Ford BF Falcon Workshop Manual Index Pages

100-00 General Information 100-00
SECTION : 100-00 General Information

VEHICLE APPLICATION : 2006.0 BF Falcon
CONTENTS PAGE
DESCRIPTION AND OPERATION
About this Manual .................................................................................................................100-00-1
Introduction ..........................................................................................................................100-00-1
Replacement Parts ...............................................................................................................100-00-1
Special Tools ........................................................................................................................100-00-1
Important Safety Instructions ...............................................................................................100-00-1
Warnings, Cautions and Notes in This Manual ....................................................................100-00-1
How to Use This Manual ......................................................................................................100-00-1
Samples ...............................................................................................................................100-00-2
Health and Safety Precautions .............................................................................................100-00-2
Introduction ..........................................................................................................................100-00-2
Acids and Alkalis ..................................................................................................................100-00-2
Air Bags ................................................................................................................................100-00-2
Air Conditioning Refrigerant .................................................................................................100-00-3
Adhesives and Sealers ........................................................................................................100-00-3
Antifreeze .............................................................................................................................100-00-4
Asbestos ..............................................................................................................................100-00-4
Battery Acids ........................................................................................................................100-00-4
Brake and Clutch Linings and Pads .....................................................................................100-00-4
Brakes Fluids (Polyalkylene Glycols) ...................................................................................100-00-4
Brazing .................................................................................................................................100-00-4
Chemical Materials ...............................................................................................................100-00-4
Chlorofluorocarbons (CFC) ..................................................................................................100-00-5
Clutch Fluids ........................................................................................................................100-00-5
Clutch Linings and Pads ......................................................................................................100-00-5
Corrosion Protection Materials .............................................................................................100-00-5
Cutting ..................................................................................................................................100-00-5
Dewaxing .............................................................................................................................100-00-5
Dusts ....................................................................................................................................100-00-5
Electric Shock ......................................................................................................................100-00-5
Engine Oils ...........................................................................................................................100-00-5
Exhaust Fumes ....................................................................................................................100-00-6
Fibre Insulation .....................................................................................................................100-00-6
Fire .......................................................................................................................................100-00-6
First Aid ................................................................................................................................100-00-6
Fluoroelastomer ...................................................................................................................100-00-6
Foams - Polyurethane ..........................................................................................................100-00-6
Freon ....................................................................................................................................100-00-6
Fuels ....................................................................................................................................100-00-6
Gas Cylinders .......................................................................................................................100-00-7
Gases ...................................................................................................................................100-00-7
Gaskets (Fluoroelastomer) ...................................................................................................100-00-7
General Workshop Tools and Equipment ............................................................................100-00-7
High Pressure Air, Lubrication and Oil Test Equipment ......................................................100-00-8
Halon ....................................................................................................................................100-00-8
Legal Aspects .......................................................................................................................100-00-8
Lubricants and Greases .......................................................................................................100-00-8
Noise ....................................................................................................................................100-00-8
Noise Insulation Materials ....................................................................................................100-00-8
01/2006 2006.0 BF Falcon

(Continued)
O-Rings (Fluoroelastomer) ...................................................................................................100-00-8

Paints ...................................................................................................................................100-00-8
Pressurized Equipment ........................................................................................................100-00-9
Solder ...................................................................................................................................100-00-9
Solvents ...............................................................................................................................100-00-9
Sound Insulation ..................................................................................................................100-00-9
Suspended Loads ................................................................................................................100-00-9
Transmission Brake Bands ..................................................................................................100-00-9
Underseal .............................................................................................................................100-00-9
Viton .....................................................................................................................................100-00-9
Welding ..............................................................................................................................100-00-10
Warning Symbols on Vehicles ...........................................................................................100-00-10
White Spirit .........................................................................................................................100-00-11
Standard Workshop Practices ............................................................................................100-00-11
Vehicle in Workshop ..........................................................................................................100-00-11
Alternative Fuel ..................................................................................................................100-00-12
Alternative Fuel — Do’s .....................................................................................................100-00-12
Alternative Fuel — Do Nots ...............................................................................................100-00-12
Towing the Vehicle .............................................................................................................100-00-12
Connecting a Slave Battery Using Jumper Cables ............................................................100-00-13
Component Cleaning .........................................................................................................100-00-13
Calibration of Essential Measuring Equipment ..................................................................100-00-14
Solvents, Sealers and Adhesives .......................................................................................100-00-14
Introduction ........................................................................................................................100-00-14
General Specifications .......................................................................................................100-00-15
Road/Roller Testing ............................................................................................................100-00-16
Pre-Test Checks ................................................................................................................100-00-16
Starting the Engine ............................................................................................................100-00-16
On Road or Roller Test Check: ..........................................................................................100-00-16
Brake Testing .....................................................................................................................100-00-16
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
Identification Codes ..............................................................................................................100-01-1
Vehicle Identification Number ..............................................................................................100-01-1
Identification Label ...............................................................................................................100-01-2
Vehicle Compliance (VC) Label .............................................................................................100-01-4
Emission Decal ....................................................................................................................100-01-5
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
Jacking ..................................................................................................................................100-02-1
Jacking/Lifting Points - Sedan/Wagon .................................................................................100-02-1
Jacking/Lifting Points - Ute ..................................................................................................100-02-1
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
Noise, Vibration and Harshness (NVH) ................................................................................100-04-1
Acceptable Noise, Vibration and Harshness .......................................................................100-04-1
Diagnostic Theory ................................................................................................................100-04-1
Glossary of Terms ................................................................................................................100-04-1
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH) ................................................................................100-04-6
1: Customer Interview ..........................................................................................................100-04-9
2: Pre-Drive Check ...............................................................................................................100-04-9
3: Preparing for the Road Test ............................................................................................100-04-9
4: Verify the Customer Concern ..........................................................................................100-04-9
5: Road Test ........................................................................................................................100-04-9
6: Check OASIS/TSBs/Repair History ...............................................................................100-04-11
7: Diagnostic Procedure .....................................................................................................100-04-11
NVH Condition and Symptom Categories .........................................................................100-04-12
Symptom Charts ................................................................................................................100-04-14
Pinpoint Tests ....................................................................................................................100-04-40
Component Tests ...............................................................................................................100-04-52
GENERAL PROCEDURES
Brake Disc Machining .........................................................................................................100-04-58
Powertrain/Drivetrain Mount Neutralizing ...........................................................................100-04-58
Exhaust System Neutralizing ..............................................................................................100-04-58
Wheel Bearing Check .........................................................................................................100-04-59
01/2006 2006.0 BF Falcon

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

Information
CONTENTS PAGE
Suspension System — General Information ..........................................................................204-00-1
Front Wheel Alignment ........................................................................................................204-00-2
Rear Wheel Alignment .........................................................................................................204-00-4
Inspection and Verification ...................................................................................................204-00-5
Symptom Chart ....................................................................................................................204-00-5
Shock Absorbers ................................................................................................................204-00-10
GENERAL PROCEDURES
Toe Adjustment ....................................................................................................................204-00-11
Toe & Steering Wheel Spoke Adjustments ..........................................................................204-00-11
Front Wheel Lock Angle Adjustment ...................................................................................204-00-11
Upper & Lower Ball Joint Inspection ....................................................................................204-00-11
XR Rear Camber Adjustment ..............................................................................................204-00-11
RLCA (Rear Lower Control Arm) to Subframe Cambolt Adjustment ...................................204-00-11
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................204-01-1
Front Suspension ...................................................................................................................204-01-2
Suspension ..........................................................................................................................204-01-3
Front Suspension ...................................................................................................................204-01-3
REMOVAL AND INSTALLATION
Lower Control Arm .................................................................................................................204-01-4
Lower Control Arm Ball Joint .................................................................................................204-01-5
Upper Control Arm .................................................................................................................204-01-5
Upper Control Arm Ball Joint .................................................................................................204-01-5
Stabilizer Bar ..........................................................................................................................204-01-6
Stabilizer Bar Centre Bushing (Front or Rear Bar) ...............................................................204-01-7
Stabilizer Bar Link Bushing ....................................................................................................204-01-7
Lower Arm Bushing ................................................................................................................204-01-7
Lower Arm - Large Bushing ...................................................................................................204-01-9
Upper Arm Bushing ..............................................................................................................204-01-10
Front Wheel Spindle and Hub ..............................................................................................204-01-11
Spring and/or Shock Absorber Assembly ............................................................................204-01-13
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................204-02A-1
Rear Suspension — IRS .....................................................................................................204-02A-2
Components ......................................................................................................................204-02A-2
Inspection and Verification ..................................................................................................204-02A-5
Stabiliser Bar .....................................................................................................................204-02A-5
Diagnosis ...........................................................................................................................204-02A-5
GENERAL PROCEDURES
FPV Cam bolt adjustment ....................................................................................................204-02A-6
RLCA to subframe cam adjustment ....................................................................................204-02A-6
Upper Control Arm Assembly (UCA) ...................................................................................204-02A-7
Front Lower Control Arm Assembly (FLCA) ........................................................................204-02A-9
Rear Lower Control Arm Assembly (RLCA) ......................................................................204-02A-10
Knuckle ..............................................................................................................................204-02A-12
Rear Lower Control Arm (RLCA) park brake cable bracket ..............................................204-02A-14
Abutment bracket ..............................................................................................................204-02A-15
Control Blade .....................................................................................................................204-02A-16
Shock Absorber .................................................................................................................204-02A-17
Spring and Upper Spring Insulator ....................................................................................204-02A-17
Stabiliser bar ......................................................................................................................204-02A-19
Upper Stabiliser Bar Insulator ............................................................................................204-02A-20
Jounce Bumper .................................................................................................................204-02A-21
Body Brace ........................................................................................................................204-02A-21
IRS Module ........................................................................................................................204-02A-22
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................204-02B-1
Rear Suspension — Beam Axle ..........................................................................................204-02B-2
Ute & Wagon Rear Suspension ........................................................................................204-02B-2
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
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................204-04-1
Wheels and Tyres ..................................................................................................................204-04-2
Wheels .................................................................................................................................204-04-2
Tyres ....................................................................................................................................204-04-2
Safety Precautions ..............................................................................................................204-04-2
Wheels and Tyres .................................................................................................................204-04-3
Symptom Chart ....................................................................................................................204-04-4
Component Tests .................................................................................................................204-04-5
GENERAL PROCEDURES
Straightening Wheels, Rims or Components .........................................................................204-04-7
Wheel and Tyre Assembly Balancing ...................................................................................204-04-7
Wheel ....................................................................................................................................204-04-8
Tyre ........................................................................................................................................204-04-8
01/2006 2006.0 BF Falcon

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

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-00-1
Driveline System ....................................................................................................................205-00-2
General Specifications .........................................................................................................205-00-2
Run in ...................................................................................................................................205-00-3
Towing ..................................................................................................................................205-00-3
Oil Changes ........................................................................................................................205-00-3
Driveline System ....................................................................................................................205-00-4
In Vehicle Diagnostics ..........................................................................................................205-00-4
Symptom Chart ....................................................................................................................205-00-5
Bearing Noise .......................................................................................................................205-00-6
Gear Tooth Contact Pattern Check .....................................................................................205-00-6
Shim and Backlash Changes ...............................................................................................205-00-7
Driveline Vibration ................................................................................................................205-00-8
Limited Slip Differentials (M78 & M86) ...............................................................................205-00-8
Inspection after Removal & Dismantling ..............................................................................205-00-9
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-01-1
Driveshaft ...............................................................................................................................205-01-2
Universal Joints ......................................................................................................................205-01-2
Driveshaft ...............................................................................................................................205-01-3
Symptom Chart ....................................................................................................................205-01-4
Take-Off Shudder .................................................................................................................205-01-4
Driveshaft Assembly ..............................................................................................................205-01-5
DISASSEMBLY AND ASSEMBLY
Flex Joint Replacement .......................................................................................................205-01-10
Universal Joint Replacement ...............................................................................................205-01-10
Centre Bearing Replacement ...............................................................................................205-01-11
CV Joint Replacement .........................................................................................................205-01-11
01/2006 2006.0 BF Falcon

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

Beam Axle
CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................205-02A-1
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-13
GENERAL PROCEDURES
In Vehicle Inspection .........................................................................................................205-02A-15
Beam Axle Oil Change .....................................................................................................205-02A-15
Flange Runout Check ........................................................................................................205-02A-16
In Vehicle Torque Check ...................................................................................................205-02A-16
Limited Slip Differential — M78 & M86 Check .................................................................205-02A-16
Limited Slip Differential Torque Check ..............................................................................205-02A-17
Limited Slip Differential — M86 Inspection for Wear .........................................................205-02A-17
Limited Slip Differential — M78 .........................................................................................205-02A-18
IN-VEHICLE REPAIRS
Pinion Oil Seal Replacement .............................................................................................205-02A-19
Axle Shaft Assembly ..........................................................................................................205-02A-20
M86 Limited Slip Differential ..............................................................................................205-02A-21
Axle Housing and Differential Assembly ...........................................................................205-02A-22
Rear Axle Wheel Bearing and Seal Replacement .............................................................205-02A-25
Differential and Drive Pinion ..............................................................................................205-02A-27
Differential Bearing Preload Spacer Selection ..................................................................205-02A-28
Drive Pinion Position — Shim Selection ............................................................................205-02A-29
Drive Pinion and Bearings .................................................................................................205-02A-30
Differential Installation and Backlash Check .....................................................................205-02A-31
Differential Case — Conventional Type M78 and M86 .....................................................205-02A-31
01/2006 2006.0 BF Falcon

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

— Full Floating Axle
CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................205-02B-1
Description And Operation ..................................................................................................205-02B-3
Drive Unit Identification ......................................................................................................205-02B-3
Drive Unit ...........................................................................................................................205-02B-3
M78 & M86 IRS (Sedan) ...................................................................................................205-02B-3
Conventional Differential ....................................................................................................205-02B-3
Limited Slip Differential ......................................................................................................205-02B-3
Diff and Pinion Bearings ....................................................................................................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
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................205-05-1
Rear Drive Halfshafts .............................................................................................................205-05-2
Halfshaft Handling ..................................................................................................................205-05-2
Rear Drive Halfshafts .............................................................................................................205-05-3
Halfshaft .................................................................................................................................205-05-4
Halfshaft Joint ........................................................................................................................205-05-5
01/2006 2006.0 BF Falcon

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

Information
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-00-1
Brake System .........................................................................................................................206-00-3
Load Proportioning Valve 1 Tonne Ute ..................................................................................206-00-4
Brake System Hydraulic Circuits ............................................................................................206-00-5
Brake System .........................................................................................................................206-00-9
Symptom Chart ..................................................................................................................206-00-10
Components Tests .............................................................................................................206-00-12
GENERAL PROCEDURES
Hydraulic System Bleeding ..................................................................................................206-00-14
Manual System Bleeding .....................................................................................................206-00-14
System Pressure Bleeding ...................................................................................................206-00-14
Service Precautions .............................................................................................................206-00-15
Changing Brake Fluid ..........................................................................................................206-00-15
Brake Pedal Clearance Check .............................................................................................206-00-15
Caliper ..................................................................................................................................206-00-15
Brake System Leak Check ...................................................................................................206-00-16
01/2006 2006.0 BF Falcon

206-00a High Series Brakes General Info 206-00a
SECTION : 206-00A High Series Brakes — General

Information
CONTENTS PAGE
SPECIFICATIONS
General Specifications .........................................................................................................206-00A-1
Torque Specifications ..........................................................................................................206-00A-2
Brake System ......................................................................................................................206-00A-3
Component Locater ...........................................................................................................206-00A-3
Brake System ......................................................................................................................206-00A-5
Inspection and Verification ................................................................................................206-00A-5
Pad Wear ...........................................................................................................................206-00A-5
Brake Disc Wear ................................................................................................................206-00A-5
Front Brake Disc Run-out ..................................................................................................206-00A-5
Brake Disc Thickness and Resurfacing .............................................................................206-00A-5
Components Tests .............................................................................................................206-00A-6
GENERAL PROCEDURES
Hydraulic System Bleeding ..................................................................................................206-00A-8
Manual System Bleeding .....................................................................................................206-00A-8
System Pressure Bleeding ..................................................................................................206-00A-8
Service Precautions .............................................................................................................206-00A-9
Changing Brake Fluid ..........................................................................................................206-00A-9
Brake Pedal Clearance Check ............................................................................................206-00A-9
Caliper .................................................................................................................................206-00A-9
Brake System Leak Check ................................................................................................206-00A-10
01/2006 2006.0 BF Falcon

206-03 Front Disk Brake 206-03
SECTION : 206-03 Front Disk Brake

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-03-1
Front Disc Brake ....................................................................................................................206-03-2
Disc Pad Running Clearance ...............................................................................................206-03-3
Wear Adjustment ..................................................................................................................206-03-3
Rotor ....................................................................................................................................206-03-3
Front Disc Brake ....................................................................................................................206-03-4
Brake Pads ............................................................................................................................206-03-5
Front Brake Hose ...................................................................................................................206-03-6
Brake Caliper Body ................................................................................................................206-03-6
Brake Disc ..............................................................................................................................206-03-7
Brake Caliper .........................................................................................................................206-03-8
01/2006 2006.0 BF Falcon

206-03a Front Disk Brake - High Series 206-03a
SECTION : 206-03A Front Disk Brake - High Series

CONTENTS PAGE
SPECIFICATIONS
Front Disc Brake ..................................................................................................................206-03A-2
Front Disc Brake Assembly Components ..........................................................................206-03A-2
Disc Pad Running Clearance ............................................................................................206-03A-3
Wear Adjustment ...............................................................................................................206-03A-3
Brake disc ..........................................................................................................................206-03A-3
Brake Calipers .....................................................................................................................206-03A-4
Inspection ..........................................................................................................................206-03A-4
Brake Pads ..........................................................................................................................206-03A-5
Front Brake Hose ................................................................................................................206-03A-6
Brake Caliper Body ..............................................................................................................206-03A-6
Brake Disc Removal ............................................................................................................206-03A-7
Brake Caliper .......................................................................................................................206-03A-8
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-04-1
Rear Disc Brake .....................................................................................................................206-04-2
Rear Disc Brake System Components ................................................................................206-04-2
Service Brake ......................................................................................................................206-04-2
Parking Brake .......................................................................................................................206-04-2
Brake Calipers .......................................................................................................................206-04-3
Inspection .............................................................................................................................206-04-3
Brake Caliper Body ................................................................................................................206-04-4
Brake Caliper Assembly .........................................................................................................206-04-4
Rear Brake Hose ...................................................................................................................206-04-4
Brake Pads ............................................................................................................................206-04-5
Brake Disc ..............................................................................................................................206-04-6
Beam Axle Brake Disc ...........................................................................................................206-04-6
Brake Caliper .........................................................................................................................206-04-7
01/2006 2006.0 BF Falcon

