Ford BA Falcon Manual Index

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

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

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

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

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

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

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

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

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

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

205-02A-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

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

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

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

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

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

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

206-05-1 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

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

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
Diagnostic Trouble Code (DTC) Chart ...............................................................................206-09-18
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

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

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

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

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

303-01b-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

303-01c-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

303-03-1 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

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

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

303-04c-2 Single Fuel LPG 303-04c-2
(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

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

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

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

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

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

307-01-2 Automatic Transmission 307-01-2
(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

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

308-02-1 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

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

308-03a-2 Manual Transmission — I6 308-03a-2
(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

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

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

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

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

310-02-1 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

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

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

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

412-03-2 Air Conditioning 412-03-2
(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

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

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

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

413-07-1 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

413-08-1 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

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

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

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

415-02-1 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

415-03-1 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

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

417-01-2 Exterior Lighting 417-01-2
(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

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

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

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

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

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

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

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

501-04-1 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

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

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

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

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

501-11-1 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

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

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

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

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

501-19-1 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

501-20a-2 Occupant Restraints — Active 501-20a-2
SPECIFICATIONS
Torque 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

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

501-20b-2 Occupant Restraints — Passive 501-20b-2
(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

501-25A-1 Body Repairs — General Information 501-25A-1
SECTION : 501-25A Body Repairs — General

Information
CONTENTS PAGE
Body Repairs — General Information .................................................................................501-25A-2
Jigs and Measuring Equipment .........................................................................................501-25A-2
Panel Repairs ....................................................................................................................501-25A-2
Replacement Body Panels ...............................................................................................501-25A-2
Sealants and Corrosion Protection ....................................................................................501-25A-2
Dust and Water Leaks .......................................................................................................501-25A-3
Wind Noise ........................................................................................................................501-25A-3
01/2003 2003.0 BA Falcon

501-25B-1 Body Repairs — Corrosion Protection 501-25B-1
SECTION : 501-25B Body Repairs — Corrosion

Protection
CONTENTS PAGE
Electro — Coat ...................................................................................................................501-25B-2
Corrosion Prevention ..........................................................................................................501-25B-2
Corrosion Protection ...........................................................................................................501-25B-2
Safety Precautions .............................................................................................................501-25B-2
GENERAL PROCEDURES
Soft Seal Locations .............................................................................................................501-25B-3
Anti — Flutter Adhesive Location .......................................................................................501-25B-5
Button Plug Locations .........................................................................................................501-25B-6
Sound Absorber Locations .................................................................................................501-25B-8
Sound Absorber ..................................................................................................................501-25B-9
01/2003 2003.0 BA Falcon

501-25C-1 Body Repairs — Plastic Repairs 501-25C-1
SECTION : 501-25C Body Repairs — Plastic

Repairs
CONTENTS PAGE
Plastic Repairs ...................................................................................................................501-25C-2
Plastic Idendification ..........................................................................................................501-25C-2
Plastic Bumper Repair .......................................................................................................501-25C-2
01/2003 2003.0 BA Falcon

501-25D-1 Body Repairs — Water Leaks 501-25D-1
SECTION : 501-25D Body Repairs — Water Leaks

CONTENTS PAGE
Water Leaks .......................................................................................................................501-25D-2
General ..............................................................................................................................501-25D-2
Practical execution of tests and checks ............................................................................501-25D-2
Rectifying the leak using recommended tools, auxiliary equipment and materials ...........501-25D-3
Water leaks according to mileage or running time ............................................................501-25D-3
Water leaks after body repairs ..........................................................................................501-25D-3
Water drainage system .....................................................................................................501-25D-3
Water leaks, diagnosis and corrective action: Front passenger compartment .................501-25D-4
01/2003 2003.0 BA Falcon

501-25E-1 Body Repairs - Wind Noise 501-25E-1
SECTION : 501-25E Body Repairs - Wind Noise

