probe the connectors on the airbag For driver side airbag module (DFCURTN) with
module. Doing so can result in airbag deployment, which can result in an open circuit (O—CIR) fault, Go to I6.
personal injury. For driver side airbag module (DFCURTN) with
a low resistance (LOWRES) fault, Go to I8.
For passenger side airbag module (PFCURTN)
WARNING: The safety belt buckle pretensioner is a with a short to battery (STB) fault, Go to I10.
pyrotechnic device. Never probe a pretensioner electrical connector. For passenger side airbag module (PFCURTN)
Doing so could result in pretensioner or airbag deployment and could with a short to ground (STG) fault, Go to I11.
result in personal injury. For passenger side airbag module (PFCURTN)
with an open circuit (O/CIR) fault, Go to I12.
For passenger side airbag module (PFCURTN)
WARNING: Never probe the electrical connector on a side with a low resistance (LOWRES) fault, Go to
airbag module. Doing so can result in side airbag deployment. I14.
NOTE: Diagnostics or repairs are not to be performed on a seat No
equipped with a seat side airbag with the seat in the vehicle. Prior to If a flagged fault of “?” was recorded in Step I1,
multiple faults exist and the entire pinpoint test
side airbag, the seat must be removed from the vehicle and the restraintmust be carried out before installing a new side
airbag module.
connectors. The restraint system diagnostic tools must be removed If a fault was flagged against driver side airbag
prior to operating the vehicle over the road. module in Step I1, INSTALL a new driver side
airbag module. REFER to Side Airbag Module in
NOTE: After diagnosing or repairing an SRS, the restraint system this section. Go to I18.
diagnostic tools must be removed before operating the vehicle over If a fault was flagged against passenger side
the road. airbag module in Step I1, INSTALL a new
passenger side airbag module. REFER to Side
NOTE: After diagnosing or repairing a seat system, the restraint system Airbag Module in this section. Go to I18.
the road.

Key in ON position.
On-Demand Self Test
G12345 en 01/2003 2003.0 BA Falcon


I4 CHECK CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR)
THE DRIVER SIDE AIRBAG MODULE
NOTE: Vehicles without side airbags are equipped with a side airbag Yes
bridge resistor on the seat. Go to I16.

Due to the shorting bar feature in the electrical
Disconnect Driver Side Side Airbag Module Restraint System connector, the fault can exist in either circuit.
Diagnostic Tool. REPAIR circuit 1257 (WH) or circuit 1258 (BR).
Vehicles with side airbags. Go to I18.
Disconnect RH Side Side Airbag Bridge Resistor.

Vehicles without side airbags.
Disconnect RCM C189b.
Key in ON position.
Measure the voltage between RCM C189b pin 3, circuit 1257 (WH),
harness side and ground; and between RCM C189b pin 4, circuit
1258 (BR), harness side and ground.
I5 CHECK CIRCUIT 1257 (WH) AND CIRCUIT 1258 (BR)

THE DRIVER SIDE AIRBAG MODULE
Go to I16.
Disconnect Driver Side Airbag Module Restraint System Diagnostic
Tool. No
Vehicles with side airbags. Due to the shorting bar feature in the electrical
connector, the fault can exist in either circuit.
REPAIR circuit 1257 (WH) or circuit 1258 (BR).
Vehicles without side airbags. Go to I18.
(WH), harness side and ground; and between RCM C189b pin 4,
circuit 1258 (BR), harness side and ground.
I6 CHECK CIRCUIT 1257 (WH) FOR AN OPEN BETWEEN

THE RCM AND THE DRIVER SIDE AIRBAG MODULE
Go to I7.
Tool. No
Vehicles with side airbags. REPAIR circuit 1257 (WH). Go to I18.
Disconnect RH Side Airbag Module Bridge Resistor.
For vehicles with side airbags, measure the resistance between
RCM C189b pin 3, circuit 1257 (WH), harness side and driver side
airbag module C342, circuit 1257 (WH), harness side.
For vehicles without side airbags, measure the resistance between
RCM C189b pin 3, circuit 1257 (WH), harness side and RH side
airbag bridge resistor C342, circuit 1257 (WH), harness side.
G12345 en 01/2003 2003.0 BA Falcon