206-04a Rear Disc Brake - High Series 206-04a
SECTION : 206-04A Rear Disc Brake - High Series

CONTENTS PAGE
SPECIFICATIONS
Torque Specifications ........................................................................................................206-04A-1
Rear Disc Brake ..................................................................................................................206-04A-2
Rear Disc Brake System Components ..............................................................................206-04A-2
Service Brake ...................................................................................................................206-04A-2
Parking Brake ....................................................................................................................206-04A-2
Brake Calipers .....................................................................................................................206-04A-3
Inspection ..........................................................................................................................206-04A-3
Brake Caliper Body ..............................................................................................................206-04A-4
Brake Caliper Assembly ......................................................................................................206-04A-4
Rear Brake Hose .................................................................................................................206-04A-4
Brake Pads ..........................................................................................................................206-04A-5
Brake Disc ...........................................................................................................................206-04A-6
Brake Caliper .......................................................................................................................206-04A-8
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-05-1
Parking Brake — Sedan ........................................................................................................206-05-2
Parking Brake — Ute/Wagon .................................................................................................206-05-2
GENERAL PROCEDURES
Parking Brake Cable Adjustment ...........................................................................................206-05-3
Parking Brake Shoe Adjustment ............................................................................................206-05-3
Major Parking Brake Service .................................................................................................206-05-4
Parking Brake Shoes .............................................................................................................206-05-5
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 ..............................................................................206-05-9
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................206-06-1
Hydraulic Brake Actuation ......................................................................................................206-06-2
Hydraulic Brake System .......................................................................................................206-06-2
Dual Hydraulic Brake System ..............................................................................................206-06-2
Brake Master Cylinder .........................................................................................................206-06-2
Dual Master Cylinder Brake System (where fitted) ..............................................................206-06-2
Power Brake Booster ...........................................................................................................206-06-3
Acronyms and Abbreviations ...............................................................................................206-06-3
Hydraulic Brake Actuation ......................................................................................................206-06-5
Function Test .......................................................................................................................206-06-6
Symptom Chart ....................................................................................................................206-06-6
Connector Circuit Reference ................................................................................................206-06-7
Pinpoint Tests ......................................................................................................................206-06-9
GENERAL PROCEDURES
Adjustable Brake Indexing ...................................................................................................206-06-15
System Bleeding ..................................................................................................................206-06-15
Power Brake Booster Testing ..............................................................................................206-06-15
Hydraulic Line Repair ...........................................................................................................206-06-15
Brake Hose Replacement ....................................................................................................206-06-15
Brake Tube Replacement ....................................................................................................206-06-15
Brake Box Assembly ............................................................................................................206-06-16
Brake Pedal Adjustment Motor ............................................................................................206-06-19
Brake Pedal Motor Cables ...................................................................................................206-06-19
Brake Pedal Control Switch (where fitted) ...........................................................................206-06-20
Brake Pedal Pads ................................................................................................................206-06-21
Power Brake Booster ...........................................................................................................206-06-21
Dual Master Cylinder ...........................................................................................................206-06-23
Electronic Throttle Control Module .......................................................................................206-06-24
Dual Master Cylinder ...........................................................................................................206-06-24
01/2006 2006.0 BF Falcon

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

Load Proportioning Valve (1 tonne option)
CONTENTS PAGE
Hydraulic Brake Actuation — Load Proportioning Valve .....................................................206-06A-1
Load Proportioning Valve ....................................................................................................206-06A-2
01/2006 2006.0 BF Falcon

211-03 Steering Linkage 211-03
SECTION : 211-03 Steering Linkage

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................211-03-1
Steering Linkage ....................................................................................................................211-03-2
Outer Tie — Rod ....................................................................................................................211-03-3
Inner Tie — Rod .....................................................................................................................211-03-4
Steering Gear Boot ................................................................................................................211-03-6
01/2006 2006.0 BF Falcon

211-04 Steering Column 211-04
SECTION : 211-04 Steering Column

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................211-04-1
Steering Column ....................................................................................................................211-04-2
Steering Column ..................................................................................................................211-04-2
Floor Plate & Intermediate Shaft ..........................................................................................211-04-3
Steering Column Air Bag .....................................................................................................211-04-3
Steering Column Lock ..........................................................................................................211-04-3
Adjustable Steering Column ................................................................................................211-04-3
Fixed Steering Column (Column Shift Automatic) ...............................................................211-04-4
Steering Column - Accident Damage and Replacement .....................................................211-04-4
Steering Column Shrouds ......................................................................................................211-04-5
Ignition Key Barrel .................................................................................................................211-04-5
Passive-Anti-Theft-System (PATS) Unit, and key illumination ..............................................211-04-6
Adjustable Steering Column ..................................................................................................211-04-6
Fixed Steering Column (Column Shift automatic) .................................................................211-04-8
Floor Plate & Intermediate Shaft ...........................................................................................211-04-8
Driver Air Bag .........................................................................................................................211-04-9
Steering Wheel ...................................................................................................................211-04-10
Setting the Steering Column Adjustment Clamp .................................................................211-04-11
Adjustable Steering Column ...............................................................................................211-04-11
Fixed Steering Column .......................................................................................................211-04-12
Gear Shift Module ................................................................................................................211-04-13
Centralizing the Clockspring ................................................................................................211-04-13
Floor Plate and Intermediate Shaft .....................................................................................211-04-14
01/2006 2006.0 BF Falcon

211-05 Steering Column Switches 211-05
SECTION : 211-05 Steering Column Switches

CONTENTS PAGE
Steering Column Switches .....................................................................................................211-05-1
Steering Column Switches ...................................................................................................211-05-1
Steering Column Switches .....................................................................................................211-05-2
Symptom Chart ....................................................................................................................211-05-2
Pinpoint Tests ......................................................................................................................211-05-4
Steering Column Multifunction Switch ...................................................................................211-05-6
Ignition Key Barrel ..................................................................................................................211-05-6
Pedal Adjust Switch ...............................................................................................................211-05-6
01/2006 2006.0 BF Falcon

303-00 Engine System General Information 303-00
SECTION : 303-00 Engine System General

Information
CONTENTS PAGE
Engine ....................................................................................................................................303-00-1
Engine ....................................................................................................................................303-00-2
Symptom Chart ....................................................................................................................303-00-2
Components Tests ...............................................................................................................303-00-4
GENERAL PROCEDURES
Camshaft Journal Diameter ...............................................................................................303-00-6
Camshaft Journal Clearance, Plastigage Method .............................................................303-00-6
Camshaft 8 End Play, OHC Engines .................................................................................303-00-6
Camshaft Lobe Surface .....................................................................................................303-00-6
Camshaft Runout .............................................................................................................303-00-7
Crankshaft Main Bearing Journal Diameter ......................................................................303-00-7
Crankshaft Main Bearing Journal Taper ...........................................................................303-00-7
Crankshaft Main Bearing Journal Clearance ....................................................................303-00-7
Crankshaft End Play ..........................................................................................................303-00-8
Crankshaft Runout ............................................................................................................303-00-8
Crankshaft Connecting Rod Journal Taper, Out of Round ...............................................303-00-9
Cylinder Bore Taper .........................................................................................................303-00-9
Cylinder Bore Out-of-Round ..............................................................................................303-00-9
Piston Inspection ..............................................................................................................303-00-9
Piston Pin to Bore Diameter ............................................................................................303-00-10
Piston Diameter ...............................................................................................................303-00-10
Piston to Cylinder Bore Clearance ..................................................................................303-00-10
Piston Ring End Gap .......................................................................................................303-00-10
Piston Ring-to-Groove Clearance ...................................................................................303-00-11
Piston Pin Diameter .........................................................................................................303-00-11
Connecting Rod Cleaning ...............................................................................................303-00-11
Connecting Rod Large End Bore ....................................................................................303-00-11
Connecting Rod Bushing Diameter .................................................................................303-00-11
Connecting Rod Bend .....................................................................................................303-00-12
Connecting Rod Twist .....................................................................................................303-00-12
Connecting Rod Bearing Journal Clearance ...................................................................303-00-12
Roller Follower Inspection ...............................................................................................303-00-12
Valve Rocker Arm/Lash Adjuster Assembly Inspection ..................................................303-00-12
Hydraulic Lash Adjuster Diagnosis ......................................................................................303-00-13
Valve Stem Diameter ......................................................................................................303-00-13
Valve Stem to Valve Guide Clearance ............................................................................303-00-13
Valve Inspection ..............................................................................................................303-00-14
Valve Guide Inner Diameter ............................................................................................303-00-14
Valve Guide Reaming .....................................................................................................303-00-14
Valve Spring Installed Length .........................................................................................303-00-14
Valve Spring Free Length ...............................................................................................303-00-15
01/2006 2006.0 BF Falcon

303-00 Engine System General Information 303-00
(Continued)
Valve Spring Squareness ................................................................................................303-00-15

Valve Spring Strength ....................................................................................................303-00-15
Valve Seat Inspection ......................................................................................................303-00-15
Valve Seat Width ............................................................................................................303-00-16
Valve Seat Runout .........................................................................................................303-00-16
Cylinder Bore Cleaning ...................................................................................................303-00-16
Cylinder Block Core Plug Replacement ..........................................................................303-00-16
Exhaust Manifold Inspection ...........................................................................................303-00-17
Bearing -Inspection ..............................................................................................................303-00-17
01/2006 2006.0 BF Falcon

303-00-17 Engine System - General Information 303-00-17
GENERAL PROCEDURES (Continued)
Expansion-Type
CAUTION: Do not contact the crown when

installing an expansion-type cylinder block core
plug. This could expand the plug before seating
and result in leakage.
1. Use tool suitable to seat the expansion-type
cylinder block core plug.
Exhaust Manifold — Inspection

1. Place a Straight edge across the exhaust
manifold flanges and check for warping with a
feeler gauge.
Item Description
1 cratering-fatigue failure
2 spot glazing-improper seating
3 scratching-dirty
4 base exposed-poor lubrication
5 both edges worn-journal damaged
6 one edge worn-journal tapered or bearing
not seated
Bearing -Inspection
1. Inspect bearings for the following defects.
Possible causes are shown:
1. cratering-fatigue failure
2. spot glazing-improper seating
3. scratching-dirty
4. base exposed-poor lubrication
5. both edges worn-journal damaged
6. one edge worn-journal tapered or bearing not
seated
BF00006 en 01/2006 2006.0 BF Falcon

303-01a Engine I6 303-01a
SECTION : 303-01a Engine I6

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01a-1
Engine I6 .........................................................................................................................303-01a-7
Engine ................................................................................................................................303-01a-12
Inspection and Verification ..............................................................................................303-01a-12
Symptom Chart ................................................................................................................303-01a-13
Component Tests .............................................................................................................303-01a-15
GENERAL PROCEDURES
Cylinder Head Inspection ...................................................................................................303-01a-18
Valve Inspection .................................................................................................................303-01a-18
Valve Measurement ..........................................................................................................303-01a-19
Valve Guide Inspection .....................................................................................................303-01a-19
Valve Guide Replacement ................................................................................................303-01a-19
Valve Seat Inspection/Repair .............................................................................................303-01a-20
Valve Spring Inspection .....................................................................................................303-01a-20
Camshaft End Play Inspection ...........................................................................................303-01a-21
Camshaft Inspection ..........................................................................................................303-01a-21
Camshaft Journal Clearance - Plastigauge Method ..........................................................303-01a-22
Roller Follower Inspection ..................................................................................................303-01a-22
Lash Adjuster Bore Inspection ...........................................................................................303-01a-22
Cylinder Block Inspection/Repair .......................................................................................303-01a-22
Cylinder Bore - Taper .........................................................................................................303-01a-23
Cylinder Bore Out-of-Round ..........................................................................................303-01a-23
Piston Inspection ................................................................................................................303-01a-23
Piston Clearance Inspection/ Repair ..................................................................................303-01a-23
Piston Ring Clearance Inspection ......................................................................................303-01a-24
Piston Pin Clearance Inspection ........................................................................................303-01a-24
Crankshaft Inspection ........................................................................................................303-01a-25
Crankshaft Main Bearing Clearance ..................................................................................303-01a-26
Crankshaft End Play Inspection/Repair .............................................................................303-01a-26
Connecting Rod Inspection ................................................................................................303-01a-26
Connecting Rod Big End Bearing Clearance .....................................................................303-01a-27
Connecting Rod Side Clearance Inspection ......................................................................303-01a-27
Piston and Connecting Rod Inspection ..............................................................................303-01a-27
Timing Chain Elongation ....................................................................................................303-01a-28
IN-VEHICLE REPAIRS
Oil Filter ..............................................................................................................................303-01a-29
Oil Level Indicator & Tube .................................................................................................303-01a-29
Cylinder Head Temperature Sensor .................................................................................303-01a-29
Cam Position Sensor .........................................................................................................303-01a-29
Crankshaft Position Sensor ...............................................................................................303-01a-30
BF00006 01/2006 2006.0 BF Falcon

303-01a Engine I6 303-01a
(Continued)
Oil Pressure & Oil Temperature Sensor ............................................................................303-01a-30

Combustion Knock Sensor ................................................................................................303-01a-30
Exhaust Gas Oxygen Sensor .............................................................................................303-01a-30
Temperature - Manifold Air Pressure Sensor ....................................................................303-01a-30
Crankshaft Vibration Damper .............................................................................................303-01a-31
Crankshaft Front Oil Seal ...................................................................................................303-01a-31
Crankshaft Rear Oil Seal ...................................................................................................303-01a-32
Flywheel/Drive Plate/Clutch Pilot Bearing ..........................................................................303-01a-32
Clutch Pilot Bearing ...........................................................................................................303-01a-32
Water Pump .......................................................................................................................303-01a-32
Electronic Throttle Body and Intake Manifold ....................................................................303-01a-33
Broadband Throttle Plate ...................................................................................................303-01a-35
Broadband Throttle Shaft Vacuum Motor ..........................................................................303-01a-35
Exhaust Manifold Assembly ...............................................................................................303-01a-36
Exhaust Manifold - Front and Rear ....................................................................................303-01a-37
Oil Control Valve Seal ........................................................................................................303-01a-37
Valve Cover .......................................................................................................................303-01a-37
Ignition Coils/Wiring Loom .................................................................................................303-01a-39
Camshafts, VCT Phaser, Oil Control Valves, & OCV Filters .............................................303-01a-41
Camshaft Removal ............................................................................................................303-01a-42
Camshaft and VCT Phasers ..............................................................................................303-01a-42
Camshaft Installation .........................................................................................................303-01a-44
Timing Chain Tensioner .....................................................................................................303-01a-45
VCT Phaser ......................................................................................................................303-01a-45
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01a-46
Rocker Arm and Lash Adjuster ..........................................................................................303-01a-47
Valve spring and Valve Stem Seal ....................................................................................303-01a-47
Front Cover ........................................................................................................................303-01a-48
Camshaft Drive ..................................................................................................................303-01a-51
Timing Chain Tensioner Release .......................................................................................303-01a-52
Cylinder Head ....................................................................................................................303-01a-52
Engine ................................................................................................................................303-01a-53
Engine Mounting ................................................................................................................303-01a-55
Engine Oil Pan ...................................................................................................................303-01a-56
Oil Pump Pickup Tube .......................................................................................................303-01a-61
Oil pump .............................................................................................................................303-01a-61
Piston and Rod Assembly ..................................................................................................303-01a-62
Main bearings/Crankshaft ..................................................................................................303-01a-62
Rear Main Bearing Cap Assembly .....................................................................................303-01a-63
Piston Ring .........................................................................................................................303-01a-63
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Key Retainer Valve Spring ............................................................................................303-01a-65
Valve Stem Seal ................................................................................................................303-01a-65
Piston and Connecting Rod Assembly ..............................................................................303-01a-66
Piston and Connecting Rod Disassembly and Assembly ..................................................303-01a-66
Connecting Rod Bolt .........................................................................................................303-01a-66
BF00006 01/2006 2006.0 BF Falcon

303-01b Engine 5.4L (3V) 303-01b
SECTION : 303-01b Engine 5.4L (3V)

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01b-1
Engine ..................................................................................................................................303-01b-5
Engine ..................................................................................................................................303-01b-7
IN-VEHICLE REPAIRS
Intake Manifold Upper ..........................................................................................................303-01b-8
Valve Cover LH and RH (shown) .........................................................................................303-01b-9
Crankshaft Pulley ..............................................................................................................303-01b-12
Crankshaft Front Oil Seal .................................................................................................303-01b-13
Engine Front Cover ...........................................................................................................303-01b-14
Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings ........303-01b-17
Camshaft (LH shown, RH opposite hand) ........................................................................303-01b-28
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01b-37
Valve Spring and Valve Stem Seal ....................................................................................303-01b-37
Exhaust Manifold (LH shown, RH opposite hand) .............................................................303-01b-38
Oil Filter Adapter ................................................................................................................303-01b-39
Oil Pressure Sender ..........................................................................................................303-01b-40
Oil Level Indicator and Tube ..............................................................................................303-01b-40
Oil Pan ...............................................................................................................................303-01b-40
Oil Pump Screen and Pickup Tube ....................................................................................303-01b-43
Drive-Plate .........................................................................................................................303-01b-43
Crankshaft Rear Oil Seal ..................................................................................................303-01b-44
Engine Mounts - RH ...........................................................................................................303-01b-45
Engine Mounts - LH ...........................................................................................................303-01b-45
Engine Removal .................................................................................................................303-01b-46
DISASSEMBLY
Engine ................................................................................................................................303-01b-55
Cylinder Head ....................................................................................................................303-01b-66
ASSEMBLY
Engine ................................................................................................................................303-01b-70
BF00006 01/2006 2006.0 BF Falcon

303-01c Engine V8 (4V) 303-01c
SECTION : 303-01c Engine V8 (4V)

CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01c-1
Engine .................................................................................................................................303-01c-4
Identification ......................................................................................................................303-01c-4
Code Information ...............................................................................................................303-01c-4
Induction System ...............................................................................................................303-01c-4
Valve Train ........................................................................................................................303-01c-4
Positive Crankcase Ventilation System ............................................................................303-01c-4
Lubrication System ............................................................................................................303-01c-4
Oil Pump ...........................................................................................................................303-01c-5
Cooling System .................................................................................................................303-01c-5
Drive Belt System ..............................................................................................................303-01c-5
Engine ...............................................................................................................................303-01c-16
IN-VEHICLE REPAIRS
Intake Manifold Upper ........................................................................................................303-01c-17
Intake Manifold Lower ...................................................................................................303-01c-17
Valve Cover RH .............................................................................................................303-01c-19
Valve Cover LH .............................................................................................................303-01c-20
Crankshaft Pulley ..............................................................................................................303-01c-21
Crankshaft Front Oil Seal ..................................................................................................303-01c-22
Engine Front Cover ...........................................................................................................303-01c-23
Timing Drive Components .................................................................................................303-01c-26
Valve Springs, Retainer and Valve Stem Seal ..............................................................303-01c-31
Hydraulic Lash Adjusters ..................................................................................................303-01c-34
Roller Followers ................................................................................................................303-01c-34
Camshaft ...........................................................................................................................303-01c-35
Exhaust Manifold LH .....................................................................................................303-01c-38
Oil Filter Adapter ...............................................................................................................303-01c-39
Oil Pressure Sender ..........................................................................................................303-01c-40
Oil Level Indicator and Tube .............................................................................................303-01c-40
Oil Pan ..............................................................................................................................303-01c-41
Oil Pump Screen and Pickup Tube ...................................................................................303-01c-43
Flexplate ............................................................................................................................303-01c-43
Crankshaft Rear Oil Seal ..................................................................................................303-01c-44
Engine Mounts RH ........................................................................................................303-01c-45
Engine Mounts LH .........................................................................................................303-01c-46
REMOVAL
Engine ...............................................................................................................................303-01c-47
BF00006 01/2006 2006.0 BF Falcon

303-01c Engine V8 (4V) 303-01c
(Continued)
DISASSEMBLY
Engine ...............................................................................................................................303-01c-51
Piston ................................................................................................................................303-01c-61
Cylinder Head RH and LH .................................................................................................303-01c-62
ASSEMBLY
Engine ...............................................................................................................................303-01c-69
INSTALLATION
Engine ...............................................................................................................................303-01c-88
BF00006 01/2006 2006.0 BF Falcon

303-03a Engine Cooling 303-03a
SECTION : 303-03a Engine Cooling

CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................303-03a-1
Engine Cooling ....................................................................................................................303-03a-3
Radiator ..............................................................................................................................303-03a-3
Electric Dual Fans ..............................................................................................................303-03a-3
Water Pump .......................................................................................................................303-03a-3
Cooling System ..................................................................................................................303-03a-3
Cooling Maintenance .........................................................................................................303-03a-4
Engine Cooling ....................................................................................................................303-03a-5
Inspection and Verification .................................................................................................303-03a-5
Symptom Chart ..................................................................................................................303-03a-6
Pinpoint Tests ....................................................................................................................303-03a-7
Pressure Test ...................................................................................................................303-03a-10
Supply Tank Cap Pressure Test ......................................................................................303-03a-10
Thermostat Test ...............................................................................................................303-03a-10
Coolant System ................................................................................................................303-03a-10
Cooling Fans Self Test - Dual Fan Models ......................................................................303-03a-10
GENERAL PROCEDURES
Coolant Level Check .........................................................................................................303-03a-11
Coolant Colour Inspection ..................................................................................................303-03a-11
Adjusting Anti Freeze Protection Level ........................................................................303-03a-12
Anti Freeze Replacement .............................................................................................303-03a-12
Draining and Filling the Cooling System ...........................................................................303-03a-12
Radiator Cleaning .............................................................................................................303-03a-12
Thermostat ........................................................................................................................303-03a-14
Thermostat Housing 8 Cylinder ....................................................................................303-03a-14
Thermostat Housing 6 Cylinder ....................................................................................303-03a-15
Water Pump 6 Cylinder .................................................................................................303-03a-15
Water Pump V8 .............................................................................................................303-03a-16
Radiator ..............................................................................................................................303-03a-16
Radiator Side Shields - 6 Cylinder (non-turbo) ..................................................................303-03a-18
Fan ....................................................................................................................................303-03a-18
Radiator Hose ...................................................................................................................303-03a-19
Coolant Supply Tank .........................................................................................................303-03a-19
Heater Water Control Valve (I6 Auto engines only) ...........................................................303-03a-20
01/2006 2006.0 BF Falcon

303-04c E-Gas LPG 303-04c
SECTION : 303-04c E-Gas LPG

CONTENTS PAGE
SPECIFICATIONS
E-Gas LPG ...........................................................................................................................303-04c-2
Introduction .........................................................................................................................303-04c-2
Aftermarket Fitment of LPG ...............................................................................................303-04c-2
Licensing Requirements ....................................................................................................303-04c-3
Important Safety Notice .....................................................................................................303-04c-3
Notes, Cautions and Warnings ..........................................................................................303-04c-4
Vehicle Identification ..........................................................................................................303-04c-5
LPG Compliance and tank number(s) plate .......................................................................303-04c-7
Description .........................................................................................................................303-04c-7
LPG System Major Components ........................................................................................303-04c-9
Converter ..........................................................................................................................303-04c-12
Engine Servicing Requirements .......................................................................................303-04c-16
Scheduled Maintenance ...................................................................................................303-04c-17
E-Gas LPG .........................................................................................................................303-04c-20
Inspection and Verification ...............................................................................................303-04c-20
Symptom Charts ...............................................................................................................303-04c-24
Functional Diagnosis ........................................................................................................303-04c-26
Connector Circuit Reference ............................................................................................303-04c-35
Primary Service ..................................................................................................................303-04c-38
LPG Filter ...........................................................................................................................303-04c-38
Tank Assembly ...................................................................................................................303-04c-38
Pressure Decanting ............................................................................................................303-04c-39
Tank Decanting ..................................................................................................................303-04c-39
Tank Ute ........................................................................................................................303-04c-40
Tank Wagon ..................................................................................................................303-04c-42
Tank Sedan ...................................................................................................................303-04c-44
Fuel Gauge and Float Assembly ........................................................................................303-04c-45
Automatic Fill Limiter ..........................................................................................................303-04c-45
Service Valve (With Relief Valve on Ute and Wagon) .......................................................303-04c-46
Fuel Filler Valve .................................................................................................................303-04c-46
Pressure Relief Valve .........................................................................................................303-04c-47
Fuel Filler Hose ..................................................................................................................303-04c-47
LPG Fuel Delivery System Hose .......................................................................................303-04c-47
Bundy Tube Connection .....................................................................................................303-04c-49
Converter Including Filter Lockoff & Solenoid ....................................................................303-04c-50
LPG Filter ...........................................................................................................................303-04c-51
Inlet/Idle/Prime Lockoff Solenoids ......................................................................................303-04c-51
Converter Assembly ...........................................................................................................303-04c-51
01/2006 2006.0 BF Falcon

303-04c E-Gas LPG 303-04c
(Continued)
Throttle Body ......................................................................................................................303-04c-52

Converter with integral Filter/Lock Off & Prime Solenoid ...................................................303-04c-53
Converter ............................................................................................................................303-04c-53
Idle Jet ................................................................................................................................303-04c-57
01/2006 2006.0 BF Falcon

303-05 Accessory Drive 303-05
SECTION : 303-05 Accessory Drive

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-05-1
Accessory Drive ....................................................................................................................303-05-2
Belt Tensioner - I6 & V8 .........................................................................................................303-05-2
Water Pump ..........................................................................................................................303-05-3
Accessory Drive ....................................................................................................................303-05-4
Symptom Chart ....................................................................................................................303-05-4
Belt Tensioner ......................................................................................................................303-05-4
Accessory Drive Belt .............................................................................................................303-05-5
Accessory Drive Belt Tensioner ............................................................................................303-05-5
Accessory Drive Belt Idler Pulley ..........................................................................................303-05-5
01/2006 2006.0 BF Falcon

303-06 Starting System 303-06
SECTION : 303-06 Starting System

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-06-1
Starting System — 6 Cylinder (Bosch) .................................................................................303-06-2
General Service ....................................................................................................................303-06-2
Description ...........................................................................................................................303-06-2
Operation .............................................................................................................................303-06-2
Roadside Service ..................................................................................................................303-06-2
Jump Starting .......................................................................................................................303-06-2
Connecting and Starting Procedure .....................................................................................303-06-3
Engine Starting .....................................................................................................................303-06-3
Starting System .....................................................................................................................303-06-4
Symptom Chart ...................................................................................................................303-06-4
Pinpoint Tests ......................................................................................................................303-06-4
Component Tests .................................................................................................................303-06-8
Inhibitor Switch Test ...........................................................................................................303-06-10
GENERAL PROCEDURES
Starting System ...................................................................................................................303-06-11
Starter Motor .......................................................................................................................303-06-14
Starter Motor .......................................................................................................................303-06-15
Solenoid Switch ..................................................................................................................303-06-16
Bearing Cap .........................................................................................................................303-06-16
Commutator End Shield .......................................................................................................303-06-17
Commutator End Shield Bush ..............................................................................................303-06-17
Drive End Shield ..................................................................................................................303-06-18
Drive End Shield Roller Bearing ..........................................................................................303-06-18
Planetary Gearbox Unit ........................................................................................................303-06-19
Armature ..............................................................................................................................303-06-19
Overrunning Clutch ..............................................................................................................303-06-19
BF00006 01/2006 2006.0 BF Falcon

303-06 Starting System 303-06
(Continued)
ASSEMBLY
Brush Holder ........................................................................................................................303-06-21
Overrunning Clutch ..............................................................................................................303-06-21
Armature ..............................................................................................................................303-06-22
Drive End Shield Roller Bearing ..........................................................................................303-06-23
Drive End Shield ..................................................................................................................303-06-23
Commutator End Shield Bush ..............................................................................................303-06-24
Commutator End Shield .......................................................................................................303-06-24
Bearing Cap .........................................................................................................................303-06-25
Solenoid Switch ...................................................................................................................303-06-25
BF00006 01/2006 2006.0 BF Falcon

303-08 Engine Emission Control 303-08
SECTION : 303-08 Engine Emission Control

CONTENTS PAGE
Engine Emission Control ........................................................................................................303-08-1
Engine Emission Control ........................................................................................................303-08-2
Positive Crankcase Ventilation Valve ...................................................................................303-08-3
01/2006 2006.0 BF Falcon

303-12 Intake Air Distribution and Filtering 303-12
SECTION : 303-12 Intake Air Distribution and

Filtering
CONTENTS PAGE
SPECIFICATIONS
Specification ...........................................................................................................................303-12-1
Intake Air Distribution and Filtering ........................................................................................303-12-2
Intake Air Distribution and Filtering ......................................................................................303-12-2
The Intake Air System ..........................................................................................................303-12-2
GENERAL PROCEDURES
Cleaning and Inspection ........................................................................................................303-12-4
Air Cleaner Body — I6 Engine ...............................................................................................303-12-5
Air Cleaner Element — I6 and V8 Engines ...........................................................................303-12-5
Engine Air Ducting — I6 and V8 Engines ..............................................................................303-12-5
BF00006 01/2006 2006.0 BF Falcon

303-14 Powertrain Control Management 303-14
SECTION : 303-14 Powertrain Control Management

CONTENTS PAGE
General Information ...............................................................................................................303-14-1
Precautions ..........................................................................................................................303-14-1
Special Notes .......................................................................................................................303-14-1
PCM Systems ........................................................................................................................303-14-5
System Overview .................................................................................................................303-14-5
Control Systems .....................................................................................................................303-14-5
Fuel System .........................................................................................................................303-14-5
Fuel tank ..............................................................................................................................303-14-5
Fuel pump ............................................................................................................................303-14-6
Fuel Supply and Return Lines .............................................................................................303-14-6
Fuel Filters ...........................................................................................................................303-14-6
Fuel Rail ...............................................................................................................................303-14-6
Fuel Injector .........................................................................................................................303-14-6
Fuel Pressure Regulator ......................................................................................................303-14-7
Intake Air System .................................................................................................................303-14-7
Air Mass Measurement System ...........................................................................................303-14-7
Variable Camshaft Timing ....................................................................................................303-14-8
5.4L, 3 Valve V8 Engine ......................................................................................................303-14-8
Intake Manifold Charge Control (IMCC) .............................................................................303-14-9
Ignition System .....................................................................................................................303-14-9
Spark Advance Map ...........................................................................................................303-14-10
Engine Cooling System ......................................................................................................303-14-10
Evaporative Emission System ...........................................................................................303-14-10
Positive Crankcase Ventilation ..........................................................................................303-14-10
Catalyst and Exhaust System ............................................................................................303-14-10
Air Conditioning System .....................................................................................................303-14-11
Traction Control ..................................................................................................................303-14-11
Automatic Transmission Control (4-Speed Only) ...............................................................303-14-11
Control Software ..................................................................................................................303-14-12
Powertrain Control Module Memory ..................................................................................303-14-12
European On-Board Diagnostics (EOBD) ..........................................................................303-14-12
Comprehensive component monitor ..................................................................................303-14-13
Combustion misfire monitor ...............................................................................................303-14-14
Additional Misfire Monitor Information ................................................................................303-14-14
Fault Code / MIL Clearing ..................................................................................................303-14-15
Misfire Fault Codes ............................................................................................................303-14-15
Fuel monitor .......................................................................................................................303-14-16
Catalytic converter efficiency monitor ................................................................................303-14-16
Operating Strategies ..........................................................................................................303-14-17
Operating Modes ................................................................................................................303-14-18
Normal Mode ......................................................................................................................303-14-19
Crank Mode ........................................................................................................................303-14-19
Under-Speed Mode ............................................................................................................303-14-19
Open Loop .........................................................................................................................303-14-20
Closed Loop .......................................................................................................................303-14-20
Powertrain Control Hardware ...............................................................................................303-14-21
Powertrain Control Module ................................................................................................303-14-21
Module Programming .........................................................................................................303-14-21
BF00006 01/2006 2006.0 BF Falcon

(Continued)
Service Procedure ..............................................................................................................303-14-21

PCM Replacement - Standard ...........................................................................................303-14-22
Vehicle Identification (VID) Block .......................................................................................303-14-22
General Procedures .............................................................................................................303-14-23
General Procedures ..........................................................................................................303-14-23
Power and Ground Signals ................................................................................................303-14-23
Testing the PCM Power Supply .........................................................................................303-14-24
EOBD Fault detection and storage ....................................................................................303-14-25
Diagnostic Trouble Codes (DTC’s) ....................................................................................303-14-26
Drive Cycle .........................................................................................................................303-14-27
Inputs ...................................................................................................................................303-14-30
Crankshaft Position Sensor (CKP) .....................................................................................303-14-30
Temperature and Manifold Absolute Pressure Sensor ......................................................303-14-31
Trimming Sensors ................................................................................................................303-14-33
Camshaft Position Sensor .................................................................................................303-14-33
Cylinder Head Temperature Sensor ..................................................................................303-14-34
Engine Oil Temperature Sensor ........................................................................................303-14-36
Engine Oil Pressure Sensor ...............................................................................................303-14-36
Boost Pressure Sensor, I6 Turbo Engine ..........................................................................303-14-37
Travel Assistance Service (TAS) .........................................................................................303-14-38
Failure Mode ......................................................................................................................303-14-38
Feedback Inputs ..................................................................................................................303-14-38
Heated Exhaust Gas Oxygen Sensor ................................................................................303-14-38
HEGO Sensor Operation ...................................................................................................303-14-39
Knock Sensor .....................................................................................................................303-14-46
Feed Forward Inputs ............................................................................................................303-14-46
Transmission Range Sensor (TRS-A1) .............................................................................303-14-46
Transmission Range Sensor (TRS-A2) .............................................................................303-14-47
Power Steering Pressure Switch (V8) ...............................................................................303-14-48
Power Steering Pressure Transducer (I6) .........................................................................303-14-49
Vehicle Speed ....................................................................................................................303-14-49
Electronic Throttle Control Inputs .........................................................................................303-14-50
Accelerator Pedal Position (APP) Sensor ..........................................................................303-14-50
Throttle Position Sensor .....................................................................................................303-14-52
Clutch Engagement Switch, Manual Transmission ............................................................303-14-54
Brake Switches ..................................................................................................................303-14-54
Reverse Gear Switch .........................................................................................................303-14-55
Speed Control Range Switch Assembly ............................................................................303-14-56
Air Conditioner Inputs ..........................................................................................................303-14-57
Air Conditioner Demand .....................................................................................................303-14-57
Air Conditioner Relay .........................................................................................................303-14-57
Air Conditioner Pressure Transducer .................................................................................303-14-58
Transmission Inputs .............................................................................................................303-14-59
Transmission Fluid Temperature Sensor ...........................................................................303-14-59
Output Actuators ..................................................................................................................303-14-60
Fuel Pump ..........................................................................................................................303-14-60
Fuel Injectors 1-8 ...............................................................................................................303-14-61
Ignition Coils .......................................................................................................................303-14-63
Actuators ..............................................................................................................................303-14-64
Intake Manifold Charge Control .........................................................................................303-14-64
Electro Drive Fans .............................................................................................................303-14-66
Variable Camshaft Timing (I6 Engine) ...............................................................................303-14-67
Variable Camshaft Timing (5.4L, 3V, V8 Engine) ..............................................................303-14-68
Electronic Throttle Body .....................................................................................................303-14-76
Evap Canister Purge Solenoid ...........................................................................................303-14-76
Turbocharger Westgate Control .........................................................................................303-14-77
BF00006 01/2006 2006.0 BF Falcon

(Continued)
Transmission Outputs ..........................................................................................................303-14-78

Shift Solenoid 1 ..................................................................................................................303-14-78
Shift Solenoid 2 ..................................................................................................................303-14-79
Shift Solenoid 3 ..................................................................................................................303-14-79
Shift Solenoid 4 ..................................................................................................................303-14-79
Variable Pressure Solenoid 5 ............................................................................................303-14-80
Power Control Solenoid 6 ..................................................................................................303-14-80
Lock up Solenoid 7 ............................................................................................................303-14-81
LPG Fuel System Outputs .................................................................................................303-14-81
LPG Prime Solenoid PRIME ..............................................................................................303-14-81
Gas Cut-out Solenoid GCO ...............................................................................................303-14-82
LPG Stepper Motor A-D .....................................................................................................303-14-82
Control Area Network (CAN) ..............................................................................................303-14-83
Smartshield Security ..........................................................................................................303-14-87
Diagnosis .............................................................................................................................303-14-88
Diagnosis System ..............................................................................................................303-14-88
Air Conditioning System Tests ...........................................................................................303-14-89
Powertrain Control Management .........................................................................................303-14-95
Powertrain Control Management .......................................................................................303-14-95
Quick Reference DTC List .................................................................................................303-14-96
Glossary ...........................................................................................................................303-14-178
GENERAL PROCEDURES
Powertrain Control Module ................................................................................................303-14-184
VCT Solenoid Valve cleaning ............................................................................................303-14-185
Crankshaft Position (CKP) Sensor (I6 Engine) ..................................................................303-14-186
Crankshaft Position (CKP) Sensor (V8 Engine) ................................................................303-14-186
Camshaft Position Sensor (I6 Engine) ...............................................................................303-14-186
Camshaft Position Sensor (v8 Engine) ..............................................................................303-14-186
Knock Sensor (I6 Engine) ..................................................................................................303-14-187
Cylinder Head Temperature (CHT) Sensor (I6 Engine) ...................................................303-14-187
Cylinder Head Temperature (CHT) Sensor (V8 Engine) ..................................................303-14-187
Throttle Position (TP) Sensor (I6, LPG and Turbo Engines) .............................................303-14-187
Throttle Position (TP) Sensor (V8 Engine) ........................................................................303-14-188
Powertrain Control Module (PCM) (I6 Engine) ..................................................................303-14-188
HEGO 11 (I6 Engine) .........................................................................................................303-14-189
HEGO Sensor 11 (Turbo) ..................................................................................................303-14-190
HEGO 12 (I6 Engine) .........................................................................................................303-14-190
HEGO 11 & 21 (V8 Engines) .............................................................................................303-14-190
HEGO 12 & 22 (V8 Engines) .............................................................................................303-14-191
Boost Pressure Sensor (Turbo Engine) .............................................................................303-14-191
Turbocharger Wastegate Control Solenoid ........................................................................303-14-191
Reverse Gear Switch .........................................................................................................303-14-191
Temperature and Manifold Absolute Pressure (T-MAP) Sensor .......................................303-14-192
Fuel Rail (I6 Engine) ..........................................................................................................303-14-192
Fuel Rail (V8 Engine) .........................................................................................................303-14-193
Brake Switches .................................................................................................................303-14-193
Clutch Engagement Switch, (Manual Transmission) .........................................................303-14-193
Pedal Position Sensor ........................................................................................................303-14-193
BF00006 01/2006 2006.0 BF Falcon