CONTENTS PAGE
Wind Noise ........................................................................................................................ 501-25E-2
General ..............................................................................................................................501-25E-2
Normal air flow noises .......................................................................................................501-25E-2
Noises caused partly by changes in the direction of air flow and by air flow around separate
components .......................................................................................................................501-25E-2
Noise caused by vibrating seals .......................................................................................501-25E-2
Escaping noises ...............................................................................................................501-25E-3
Cavity noises ....................................................................................................................501-25E-3
Wind noise with the sun roof open ....................................................................................501-25E-3
Wind noises from the door seals .......................................................................................501-25E-3
Wind noises ......................................................................................................................501-25E-4
Summary ..........................................................................................................................501-25E-4
Problem sources in practice ..............................................................................................501-25E-4
Sequence for performing a wind noise diagnosis (diagram) .............................................501-25E-6
Workshop diagnosis ..........................................................................................................501-25E-6
01/2003 2003.0 BA Falcon

501-25G-1 Body Repairs - Noise, Vibration and Harshness 501-25G-1
SECTION : 501-25G Body Repairs - Noise,

Vibration and Harshness
CONTENTS PAGE
Noise, Vibration and Harshness ..........................................................................................501-25G-2
Introduction ........................................................................................................................501-25G-2
What is understood by NVH in vehicle technology ...........................................................501-25G-2
Types of noise in NVH technology ....................................................................................501-25G-2
Noise transmission through air ..........................................................................................501-25G-2
Sound transmission through a body .................................................................................501-25G-2
Combination of transmission through air and bodies ........................................................501-25G-3
Vibration technology ..........................................................................................................501-25G-3
Noise and oscillation behaviour in a vehicle .....................................................................501-25G-6
Noise and oscillation behaviour of intake and exhaust systems .......................................501-25G-6
Bodywork ...........................................................................................................................501-25G-8
01/2003 2002.50 BA Falcon

501-26-1 Body Repairs- Tolerance Checks 501-26-1
SECTION 501-26: Body Repairs- Tolerance Checks

CONTENTS
WELD INFORMATION
Dimensional Check Underbody Plan View ............................................................................501-26-2
Dimensional Check Underbody Side View ............................................................................501-26-3
Dimensional Check Underbody Wagon Plan View ................................................................501-26-4
Dimensional Check Underbody Wagon Side View ................................................................501-26-5
Dimensional Check Front End ...............................................................................................501-26-6
Dimensional Check Rear End ................................................................................................501-26-7
Dimensional Check Wagon Liftgate Aperture ........................................................................501-26-8
Dimensional Check Body Shell Width Sedan ........................................................................501-26-9
Dimensional Check Body Shell Width Wagon .....................................................................501-26-10
Dimensional Check Front Door Aperture .............................................................................501-26-11
Dimensional Check Rear Door Aperture Sedan ..................................................................501-26-12
Dimensional Check Rear Door Aperture Wagon .................................................................501-26-13
Body Gap Dimensions Front End 1 .....................................................................................501-26-14
Body Gap Dimensions Front End 2 .....................................................................................501-26-15
Body Gap Dimensions Front Side .......................................................................................501-26-16
Body Gap Dimensions .........................................................................................................501-26-17
Body Gap Dimensions .........................................................................................................501-26-18
Body Gap Dimension Rear Quarter Panel ...........................................................................501-26-19
Body Gap Dimension Rear End ...........................................................................................501-26-20
01/2003 2003.0 BA Falcon

501-27-1 Front End Sheet Metal Repairs 501-27-1
SECTION 501-27: Front End Sheet Metal Repairs

CONTENTS
WELD INFORMATION
Radiator Cross Member 1 ......................................................................................................501-27-2
Radiator Cross Member 1a ....................................................................................................501-27-3
Towel Rail Replacement ........................................................................................................501-27-3
Apron and Side Member ........................................................................................................501-27-5
Front Apron LHS ....................................................................................................................501-27-5
Front Apron RHS ...................................................................................................................501-27-6
Fender to Body LHS ..............................................................................................................501-27-6
Fender to Body RHS ..............................................................................................................501-27-7
Front Apron LHS 1 .................................................................................................................501-27-7
Front Apron RHS 1 ................................................................................................................501-27-8
01/2003 2003.0 BA Falcon

501-28-1 Roof Sheet Metal Repairs 501-28-1
SECTION 501-28: Roof Sheet Metal Repairs