I7 CHECK CIRCUIT 1258 (BR) FOR AN OPEN BETWEEN
THE RCM AND THE DRIVER SIDE AIRBAG MODULE
For vehicles with side airbags, measure the resistance between Yes
RCM C189b pin 4, circuit 1258 (BR), harness side and driver side Go to I16.
airbag module C342, circuit 1258 (BR), harness side.
No
For vehicles without side airbags, measure the resistance between REPAIR circuit 1258 (BR). Go to I18.
RCM C189b pin 4, circuit 1258 (BR), harness side and RH side airbag
bridge resistor C342, circuit 1258 (BR), harness side.
I8 CHECK FOR LOW RESISTANCE ON CIRCUIT 1257 (WH)

AND CIRCUIT 1258 (BR) BETWEEN THE DRIVER SIDE
AIRBAG MODULE AND THE RCM
Go to I16.
Tool. No
Vehicles with side airbags. Go to I9.
For vehicles with side airbags, measure the resistance between
driver side airbag module C342, circuit 1257 (WH) and 1258 (BR),
harness side.
For vehicles without side airbags, measure the resistance between
RH side airbag bridge resistor C342, circuit 1257 (WH) and circuit
1258 (BR), harness side.
Is the resistance greater than 10, 000 ohms?
I9 MEASURE THE RESISTANCE BETWEEN RCM CIRCUIT

1257 (WH) AND CIRCUIT 1258 (BR)
Disconnect RCM C189b. Yes
REPAIR circuit 1257 (WH) and circuit 1258
Measure the resistance between RCM C189b pin 3, circuit 1257 (BR). Go to I18.
(WH), and pin 4, circuit 1258 (BR), component side.
Is the resistance greater than 10,000 ohms? No
Go to I16.
I10 CHECK CIRCUIT 1259 (W/Y) AND CIRCUIT 1260 (BN/YE)

THE PASSENGER SIDE AIRBAG MODULE
Go to I16.
Disconnect Passenger Side Airbag Restraint System Diagnostic Tool.
Disconnect RCM C189b. No
Due to the shorting bar feature in the electrical
Key in ON position. connector, the fault can exist in either circuit.
Measure the voltage between RCM C189b pin 5, circuit 1259 (W/Y), REPAIR circuit 1259 (W/Y) or circuit 1260
harness side and ground; and between RCM C189b pin 6, circuit (BN/YE). Go to I18.
1260 (BN/YE), harness side and ground.

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

SECTION : 100-00 General Information

01/2003 2003.0 BA Falcon

O-Rings (Fluoroelastomer) .................................................................................................100-00-10

01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION

G17365 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

G17365 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Air Bags - Do Nots Solvent-based Adhesives/Sealers - See

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

those based on solvents, in confined spaces, for Cutting

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

hydrocarbons. Engines should be run only under Foams - Polyurethane

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Prolonged and repeated contact with mineral oil will Noise

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Arc Welding Warning Symbols on Vehicles

G17372 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

6. Displaying this symbol warn that children should

G17373 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

G17373 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

CAUTION: Compressed air is sometimes

G17374 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

substance, particularly a solvent, DO NOT use it.

CAUTION: If in doubt about the suitability of

G17374 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

All instrument gauges (except fuel gauge) read Brake Testing

G17375 en 01/2003 2003.0 BA Falcon

SECTION : 100-01 Identification Codes

01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION

Identification Label (engine bay)

G86656 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Identification Label (A-pillar)

G86656 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Body Style Code

G86656 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Vehicle Compliance (VC) Label

G86657 en 01/2003 2003.0 BA Falcon

DESCRIPTION AND OPERATION (Continued)

Compliance Plate (A-pillar)

G86657 en 01/2003 2003.0 BA Falcon

SECTION : 100-02 Jacking and Lifting