(Continued)
Air Conditioning Relay .......................................................................................................303-14-194

Air Conditioner Pressure Transducer .................................................................................303-14-194
Transmission Fluid Temperature Sensor ..........................................................................303-14-194
Fuel Pump .........................................................................................................................303-14-194
Transmission Range Sensor (TRSA1) .............................................................................303-14-194
Transmission Range Sensor (TRSA2) .............................................................................303-14-194
Phaser removal .................................................................................................................303-14-194
OCV removal ....................................................................................................................303-14-194
CID sensor removal ..........................................................................................................303-14-194
VCT oil filter removal ..........................................................................................................303-14-194
EVAP Canister Purge Solenoid .........................................................................................303-14-194
Power Steering Pressure Switch .......................................................................................303-14-195
BF00006 01/2006 2006.0 BF Falcon

307-01a Automatic Transmission/Transaxle - 4 speed 307-01a
SECTION : 307-01a Automatic

Transmission/Transaxle - 4 speed
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................307-01-1
Automatic Transmission .........................................................................................................307-01-2
BTR Model 93/97LE Automatic transmission general description .......................................307-01-2
The Electronic Control System ............................................................................................307-01-8
Adaptive Shift Strategy ......................................................................................................307-01-13
Automatic Transmission .......................................................................................................307-01-38
Electronic Control System ..................................................................................................307-01-38
Symptom Chart ..................................................................................................................307-01-38
Connector Circuit Reference ..............................................................................................307-01-43
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 ............................................................................................................................307-01-48
Air Pressure checks .............................................................................................................307-01-48
Transmission fluid level adjustment .....................................................................................307-01-50
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 ................................................................................................................307-01-52
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
BF00006 01/2006 2006.0 BF Falcon

307-01a Automatic Transmission/Transaxle - 4 speed 307-01a
(Continued)
Extension housing bush .......................................................................................................307-01-60

Oil Pan and Filter .................................................................................................................307-01-60
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 ............................................................................................307-01-75
Rear Band ............................................................................................................................307-01-77
Rear Servo ...........................................................................................................................307-01-77
Planet Carrier and Centre Support ......................................................................................307-01-77
Extension Housing ...............................................................................................................307-01-78
Front Servo ..........................................................................................................................307-01-78
Front Band ...........................................................................................................................307-01-78
C2/C4 Clutch ........................................................................................................................307-01-78
C3 Clutch, Reverse Sun Gear & Forward Sun Gear Assembly ..........................................307-01-82
C1 Clutch Overdrive Shaft & Input Shaft .............................................................................307-01-84
Clutch ...................................................................................................................................307-01-85
Pump Cover & Converter Support .......................................................................................307-01-86
Valve Bodies ........................................................................................................................307-01-93
Oil Filter and Pan Assembly ................................................................................................307-01-98
Torque Converter & Housing ...............................................................................................307-01-99
BF00006 01/2006 2006.0 BF Falcon

307-01b ZF 6HP26/X 6 Speed Automatic Transmission 307-01b
SECTION : 307-01b ZF 6HP26/X 6 Speed Automatic

Transmission
CONTENTS PAGE
Gear Train ..........................................................................................................................307-01b-1
Driver Characterisation ......................................................................................................307-01b-1
Enhanced Adaptive Shift Strategy .....................................................................................307-01b-1
Advanced 6-Speed Features ...............................................................................................307-01b-1
Upshift prevention going down steep hill (not in "manual" mode) ....................................307-01b-1
Emergency downshifts in Sequential Sports Shift ("manual") mode only ..........................307-01b-1
Downshift on braking downhill (excluding XR6 Turbo & XR8) (not in "manual" mode) .....307-01b-1
Advanced Features Dependent on Driver Characterization ................................................307-01b-1
Gearhold around corners (not in "manual" mode) .............................................................307-01b-1
Early downshifts with hard braking (not in "manual" mode) ..............................................307-01b-1
Gearhold going uphill/downhill (not in "manual" mode) .....................................................307-01b-1
Upshift prevention with fast-off accelerator pedal (not in "manual" mode) ........................307-01b-2
New fine-feel shift-lever .....................................................................................................307-01b-2
Drive and Reverse Engagement ........................................................................................307-01b-2
Sequential Sports Shift (carryover from 4-speed) ..............................................................307-01b-2
All clutch no bands .............................................................................................................307-01b-2
Converter clutch lock-up in all gears ..................................................................................307-01b-2
Closed-loop shift control ....................................................................................................307-01b-2
Internal Transmission Control Module (TCM) ....................................................................307-01b-2
Improved Transmission Cooling ........................................................................................307-01b-2
Upshifts ..............................................................................................................................307-01b-3
Downshifts ..........................................................................................................................307-01b-3
Coastdown .........................................................................................................................307-01b-3
Torque Demand .................................................................................................................307-01b-3
Kickdown ............................................................................................................................307-01b-3
Sequential Sports Shift (Range Selection) ........................................................................307-01b-3
Operating the 6-speed transmission ....................................................................................307-01b-4
Gear Selection ...................................................................................................................307-01b-4
Adaptive Automatic Mode ..................................................................................................307-01b-4
Forced downshifting kickdown. .......................................................................................307-01b-5
Performance Automatic (Sport) Mode ...............................................................................307-01b-5
Manual Mode .....................................................................................................................307-01b-5
1 = First ..............................................................................................................................307-01b-5
2 = Second .........................................................................................................................307-01b-5
3 = Third .............................................................................................................................307-01b-5
4 = Forth .............................................................................................................................307-01b-6
5 & 6 = Fifth and Sixth .......................................................................................................307-01b-6
Forced downshifting - emergency kickdown ......................................................................307-01b-6
Transmission fault ..............................................................................................................307-01b-6
Transmission overheat .......................................................................................................307-01b-6
Torque converter ..................................................................................................................307-01b-6
Torque Converter Lock-up Clutch ........................................................................................307-01b-8
Geartrain ..............................................................................................................................307-01b-8
Gear Ratio ..........................................................................................................................307-01b-8
Single Planetary Gearset ...................................................................................................307-01b-9
Double Planetary Gearset ................................................................................................307-01b-10
01/2006 2006.0 BF Falcon

(Continued)
Apply Components .............................................................................................................307-01b-11

Shift Elements ..................................................................................................................307-01b-11
Shift overlap control .........................................................................................................307-01b-14
Hydraulic System ...............................................................................................................307-01b-14
Fluid Pump .......................................................................................................................307-01b-14
Fluid Pan, Gasket and Filter ............................................................................................307-01b-17
Transmission Control Module (TCM) and Main Control Valve Body .................................307-01b-17
Electrostatic Discharge (ESD) .........................................................................................307-01b-17
Personal Wrist-Band Earthing ..........................................................................................307-01b-18
Shoes and Foot Earthing Straps ......................................................................................307-01b-18
Transmission Link Harness Electrical Connector Layout ................................................307-01b-18
Transmission Electronic System ......................................................................................307-01b-20
TCM .................................................................................................................................307-01b-20
Solenoids .........................................................................................................................307-01b-20
Controller Area Network (CAN) Interface .........................................................................307-01b-20
Brake Pedal Position (BPP) Switch .................................................................................307-01b-20
Engine Coolant Temperature (ECT) Sensor ....................................................................307-01b-20
Accelerator Pedal Position (APP) Sensor ........................................................................307-01b-21
Input Shaft Speed (ISS) Sensor ......................................................................................307-01b-21
Output Shaft Speed (OSS) Sensor ..................................................................................307-01b-21
Transmission Fluid Temperature (TFT) Sensor ...............................................................307-01b-21
Position sensor .................................................................................................................307-01b-21
3-Bit Code ........................................................................................................................307-01b-21
Sport mode shifter position ..............................................................................................307-01b-21
TCM Monitoring Functions ...............................................................................................307-01b-21
Supply Monitoring ............................................................................................................307-01b-21
Solenoid Supply Monitoring .............................................................................................307-01b-21
Sensor Supply Monitoring ................................................................................................307-01b-22
Electronically Erasable Program Read Only Memory (EEPROM) Monitoring .................307-01b-22
Watchdog Monitoring .......................................................................................................307-01b-22
Monitoring the Substrate Temperature Sensor ................................................................307-01b-22
Plausibility Checking ........................................................................................................307-01b-22
Pressure Regulator/Solenoid Monitoring .........................................................................307-01b-22
Output Speed Monitor ......................................................................................................307-01b-22
Input Speed Monitor .........................................................................................................307-01b-22
Transmission Fluid Temperature Sensor Monitoring .......................................................307-01b-22
Position Sensor Monitoring ..............................................................................................307-01b-23
Gear Ratio Monitoring ......................................................................................................307-01b-23
Torque Converter Monitoring ...........................................................................................307-01b-23
Torque Converter Lock-up Control ..................................................................................307-01b-23
Shift Energy Management ...............................................................................................307-01b-23
Pressure Modulation ........................................................................................................307-01b-23
Shift Quality Adapts .........................................................................................................307-01b-23
Shift Point Selection .........................................................................................................307-01b-23
Transmission Shift selection ..............................................................................................307-01b-24
Shift Map Selection ..........................................................................................................307-01b-24
Normal Mode ....................................................................................................................307-01b-24
Cruise Mode .....................................................................................................................307-01b-24
Hot Mode ..........................................................................................................................307-01b-24
Traction Control Mode .....................................................................................................307-01b-24
Hill/Trailer Towing Mode ..................................................................................................307-01b-24
Driving Mode Priority ........................................................................................................307-01b-24
Adaptive Shift Strategies ..................................................................................................307-01b-25
Safety features .................................................................................................................307-01b-25
01/2006 2006.0 BF Falcon

(Continued)

Diagnostic Strategy ............................................................................................................307-01b-26
Basic Diagnosis .................................................................................................................307-01b-27
Check Fluid Level & Condition .........................................................................................307-01b-27
TRANSMISSION QUICK REFERENCE DTC LIST ...........................................................307-01b-28
CONTINUOUS (Cont.) .....................................................................................................307-01b-28
KEY-ON ENGINE-OFF (KOEO) ......................................................................................307-01b-28
KEY-ON ENGINE-RUN (KOER) ......................................................................................307-01b-28
MIL ON Y/N ......................................................................................................................307-01b-28
General note when encountering multiple DTCs ............................................................307-01b-28
Using the World-wide Diagnostic System (WDS) ............................................................307-01b-29
Transmission Fluid Level Checks. ...................................................................................307-01b-29
Transmission Link Harness Electrical Connector Layout ..................................................307-01b-63
Electrostatic Discharge (ESD) .........................................................................................307-01b-63
Personal Wrist-Band Earthing ..........................................................................................307-01b-63
Shoes and Foot Earthing Straps ......................................................................................307-01b-63
Transmission Link Harness Electrical Connector Layout ................................................307-01b-63
System inputs and outputs .................................................................................................307-01b-66
GENERAL PROCEDURES
Transmission fluid level check ...........................................................................................307-01b-67
Transmission Fluid Drain and Refill ...................................................................................307-01b-68
Transmission Fluid leak RectificationProcedures. (Transmission Installed) ......................307-01b-68
Oil pan / Oil pan gasket replace ........................................................................................307-01b-69
Parking lock seal ................................................................................................................307-01b-69
Output shaft seal ................................................................................................................307-01b-70
Mechatronic plug O-ring seal replacement ........................................................................307-01b-74
Selector Shaft Seal ............................................................................................................307-01b-75
Gearbox Breather Pipe replacement .................................................................................307-01b-76
Mechatronic unit and mechatronic unit seals .....................................................................307-01b-77
Renew the torque converter and shaft sealing ring on the oil pump .................................307-01b-82
Transmission ......................................................................................................................307-01b-84
01/2006 2006.0 BF Falcon

307-02 Transmission And Transaxle Cooling 307-02
SECTION : 307- 02 Transmission And Transaxle

Cooling
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................307-02-1
Transmission Cooling ............................................................................................................307-02-2
Inspection and Verification .....................................................................................................307-02-3
General Diagnosis ................................................................................................................307-02-3
Auxilary Transmission Fluid Cooler .......................................................................................307-02-4
Remote Transmission Fluid Warmer/Cooler) .........................................................................307-02-4
Radiator Intake Transmission Fluid Cooler ............................................................................307-02-6
Transmission Fluid Cooler Tubes I6 ......................................................................................307-02-6
Transmission Fluid Cooler Tubes V8 .....................................................................................307-02-7
01/2006 2006.0 BF Falcon

307-05 Automatic Transmission External Controls 307-05
SECTION : 307- 05 Automatic Transmission

External Controls
CONTENTS PAGE
Automatic Transmission External Controls ...........................................................................307-05-1
Sequential Sport Shift Selector ............................................................................................307-05-1
Automatic Transmission External Controls ...........................................................................307-05-2
GENERAL PROCEDURES
Selector Cable Adjustment ...................................................................................................307-05-3
Handle Assembly ..................................................................................................................307-05-4
Torsion Spring .......................................................................................................................307-05-5
Housing Sub Assembly .........................................................................................................307-05-6
Gear Indicator Globe .............................................................................................................307-05-7
Cap .......................................................................................................................................307-05-8
Loom PCB (Printed Circuit Board)(4-Speed) .........................................................................307-05-9
Loom PCB (Printed Circuit Board)(6-Speed) .......................................................................307-05-10
Shifter Bump Stops ..............................................................................................................307-05-11
Guide Lever ........................................................................................................................307-05-10
Gearshift Assembly .............................................................................................................307-05-12
Bucket (Metal Pressing) ......................................................................................................307-05-13
Base and Lever Assembly ..................................................................................................307-05-14
Spring Leaf Detent ..............................................................................................................307-05-15
Selector Lever Cable ..........................................................................................................307-05-16
01/2006 2006.0 BF Falcon

308-01 Clutch 308-01
SECTION : 308-01 Clutch

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................308-01-1
Clutch .....................................................................................................................................308-01-2
Introduction ..........................................................................................................................308-01-2
Clutch Function ....................................................................................................................308-01-2
System Components - STD I6 .............................................................................................308-01-3
System Components - XR6 Turbo .......................................................................................308-01-4
System Components - V8 ....................................................................................................308-01-5
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 (All Clutches Except For I6) ............................................308-01-8
Disc and Pressure Plate ........................................................................................................308-01-9
Flywheel-I6 (all variants) ......................................................................................................308-01-10
Flywheel-All V8 Vehicles (incl XR8 & GT) ...........................................................................308-01-11
Pilot Bearing-All Vehicles .....................................................................................................308-01-11
01/2006 2006.0 BF Falcon

308-02 Clutch Controls 308-02
SECTION : 308-02 Clutch Controls

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................308-02-1
Clutch Controls .....................................................................................................................308-02-2
Clutch Controls .....................................................................................................................308-02-4
Inspection and Verification - Clutch .....................................................................................308-02-4
Function Test .......................................................................................................................308-02-5
Symptom Chart ....................................................................................................................308-02-6
Pinpoint Tests ......................................................................................................................308-02-7
GENERAL PROCEDURES
Clutch Bleeding ...................................................................................................................308-02-10
Clutch Pedal ........................................................................................................................308-02-11
Clutch Master Cylinder ........................................................................................................308-02-11
Concentric Slave Cylinder (CSC) (All I6 5-Speed Manual Transmissions) .........................308-01-12
Concentric Slave Cylinder (CSC) (All V8 5-Speed Manual Transmissions) ........................308-01-13
Concentric Slave Cylinder (CSC) (All I6 6-Speed Manual Transmissions) .........................308-01-13
Concentric Slave Cylinder (CSC) (All V8 6-Speed Manual Transmissions) ........................308-01-15
Clutch Hydraulic Fluid Tubes ..............................................................................................308-02-15
Clutch Reservoir .................................................................................................................308-02-16
01/2006 2006.0 BF Falcon

308-03a 5-Speed Manual Transmission 308-03a
SECTION : 308-03a 5-Speed Manual Transmission

CONTENTS PAGE
SPECIFICATIONS
Manual Transmission ..........................................................................................................308-03a-2
Manual Transmission .........................................................................................................308-03a-2
Reverse Brake ...................................................................................................................308-03a-6
Manual Transmission ..........................................................................................................308-03a-7
Symptom Chart ..................................................................................................................308-03a-7
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
Transmission Damper .......................................................................................................308-03a-14
Reversing Light Switch .....................................................................................................308-03a-14
Transmission Cross - Member ..........................................................................................308-03a-14
REMOVAL
Transmission .....................................................................................................................308-03a-16
INSTALLATION
Transmission .....................................................................................................................308-03a-18
DISASSEMBLY
Transmission .....................................................................................................................308-03a-19
Input Shaft Bearing ...........................................................................................................308-03a-25
Input shaft to output shaft bearing cup ....................................................................308-03a-26
Output Shaft ......................................................................................................................308-03a-27
Countershaft Bearing Front ..........................................................................................308-03a-34
Synchronizers ...................................................................................................................308-03a-35
01/2006 2006.0 BF Falcon