CONTENTS
WELD INFORMATION
Sedan Roof Panels 1 .............................................................................................................501-28-2
Wagon Roof Panels 1 ............................................................................................................501-28-5
01/2003 2003.0 BA Falcon

501-29-1 Side Panel Sheet Metal Repairs 501-29-1
SECTION 501-29: Side Panel Sheet Metal Repairs

CONTENTS
WELD INFORMATION
Sedan Body Side 1 ................................................................................................................501-29-3
Sedan Body Side 2 ................................................................................................................501-29-3
Sedan Body Side 3 ................................................................................................................501-29-4
Sedan Body Side 4 ................................................................................................................501-29-4
Sedan Body Side 5 ................................................................................................................501-29-5
Sedan Body Side 6 ................................................................................................................501-29-5
Wagon Body Side 1 ...............................................................................................................501-29-6
Wagon Body Side 2 ...............................................................................................................501-29-6
Wagon Body Side 3 ...............................................................................................................501-29-7
Wagon Body Side 4 ...............................................................................................................501-29-7
Wagon Body Side 5 ...............................................................................................................501-29-8
Wagon Body Side 6 ...............................................................................................................501-29-8
Wagon Body Side 7 ...............................................................................................................501-29-9
Wagon Body Side 8 ...............................................................................................................501-29-9
Wagon Body Side 9 .............................................................................................................501-29-10
Wagon Body Side 10 ...........................................................................................................501-29-10
Wagon Body Side 11 ...........................................................................................................501-29-11
Wagon Body Side 12 ...........................................................................................................501-29-11
Wagon Body Side 13 ...........................................................................................................501-29-12
Wagon and Sedan Side Impact Crash Sensor Bracket .......................................................501-29-12
Wagon Liftgate 1 ..................................................................................................................501-29-13
Wagon Liftgate 2 ..................................................................................................................501-29-14
Front Door 1 .........................................................................................................................501-29-14
Front Door 2 .........................................................................................................................501-29-15
Front Door 3 .........................................................................................................................501-29-15
Front Door 4 .........................................................................................................................501-29-16
Front Door 5 .........................................................................................................................501-29-16
Front Door 6 .........................................................................................................................501-29-17
01/2003 2003.0 BA Falcon

501-29-2 Side Panel Sheet Metal Repairs 501-29-2
(Continued)
Front Door 7 .........................................................................................................................501-29-17

Sedan Rear Door 1 ..............................................................................................................501-29-18
Sedan Rear Door 2 ..............................................................................................................501-29-18
Sedan Rear Door 3 ..............................................................................................................501-29-19
Wagon Rear Door 1 .............................................................................................................501-29-19
Wagon Rear Door 2 .............................................................................................................501-29-20
Wagon Rear Door 3 .............................................................................................................501-29-20
Wagon Rear Door 4 .............................................................................................................501-29-21
SWB Sedan Side Floor Plan Assembly 1 ............................................................................501-29-21
SWB Sedan Side Floor Plan Assembly 2 ............................................................................501-29-22
Wagon Side Floor Plan Assembly 1 ....................................................................................501-29-22
Wagon Side Floor Plan Assembly 2 ....................................................................................501-29-23
Ute Side Floor Plan Assembly 1 ..........................................................................................501-29-23
Ute Side Floor Plan Assembly 2 ..........................................................................................501-29-24
Ute Body Side 1 ...................................................................................................................501-29-24
Ute Body Side 2 ...................................................................................................................501-29-25
Ute Body Side 3 ...................................................................................................................501-29-25
Ute Body Side 4 ...................................................................................................................501-29-26
Ute Body Side 5 ...................................................................................................................501-29-26
01/2003 2003.0 BA Falcon

501-30-1 Rear End Sheet Metal Repairs 501-30-1
SECTION 501-30: Rear End Sheet Metal Repairs