308-03b Manual Transaxle/Transmission-T56 308-03b
SECTION : 308-03b Manual

Transaxle/Transmission-T56
CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................308-03b-1
Manual Transmission ..........................................................................................................308-03b-3
Transmission Identification ...............................................................................................308-03b-3
Manual Transmission ..........................................................................................................308-03b-4
GENERAL PROCEDURES
Transmission Draining and Filling .......................................................................................308-03b-7
Snap Rings ..........................................................................................................................308-03b-8
REMOVAL
Transmission .......................................................................................................................308-03b-9
DISASSEMBLY
Transmission .....................................................................................................................308-03b-11
Input Shaft and Bearing ....................................................................................................308-03b-20
Output Shaft ......................................................................................................................308-03b-23
Countershaft .......................................................................................................................308-03b-31
Synchronizers ...................................................................................................................308-03b-36
Extension Housing ............................................................................................................308-03b-37
Gearshift Rail and Fork .....................................................................................................308-03b-42
Transmission Case ............................................................................................................308-03b-44
ASSEMBLY
Transmission .....................................................................................................................308-03b-46
INSTALLATION
Transmission .....................................................................................................................308-03b-58
01/2006 2006.0 BF Falcon

308-06 Manual Transmission External Controls 308-06
SECTION : 308-06 Manual Transmission External

Controls
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................308-06-1
External Controls ..................................................................................................................308-06-2
Symptom Chart ....................................................................................................................308-06-2
Pinpoint Tests ......................................................................................................................308-06-3
Gearshift Lever .....................................................................................................................308-06-4
Gearshift Boot and Retainer Assembly .................................................................................308-06-4
01/2006 2006.0 BF Falcon

309-00 Exhaust System 309-00
SECTION : 309-00 Exhaust System

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................309-00-1
Exhaust System .....................................................................................................................309-00-2
Exhaust System .....................................................................................................................309-00-3
Pinpoint Tests ......................................................................................................................309-00-3
GENERAL PROCEDURES
Exhaust System Alignment ...................................................................................................309-00-4
All Rear Muffler Assemblies ...................................................................................................309-00-5
All Intermediate Muffler Assemblies .......................................................................................309-00-5
6 Cylinder Catalyst Assembly ................................................................................................309-00-5
8 Cylinder Catalyst Assemblies (LHS & RHS) .......................................................................309-00-6
8 Cylinder Y - Pipe Assemblies .............................................................................................309-00-6
System Diagrams ...................................................................................................................309-00-7
01/2006 2006.0 BF Falcon

310-00 Fuel System 310-00
SECTION : 310-00 Fuel System

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................310-00-1
Fuel System ..........................................................................................................................310-00-2
Electrical Fuel Pump .............................................................................................................310-00-3
Evaporative Emission Control System ..................................................................................310-00-3
Fuel Filters ............................................................................................................................310-00-4
Fuel system shut off switch ..................................................................................................310-00-4
Fuel pressure regulator ........................................................................................................310-00-5
Fuel System ..........................................................................................................................310-00-6
Symptom Chart ....................................................................................................................310-00-6
Pinpoint Tests ......................................................................................................................310-00-6
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 .....................................................................................310-00-13
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
01/2006 2006.0 BF Falcon

412-00 Climate Control System — General Information 412-00
SECTION : 412- 00 Climate Control System -

General Information
CONTENTS PAGE
Climate Control System — General Information ...................................................................412-00-1
Climate Control System .......................................................................................................412-00-1
Control Components ............................................................................................................412-00-1
Air Distribution ......................................................................................................................412-00-1
HVAC Case ..........................................................................................................................412-00-1
Air Conditioning ....................................................................................................................412-00-2
Climate Control System — General Information ...................................................................412-00-3
Acronyms and Abbreviations ..............................................................................................412-00-3
BF00006 01/2006 2006.0 BF Falcon

412-02 Heating and Ventilation 412-02
SECTION : 412-02 Heating and Ventilation

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................412-02-1
Heating and Ventilation .........................................................................................................412-02-2
Distribution Modes ...............................................................................................................412-02-4
Air Filtering ...........................................................................................................................412-02-5
Dual Zone Automatic Climate Control System ....................................................................412-02-6
HVAC Ducting ......................................................................................................................412-02-9
Acronyms and Abbreviations .............................................................................................412-02-13
Heating and Ventilation .......................................................................................................412-02-14
Inspection and Verification .................................................................................................412-02-14
Symptom Chart ..................................................................................................................412-02-15
PID Chart ...........................................................................................................................412-02-18
DTC Chart ..........................................................................................................................412-02-19
Pinpoint Tests ....................................................................................................................412-02-19
Blower Fan Assembly .........................................................................................................412-02-26
HVAC Assembly .................................................................................................................412-02-26
Case Assy Recirc Door Complete ..................................................................................412-02-28
HVAC Case Scroll ...............................................................................................................412-02-29
Heater Core Assembly ........................................................................................................412-02-29
HIM Assy .............................................................................................................................412-02-30
Actuator Electric Airmix (ACC only) ...............................................................................412-02-33
Shaft Airmix Door SZ .....................................................................................................412-02-34
Shaft Airmix Door DZ .....................................................................................................412-02-37
Dual Zone Sub Harness .....................................................................................................412-02-40
Filter and Cover Assembly Mesh (Standard Fitment) ....................................................412-02-40
Filter Particle (Optional Fitment) ....................................................................................412-02-41
Vent Outlet Register Outboard Register ........................................................................412-02-41
Vent Outlet Register Centre Register .............................................................................412-02-42
Vent Outlet Register Floor Console Register .................................................................412-02-43
Floor Console Duct .............................................................................................................412-02-43
BF00006 01/2006 2006.0 BF Falcon

412-03 Air Conditioning 412-03
SECTION : 412-03 Air Conditioning

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................412-03-1
Air Conditioning Safety Precautions ......................................................................................412-03-2
Climate Control System .......................................................................................................412-03-3
A/C Compressor and Clutch Assembly ................................................................................412-03-4
A/C Compressor Pressure Relief Valve ...............................................................................412-03-5
A/C Condenser Core ............................................................................................................412-03-5
Refrigerant Lines ..................................................................................................................412-03-5
A/C Evaporator Core ............................................................................................................412-03-6
A/C Orifice Tube Assembly ..................................................................................................412-03-6
Refrigerant Dye ....................................................................................................................412-03-6
Suction Accumulator ............................................................................................................412-03-7
A/C Cycling Switch (evaporator thermistor) .........................................................................412-03-7
A/C Pressure Cut-Off Switch (Pressure Transducer) ..........................................................412-03-7
Charge Port Valves ..............................................................................................................412-03-8
Engine Cooling Fans (Condenser Fans) .............................................................................412-03-8
Quick Joint Connection ........................................................................................................412-03-9
Air Conditioning Joint Design .............................................................................................412-03-10
Air Conditioning Relay .......................................................................................................412-03-10
Air Conditioning ....................................................................................................................412-03-11
A/C Functional Inspection Chart ........................................................................................412-03-11
A/C Fault Symptom Chart ..................................................................................................412-03-12
Air Conditioning System Performance Test .......................................................................412-03-18
A/C System Leak Test .......................................................................................................412-03-25
A/C System Noise Test ......................................................................................................412-03-26
A/C Noise Symptom Chart .................................................................................................412-03-28
Module Configuration .........................................................................................................412-03-28
WDS Parameter Identifier (PID) chart ................................................................................412-03-28
WDS Diagnostic Trouble Code (DTC) chart ......................................................................412-03-29
A/C disable strategy chart ..................................................................................................412-03-32
Air Conditioning & HVAC Relay and Fuses .......................................................................412-03-36
Pinpoint Tests ....................................................................................................................412-03-37
GENERAL PROCEDURES
Manifold Gauge Set Connection ..........................................................................................412-03-44
Electronic Leak Detection ....................................................................................................412-03-45
Fluorescent Dye Leak Detection ..........................................................................................412-03-45
A/C System Discharging and Recovery ...............................................................................412-03-48
A/C System Evacuation and Charging ................................................................................412-03-48
Refrigerant Oil Replacement Quantity .................................................................................412-03-49
Replenishment of Refrigerant Oil .........................................................................................412-03-50
BF00006 01/2006 2006.0 BF Falcon

412-03 Air Conditioning 412-03
(Continued)
A/C System Flushing ...........................................................................................................412-03-50

A/C Hose/Tube Pad Fitting ..................................................................................................412-03-51
O-Ring Removal and Lubrication .........................................................................................412-03-52
Air Conditioning (A/C) Compressor — I6 Engine .................................................................412-03-53
Air Conditioning (A/C) Compressor — V8 Engine ...............................................................412-03-54
Compressor Clutch, Compressor Pressure Relief Valve and Compressor Shaft Seal .......412-03-55
Air Conditioning (A/C) Compressor Bracket - I6/V8 .............................................................412-03-55
Evaporator Core ...................................................................................................................412-03-56
Orifice Tube Assembly .........................................................................................................412-03-58
Quick Joint Clamp ................................................................................................................412-03-60
Suction Accumulator ............................................................................................................412-03-61
Pressure Cut-off Switch (Pressure Transducer) ..................................................................412-03-63
Condenser Assembly ...........................................................................................................412-03-63
Condenser Inlet Hose Assembly (Discharge Hose) ............................................................412-03-65
Compressor Inlet Hose Assembly (I6 & V8 — Suction Hose) and Accumulator Outlet Tube
Assembly (V8 — Suction Tube) ...........................................................................................412-03-66
Condenser to Evaporator tube assembly (A/C liquid line) ...................................................412-03-67
Evaporator clamp (E-Clamp) ...............................................................................................412-03-70
Air Conditioning Cycling Switch (evaporator thermistor) .....................................................412-03-70
Engine Cooling Fan(s) (Condenser Fans) and Shroud Assembly .......................................412-03-71
BF00006 01/2006 2006.0 BF Falcon

412-04 Control Components 412-04
SECTION : 412-04 Control Components

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................412-04-1
Control Components .............................................................................................................412-04-2
HVAC Integrated Module (“HIM” Module) ............................................................................412-04-2
Climate Control Sensors ......................................................................................................412-04-2
CAN Bus Information ...........................................................................................................412-04-4
HIM Feature and Benefit Summary ......................................................................................412-04-6
HIM Module ...........................................................................................................................412-04-7
Module Configuration .........................................................................................................412-04-10
HIM Calibration File Down Load ........................................................................................412-04-10
Cabin Temperature Sensor Calibration Factor ..................................................................412-04-10
HVAC On-Demand Self Test .............................................................................................412-04-10
DTC Chart ..........................................................................................................................412-04-11
PID Chart ...........................................................................................................................412-04-14
Symptom Chart ..................................................................................................................412-04-16
Air Conditioning & HVAC Relay and Fuses .......................................................................412-04-18
Pinpoint Tests ....................................................................................................................412-04-19
Control Components ...........................................................................................................412-04-38
Cabin Temperature Sensor .................................................................................................412-04-38
Sunload sensor/Twilight sensor ...........................................................................................412-04-38
Ambient Temperature Sensor .............................................................................................412-04-38
Evaporator Temperature Sensor (Evaporator Thermistor) .................................................412-04-38
BF00006 01/2006 2006.0 BF Falcon

413-01 Instrument Cluster 413-01
SECTION : 413-01 Instrument Cluster

CONTENTS PAGE
Instrument Cluster .................................................................................................................413-01-1
Principles of Operation .........................................................................................................413-01-4
Instrument Cluster Gauges ..................................................................................................413-01-4
Warning Indicators ...............................................................................................................413-01-5
General Operation ................................................................................................................413-01-7
Audible Warnings .................................................................................................................413-01-8
Instrument Cluster .................................................................................................................413-01-9
Self Tests ...........................................................................................................................413-01-10
Functional Tests .................................................................................................................413-01-11
DTC Chart ..........................................................................................................................413-01-13
Pid Chart ............................................................................................................................413-01-14
CAN Data Information ........................................................................................................413-01-15
Symptom Chart ..................................................................................................................413-01-17
Pinpoint Tests ....................................................................................................................413-01-23
Instrument Cluster ...............................................................................................................413-01-31
01/2006 2006.0 BF Falcon

413-06 Horn 413-06
SECTION : 413-06 Horn

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................413-06-1
Horn ......................................................................................................................................413-06-2
Horn ......................................................................................................................................413-06-3
Symptom Chart ....................................................................................................................413-06-4
Pinpoint Tests ......................................................................................................................413-06-4
Horn ......................................................................................................................................413-06-8
01/2006 2006.0 BF Falcon

413-07 Clock 413-07
SECTION : 413-07 Clock

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................413-07-1
Clock .....................................................................................................................................413-07-2
Clock .....................................................................................................................................413-07-3
Symptom Chart ....................................................................................................................413-07-3
Pinpoint Tests ......................................................................................................................413-07-3
Clock .....................................................................................................................................413-07-5
01/2006 2006.0 BF Falcon

413-08 Interior Command Centre 413-08
SECTION : 413-08 Interior Command Centre

CONTENTS PAGE
Interior Command Centre .....................................................................................................413-08-1
ICC Handling and Storage ....................................................................................................413-08-1
Interior Command Centre .....................................................................................................413-08-3
Principles Operation .............................................................................................................413-08-3
CAN Information ...................................................................................................................413-08-5
DTC Chart ............................................................................................................................413-08-5
PID Chart .............................................................................................................................413-08-7
Symptom Chart ....................................................................................................................413-08-8
Service Procedures ............................................................................................................413-08-10
Pinpoint Tests ....................................................................................................................413-08-10
Interior Command Centre (ICC) ...........................................................................................413-08-18
Service Body Computer (BEM) ...........................................................................................413-08-21
Service Remote Key Receiver (RKR) .................................................................................413-08-23
Service Air Register ............................................................................................................413-08-24
Cabin Temperature Sensor ..................................................................................................413-08-25
01/2006 2006.0 BF Falcon

413-13 Parking Aid 413-13
SECTION : 413-13 Parking Aid

CONTENTS PAGE
Reverse Sensing System ......................................................................................................413-13-1
System Components ............................................................................................................413-13-2
Other Information .................................................................................................................413-13-3
Parking Aid ............................................................................................................................413-13-5
WDS Test Procedure ...........................................................................................................413-13-5
DTC Chart ............................................................................................................................413-13-5
PID Chart .............................................................................................................................413-13-6
Symptom Chart PAM ...........................................................................................................413-13-7
Pinpoint tests ........................................................................................................................413-13-8
Reverse Sensing System ECU ...........................................................................................413-13-14
Sensors ...............................................................................................................................413-13-14
01/2006 2006.0 BF Falcon

414-01 Battery, Mounting and Cables 414-01
SECTION : 414-01 Battery, Mounting and Cables

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................414-01-1
Battery and Cables ...............................................................................................................414-01-2
Battery ...................................................................................................................................414-01-3
Pinpoint Tests ......................................................................................................................414-01-3
Component Tests .................................................................................................................414-01-3
Battery and Cables ...............................................................................................................414-01-5
Battery Shroud ......................................................................................................................414-01-5
01/2006 2006.0 BF Falcon

415-00 Entertainment System — General Information 415-00
SECTION : 415-00 Entertainment System —

General Information
CONTENTS PAGE
Audio System ........................................................................................................................415-00-1
Self Tests .............................................................................................................................415-00-1
Function Tests ......................................................................................................................415-00-2
DTC Chart ............................................................................................................................415-00-2
Symptom Chart ....................................................................................................................415-00-4
PID Chart .............................................................................................................................415-00-4
Service Procedures ..............................................................................................................415-00-6
Pinpoint Tests ......................................................................................................................415-00-7
BF00006 01/2006 2006.0 BF Falcon

415-01 Audio Unit 415-01
SECTION : 415-01 Audio Unit

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-01-1
Audio System ........................................................................................................................415-01-2
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
BF00006 01/2006 2006.0 BF Falcon

415-02 Antenna 415-02
SECTION : 415-02 Antenna

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-02-1
Antenna .................................................................................................................................415-02-2
Antenna .................................................................................................................................415-02-3
GENERAL PROCEDURES
Antenna Grid Wire Repair .....................................................................................................415-02-4
Antenna — Sedan .................................................................................................................415-02-5
Antenna — Wagon ................................................................................................................415-02-5
Antenna — Ute .....................................................................................................................415-02-5
Antenna Lead — in Cable .....................................................................................................415-02-5
01/2006 2006.0 BF Falcon

415-03 Speakers 415-03
SECTION : 415-03 Speakers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................415-03-1
Speakers ...............................................................................................................................415-03-2
Speakers — Door Mounted ..................................................................................................415-03-3
Speakers — Package Tray ...................................................................................................415-03-3
Speaker — Package Tray Subwoofer ..................................................................................415-03-3
Speaker — Tweeter A-pillar ..................................................................................................415-03-3
Speaker — Wagon Rear Quarter Panel ...............................................................................415-03-4
Speaker — Ute Rear Quarter Panel .....................................................................................415-03-4
01/2006 2006.0 BF Falcon

417-01 Exterior Lighting 417-01
SECTION : 417-01 Exterior Lighting

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................417-01-1
Exterior Lighting .....................................................................................................................417-01-2
Twilight Sensor/Sun Load Sensor ........................................................................................417-01-2
Headlamps .............................................................................................................................417-01-3
Symptom Chart ....................................................................................................................417-01-7
Pinpoint Tests ......................................................................................................................417-01-8
Turn Signal and Hazard Lamps ...........................................................................................417-01-13
Symptom Chart ..................................................................................................................417-01-18
Pinpoint Tests ....................................................................................................................417-01-18
Stop Lamps ..........................................................................................................................417-01-21
Symptom Chart ..................................................................................................................417-01-25
Pinpoint Tests ....................................................................................................................417-01-25
Fog Lamps ...........................................................................................................................417-01-27
Symptom Chart ..................................................................................................................417-01-29
Pinpoint Tests ....................................................................................................................417-01-29
Parking, Rear and Licence Lamps .......................................................................................417-01-32
Symptom Chart ..................................................................................................................417-01-37
Pinpoint Tests ....................................................................................................................417-01-37
Reverse Lamps ....................................................................................................................417-01-39
Symptom Chart ..................................................................................................................417-01-42
Pinpoint Tests ....................................................................................................................417-01-42
GENERAL PROCEDURES
Headlamp Adjustment ..........................................................................................................417-01-45
Headlamp Assembly ............................................................................................................417-01-49
Headlamp Bulb High Beam H7 .......................................................................................417-01-49
Headlamp Bulb Low Beam H4 ........................................................................................417-01-49
Turn Signal Bulb ..................................................................................................................417-01-50
BF00006 01/2006 2006.0 BF Falcon

417-01 Exterior Lighting 417-01
(Continued)
Parklamp Bulb ......................................................................................................................417-01-50

Fog Lamp (XR) ....................................................................................................................417-01-50
Fog Lamp Bulb (XR) ............................................................................................................417-01-50
Fog Lamp (Ghia) ..................................................................................................................417-01-51
Fog Lamp Bulb (Ghia) ..........................................................................................................417-01-51
Tail Lamp Assembly Sedan ............................................................................................417-01-51
Tail Lamp Assembly Wagon ...........................................................................................417-01-52
Tail Lamp, Reverse Lamp and Rear Indicator Bulb Sedan And Wagon .........................417-01-52
Tail Lamp Assembly Style Side Box ...............................................................................417-01-52
Rear Light Bulbs Replacement Style Side Box ...............................................................417-01-53
Reverse Light Replacement Style Side Box ...................................................................417-01-53
Tail Lamp Assembly Tray ................................................................................................417-01-53
Rear Light Bulbs Replacement Cable/Chassis and Tray ................................................417-01-54
Licence Plate Lamp Assembly .............................................................................................417-01-54
Licence Plate Bulb ...............................................................................................................417-01-55
Rear Licence Plate Lamp Replacement Style Side Box .................................................417-01-55
Rear Licence Plate Lamp Replacement Chassis/Cab and Tray .....................................417-01-55
Side Indicator Lamps ...........................................................................................................417-01-55
High Mount Stop Lamp Sedan (Except LWB) .................................................................417-01-56
High Mount Stop Lamp XR Series Sedan ......................................................................417-01-56
High Mount Stop Lamp Bulb Wagon ...............................................................................417-01-56
High Mount Stop Lamp LWB ...........................................................................................417-01-57
Twilight Sensor/Sun Load Sensor ........................................................................................417-01-57
BF00006 01/2006 2006.0 BF Falcon

417-02 Interior Lighting 417-02
SECTION : 417-02 Interior Lighting

CONTENTS PAGE
Interior Lighting .....................................................................................................................417-02-1
Interior Lighting .....................................................................................................................417-02-2
Visual Inspection Chart ........................................................................................................417-02-2
Symptom Chart ....................................................................................................................417-02-2
Pinpoint Tests ......................................................................................................................417-02-3
Interior Lamp .........................................................................................................................417-02-6
Map Reading Lamp ...............................................................................................................417-02-6
Front Vanity Lamp .................................................................................................................417-02-6
Luggage Compartment Lamp — Wagon ..............................................................................417-02-6
Luggage Compartment Lamp — Sedan ...............................................................................417-02-7
Console Lamp (Low Series) .................................................................................................417-02-7
Console Lamp (High Series) .................................................................................................417-02-7
01/2006 2006.0 BF Falcon

418-00 Module Communications Network 418-00
SECTION : 418-00 Module Communications

Network
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................418-00-1
Communications Network .....................................................................................................418-00-2
Communications Network .....................................................................................................418-00-3
Symptom Chart ....................................................................................................................418-00-4
Pinpoint Tests ......................................................................................................................418-00-8
GENERAL PROCEDURES
Communication Circuit Wiring Repair .................................................................................418-00-21
01/2006 2006.0 BF Falcon

419-07 Satellite Navigation 419-07
SECTION : 419-07 Satellite Navigation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................419-07-1
Satellite Navigation ................................................................................................................419-07-2
GPS (Global Positioning System) ........................................................................................419-07-2
Component Layout ...............................................................................................................419-07-2
Satellite Navigation ................................................................................................................419-07-4
Symptom Chart ....................................................................................................................419-07-4
Pinpoint Tests ......................................................................................................................419-07-5
Navigation System Module ..................................................................................................419-07-13
Navigation System Antenna .................................................................................................419-07-13
Navigation System Display Module .....................................................................................419-07-13
01/2006 2006.0 BF Falcon

419-08 Cellular Phone 419-08
SECTION : 419-08 Cellular Phone

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................419-08-1
Mobile Telephone Wiring ......................................................................................................419-08-2
Mobile Telephone Platform ...................................................................................................419-08-2
Cellular Phone .......................................................................................................................419-08-3
Mobile Telephone Platform ...................................................................................................419-08-4
Mobile Telephone Kit ............................................................................................................419-08-4
01/2006 2006.0 BF Falcon

419-10 Body Electronics Module (BEM) 419-10
SECTION : 419-10 Body Electronics Module (BEM)

CONTENTS PAGE
Body Electronics Module ......................................................................................................419-10-1
Body Electronics Module ......................................................................................................419-10-8
BEM Diagnostic Trouble Code Index .................................................................................419-10-10
Symptom Chart ..................................................................................................................419-10-12
Pinpoint Tests ....................................................................................................................419-10-23
GENERAL PROCEDURES
Remote Key Teaching ........................................................................................................419-10-29
Receiver Resynchronization ...............................................................................................419-10-29
Dealer DST Ignition Key Teach Mode ................................................................................419-10-29
Customer DST Ignition Key Teach .....................................................................................419-10-29
Lost Keys ............................................................................................................................419-10-29
Customer Key Erasure ........................................................................................................419-10-29
PCM Parameter Reset ........................................................................................................419-10-29
Cabin Temperature Sensor Calibration Factor ...................................................................419-10-29
Changing BEM ....................................................................................................................419-10-30
The BEM and Remote Receiver .........................................................................................419-10-31
01/2006 2006.0 BF Falcon

SECTION : 501-00 Body System - General

Information
VEHICLE APPLICATION :2006.0 BF Falcon
CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-00-1
Body .......................................................................................................................................501-00-2
Body System ........................................................................................................................501-00-2
Insulation ..............................................................................................................................501-00-2
Body Sealer Type and Application .......................................................................................501-00-2
Body System ..........................................................................................................................501-00-3
Symptom Chart ....................................................................................................................501-00-3
01/2006 2006.0 BF Falcon

501-02 Front End Body Panels 501-02
SECTION : 501-02 Front End Body Panels

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-02-1
Front End Body Panels .........................................................................................................501-02-2
GENERAL PROCEDURES
Hood Alignment ....................................................................................................................501-02-3
Fender Alignment ..................................................................................................................501-02-3
Air Deflector ..........................................................................................................................501-02-6
Fender Splash Shield ............................................................................................................501-02-6
Cowl Panel Grille ..................................................................................................................501-02-6
Fender ...................................................................................................................................501-02-7
Modestry Panel .....................................................................................................................501-02-7
Hood Prop .............................................................................................................................501-02-7
Hood/Hood Hinge .................................................................................................................501-02-8
01/2006 2006.0 BF Falcon

501-03 Body Closures 501-03
SECTION : 501-03 Body Closures

CONTENTS PAGE
Door Windlace ......................................................................................................................501-03-1
Weatherstrip Front and Rear Doors ......................................................................................501-03-2
Decklid Weatherstrip .............................................................................................................501-03-3
Liftgate Weatherstrip .............................................................................................................501-03-3
Roof Side Rail - Sedan .........................................................................................................501-03-3
Roof Side Rail — Wagon ......................................................................................................501-03-4
Dash Panel Upper Seal ........................................................................................................501-03-5
Hood Inner Seal ....................................................................................................................501-03-5
Front Door Beltline Outer ......................................................................................................501-03-6
Rear Door Beltline Outer ......................................................................................................501-03-6
Rear Door Beltline Inner .......................................................................................................501-03-6
Rear Door Beltline Inner .......................................................................................................501-03-6
B Pillar Aplique ......................................................................................................................501-03-7
Rocker Margin Seal ..............................................................................................................501-03-7
Weatherstrip Door Outer — Ute ...........................................................................................501-03-7
Exterior — Ute ......................................................................................................................501-03-7
Front Door Glass Run ...........................................................................................................501-03-8
Rear Door Glass Run ...........................................................................................................501-03-8
01/2006 2006.0 BF Falcon

501-05-1 Interior Trim and Ornamentation 501-05-1
SECTION : 501-05 Interior Trim and Ornamentation

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-05-1
Interior Trim and Ornamentation ............................................................................................501-05-2
Interior Trim ..........................................................................................................................501-05-2
Luggage compartment Interior Trim System ........................................................................501-05-2
A — Pillar Trim Panel ............................................................................................................501-05-3
B — Pillar Upper & Lower Trim Panel ...................................................................................501-05-3
C — Pillar Trim Panel ............................................................................................................501-05-3
D — Pillar Trim Panel — Wagon ...........................................................................................501-05-3
Front Door Trim Panel ...........................................................................................................501-05-4
Rear Door Low Series Trim Panel .........................................................................................501-05-4
Rear Quarter Trim Panel — Wagon ......................................................................................501-05-5
Quarter Trim Panel — Ute .....................................................................................................501-05-5
Loadspace Trim Panel — Ute ................................................................................................501-05-6
Liftgate Upper Trim ................................................................................................................501-05-6
Liftgate Lower Trim ................................................................................................................501-05-6
Parcel Shelf ............................................................................................................................501-05-6
Sunvisor .................................................................................................................................501-05-7
Headliner — Wagon ...............................................................................................................501-05-7
Headliner — Sedan ................................................................................................................501-05-7
Headliner — Ute ....................................................................................................................501-05-7
Luggage Compartment Cover Lower Back ............................................................................501-05-8
Luggage Compartment Quarter Trims ...................................................................................501-05-9
Luggage Compartment Load Floor Carpet ............................................................................501-05-9
Spare Wheel Board ................................................................................................................501-05-9
Package Tray Insulator ........................................................................................................501-05-10
Decklid Trim ........................................................................................................................501-05-10
Hip Bolster ...........................................................................................................................501-05-11
Front Door Watershield ........................................................................................................501-05-11
Front Inner Scuff Plate (RH) ................................................................................................501-05-12
Front Inner Scuff Plate (LH) .................................................................................................501-05-12
Rear Inner Scuff Plate ..........................................................................................................501-05-12
Rear Outer Scuff Plate .........................................................................................................501-05-13
Front Carpet .........................................................................................................................501-05-13
01/2006 2006.0 BF Falcon

501-08 Exterior Trim and Ornamentation 501-08
SECTION : 501-08 Exterior Trim and

Ornamentation
CONTENTS PAGE
Exterior Trim and Ornamentation .........................................................................................501-08-1
Radiator Grille .......................................................................................................................501-08-2
Licence Plate Housing ..........................................................................................................501-08-2
Rear Decklid Moulding — High Series, SWB Sedan ............................................................501-08-3
Rear Decklid Moulding — Low Series, SWB Sedan ............................................................501-08-3
Rear Liftgate Moulding — Wagon .........................................................................................501-08-4
Rear Decklid Moulding — Wagon .........................................................................................501-08-4
Window Moulding ..................................................................................................................501-08-4
Door Moulding — All Vehicles ..............................................................................................501-08-5
Rocker Panel Moulding — SWB & LWB ..............................................................................501-08-6
Body Side Protection Moulding .............................................................................................501-08-6
Roof Ditch Moulding ..............................................................................................................501-08-7
Decklid Spoiler ......................................................................................................................501-08-7
01/2006 2006.0 BF Falcon

501-09 Rear View Mirrors 501-09
SECTION : 501-09 Rear View Mirrors

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................501-09-1
Rear View Mirrors ..................................................................................................................501-09-2
Rear View Mirrors ..................................................................................................................501-09-3
Symptom Chart ....................................................................................................................501-09-3
Pinpoint Tests ......................................................................................................................501-09-6
Power Mirror Switch ............................................................................................................501-09-11
Exterior Mirror Glass ...........................................................................................................501-09-12
Exterior Mirror & Round Plug in Door Trim ..........................................................................501-09-13
Interior Rear View Mirror .....................................................................................................501-09-13
Ambient Temperature Sensor ..............................................................................................501-09-13
01/2006 2006.0 BF Falcon

501-10 Seating 501-10
SECTION : 501-10 Seating

CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................501-10-21
Seating ..................................................................................................................................501-10-2
Seats ....................................................................................................................................501-10-2
Seats .....................................................................................................................................501-10-3
Symptom Chart ....................................................................................................................501-10-4
Pinpoint Tests ....................................................................................................................501-10-16
Front Seat Assembly .........................................................................................................501-10-235
Rear Seat Cushion ..............................................................................................................501-10-24
Rear Seat Bolster ................................................................................................................501-10-25
Rear Seat Back ...................................................................................................................501-10-25
Front Head Restraint ...........................................................................................................501-10-27
Back Cover .........................................................................................................................501-10-27
Headrest Guides .................................................................................................................501-10-28
Lumbar Knob ......................................................................................................................501-10-28
Inner Side Cover .................................................................................................................501-10-29
Recliner Knob and Outer Side Cover ..................................................................................501-10-30
Front Seat Back ..................................................................................................................501-10-30
Airbag ..................................................................................................................................501-10-34
Front Seat Back Trim Cover ...............................................................................................501-10-36
Pre-tensioner ......................................................................................................................501-10-37
Seat Operating Switch ........................................................................................................501-10-38
Front Seat Cushion ..............................................................................................................501-10-40
Front Seat Track Replacement ............................................................................................501-10-41
01/2006 2006.0 BF Falcon

501-11 Glass, Frames and Mechanisms 501-11
SECTION : 501-11 Glass, Frames and Mechanisms

CONTENTS PAGE
Glass, Frames and Mechanisms ..........................................................................................501-11-1
Glass, Frames and Mechanisms ..........................................................................................501-11-2
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 ........................................................................501-11-6
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
01/2006 2006.0 BF Falcon

501-12 Instrument Panel and Console 501-12
SECTION : 501-12 Instrument Panel and Console

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-12-1
Instrument Panel ....................................................................................................................501-12-2
Instrument Panel ....................................................................................................................501-12-3
Floor Console & Duct Assembly ............................................................................................501-12-5
Overhead Console .................................................................................................................501-12-7
Sun Load Sensor ...................................................................................................................501-12-7
Vent Outlet Registers .............................................................................................................501-12-7
Demist Nozzles ......................................................................................................................501-12-7
01/2006 2006.0 BF Falcon

501-14 Handles, Locks, Latches and Entry Systems 501-14
SECTION : 501-14 Handles, Locks, Latches and

Entry Systems
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-14-1
Latches .................................................................................................................................501-14-2
GENERAL PROCEDURES
Wagon Liftgate Latch ............................................................................................................501-14-3
Hood Latch ............................................................................................................................501-14-4
Front Door Latch ...................................................................................................................501-14-4
Rear Door Latch ....................................................................................................................501-14-4
Door Latch Striker .................................................................................................................501-14-5
Liftgate Latch and Actuator ...................................................................................................501-14-5
Liftgate Latch Striker .............................................................................................................501-14-6
Hood Latch Release Cable ...................................................................................................501-14-6
Decklid Latch and Emergency Release Cable .....................................................................501-14-6
Decklid Latch Striker .............................................................................................................501-14-7
Exterior Front Door Handle ...................................................................................................501-14-7
Exterior Rear Door Handle ...................................................................................................501-14-7
Interior Door Handle ..............................................................................................................501-14-8
Ignition Lock ..........................................................................................................................501-14-8
Interior Lock Button ................................................................................................................501-14-8
Grab Handles — Ute ............................................................................................................501-14-9
Grab Handles — Sedan ........................................................................................................501-14-9
Fuel Filler ..............................................................................................................................501-14-9
Fuel Filler Door Release Switch ...........................................................................................501-14-9
Door and Liftgate Locks ......................................................................................................501-14-10
Ignition Lock ........................................................................................................................501-14-10
01/2006 2006.0 BF Falcon

501-16 Wipers And Washers 501-16
SECTION : 501-16 Wipers And Washers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-16-1
Wipers and Washers — Front ..............................................................................................501-16-2
Wipers and Washers — Rear ...............................................................................................501-16-2
Wipers And Washers ............................................................................................................501-16-3
Rear Window Wiper Washer ................................................................................................501-16-3
GENERAL PROCEDURES
Windshield Wiper Blade and Pivot Arm Adjustment .............................................................501-16-5
Rear Window Wiper Blade and Pivot Arm Adjustment .........................................................501-16-5
Washer Hose Repair .............................................................................................................501-16-5
Windscreen wiper motor test ................................................................................................501-16-5
Windscreen Wiper Blade Insert ............................................................................................501-16-6
Windscreen Wiper Arm and Blade ........................................................................................501-16-6
Windscreen Wiper Motor and Linkage Assembly .................................................................501-16-6
Wiper Motor from W/S Wiper Linkage Assembly .................................................................501-16-7
Washer Pump .......................................................................................................................501-16-7
Low Level Sensor .................................................................................................................501-16-7
Windshield Washer Reservoir — Sedan ..............................................................................501-16-8
Windshield Washer reservoir Sedan — High Series ............................................................501-16-8
Windshield Washer Reservoir Wagon ..................................................................................501-16-9
Liftgate Wiper Assembly .....................................................................................................501-16-10
Washer Hose ......................................................................................................................501-16-10
Windshield Wiper/Washer Switch and/or Rear Window Wiper Switch ...............................501-16-10
01/2006 2006.0 BF Falcon

501-17 Sunroof 501-17
SECTION : 501-17 Sunroof

CONTENTS PAGE
Roof Opening Panel ..............................................................................................................501-17-1
Operating Instruction ............................................................................................................501-17-3
Wiring Routing ......................................................................................................................501-17-5
Sunroof .................................................................................................................................501-17-6
Symptom Chart ....................................................................................................................501-17-6
Pinpoint Tests ......................................................................................................................501-17-8
GENERAL PROCEDURES
Sunshade Check .................................................................................................................501-17-11
Glass Panel Adjustment ......................................................................................................501-17-11
Glass Panel Seal Adjustment .............................................................................................501-17-11
Ventilation Tray Adjustment ................................................................................................501-17-12
Wind Deflector Adjustment .................................................................................................501-17-12
Mechanism Covers Adjustment ..........................................................................................501-17-12
Motor ...................................................................................................................................501-17-13
Sunroof Control Unit (SCU) ................................................................................................501-17-13
Drive Cables .......................................................................................................................501-17-13
Drive Cables Timing ............................................................................................................501-17-14
Glass Panel Seal ................................................................................................................501-17-15
Retraction Mechanism ........................................................................................................501-17-15
Guide Rail Mechanism ........................................................................................................501-17-15
Blocking Catch ....................................................................................................................501-17-16
Drain Channel .....................................................................................................................501-17-16
01/2006 2006.0 BF Falcon

501-19 Bumpers 501-19
SECTION : 501-19 Bumpers

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-19-1
Bumpers ................................................................................................................................501-19-2
Front Bumper ........................................................................................................................501-19-3
Rear Bumper — Sedan ........................................................................................................501-19-4
Rear Bumper — Wagon .......................................................................................................501-19-5
Rear Bumper — Ute .............................................................................................................501-19-6
01/2006 2006.0 BF Falcon

501-20a Occupant Restraints — Active 501-20a
SECTION : 501-20a Occupant Restraints — Active