CONTENTS
WELD INFORMATION
Petrol Rear Floorpan Assembly .............................................................................................501-30-3
Petrol Rear Floor Pan Assembly - View A .............................................................................501-30-3
Petrol Rear Floor Pan Assembly - View B .............................................................................501-30-4
Petrol Rear Floorpan Sill Assembly .......................................................................................501-30-4
Petrol Rear Floorpan Sill Assembly - View A ........................................................................501-30-5
Petrol Rear Floorpan Sill Assembly - View B ........................................................................501-30-5
Petrol Rear Floorpan Sill Assembly - View C ........................................................................501-30-6
Rear Sill to Rear Floorpan Assembly .....................................................................................501-30-6
Rear Sill to Rear Floorpan - View A .......................................................................................501-30-7
Rear Sill to Rear Floorpan - View B .......................................................................................501-30-7
Rear Sill to Rear Floorpan - View C ......................................................................................501-30-8
Dedicated LPG Rear Floorpan Assembly 1 ...........................................................................501-30-8
Dedicated LPG Rear Floorpan Assembly - View A ...............................................................501-30-9
Dedicated LPG Rear Floorpan Assembly - View B ...............................................................501-30-9
Dedicated LPG Rear Floorpan Sill Assembly ......................................................................501-30-10
Dedicated LPG Rear Floorpan Sill View A ..........................................................................501-30-10
Dedicated LPG Rear Floorpan Sill View B ..........................................................................501-30-11
Dedicated LPG Rear Floorpan Sill Assembly ......................................................................501-30-11
Dedicated LPG Rear Floorpan Sill Assembly View A ..........................................................501-30-12
Petrol/Dedicated LPG Rear Bumper Mount Assembly - LH ................................................501-30-12
Petrol/Dedicated LPG Rear Bumper Mount Assembly - RH ...............................................501-30-13
Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-13
Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-14
Rear Floorpan Reinforcement Member View A ...................................................................501-30-14
Rear Floorpan Reinforcement Member View B ...................................................................501-30-15
Petrol Rear Floorpan Sill Assembly .....................................................................................501-30-15
Rear Sill to Rear Floorpan View A .......................................................................................501-30-16
Wagon Rear Side Support 1 ................................................................................................501-30-16
01/2003 2003.0 BA Falcon

501-30-2 Rear End Sheet Metal Repairs 501-30-2
(Continued)

Wagon Rear Cross Members 1 ...........................................................................................501-30-18
Wagon Rear Cross Members 2 ...........................................................................................501-30-19
Wagon Rear Floorpan 1 .......................................................................................................501-30-19
Wagon Rear Floorpan 2 .......................................................................................................501-30-20
Wagon Rear Floorpan Bumper Mounting 1 .........................................................................501-30-20
Wagon Rear Floorpan Bumper Mounting 2 .........................................................................501-30-21
Wagon Rear Cross Member ................................................................................................501-30-21
Wagon Rear Sill to Floorpan ................................................................................................501-30-22
01/2003 2003.0 BA Falcon

501-31-1 Body Welding and High Strength Steel 501-31-1
SECTION 501-31: Body Welding and High Strength

Steel
CONTENTS
GENERAL PROCEDURES
Welding Requirements ...........................................................................................................501-31-2
Protection of Electronics ........................................................................................................501-31-2
Precautions ............................................................................................................................501-31-2
High Strength Steels ..............................................................................................................501-31-2
High Strength Low Alloy Steels (HSLA) .................................................................................501-31-2
Heating HSLA Steel ...............................................................................................................501-31-2
Welding HSLA Steels .............................................................................................................501-31-2
WELD INFORMATION
HSLA Steel Location - Front End Section .............................................................................501-31-4
HSLA Steel Location - Side Section ......................................................................................501-31-5
HSLA Steel Location - Sedan Rear Section - Petrol .............................................................501-31-6
HSLA Steel Location - Sedan Rear Section - DLPG .............................................................501-31-7
HSLA Steel Location -Wagon Rear Side Member Reinforcement ........................................501-31-8
HSLA Steel Location - Sedan Floor and Members ................................................................501-31-9
HSLA Steel Location - Wagon Floor and Members .............................................................501-31-10
HSLA Steel Location - Ute Floor and Members ..................................................................501-31-11
HSLA Steel Location - Doors ...............................................................................................501-31-12
HSLA Steel Location - Wagon Side and Rear .....................................................................501-31-13
HSLA Steel Location - Dash and Cowl ................................................................................501-31-14
01/2003 2003.0 BA Falcon