CONTENTS PAGE
SPECIFICATIONS
Occupant Restraint System ................................................................................................501-20a-2
Safety Belt Buckle Pretensioner and Switch .....................................................................501-20a-2
Energy Management Retractor ..........................................................................................501-20a-3
Web Grabber Retractor ......................................................................................................501-20a-3
Child Restraint System .......................................................................................................501-20a-3
Occupant Restraint System ................................................................................................501-20a-5
Symptom Chart ..................................................................................................................501-20a-5
Component Tests ...............................................................................................................501-20a-5
GENERAL PROCEDURES
Occupant Restraints — Active ............................................................................................501-20a-6
Belt Minder Deactivation/Activation ....................................................................................501-20a-6
Front Safety Belt Retractor .................................................................................................501-20a-7
Rear Outer Safety Belt Retractor ........................................................................................501-20a-7
Rear Centre Safety Belt Retractor — Sedan ......................................................................501-20a-9
Rear Centre Safety Belt Buckle/Minibuckle — Wagon .....................................................501-20a-10
Rear Centre Safety Belt Rectractor — Wagon .................................................................501-20a-10
Rear Centre Safety Belt Buckles ......................................................................................501-20a-11
Safety Belt Buckle and Pretensioner ................................................................................501-20a-12
Front Centre Seat Safety Belt Retractor — Ute ................................................................501-20a-12
01/2006 2006.0 BF Falcon

501-20b Occupant Restraints — Passive 501-20b
SECTION : 501-20b Occupant Restraints —

Passive
CONTENTS PAGE
SPECIFICATIONS
Specifications ......................................................................................................................501-20b-1
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ....................501-20b-2
Side Airbag Bridge Resistor ..............................................................................................501-20b-6
Driver Airbag Module ........................................................................................................501-20b-6
Clockspring .......................................................................................................................501-20b-6
Passenger Airbag Module .................................................................................................501-20b-6
Passenger Airbag Bridge Resistor .....................................................................................501-20b-6
Safety Belt Pretensioners .................................................................................................501-20b-6
Safety Belt Buckle Switches .............................................................................................501-20b-6
Seat Track Position Sensor ..............................................................................................501-20b-6
Restraints Control Module (RCM) .....................................................................................501-20b-6
Electrical System ..............................................................................................................501-20b-7
Sensors .............................................................................................................................501-20b-7
Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ....................501-20b-8
Restraint System Diagnostic Tool Warning .......................................................................501-20b-8
Diagnosing Customer Concerns Without Hard DTCs ........................................................501-20b-8
Diagnosing Customer Concerns with Hard DTCs .............................................................501-20b-8
Prove Out Procedure .......................................................................................................501-20b-10
Glossary ...........................................................................................................................501-20b-10
Airbag Reconnect Checklist .............................................................................................501-20b-11
Diagnostic Instructions — Airbag and Safety Belt Pretensioner Supplemental Restraint System
(SRS) ................................................................................................................................501-20b-11
Diagnostic Test Modes ....................................................................................................501-20b-12
Bit-Mapped Diagnostic Trouble Codes (DTCs) ................................................................501-20b-12
PID/Data Monitor and Record ..........................................................................................501-20b-12
Active Commands ...........................................................................................................501-20b-13
Inspection and Verification ...............................................................................................501-20b-15
Symptom Chart ................................................................................................................501-20b-16
Connector Circuit Reference ............................................................................................501-20b-16
Pinpoint Tests — Airbag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
...........................................................................................................................................501-20b-22
Restraint System Diagnostic Tool Warning .....................................................................501-20b-22
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-23
Pinpoint Test B: DTC B1869 — Lamp Airbag Warning Indicator Circuit Open or Short to
Ground .............................................................................................................................501-20b-25
Pinpoint Test C: DTC B1870 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-29
Pinpoint Test D: DTC B1891 — Airbag Warning Indicator Circuit Short to Battery ........501-20b-32
Pinpoint Test E: LFC 53/DTC B1892 — Airbag Tone Warning Indicator Circuit Shorted to Ground
or Open ............................................................................................................................501-20b-36
Pinpoint Test F: LFC 14/DTC B1921 — Airbag Diagnostic Monitor Ground Circuit
01/2006 2006.0 BF Falcon

501-20b Occupant Restraints — Passive 501-20b
(Continued)
Open ................................................................................................................................501-20b-39
Pinpoint Test G: LFC 33 and 34/DTC B2292 - Restraint System Safety Belt Pretensioner
Status ...............................................................................................................................501-20b-44
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-61
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-82
Pinpoint Test L: LFC 51/DTC B2434 - Driver Safety Belt Buckle Switch Circuit Short to
Ground .............................................................................................................................501-20b-86
Pinpoint Test M: LFC 51/DTC B2435 - Driver Safety Belt Buckle Switch Current Out of
Range ...............................................................................................................................501-20b-90
Pinpoint Test N: LFC 52/DTC B2692 - Passenger Safety Belt Buckle Switch Circuit
Fault .................................................................................................................................501-20b-94
Pinpoint Test O: LFC 52/DTC B2438 - Passenger Safety Belt Buckle Switch Circuit Short to
Ground .............................................................................................................................501-20b-98
Pinpoint Test P: LFC 52/DTC B2439 - Passenger Safety Belt Buckle Switch Resistance Out of
Range .............................................................................................................................501-20b-102
Pinpoint Test Q: LFC 15/DTC C1414 - Incorrect Vehicle ID .........................................501-20b-106
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-113
Pinpoint Test T: LFC 49/DTC C1982 - Seat Track Position Sensor Circuit Fault .........501-20b-117
Pinpoint Test U: No Communication With The Restraints Control Module (RCM) ........501-20b-121
GENERAL PROCEDURES
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment ......501-20b-124
Airbag Disposal — Deployed Airbag ..............................................................................501-20b-124
Airbag Disposal — Undeployed, Inoperative ..................................................................501-20b-124
Airbag Disposal — Driver, Undeployed, Scrapped Vehicle ............................................501-20b-125
Airbag Disposal — Passenger, Undeployed, Scrapped Vehicle ....................................501-20b-126
Airbag Disposal — Side Airbag, Undeployed, Scrapped Vehicle ...................................501-20b-127
Safety Belt Pretensioner Disposal — Deployed .............................................................501-20b-128
Safety Belt Pretensioner Disposal — Undeployed, Inoperative .....................................501-20b-128
Safety Belt Pretensioner Disposal — Undeployed, Scrapped Vehicle ...........................501-20b-128
Supplemental Restraint System (SRS) Deactivation and Reactivation ..........................501-20b-129
Weld Nut Repair — Missing Weld Nut ............................................................................501-20b-133
Weld Nut Repair — Stripped Weld Nut ..........................................................................501-20b-134
Front Impact Severity Sensor .........................................................................................501-20b-135
Side Impact Sensor — First Row, B — Pillar .................................................................501-20b-137
Restraints Control Module (RCM) ...................................................................................501-20b-139
Driver Airbag Module ......................................................................................................501-20b-142
Passenger Airbag Module ...............................................................................................501-20b-147
Clockspring .....................................................................................................................501-20b-150
Side Airbag Bridge Resistor ............................................................................................501-20b-154
Seat Position Sensor ......................................................................................................501-20b-155
Side Airbag Module ..........................................................................................................501-20b-157
01/2006 2006.0 BF Falcon

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

Information
CONTENTS PAGE
Interpretation of Weld Symbols ...........................................................................................501-25A-1
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
01/2006 2006.0 BF Falcon

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

Protection
CONTENTS PAGE
Electro — Coat ...................................................................................................................501-25B-1
Corrosion Prevention ..........................................................................................................501-25B-1
Corrosion Protection ...........................................................................................................501-25B-1
Safety Precautions .............................................................................................................501-25B-1
GENERAL PROCEDURES
Soft Seal Locations .............................................................................................................501-25B-2
Anti — Flutter Adhesive Location .......................................................................................501-25B-4
Button Plug Locations .........................................................................................................501-25B-5
Sound Absorber Locations .................................................................................................501-25B-6
Sound Absorber ..................................................................................................................501-25B-7
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
Water Leaks .......................................................................................................................501-25D-1
General ..............................................................................................................................501-25D-1
Practical execution of tests and checks ............................................................................501-25D-1
Rectifying the leak using recommended tools, auxiliary equipment and materials ...........501-25D-2
Water leaks according to mileage or running time ............................................................501-25D-2
Water leaks after body repairs ..........................................................................................501-25D-2
Water drainage system .....................................................................................................501-25D-2
Water leaks, diagnosis and corrective action: Front passenger compartment .................501-25D-3
01/2006 2006.0 BF Falcon

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

CONTENTS PAGE
Wind Noise .........................................................................................................................501-25E-1
General ..............................................................................................................................501-25E-1
Normal air flow noises .......................................................................................................501-25E-1
Noises caused partly by changes in the direction of air flow and by air flow around separate
components .......................................................................................................................501-25E-1
Noise caused by vibrating seals .......................................................................................501-25E-1
Escaping noises ...............................................................................................................501-25E-2
Cavity noises ....................................................................................................................501-25E-2
Wind noise with the sun roof open ....................................................................................501-25E-2
Wind noises from the door seals .......................................................................................501-25E-2
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
01/2006 2006.0 BF Falcon

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

CONTENTS
WELD INFORMATION
Dimensional Check Underbody Plan View ............................................................................501-26-1
Dimensional Check Underbody Side View ............................................................................501-26-2
Dimensional Check Underbody Wagon Plan View ................................................................501-26-3
Dimensional Check Underbody Wagon Side View ................................................................501-26-4
Dimensional Check Front End ...............................................................................................501-26-5
Dimensional Check Rear End ................................................................................................501-26-6
Dimensional Check Wagon Liftgate Aperture ........................................................................501-26-7
Dimensional Check Body Shell Width Sedan ........................................................................501-26-8
Dimensional Check Body Shell Width Wagon .......................................................................501-26-9
Dimensional Check Front Door Aperture .............................................................................501-26-10
Dimensional Check Rear Door Aperture Sedan ..................................................................501-26-11
Dimensional Check Rear Door Aperture Wagon .................................................................501-26-12
Body Gap Dimensions Front End 1 .....................................................................................501-26-13
Body Gap Dimensions Front End 2 .....................................................................................501-26-14
Body Gap Dimensions Front Side .......................................................................................501-26-15
Body Gap Dimensions .........................................................................................................501-26-16
Body Gap Dimensions .........................................................................................................501-26-17
Body Gap Dimension Rear Quarter Panel ...........................................................................501-26-18
Body Gap Dimension Rear End ...........................................................................................501-26-19
01/2006 2006.0 BF Falcon

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

CONTENTS
WELD INFORMATION
Interpretation of Weld Symbols ..............................................................................................501-27-1
Radiator Cross Member 1 ......................................................................................................501-27-2
Radiator Cross Member 1a ....................................................................................................501-27-3
Towel Rail Replacement ........................................................................................................501-27-4
Apron and Side Member ........................................................................................................501-27-6
Front Apron LHS ....................................................................................................................501-27-6
Front Apron RHS ...................................................................................................................501-27-7
Fender to Body LHS ..............................................................................................................501-27-7
Fender to Body RHS ..............................................................................................................501-27-8
Front Apron LHS 1 .................................................................................................................501-27-8
Front Apron RHS 1 ................................................................................................................501-27-9
01/2006 2006.0 BF Falcon

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

CONTENTS
WELD INFORMATION
Sedan Roof Panels 1 .............................................................................................................501-28-2
Wagon Roof Panels 1 ............................................................................................................501-28-5
01/2006 2006.0 BF Falcon

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

CONTENTS
WELD INFORMATION
Sedan Body Side 1 ................................................................................................................501-29-2
Sedan Body Side 2 ................................................................................................................501-29-2
Sedan Body Side 3 ................................................................................................................501-29-3
Sedan Body Side 4 ................................................................................................................501-29-3
Sedan Body Side 5 ................................................................................................................501-29-4
Sedan Body Side 6 ................................................................................................................501-29-4
Wagon Body Side 1 ...............................................................................................................501-29-5
Wagon Body Side 2 ...............................................................................................................501-29-5
Wagon Body Side 3 ...............................................................................................................501-29-6
Wagon Body Side 4 ...............................................................................................................501-29-6
Wagon Body Side 5 ...............................................................................................................501-29-7
Wagon Body Side 6 ...............................................................................................................501-29-7
Wagon Body Side 7 ...............................................................................................................501-29-8
Wagon Body Side 8 ...............................................................................................................501-29-8
Wagon Body Side 9 ...............................................................................................................501-29-9
Wagon Body Side 10 .............................................................................................................501-29-9
Wagon Body Side 11 ...........................................................................................................501-29-10
Wagon Body Side 12 ...........................................................................................................501-29-10
Wagon Body Side 13 ...........................................................................................................501-29-11
Wagon and Sedan Side Impact Crash Sensor Bracket .......................................................501-29-11
Wagon Liftgate 1 ..................................................................................................................501-29-12
Wagon Liftgate 2 ..................................................................................................................501-29-13
Front Door 1 .........................................................................................................................501-29-15
Front Door 2 .........................................................................................................................501-29-14
Front Door 3 .........................................................................................................................501-29-14
Front Door 4 .........................................................................................................................501-29-15
Front Door 5 .........................................................................................................................501-29-15
01/2006 2006.0 BF Falcon

501-29 Side Panel Sheet Metal Repairs 501-29
(Continued)
Front Door 6 .........................................................................................................................501-29-16

Front Door 7 .........................................................................................................................501-29-16
Sedan Rear Door 1 ..............................................................................................................501-29-17
Sedan Rear Door 2 ..............................................................................................................501-29-17
Sedan Rear Door 3 ..............................................................................................................501-29-18
Wagon Rear Door 1 .............................................................................................................501-29-18
Wagon Rear Door 2 .............................................................................................................501-29-19
Wagon Rear Door 3 .............................................................................................................501-29-19
Wagon Rear Door 4 .............................................................................................................501-29-20
SWB Sedan Side Floor Plan Assembly 1 ............................................................................501-29-20
SWB Sedan Side Floor Plan Assembly 2 ............................................................................501-29-21
Wagon Side Floor Plan Assembly 1 ....................................................................................501-29-21
Wagon Side Floor Plan Assembly 2 ....................................................................................501-29-22
Ute Side Floor Plan Assembly 1 ..........................................................................................501-29-22
Ute Side Floor Plan Assembly 2 ..........................................................................................501-29-23
Ute Body Side 1 ...................................................................................................................501-29-23
Ute Body Side 2 ...................................................................................................................501-29-24
Ute Body Side 3 ...................................................................................................................501-29-24
Ute Body Side 4 ...................................................................................................................501-29-25
Ute Body Side 5 ...................................................................................................................501-29-25
01/2006 2006.0 BF Falcon

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

CONTENTS
WELD INFORMATION
Petrol Rear Floorpan Assembly .............................................................................................501-30-2
Rear Floor Pan Assembly - View A .......................................................................................501-30-2
Petrol Rear Floor Pan Assembly - View B .............................................................................501-30-3
Petrol Rear Floorpan Sill Assembly .......................................................................................501-30-3
Petrol Rear Floorpan Sill Assembly - View A ........................................................................501-30-4
Petrol Rear Floorpan Sill Assembly - View B ........................................................................501-30-4
Petrol Rear Floorpan Sill Assembly - View C ........................................................................501-30-5
Rear Sill to Rear Floorpan Assembly .....................................................................................501-30-5
Rear Sill to Rear Floorpan - View A .......................................................................................501-30-6
Rear Sill to Rear Floorpan - View B .......................................................................................501-30-6
Rear Sill to Rear Floorpan - View C ......................................................................................501-30-7
Dedicated LPG Rear Floorpan Assembly 1 ...........................................................................501-30-7
Dedicated LPG Rear Floorpan Assembly - View A ...............................................................501-30-8
Dedicated LPG Rear Floorpan Assembly - View B ...............................................................501-30-8
Dedicated LPG Rear Floorpan Sill Assembly ........................................................................501-30-9
Dedicated LPG Rear Floorpan Sill View A ............................................................................501-30-9
Dedicated LPG Rear Floorpan Sill View B ..........................................................................501-30-10
Dedicated LPG Rear Floorpan Sill Assembly ......................................................................501-30-10
Dedicated LPG Rear Floorpan Sill Assembly View A ..........................................................501-30-11
Petrol/Dedicated LPG Rear Bumper Mount Assembly - LH ................................................501-30-11
Petrol/Dedicated LPG Rear Bumper Mount Assembly - RH ...............................................501-30-12
Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-12
Dedicated LPG Rear Floor Corssmember Assembly ..........................................................501-30-13
Rear Floorpan Reinforcement Member View A ...................................................................501-30-13
Rear Floorpan Reinforcement Member View B ...................................................................501-30-14
Petrol Rear Floorpan Sill Assembly .....................................................................................501-30-14
Rear Sill to Rear Floorpan View A .......................................................................................501-30-15
01/2006 2006.0 BF Falcon

501-30 Rear End Sheet Metal Repairs 501-30
(Continued)
Wagon Rear Side Support 1 ................................................................................................501-30-15

Wagon Rear Cross Members 1 ...........................................................................................501-30-17
Wagon Rear Cross Members 2 ...........................................................................................501-30-18
Wagon Rear Floorpan 1 .......................................................................................................501-30-18
Wagon Rear Floorpan 2 .......................................................................................................501-30-19
Wagon Rear Floorpan Bumper Mounting 1 .........................................................................501-30-19
Wagon Rear Floorpan Bumper Mounting 2 .........................................................................501-30-20
Wagon Rear Cross Member ................................................................................................501-30-20
Wagon Rear Sill to Floorpan ................................................................................................501-30-21
01/2006 2006.0 BF Falcon

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

Steel
CONTENTS
GENERAL PROCEDURES
Welding Requirements ...........................................................................................................501-31-1
Protection of Electronics ........................................................................................................501-31-1
Precautions ............................................................................................................................501-31-1
High Strength Steels ..............................................................................................................501-31-1
High Strength Low Alloy Steels (HSLA) .................................................................................501-31-1
Heating HSLA Steel ...............................................................................................................501-31-1
Welding HSLA Steels .............................................................................................................501-31-1
WELD INFORMATION
HSLA Steel Location - Front End Section .............................................................................501-31-3
HSLA Steel Location - Side Section ......................................................................................501-31-4
HSLA Steel Location - Sedan Rear Section - Petrol .............................................................501-31-5
HSLA Steel Location - Sedan Rear Section - DLPG .............................................................501-31-6
HSLA Steel Location -Wagon Rear Side Member Reinforcement ........................................501-31-7
HSLA Steel Location - Sedan Floor and Members ................................................................501-31-8
HSLA Steel Location - Wagon Floor and Members ...............................................................501-31-9
HSLA Steel Location - Ute Floor and Members ..................................................................501-31-10
HSLA Steel Location - Doors ...............................................................................................501-31-11
HSLA Steel Location - Wagon Side and Rear .....................................................................501-31-12
HSLA Steel Location - Dash and Cowl ................................................................................501-31-13
01/2006 2006.0 BF Falcon

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

Application
CONTENTS PAGE
Paint Preparation and Application ........................................................................................501-32-1
Paint Colour Codes ..............................................................................................................501-32-1
Checking Paint Condition .....................................................................................................501-32-1
Safety Precautions ...............................................................................................................501-32-1
Factory Finish .......................................................................................................................501-32-2
Two Pack Paints - Surface Preparation ...............................................................................501-32-2
Mixing ...................................................................................................................................501-32-3
Application ............................................................................................................................501-32-3
After Spraying ......................................................................................................................501-32-3
Painting Plastic Bumper Bars ..............................................................................................501-32-4
Repairing Color Coat Plastic Bumpers ................................................................................501-32-5
Painting Plastic Components - General Hints ......................................................................501-32-5
Plastics Including Nylon .......................................................................................................501-32-6
Top Coat - DG Solid Colors .................................................................................................501-32-6
Pearl/Metalic Clear Over Base .............................................................................................501-32-6
Clear Coat ............................................................................................................................501-32-6
Flexible Additive ...................................................................................................................501-32-6
01/2006 2006.0 BF Falcon

2006 FPV
Workshop Manual
Supplement
Specifications List
Table of Contents
Group 2 - Chassis
Suspension 204-04 Wheels & Tyres
FPV Performance Brake System - General

Brake System 206-00B
Information
206-00C FPV Premium Brake System - General Information
206-03B Front Disc Brake - FPV Performance
206-03C Front Disc Brake - FPV Premium
206-06 Hydraulic Brake Actuation
Group 3 - Powertrain
Engine 303-01C Engine - V8 (4v)
303-03 Engine Cooling
303-12 Intake Air Distribution and Filtering
Manual
Transmission/ 308-01 Clutch
Transaxle
Exhaust System 309-00 Exhaust System
Fuel System 310-00 Fuel System
Group 4 - Electrical
Instrumentation
and Warning
System
413-07 Windscreen Mounted Clock
Electronic
419-01 Alarm System
Features Group
Group 5 - Body & Paint

Body 501-02 Front End Body Panels
501-19 Bumpers
100-01 Identification Codes 100-01
SECTION : 100-01 Identification Codes

VEHICLE APPLICATION : 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit, F6
Typhoon and F6 Tornado
CONTENTS PAGE
Vehicle Compliance (VC) Label .............................................................................................100-01-1
Emission Decal ....................................................................................................................100-01-2
Microdot Security Identification ............................................................................................100-01-2
FPV00006 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit, F6 Typhoon and F6 Tornado
204-00 Suspension System - General Information 204-00
SECTION : 204-00 Suspension System — General

Information
CONTENTS PAGE
Rear Wheel Alignment .........................................................................................................204-00-2
204-04 Wheels and Tyres 204-04
SECTION : 204-04 Wheels and Tyres

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................204-04-1
Wheels and Tyres ..................................................................................................................204-04-2
Wheels .................................................................................................................................204-04-2
Tyres ....................................................................................................................................204-04-2
Safety Precautions ..............................................................................................................204-04-2
Wheels and Tyres .................................................................................................................204-04-3
GENERAL PROCEDURES
Wheel and Tyre Rotation .......................................................................................................204-04-4
Removing and Installing the Centre Cap ...............................................................................204-04-5
206-00b-1 FPV Performance Brake System - General Information 206-00b-1
SECTION : 206-00B FPV Performance Brake

System - General Information
CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................206-00B-1
General Specifications .........................................................................................................206-00B-1
Torque Specifications ..........................................................................................................206-00B-2
Brake System ......................................................................................................................206-00B-3
Brake System ......................................................................................................................206-00B-4
Pad Wear ...........................................................................................................................206-00B-4
Disc Wear and Runout ......................................................................................................206-00B-4
Disc Thickness and Refinishing .........................................................................................206-00B-4
206-00c FPV Premium Brake System - General Information 206-00c
SECTION : 206-00C FPV Premium Brake System -

General Information
CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................206-00C-1
General Specifications ........................................................................................................206-00C-1
Torque Specifications ..........................................................................................................206-00C-2
Brake System ......................................................................................................................206-00C-3
Brake System ......................................................................................................................206-00C-4
Pad Wear ...........................................................................................................................206-00C-4
Disc Wear and Runout ......................................................................................................206-00C-4
Disc Thickness and Resurfacing .......................................................................................206-00C-4
206-03b FPV PERFORMANCE FRONT DISC BRAKE 206-03b
SECTION : 206-03B FPV PERFORMANCE FRONT

DISC BRAKE
CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................206-03B-1
General Specifications .........................................................................................................206-03B-1
Torque Specifications ..........................................................................................................206-03B-1
Front Disc Brake ..................................................................................................................206-03B-2
Brake Pads ..........................................................................................................................206-03B-3
Front Brake Hose ................................................................................................................206-03B-5
Brake Caliper .......................................................................................................................206-03B-6
Brake Disc ...........................................................................................................................206-03B-7
206-04 FPV Performance Rear Brake System 206-04
SECTION : 206-04 FPV Performance Rear Brake

System
CONTENTS PAGE
206-06 Hydraulic Brake Actuation 206-06
SECTION : 206-06 Hydraulic Brake Actuation

CONTENTS PAGE
Brake and Accelerator Pedal Pads ........................................................................................206-06-1
Automatic Vehicles ...............................................................................................................206-06-1
Manual Vehicles ...................................................................................................................206-06-2
303-00 Engine System - General Information 303-00
SECTION : 303-00 Engine System - General

Information
CONTENTS PAGE
303-01c Engine — V8 (4V) 303-01c
SECTION : 303-01c Engine — V8 (4V)

VEHICLE APPLICATION : 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit
CONTENTS PAGE
SPECIFICATIONS
Engine .................................................................................................................................303-01c-5
Identification ......................................................................................................................303-01c-5
Code Information ...............................................................................................................303-01c-5
Induction System ...............................................................................................................303-01c-5
Valve Train ........................................................................................................................303-01c-5
Positive Crankcase Ventilation System ............................................................................303-01c-5
Lubrication System ............................................................................................................303-01c-5
Oil Pump ...........................................................................................................................303-01c-6
Cooling System .................................................................................................................303-01c-6
Drive Belt System ..............................................................................................................303-01c-6
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-36
Camshaft ...........................................................................................................................303-01c-36
Exhaust Manifold — LH .....................................................................................................303-01c-40
Oil Filter Adapter ...............................................................................................................303-01c-41
Oil Pressure Sender ..........................................................................................................303-01c-43
Oil Level Indicator and Tube .............................................................................................303-01c-43
Oil Pan ..............................................................................................................................303-01c-43
Oil Pump Screen and Pickup Tube ...................................................................................303-01c-46
Flexplate ............................................................................................................................303-01c-46
Crankshaft Rear Oil Seal ..................................................................................................303-01c-47
Engine Mounts — RH ........................................................................................................303-01c-48
Engine Mounts — LH .........................................................................................................303-01c-48
REMOVAL
Engine ...............................................................................................................................303-01c-50
FPV00006 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit

303-01c Engine — V8 (4V) 303-01c
(Continued)
DISASSEMBLY
Engine ...............................................................................................................................303-01c-54
Piston ................................................................................................................................303-01c-64
Cylinder Head RH and LH .................................................................................................303-01c-65
ASSEMBLY
Engine ...............................................................................................................................303-01c-72
INSTALLATION
Engine ...............................................................................................................................303-01c-91
FPV00006 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit

303-03 Engine Cooling 303-03
SECTION : 303-03 Engine Cooling

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................303-03-1
Engine Cooling ......................................................................................................................303-03-3
Radiator ................................................................................................................................303-03-3
Electric Dual Fans ................................................................................................................303-03-3
Electric Single Fan ...............................................................................................................303-03-3
Water Pump .........................................................................................................................303-03-3
Cooling System ....................................................................................................................303-03-3
Cooling Maintenance ...........................................................................................................303-03-4
Engine Cooling ......................................................................................................................303-03-5
Symptom Chart ....................................................................................................................303-03-6
Pinpoint Tests ......................................................................................................................303-03-7
Pressure Test .......................................................................................................................303-03-9
Supply Tank Cap Pressure Test ..........................................................................................303-03-9
Thermostat Test .....................................................................................................................303-03-9
Thermostat Removed ...........................................................................................................303-03-9
Coolant System ....................................................................................................................303-03-9
Cooling Fans Self Test - Dual Fan Models ..........................................................................303-03-9
Cooling Fans Self Test - Single Fan Models .....................................................................303-03-10
GENERAL PROCEDURES
Coolant Level Check ...........................................................................................................303-03-11
Coolant Colour Inspection ....................................................................................................303-03-11
Adjusting Anti — Freeze Protection Level ..........................................................................303-03-12
Anti — Freeze Replacement ...............................................................................................303-03-12
Draining and Filling the Cooling System .............................................................................303-03-12
Radiator Cleaning ...............................................................................................................303-03-12
Thermostat ..........................................................................................................................303-03-14
Thermostat Housing — 8 Cylinder ......................................................................................303-03-14
Thermostat Housing — 6 Cylinder ......................................................................................303-03-14
Water Pump — 6 Cylinder ...................................................................................................303-03-15
Water Pump — V8 ...............................................................................................................303-03-16
Radiator ................................................................................................................................303-03-16
Fan ......................................................................................................................................303-03-18
Radiator Hose .....................................................................................................................303-03-18
303-03 Engine Cooling 303-03
(Continued)
Coolant Supply Tank ...........................................................................................................303-03-19

Water Pump - 6 Cylinder .....................................................................................................303-03-19
Heater Water Control Valve (I6 Auto engines only) .............................................................303-03-20
Engine Oil Cooling ...............................................................................................................303-03-21
Engine Oil Cooler ...............................................................................................................303-03-21
303-12 Intake Air Distribution and Filtering 303-12
SECTION : 303-12 Intake Air Distribution and

Filtering
CONTENTS PAGE
SPECIFICATIONS
Specification ...........................................................................................................................303-12-1
Intake Air Distribution and Filtering ......................................................................................303-12-2
The Intake Air System ..........................................................................................................303-12-2
GENERAL PROCEDURES
Cleaning and Inspection ........................................................................................................303-12-4
Air Cleaner Body - I6 and V8 Engine .....................................................................................303-12-5
Air Cleaner Element - I6 and V8 Engines ..............................................................................303-12-5
Engine Air Ducting — I6 and V8 Engines ..............................................................................303-12-5
308-01 Clutch 308-01
SECTION : 308-01 Clutch

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................308-01-1
Clutch (F6 Only) .....................................................................................................................308-01-2
Introduction ..........................................................................................................................308-01-2
Clutch Function ....................................................................................................................308-01-2
System Diagrams ...................................................................................................................308-01-3
Clutch .....................................................................................................................................308-01-7
Symptom Chart ....................................................................................................................308-01-7
GENERAL PROCEDURES
Clutch spin down time - Evaluation ......................................................................................308-01-10
Removal of clutch ................................................................................................................308-01-11
Clutch Inspection .................................................................................................................308-01-12
Replacement of the wear plates and the rubbing strips ......................................................308-01-12
Installation of clutch .............................................................................................................308-01-14
Removal of Flywheel ............................................................................................................308-01-16
Flywheel inspection ..............................................................................................................308-01-16
Flywheel installation .............................................................................................................308-01-16
Pilot Bearing .........................................................................................................................308-01-17
309-00 Exhaust System 309-00
SECTION : 309-00 Exhaust System

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................309-00-1
6 Cylinder Torque Specifications .........................................................................................309-00-1
8 Cylinder Torque Specifications .........................................................................................309-00-1
Exhaust System .....................................................................................................................309-00-2
Precautions ..........................................................................................................................309-00-2
Heat Shields .........................................................................................................................309-00-2
Exhaust System .....................................................................................................................309-00-3
Inspection and Verification .....................................................................................................309-00-3
Pinpoint Tests ........................................................................................................................309-00-3
Engine performance .............................................................................................................309-00-3
Leaks ....................................................................................................................................309-00-3
Noise/Vibration .....................................................................................................................309-00-3
GENERAL PROCEDURES
Exhaust System Alignment ....................................................................................................309-00-4
All Rear Muffler Assemblies ...................................................................................................309-00-5
All Intermediate Muffler Assemblies .......................................................................................309-00-5
6 Cylinder Catalyst Assembly ................................................................................................309-00-5
8 Cylinder Catalyst Assemblies (LHS & RHS) .......................................................................309-00-5
8 Cylinder Y - Pipe Assemblies .............................................................................................309-00-6
GT Dual Exhaust - LHS Tailpipe Assembly ...........................................................................309-00-6
System Diagrams ...................................................................................................................309-00-7
F6 Typhoon ..........................................................................................................................309-00-7
F6 Tornado ...........................................................................................................................309-00-8
GT & GT-P ...........................................................................................................................309-00-9
Pursuit & Super Pursuit ......................................................................................................309-00-10
310-00 Fuel System 310-00
SECTION : 310-00 Fuel System

CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................310-00-01
General Specifications .........................................................................................................310-00-01
Electrical Fuel Pump ............................................................................................................310-00-02
413-01 Instrument Cluster 413-01
SECTION : 413-01 Instrument Cluster

CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................413-01-01
413-07 Windscreen Mounted Clock 413-07
SECTION : 413-07 Windscreen Mounted Clock

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................413-07-1
Clock .....................................................................................................................................413-07-2
Clock .....................................................................................................................................413-07-3
Symptom Chart ....................................................................................................................413-07-3
Pinpoint Tests ......................................................................................................................413-07-3
Clock .....................................................................................................................................413-07-5
419-01 Alarm System 419-01
SECTION : 419-01 Alarm System

CONTENTS PAGE
SPECIFICATIONS
Specifications .........................................................................................................................419-01-1
Operation ...............................................................................................................................419-01-2
Component Layout .................................................................................................................419-01-2
Wiring Loom .........................................................................................................................419-01-2
Siren .....................................................................................................................................419-01-2
Control Module .....................................................................................................................419-01-2
Symptom Chart ......................................................................................................................419-01-3
Pinpoint Tests ........................................................................................................................419-01-3
Siren .......................................................................................................................................419-01-7
Control Module .......................................................................................................................419-01-7
Manual Override ....................................................................................................................419-01-7
Programmable Features ........................................................................................................419-01-7
Auto Arming (Factory Set "OFF") ...........................................................................................419-01-7
Auto Arming Option 1/ Option 2 .............................................................................................419-01-8
Exterior illumination (Factory Set "OFF") ...............................................................................419-01-8
Wiring Connectors .................................................................................................................419-01-9
501-02 Front End Body Panels 501-02
SECTION : 501-02 Front End Body Panels

CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................................................................501-02-1
Front End Body Panels .........................................................................................................501-02-2
GENERAL PROCEDURES
Hood Alignment ....................................................................................................................501-02-3
Fender Alignment ..................................................................................................................501-02-3
Air Deflector ..........................................................................................................................501-02-5
Fender Splash Shield ............................................................................................................501-02-5
Cowl Panel Grille ..................................................................................................................501-02-6
Fender ...................................................................................................................................501-02-6
Modestry Panel .....................................................................................................................501-02-7
Hood Prop .............................................................................................................................501-02-7
Hood/Hood Hinge .................................................................................................................501-02-7
501-05 Interior Trim and Ornamentation 501-05
SECTION : 501-05 Interior Trim and Ornamentation

CONTENTS PAGE
Interior Trim and Ornamentation ............................................................................................501-05-1
Aluminium Pedal Covers ........................................................................................................501-05-2
Removable Floor Mats ...........................................................................................................501-05-2

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100-00 General Information 100-00

SECTION : 100-00 General Information

01/2006 2006.0 BF Falcon

O-Rings (Fluoroelastomer) ...................................................................................................100-00-8

01/2006 2006.0 BF Falcon

SECTION : 100-01 Identification Codes

01/2006 2006.0 BF Falcon

SECTION : 100-02 Jacking and Lifting

01/2006 2006.0 BF Falcon

SECTION : 100-04 Noise, Vibration and Harshness

01/2006 2006.0 BF Falcon

SECTION : 204-00 Suspension System — General

01/2006 2006.0 BF Falcon

SECTION : 204-01 Front Suspension

01/2006 2006.0 BF Falcon

SECTION : 204-02A Rear Suspension — IRS

01/2006 2006.0 BF Falcon

SECTION : 204-02B Rear Suspension — Beam Axle

01/2006 2006.0 BF Falcon

SECTION : 204-04 Wheels and Tyres

01/2006 2006.0 BF Falcon

SECTION : 205-00 Driveline System — General

01/2006 2006.0 BF Falcon

SECTION : 205-01 Driveshaft

01/2006 2006.0 BF Falcon

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

01/2006 2006.0 BF Falcon

SECTION : 205-02B Independent Rear Suspension

01/2006 2006.0 BF Falcon

SECTION : 205-05 Rear Drive Halfshafts

01/2006 2006.0 BF Falcon

SECTION : 206-00 Brake System — General

01/2006 2006.0 BF Falcon

SECTION : 206-00A High Series Brakes — General

01/2006 2006.0 BF Falcon

SECTION : 206-03 Front Disk Brake

01/2006 2006.0 BF Falcon

SECTION : 206-03A Front Disk Brake - High Series

01/2006 2006.0 BF Falcon

SECTION : 206-04 Rear Disc Brake

01/2006 2006.0 BF Falcon

SECTION : 206-04A Rear Disc Brake - High Series

01/2006 2006.0 BF Falcon

SECTION : 206-05 Parking Brake and Actuation

01/2006 2006.0 BF Falcon

SECTION : 206-06 Hydraulic Brake Actuation

01/2006 2006.0 BF Falcon

SECTION : 206-06A Hydraulic Brake Actuation —

01/2006 2006.0 BF Falcon

SECTION : 211-03 Steering Linkage

01/2006 2006.0 BF Falcon

SECTION : 211-04 Steering Column

01/2006 2006.0 BF Falcon

SECTION : 211-05 Steering Column Switches

01/2006 2006.0 BF Falcon

SECTION : 303-00 Engine System  General

01/2006 2006.0 BF Falcon

Valve  Spring Squareness ................................................................................................303-00-15

01/2006 2006.0 BF Falcon

GENERAL PROCEDURES (Continued)

CAUTION: Do not contact the crown when

Exhaust Manifold — Inspection

BF00006 en 01/2006 2006.0 BF Falcon

SECTION : 303-01a Engine  I6

SECTION : 303-00 Engine System General

Valve Spring Squareness ................................................................................................303-00-15

SECTION : 303-01a Engine I6

SECTION : 303-01b Engine 5.4L (3V)

SECTION : 303-01c Engine V8 (4V)