501-32-1 Paint Preparation and Application 501-32-1
SECTION : 501-32 Paint Preparation and

Application
CONTENTS PAGE
Paint Preparation and Application ........................................................................................501-32-2
Paint Colour Codes ..............................................................................................................501-32-2
Checking Paint Condition .....................................................................................................501-32-2
Safety Precautions ...............................................................................................................501-32-2
Factory Finish .......................................................................................................................501-32-3
Two Pack Paints - Surface Preparation ...............................................................................501-32-3
Mixing ...................................................................................................................................501-32-4
Application ............................................................................................................................501-32-4
After Spraying ......................................................................................................................501-32-4
Painting Plastic Bumper Bars ..............................................................................................501-32-5
Repairing Color Coat Plastic Bumpers ................................................................................501-32-6
Painting Plastic Components - General Hints ......................................................................501-32-6
Plastics Including Nylon .......................................................................................................501-32-6
Top Coat - DG Solid Colors .................................................................................................501-32-7
Pearl/Metalic Clear Over Base .............................................................................................501-32-7
Clear Coat ............................................................................................................................501-32-7
Flexible Additive ...................................................................................................................501-32-7
01/2003 2003.0 BA Falcon

Ford BA Falcon Manual Index

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ford BA Falcon Manual Index

Uploaded by

Copyright:

Available Formats

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

SECTION : 100-01 Identification Codes

01/2003 2003.0 BA Falcon

SECTION : 100-04 Noise, Vibration and Harshness

01/2003 2003.0 BA Falcon

SECTION : 204-00 Suspension System — General

01/2003 2003.0 BA Falcon

SECTION : 204-01 Front Suspension

01/2003 2003.0 BA Falcon

SECTION : 204-02a Rear Suspension — IRS

01/2003 2003.0 BA Falcon

SECTION : 204-02b Rear Suspension — Beam Axle

01/2003 2003.0 BA Falcon

SECTION : 204-04 Wheels and Tyres

01/2003 2003.0 BA Falcon

SECTION : 205-00 Driveline System — General

01/2003 2003.0 BA Falcon

SECTION : 205-01 Driveshaft

01/2003 2003.0 BA Falcon

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

01/2003 2003.0 BA Falcon

SECTION : 205-02B Independent Rear Suspension

01/2003 2003.0 BA Falcon

SECTION : 205-05 Rear Drive Halfshafts

01/2003 2003.0 BA Falcon

SECTION : 206-09 Anti Lock Control

01/2003 2003.0 BA Falcon

SECTION : 206-00 Brake System — General

01/2003 2003.0 BA Falcon

SECTION : 206-03 Front Disk Brake

01/2003 2003.0 BA Falcon

SECTION : 206-04 Rear Disc Brake

01/2003 2003.0 BA Falcon

SECTION : 206-05 Parking Brake and Actuation

01/2003 2003.0 BA Falcon

SECTION : 206-06 Hydraulic Brake Actuation

01/2003 2003.0 BA Falcon

SECTION : 206-09 Anti Lock Control

01/2003 2003.0 BA Falcon

SECTION : 211-00 Steering System — General

01/2003 2003.0 BA Falcon

SECTION : 211-02 Power Steering

01/2003 2003.0 BA Falcon

SECTION : 211-03 Steering Linkage

01/2003 2003.0 BA Falcon

SECTION : 303-01a Engine — I6

01/2003 2003.0 BA Falcon

Oil Pressure & Oil Temperature Sensor ............................................................................303-01a-27

01/2003 2003.0 BA Falcon

SECTION : 303-01b Engine — 5.4L (3V)

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

01/2003 2003.0 BA Falcon

SECTION : 303-01c Engine — V8 (4V)

01/2003 2003.0 BA Falcon

01/2003 2003.0 BA Falcon

SECTION : 303-03 Engine Cooling

01/2003 2003.0 BA Falcon

SECTION : 303-04b Fuel Charging and Controls —

01/2003 2003.0 BA Falcon

SECTION : 303-04c Single Fuel LPG